U.S. patent application number 15/799385 was filed with the patent office on 2019-05-02 for semiconductor device and manufacturing method thereof.
This patent application is currently assigned to TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.. The applicant listed for this patent is TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.. Invention is credited to Wen-Hsing HSIEH, Ching-Fang HUANG, Chun-An LIN, Chun-Hsiung LIN, Sai-Hooi YEONG, Chia-Ta YU.
Application Number | 20190131423 15/799385 |
Document ID | / |
Family ID | 66244324 |
Filed Date | 2019-05-02 |
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United States Patent
Application |
20190131423 |
Kind Code |
A1 |
LIN; Chun-An ; et
al. |
May 2, 2019 |
SEMICONDUCTOR DEVICE AND MANUFACTURING METHOD THEREOF
Abstract
A semiconductor device includes a substrate, a bottom
semiconductor fin, at least one sidewall structure, a top
semiconductor fin, and a gate structure. The bottom semiconductor
fin is disposed on the substrate. The sidewall structure protrudes
from the semiconductor fin. The top semiconductor fin is disposed
on the bottom semiconductor fin. The top semiconductor fin includes
a channel portion and at least one source/drain portion. The
source/drain portion is disposed between the channel portion and
the sidewall structure. The gate structure covers the channel
portion of the top semiconductor fin.
Inventors: |
LIN; Chun-An; (Tainan City,
TW) ; LIN; Chun-Hsiung; (Hsinchu County, TW) ;
YU; Chia-Ta; (New Taipei City, TW) ; YEONG;
Sai-Hooi; (Hsinchu County, TW) ; HUANG;
Ching-Fang; (Taipei City, TW) ; HSIEH; Wen-Hsing;
(Hsinchu City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD. |
Hsinchu |
|
TW |
|
|
Assignee: |
TAIWAN SEMICONDUCTOR MANUFACTURING
CO., LTD.
Hsinchu
TW
|
Family ID: |
66244324 |
Appl. No.: |
15/799385 |
Filed: |
October 31, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 21/823807 20130101;
H01L 21/823431 20130101; H01L 29/6681 20130101; H01L 29/1054
20130101; H01L 21/823412 20130101; H01L 21/823821 20130101; H01L
21/3065 20130101; H01L 29/785 20130101; H01L 29/1083 20130101; H01L
29/1033 20130101; H01L 29/7851 20130101; H01L 21/31116 20130101;
H01L 27/0886 20130101; H01L 29/66795 20130101 |
International
Class: |
H01L 29/66 20060101
H01L029/66; H01L 29/78 20060101 H01L029/78; H01L 29/10 20060101
H01L029/10; H01L 27/088 20060101 H01L027/088; H01L 21/8234 20060101
H01L021/8234 |
Claims
1. A semiconductor device, comprising: a substrate; a bottom
semiconductor fin disposed on the substrate; first and second
sidewall structures protruding from the bottom semiconductor fin; a
top semiconductor fin disposed on the bottom semiconductor fin,
wherein the top semiconductor fin and the bottom semiconductor fin
are made of different semiconductive materials, the top
semiconductor fin is sandwiched between the first and second
sidewall structures, and the top semiconductor fin comprises: a
channel portion; and source and drain portions, wherein the source
portion is between the channel portion and the first sidewall
structure, and the drain portion is between the channel portion and
the second sidewall structure; and a gate structure over the
channel portion of the top semiconductor fin.
2. The semiconductor device of claim 1, wherein the top
semiconductor fin is in contact with the first and second sidewall
structures and the bottom semiconductor fin.
3. The semiconductor device of claim 1, wherein the first and
second sidewall structures are located on opposite ends of the top
semiconductor fin.
4. The semiconductor device of claim 1, further comprising first
and second epitaxy structures respectively partially embedded in
the source and drain portions of the top semiconductor fin, wherein
the first epitaxy structure is between the first sidewall structure
and the channel portion.
5. The semiconductor device of claim 4, wherein the first sidewall
structure is separated from the first epitaxy structure.
6. The semiconductor device of claim 5, wherein a portion of the
top semiconductor fin is disposed between and in contact with the
first sidewall structure and the first epitaxy structure.
7. The semiconductor device of claim 4, wherein a bottom portion of
the first sidewall structure is lower than a bottom surface of the
first epitaxy structure.
8. The semiconductor device of claim 1, further comprising an
interlayer dielectric (ILD) layer disposed over the substrate,
wherein the first sidewall structure is located between the ILD
layer and the top semiconductor fin.
9. The semiconductor device of claim 1, further comprising an
isolation structure disposed around the bottom semiconductor fin,
wherein a bottom surface of the top semiconductor fin is higher
than a top surface of the isolation structure.
10. The semiconductor device of claim 1, wherein the first and
second sidewall structures and the bottom semiconductor fin are
made of the same semiconductive material.
11. The semiconductor device of claim 10, wherein a lattice
constant of the top semiconductor fin is greater than that of the
first and second sidewall structures and the bottom semiconductor
fin.
12. A semiconductor device, comprising: a substrate; a bottom
semiconductor fin disposed on the substrate; a top semiconductor
fin disposed on the bottom semiconductor fin; a first sidewall
structure and a second sidewall structure disposed on opposite ends
of the top semiconductor fin, wherein the top semiconductor fin is
made of a material that is different from that of the first
sidewall structure and the second sidewall structure, and a top
surface of the top semiconductor fin is substantially coplanar with
top surfaces of the first and second sidewall structures; and a
gate structure straddling across the top semiconductor fin.
13. The semiconductor device of claim 12, wherein the first
sidewall structure and the second sidewall structure protrude from
the bottom semiconductor fin.
14. The semiconductor device of claim 12, wherein the top
semiconductor fin is in contact with the bottom semiconductor fin,
the first sidewall structure and the second sidewall structure.
15. The semiconductor device of claim 12, wherein the top
semiconductor fin comprises a channel region located between the
first sidewall structure and the second sidewall structure and
below the gate structure.
16. (canceled)
17. A method for manufacturing a semiconductor device comprising:
forming a fin structure on a substrate; forming an isolation
material surrounding the fin structure; removing a portion of the
fin structure to form a bottom semiconductor fin and sidewall
structures over the bottom semiconductor fin, wherein the sidewall
structures are in contact with the isolation material, and the
bottom semiconductor fin and the sidewall structures define a
trench therebetween; forming a top semiconductor fin in the trench,
wherein the top semiconductor fin is between the sidewall
structures and over the bottom semiconductor fin, the fin structure
is made of a semiconductive material, and the top semiconductor fin
is made of an epitaxy material that is different from the
semiconductive material; and forming a gate structure on the top
semiconductor fin.
18. The method of claim 17, further comprising: forming a patterned
mask layer over the isolation material and the fin structure,
wherein the portion of the fin structure is removed through the
patterned mask layer, and the sidewall structures are covered by
the patterned mask layer.
19. The method of claim 17, wherein forming the top semiconductor
fin in the trench comprises: epitaxially growing the epitaxy
material at least in the trench and over the bottom semiconductor
fin; and removing the epitaxy material above a top surface of the
isolation material to form the top semiconductor fin in the trench
and over the bottom semiconductor fin.
20. The method of claim 19, wherein epitaxially growing the epitaxy
material at least in the trench comprises epitaxially growing the
epitaxy material at least from the sidewall structures.
21. The method of claim 17, wherein forming the top semiconductor
fin is performed such that the top semiconductor fin is in contact
with the isolation material.
Description
BACKGROUND
[0001] As the semiconductor industry has progressed into nanometer
technology process nodes in pursuit of higher device density,
higher performance, and lower costs, challenges from both
fabrication and design issues have resulted in the development of
three-dimensional designs, such as a fin field effect transistor
(Fin FET). Fin FET devices include semiconductor fins with high
aspect ratios and in which channel and source/drain regions of
semiconductor transistor devices are formed. A gate is formed over
and along the sides of the fin structure (e.g., wrapping) utilizing
the increased surface area of the channel and source/drain regions
to produce faster, more reliable and better-controlled
semiconductor transistor devices. In some devices, strained
materials in source/drain (S/D) portions of the FinFET utilizing,
for example, silicon germanium (SiGe), silicon phosphide (SiP) or
silicon carbide (SiC), may be used to enhance carrier mobility.
Further, channel on oxide structures have been proposed to improve
carrier mobility and to maintain a straight fin profile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Aspects of the present disclosure are best understood from
the following detailed description when read with the accompanying
figures. It is noted that, in accordance with the standard practice
in the industry, various features are not drawn to scale. In fact,
the dimensions of the various features may be arbitrarily increased
or reduced for clarity of discussion.
[0003] FIGS. 1A-8A are top views of a local semiconductor device at
various stages of fabrication in accordance with some embodiments
of the present disclosure;
[0004] FIGS. 1B-8B are cross-sectional views along sections A-A in
FIGS. 1A-8A respectively; and
[0005] FIGS. 9-19 are cross-sectional views of a local
semiconductor device at various stages of fabrication in accordance
with some embodiments of the present disclosure.
DETAILED DESCRIPTION
[0006] The following disclosure provides many different
embodiments, or examples, for implementing different features of
the provided subject matter. Specific examples of components and
arrangements are described below to simplify the present
disclosure. These are, of course, merely examples and are not
intended to be limiting. For example, the formation of a first
feature over or on a second feature in the description that follows
may include embodiments in which the first and second features are
formed in direct contact, and may also include embodiments in which
additional features may be formed between the first and second
features, such that the first and second features may not be in
direct contact. In addition, the present disclosure may repeat
reference numerals and/or letters in the various examples. This
repetition is for the purpose of simplicity and clarity and does
not in itself dictate a relationship between the various
embodiments and/or configurations discussed.
[0007] Further, spatially relative terms, such as "beneath,"
"below," "lower," "above," "upper" and the like, may be used herein
for ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as illustrated in
the figures. The spatially relative terms are intended to encompass
different orientations of the device in use or operation in
addition to the orientation depicted in the figures. The apparatus
may be otherwise oriented (rotated 90 degrees or at other
orientations) and the spatially relative descriptors used herein
may likewise be interpreted accordingly.
[0008] The fins may be patterned by any suitable method. For
example, the fins may be patterned using one or more
photolithography processes, including double-patterning or
multi-patterning processes. Generally, double-patterning or
multi-patterning processes combine photolithography and
self-aligned processes, allowing patterns to be created that have,
for example, pitches smaller than what is otherwise obtainable
using a single, direct photolithography process. For example, in
some embodiments, a sacrificial layer is formed over a substrate
and patterned using a photolithography process. Spacers are formed
alongside the patterned sacrificial layer using a self-aligned
process. The sacrificial layer is then removed, and the remaining
spacers may then be used to pattern the fins.
[0009] Illustrative embodiments for forming a semiconductor device
will be described below with reference to FIGS. 1A-19. The
structures illustrate operations which may be used in the process
of forming a semiconductor device. FIGS. 1A-8A are top views of a
local semiconductor device 10 at various stages of fabrication in
accordance with some embodiments of the present disclosure. FIGS.
1B-8B are cross-sectional views along sections A-A in FIGS. 1A-8A
respectively. FIGS. 9-19 are cross-sectional views of a local
semiconductor device 10 at various stages of fabrication in
accordance with some embodiments of the present disclosure.
[0010] Reference is made to FIGS. 1A and 1B. FIG. 1A is a top view
of a local semiconductor device 10. FIG. 1B is cross-sectional
views along sections A-A in FIG. 1A. A substrate 100 is provided.
The substrate 100 has a top surface 102. A patterned mask layer 200
(may be a hard mask layer) is disposed on the top surface 102 of
the substrate 100. In some embodiments, the substrate 100 may
include silicon (Si). Alternatively, the substrate 100 may include
germanium (Ge), silicon germanium, gallium arsenide (GaAs) or other
appropriate semiconductor materials. Also alternatively, the
substrate 100 may include an epitaxial layer. For example, the
substrate 100 may have an epitaxial layer overlying a bulk
semiconductor. Further, the substrate 100 may be strained for
performance enhancement. For example, the epitaxial layer may
include a semiconductor material different from those of the bulk
semiconductor such as a layer of silicon germanium overlying a bulk
silicon or a layer of silicon overlying a bulk silicon germanium
formed by a process including selective epitaxial growth (SEG).
Furthermore, the substrate 100 may include a
semiconductor-on-insulator (SOI) structure such as a buried
dielectric layer. Also alternatively, the substrate 100 may include
a buried dielectric layer such as a buried oxide (BOX) layer, such
as that formed by a method referred to as separation by
implantation of oxygen (SIMOX) technology, wafer bonding, SEG, or
other appropriate method. In various embodiments may include any of
a variety of substrate structures and material.
[0011] The mask layer 200 maintains the integrity of the patterns
during etching of a recess 106 (see FIGS. 2A and 2B) formed in the
substrate 100. In some embodiments, the mask layer 200 is used as a
planarization stop layer during the removal of excess flowable
dielectric layer that fills the recess 106 (discussed in the
process of FIGS. 3A and 3B). In some embodiments, the mask layer
200 includes nitride. For example, the mask layer 200 is made of
silicon nitride (SiN). However, other materials, such as SiON,
silicon carbide, or a combination thereof, may also be used. The
mask layer 200 may be formed by a process such as chemical vapor
deposition (CVD), plasma enhanced chemical vapor deposition
(PECVD), or low pressure chemical vapor deposition (LPCVD).
Alternatively, the mask layer 200 may be first made of a silicon
oxide and then converted to SiN by nitridation.
[0012] In some embodiments, a protective layer 210 is formed over
the top surface 102 of the substrate 100 and between the mask layer
200 and the substrate 100. The protective layer 210 protects the
top surface 102 from direct contact with the mask layer 200. For
example, for a portion of the substrate 100 next to the recess 106
(see FIGS. 2A and 2B) which is filled by the isolation material 110
(see FIGS. 3A and 3B), the protective layer 210 can protect active
regions 104 and 105 formed in the portion of the substrate 100. The
active regions 104 and 105 are used for forming devices (such as
transistors, resistors, etc.) after the isolation material 110 are
formed. Depending upon the devices to be formed, the active regions
104 and 105 may include either a p-well or an n-well as determined
by the design conditions. In some embodiments, the protective layer
210 is made of a thermal oxide. Once formed, the mask layer 200 and
the protective layer 210 are patterned through suitable
photolithographic and etching processes to form openings 202 and
212 over the top surface 102 for the recess 106 of FIGS. 2A and
2B.
[0013] Reference is made to FIGS. 2A and 2B. FIG. 2A is a top view
of the local semiconductor device 10. FIG. 2B is cross-sectional
views along sections A-A in FIG. 2A. The substrate 100 of FIGS. 1A
and 1B are patterned to form semiconductor fins 108 and 109. The
semiconductor fins 108 and 109 extend along a direction D1 and
protrude from the substrate 100 along a direction D2. The direction
D1 intersects with the direction D2. In some embodiments, the
direction D1 is orthogonal to the direction D2. The exposed
portions of the substrate 100 through the openings 202 and 212 are
removed by an etching process, such as reactive ion etching (RIE),
in order to form the recess 106 in the substrate 100. The recess
106 faces the top surface 102 of the substrate 100 and separates
the active regions 104 and 105 near the top surface 102 of the
substrate 100. In some embodiments, the semiconductor device can be
a Fin field effect transistor (FinFET), and the recess 106 is
configured to separate adjacent two semiconductor fins 108 and 109
formed in the substrate 100.
[0014] Reference is made to FIGS. 3A and 3B. FIG. 3A is a top view
of the local semiconductor device 10. FIG. 3B is cross-sectional
views along sections A-A in FIG. 3A. After the forming of the
semiconductor fins 108 and 109, a flowable dielectric material is
deposited to form an isolation material 110 at least in the recess
106 around the semiconductor fins 108 and 109. A flowable
dielectric material overfills the recess 106 and the mask layer 210
to form a flowable dielectric layer. The flowable dielectric layer
can be formed by using a spin on dielectric (SOD) formation
process, or by depositing a flowable dielectric by a chemical vapor
deposition (CVD) process, such as radical-component CVD. The
examples of flowable silicon oxide precursors, include a silicate,
a siloxane, a methyl SilsesQuioxane (MSQ), a hydrogen SisesQuioxane
(HSQ), an MSQ/HSQ, a perhydrosilazane (TCPS), a
perhydro-polysilazane (PSZ), a tetraethyl orthosilicate (TEOS), or
a silyl-amine (SA). Then, a planarization process is performed to
remove the flowable dielectric layer outside the recess 106 to form
the isolation material 110. That is, a top surface of the isolation
material 110 and top surfaces of the semiconductor fins 108 and 109
are coplanar. In some embodiments, the planarization process is a
chemical-mechanical polishing (CMP) process. In some embodiments,
the planarization process removes the flowable dielectric layer
outside the recess 106. In some embodiments, the planarization
process also removes the mask layer 210 and the protective layer
210 (see FIGS. 2A and 2B). In some other embodiments, the
planarization process removes the mask layer 210, however, the
protective layer 210 is removed by an etching process.
[0015] Reference is made to FIGS. 4A and 4B. FIG. 4A is a top view
of the local semiconductor device 10. FIG. 4B is cross-sectional
views along sections A-A in FIG. 4A. After the forming of the
isolation material 110, a tri-layer photoresist 120 is formed on
the substrate 100 and the isolation material 110.
[0016] In some embodiments, the tri-layer photoresist 120 may be
used, including a photoresist (PR) layer 121 as the top or
uppermost portion, a middle layer 122, and a bottom layer 124. The
tri-layer photoresist 120 is disposed on the substrate 100 and the
isolation material 110. The middle layer 122 of the tri-layer
photoresist 120 which may include anti-reflective layers or
backside anti-reflective layers to aid in the exposure and focus of
the PR processing, and the bottom layer 124 which may be a hard
mask material; for example, an oxide. To pattern the tri-layer
photoresist 120, the PR layer 121 is patterned using a mask,
exposure to radiation, such as light or an excimer laser, for
example, a bake or cure operation to harden the resist, and use of
a developer to remove either the exposed or unexposed portions of
the resist, depending on whether a positive resist or a negative
resist is used, to form the pattern from the mask in the PR layer
121. The PR layer 121 is patterned to form an opening 128 above the
semiconductor fin 108. Specifically, the vertically projection of
the opening 128 is locates on the semiconductor fin 108 and outside
the semiconductor fin 109. The opening 128 has a width W2 along the
direction D1. The semiconductor fin 108 has a width W1 along the
direction D1, and the width W1 is larger than the width W2. This
patterned PR layer 121 is then used to etch the underlying middle
layer 122 and bottom layer 124 to form an etch mask for the target
layer; here, the semiconductor fin 108 from the opening 128.
[0017] Reference is made to FIGS. 5A and 5B. FIG. 5A is a top view
of the local semiconductor device 10. FIG. 5B is cross-sectional
views along sections A-A in FIG. 5A. After the forming of the
tri-layer photoresist 120, the middle layer 122 of FIGS. 4A and 4B
are patterned to form an opening 228. A trench etching is performed
to form a patterned middle layer 122' having the opening 228
therein. The opening 228 has a width W3 along the direction D1
substantially equal to the width W2 of opening 128 and smaller than
the width W1 of the semiconductor fin 108. In FIGS. 5A and 5B, the
patterned PR layer 121 is used as a mask during the trench etching.
The term "substantially" as used herein may be applied to modify
any quantitative representation which could permissibly vary
without resulting in a change in the basic function to which it is
related. In the trench etching, the middle layer 122 (see FIGS. 4A
and 4B) may be etched by various methods, including a dry etch, a
wet etch, or a combination of dry etch and wet etch. The dry
etching process may implement fluorine-containing gas (e.g.,
CF.sub.4, SF.sub.6, CH.sub.2F.sub.2, CHF.sub.3, and/or
C.sub.2F.sub.6), chlorine-containing gas (e.g., Cl.sub.2,
CHCl.sub.3, CCl.sub.4, and/or BCH), bromine-containing gas (e.g.,
HBr and/or CHBR.sub.3), oxygen-containing gas, iodine-containing
gas, other suitable gases and/or plasmas, or combinations thereof.
The etching process may include a multiple-step etching to gain
etch selectivity, flexibility and desired etch profile.
[0018] Reference is made to FIGS. 6A and 6B. FIG. 6A is a top view
of the local semiconductor device 10. FIG. 6B is cross-sectional
views along sections A-A in FIG. 6A. After the patterned of the
middle layer 122 (see FIG. 5B), the bottom layer 124 of FIG. 5B is
patterned to form an opening 127. After the mask layer 124 is
patterned, the patterned PR layer 121 and the patterned middle
layer 122' are removed, and then the semiconductor fin 108 is
etched to form a trench 129 through the opening 127. That is, using
the patterned bottom layer 124' as a mask, the semiconductor fin
108 is etched to form an etched semiconductor fin 108' having the
trench 129 therein.
[0019] In other words, the etched semiconductor fin 108' is formed
by removing the portion thereof, thereby forming a bottom
semiconductor fin 1080, and forming a first sidewall structure
1082a and a second sidewall structure 1082b disposed over the
bottom semiconductor fin 1080. Specifically, the bottom
semiconductor fin 1080 is disposed on the substrate 100, and
extends along the direction D1 as the semiconductor fin 108. The
first sidewall structure 1082a and the second sidewall structure
1082b protrude from the bottom semiconductor fin 1080 facing away
the substrate 100, and define the trench 129 with the bottom
semiconductor fin 1080 therebetween. That is, the trench 129 is
formed by inner surfaces of the first sidewall structure 1082a and
the second sidewall structure 1082b and a top surface the bottom
semiconductor fin 1080. In addition, the first sidewall structure
1082a and a second sidewall structure 1082b are covered by the
patterned bottom layer 124'. The opening 127 of the patterned
bottom layer 124' and the trench 129 of the semiconductor fin 108
have a width W4 and a width W5 along the direction D1 respectively.
The width W4 and the width W5 is substantially the same and both
smaller than the width W1 of the semiconductor fin 108.
[0020] In some embodiments, the trench 129 is formed by various
methods, including a dry etch, a wet etch, or a combination of dry
etch and wet etch. The dry etching process may implement
fluorine-containing gas (e.g., CF.sub.4, SF.sub.6, CH.sub.2F.sub.2,
CHF.sub.3, and/or C.sub.2F.sub.6), chlorine-containing gas (e.g.,
Cl.sub.2, CHCl.sub.3, CCl.sub.4, and/or BCl.sub.3),
bromine-containing gas (e.g., HBr and/or CHBr.sub.3),
oxygen-containing gas, iodine-containing gas, other suitable gases
and/or plasmas, or combinations thereof. The etching process may
include a multiple-step etching to gain etch selectivity,
flexibility and desired etch profile.
[0021] Reference is made to FIGS. 7A and 7B. FIG. 7A is a top view
of the local semiconductor device 10. FIG. 7B is cross-sectional
views along sections A-A in FIG. 7A. After the etched of the
semiconductor fin 108 to form the trench 129, a top semiconductor
fin 130 as the active region 104 (see FIGS. 1B and 2B) is formed in
the trench 129. An epitaxial growth process is performed on exposed
parts of the first sidewall structure 1082a and the second sidewall
structure 1082b, and performed on exposed parts of the bottom
semiconductor fin 1080 from the opening 127. Then, an epitaxy
material is formed in the trench 129.
[0022] Specifically, the epitaxy material epitaxial grows at least
from the first sidewall structure 1082a, the second sidewall
structure 1082b, and the bottom semiconductor fin 1080. Then, a
portion of the epitaxy material above a top surface of the
isolation material 110 is removed to form the top semiconductor fin
130 in the trench 129 and over the bottom semiconductor fin 1080.
Therefore, the top semiconductor fin 130 is formed between the
first sidewall structure 1082a and the second sidewall structure
1082b and on the bottom semiconductor fin 1080. As such, opposite
sidewalls of the top semiconductor fin 130 are in contact with the
first sidewall structure 1082a and the second sidewall structure
1082b, and a bottom portion of the top semiconductor fin 130 is in
contact with the bottom semiconductor fin 1080. On the other hand,
the first sidewall structure 1082a and the second sidewall
structure 1082b are located on two opposite ends of the top
semiconductor fin 130, respectively disposed between and extends
pass the top semiconductor fin 130 and the isolation material 110,
and arranged in the direction D1.
[0023] In some embodiments, at least one of the first sidewall
structure 1082a and the second sidewall structure 1082b is made of
a material that is the same as the bottom semiconductor fin 1080,
and the top semiconductor fin 130 is made of a material that is
different from that of the bottom semiconductor fin 1080. In some
embodiments, the top semiconductor fin 130 is made of the material
whose lattice constant is greater than that of the at least one the
first sidewall structure 1082a, the second sidewall structure
1082b, and the bottom semiconductor fin 1080. In some embodiments,
the bottom semiconductor fin 1080, the first sidewall structure
1082a, and the second sidewall structure 1082b may include a
material such as Si, and the top semiconductor fin 130 may include
a material such as SiGe.
[0024] With such configuration, the first sidewall structure 1082a,
the second sidewall structure 1082b, and the bottom semiconductor
fin 1080 are positioned such that subsequent epitaxial growth
processes that forming the top semiconductor fin 130 during device
fabrication do not in contact with the isolation material 110 on
ends of the bottom semiconductor fin 1080. Here, if the top
semiconductor fin 130 is not formed on the first sidewall structure
1082a and the second sidewall structure 1082b, defects such as
voids or dislocations may be formed at an interface of the
isolation material 110 and the top semiconductor fin 130, because
the isolation material 110 is less easily grown on the oxide
surface. In contrast, since the top semiconductor fin 130 is in
contact with the first sidewall structure 1082a and the second
sidewall structure 1082b, the epitaxial growth of the top
semiconductor fin 130 is enhanced.
[0025] Reference is made to FIGS. 8A and 8B. FIG. 8A is a top view
of the local semiconductor device 10. FIG. 8B is cross-sectional
views along sections A-A in FIG. 8A. After the forming of the top
semiconductor fin 130, the patterned bottom layer 124' is removed
and the isolation material 110 is recessed to form an isolation
structure 110'. An anisotropic etch is used to recess the isolation
material 110 into the substrate 100 to form the isolation structure
110'. The isolation structure 110' surrounds the etched
semiconductor fin 108' and the semiconductor fin 109. The etched
semiconductor fin 108' and the semiconductor fin 109 are exposed
above the isolation structure 110'. That is, a top portion of the
etched semiconductor fin 108' and the semiconductor fin 109 are not
covered by the isolation structure 110', and a bottom surface of
the top semiconductor fin 130 is higher than a top surface 11 of
the isolation structure 110'.
[0026] Specifically, as shown in FIGS. 8A and 8B, the isolation
structure 110' is disposed on the substrate 100, and from the top
surface of the isolation structure 110', a total of the first
sidewall structure 1082a, the second sidewall structure 1082b, and
the top semiconductor fin 130 are exposed. The first sidewall
structure 1082a and the second sidewall structure 1082b cap the top
semiconductor fin 130. The first sidewall structure 1082a and the
second sidewall structure 1082b are respectively located between
the isolation structure 110' and the top semiconductor fin 130.
Furthermore, a bottom portion of at least one of the first sidewall
structure 1082a, the second sidewall structure 1082b, and the top
semiconductor fin 130 is higher than a top surface 11 of the
isolation structure 110'.
[0027] Reference is made to FIG. 9. FIG. 9 is a cross-sectional
view of the local semiconductor device 10. After the removing the
patterned bottom layer 124' and the recessed of the isolation
structure 110, an interlayer dielectric 140 and a dummy layer 150
are disposed on the isolation structure 110', the etched
semiconductor fin 108', and the semiconductor fin 109.
[0028] The interlayer dielectric 140 is formed to cover the
isolation structure 110', the etched semiconductor fin 108', and
the semiconductor fin 109. The interlayer dielectric 140 may be
formed by thermal oxidation, chemical vapor deposition, sputtering,
or other methods known and used in the art for forming a gate
dielectric. The interlayer dielectric 140 may include, for example,
a high-k dielectric material such as metal oxides, metal nitrides,
metal silicates, transition metal-oxides, transition
metal-nitrides, transition metal-silicates, oxynitrides of metals,
metal aluminates, zirconium silicate, zirconium aluminate, or
combinations thereof. Some embodiments may include hafnium oxide
(HfO.sub.2), hafnium silicon oxide (HfSiO), hafnium silicon
oxynitride (HfSiON), hafnium tantalum oxide (HfTaO), hafnium
titanium oxide (HMO), hafnium zirconium oxide (HfZrO), lanthanum
oxide (LaO), zirconium oxide (ZrO), titanium oxide (TiO), tantalum
oxide (Ta.sub.2O.sub.5), yttrium oxide (Y.sub.2O.sub.3), strontium
titanium oxide (SrTiO.sub.3, STO), barium titanium oxide
(BaTiO.sub.3, BTO), barium zirconium oxide (BaZrO), hafnium
lanthanum oxide (HfLaO), lanthanum silicon oxide (LaSiO), aluminum
silicon oxide (AlSiO), aluminum oxide (Al.sub.2O.sub.3), silicon
nitride (Si.sub.3N.sub.4), oxynitrides (SiON), and combinations
thereof. The interlayer dielectric 140 may have a multilayer
structure such as one layer of silicon oxide (e.g., interfacial
layer) and another layer of high-k material. The interlayer
dielectric 140 may be formed using chemical vapor deposition (CVD),
physical vapor deposition (PVD), atomic layer deposition (ALD),
thermal oxide, ozone oxidation, other suitable processes, or
combinations thereof.
[0029] The dummy layer 150 is formed on the interlayer dielectric
140. The dummy layer 150 may be deposited by chemical vapor
deposition (CVD), by sputter deposition, or by other techniques
known and used in the art for depositing conductive materials. The
dummy layer 150 may include polycrystalline-silicon (poly-Si) or
poly-crystalline silicon-germanium (poly-SiGe). Further, the dummy
layer 150 may be doped poly-silicon with uniform or non-uniform
doping.
[0030] Reference is made to FIG. 10. FIG. 10 is a cross-sectional
view of the local semiconductor device 10. After the forming the
interlayer dielectric 140 and the dummy layer 150, a patterned mask
layer is formed on the dummy layer 150. The patterned mask layer
includes masks 214 and 215. The mask 214 defines a profile of a
gate electrode disposed on the top semiconductor fin 130, and the
mask 215 covers the dummy layer 150 disposed on the semiconductor
fin 109.
[0031] Reference is made to FIG. 11. FIG. 11 is a cross-sectional
view of the local semiconductor device 10. After the forming of the
masks 214 and 215, the dummy layer 150 of FIG. 10 disposed on the
top semiconductor fin 130 is then patterned to form a dummy gate
electrode 152 by using the mask 214 (see FIG. 10). The dummy gate
electrode 152 is disposed between the first sidewall structure
1082a and the second sidewall structure 1082b, is disposed on and
straddles across the top semiconductor fin 130. The dummy layer 150
may be patterned by an etching process, such as a dry plasma
etching process or a wet etching process. At least one parameter,
such as etchant, etching temperature, etching solution
concentration, etching pressure, source power, radio frequency (RF)
bias voltage, etchant flow rate, of the patterning (or etching)
recipe can be tuned.
[0032] After the patterning process, the masks 214 and 215 of FIG.
10 may then be removed. The portion of the interlayer dielectric
140 disposed on the top semiconductor fin 130 and not covered by
the dummy gate electrode 152 may or may not be removed during the
etching process. In the case where some interlayer dielectric 140
remains on the top semiconductor fin 130 not covered by the dummy
gate electrode 152, the interlayer dielectric 140 may be
subsequently removed by dry or wet etching to form a gate
dielectric 142. The gate dielectric 142 and the dummy gate
electrode 152 can refer to as a gate structure 302. Thus, the gate
structure 302 is disposed between the first sidewall structure
1082a and the second sidewall structure 1082b, and is disposed on
and straddles across the top semiconductor fin 130.
[0033] Reference is made to FIG. 12. FIG. 12 is a cross-sectional
view of the local semiconductor device 10. After the forming the
dummy gate electrode 152 and the gate dielectric 142, another
patterned mask layer is formed on the remaining dummy layer 150 and
the dummy gate electrode 152. The patterned mask layer includes
masks 216 and 217. The mask 217 defines a profile of a dummy gate
electrode 154 (see FIG. 13) disposed on the semiconductor fin 109,
and the mask 216 covers the dummy gate electrode 152, the top
semiconductor fin 130, the etched semiconductor fin 108', and the
isolation structure 110'.
[0034] Reference is made to FIG. 13. FIG. 13 is a cross-sectional
view of the local semiconductor device 10. After the forming the
other patterned mask layer, the remaining dummy layer 150 of FIG.
12 disposed on the semiconductor fin 109 is then patterned to form
a dummy gate electrode 154 by using the mask 217 (see FIG. 12). The
remaining dummy layer 150 may be patterned by an etching process,
such as a dry plasma etching process or a wet etching process. At
least one parameter, such as etchant, etching temperature, etching
solution concentration, etching pressure, source power, radio
frequency (RF) bias voltage, etchant flow rate, of the patterning
(or etching) recipe can be tuned.
[0035] After the patterning process, the masks 216 and 217 of FIG.
12 may then be removed. The portion of the interlayer dielectric
140 not covered by the dummy gate electrode 154 may or may not be
removed during the etching process. In the case where some
interlayer dielectric 140 remains on the semiconductor fin 109 not
covered by the dummy gate electrode 154, the interlayer dielectric
140 may be subsequently removed by dry or wet etching to form a
gate dielectric 144. The gate dielectric 144 and the dummy gate
electrode 154 can refer to as a gate structure 304.
[0036] It is noted that although in FIGS. 10 to 13, the gate
structures 302 and 304 are formed in separated processes, the gate
structures 302 and 304 can be formed in the same process in some
other embodiments. For example, in FIG. 10, two patterned mask
layers can be formed over the dummy layer 150 and respectively over
the top semiconductor fin 130 and the semiconductor fin 109. The
dummy layer 150 is then patterned using the patterned mask layers
as masks and form the gate structures 302 and 304 respectively over
and straddle across the top semiconductor fin 130 and the
semiconductor fin 109.
[0037] Reference is made to FIG. 14. FIG. 14 is a cross-sectional
view of the local semiconductor device 10. After the forming of the
gate structures 302 and 304, a pair of gate spacers 162 is formed
on the top semiconductor fin 130 and along the dummy gate electrode
152, and a pair of gate spacers 164 is formed on the semiconductor
fin 109 and along the dummy gate electrode 164. In some
embodiments, the gate spacers 162 and 164 may include silicon
oxide, silicon nitride, silicon oxy-nitride, or other suitable
material. The gate spacers 162 and 164 may include a single layer
or multilayer structure. To form the gate spacers 162 and 164, a
blanket layer may be formed on the top semiconductor fin 130 and
the semiconductor fin 109 by CVD, PVD, ALD, or other suitable
technique. Then, an anisotropic etching is performed on the blanket
layer to form the gate spacers 162 and 164 respectively on two
sides of the dummy gate electrodes 152 and 154.
[0038] Furthermore, the top semiconductor fin 130 includes a
channel portion (may also refer to as a channel region) 132 and
source/drain portions (may also refer to as source/drain regions)
134 and 136 disposed therein. The channel portion 132 is disposed
in the top semiconductor fin 130, below the gate structure 302 and
the pair of gate spacers 162, and between the first sidewall
structure 1082a and the second sidewall structure 1082b. On the
other hand, the gate structure 302 covers the channel portion 132
of the top semiconductor fin. In addition, the source/drain
portions 134 and 136 are disposed on opposite sides of the dummy
gate electrode 152 and uncovered by the gate structure 302. The
source/drain portions 134 is disposed between the channel portion
132 and the first sidewall structure 1082a, and the source/drain
portions 136 is disposed between the channel portion 132 and the
second sidewall structure 1082b.
[0039] With such configuration, the top semiconductor fin 130 is in
contact with the first sidewall structure 1082a, the second
sidewall structure 1082b, and the bottom semiconductor fin 1080,
whereby enabling the channel portion 132 of the top semiconductor
fin 130 to improve fully strain channel (FSC) due to the two
opposite ends of the top semiconductor fin 130 strain with the
first sidewall structure 1082a and the second sidewall structure
1082b of the etched semiconductor fin 108' respectively, thus to
improve performance of said two opposite ends. As such, a stress
relaxation occurring at the two opposite ends of the top
semiconductor fin 130 reduces epitaxial defects, such as, voids or
dislocations, at an interface of the sidewall structure 1082a
(1082b) and the top semiconductor fin 130. Further, the epitaxial
defects of the two opposite ends of the top semiconductor fin 130
will be reduced. Hence, the epitaxial quality of the channel
portion 132 of top semiconductor fin 130 will also be enhanced,
such that the performance of the channel portion 132 will be
improved.
[0040] Reference is made to FIG. 15. FIG. 15 is a cross-sectional
view of the local semiconductor device 10. After the forming the
pairs of the gate spacers 162 and 164, portions of the top
semiconductor fin 130 and the semiconductor fin 109 exposed both by
the dummy gate electrodes 152 and 154 and the gate spacers 162 and
164 are removed (or recessed) to form recesses 232 and 234 therein.
Any suitable amount of material may be removed. Furthermore, after
the removing of portions of the top semiconductor fin 130, the top
semiconductor fin 130 forms protruding portions 130a and 130b
located on two opposite ends thereof, respectively adjacent to and
in contact with the first sidewall structure 1082a and the second
sidewall structure 1082b, and arranged in the direction D1.
[0041] Removing portions of the top semiconductor fin 130 and the
semiconductor fin 109 may include forming a photoresist layer or a
capping layer (such as an oxide capping layer) over the structure
of FIG. 14, patterning the photoresist or capping layer to have
openings that expose a portion of the top semiconductor fin 130 and
the semiconductor fin 109, and etching back material from the top
semiconductor fin 130 and the semiconductor fin 109. In some
embodiments, the top semiconductor fin 130 and the semiconductor
fin 109 can be etched using a dry etching process. Alternatively,
the etching process is a wet etching process, or combination dry
and wet etching process. Removal may include a lithography process
to facilitate the etching process. The lithography process may
include photoresist coating (e.g., spin-on coating), soft baking,
mask aligning, exposure, post-exposure baking, developing the
photoresist, rinsing, drying (e.g., hard baking), other suitable
processes, or combinations thereof. Alternatively, the lithography
process is implemented or replaced by other methods, such as
maskless photolithography, electron-beam writing, and ion-beam
writing. In yet some other embodiments, the lithography process
could implement nanoimprint technology. In some embodiments, a
pre-cleaning process may be performed to clean the recesses 232 and
234 with HF or other suitable solution.
[0042] Reference is made to FIG. 16. FIG. 16 is a cross-sectional
view of the local semiconductor device 10. After the forming the
recesses 232 and 234, a plurality of epitaxy structures 172 and 174
are respectively formed in the recesses 232 and 234 of the top
semiconductor fin 130 and the semiconductor fin 109. The epitaxy
structures 172 are at least partially embedded in the source/drain
portions 134 and 136 of the top semiconductor fin 130, and disposed
between the first sidewall structure 1082a and the gate structure
302 and between the second sidewall structure 1082b and the gate
structure 302 respectively.
[0043] On the other hand, the first sidewall structure 1082a and
the second sidewall structure 1082b are separated from the epitaxy
structures 172. In other words, protruding portion 130a of the top
semiconductor fin 130 is disposed between and in contact with the
first sidewall structure 1082a and the epitaxy structures 172, and
protruding portion 130b is disposed between and in contact with the
second sidewall structure 1082b and the epitaxy structures 172. In
some embodiments, a bottom portion of the first sidewall structure
1082a and the second sidewall structure 1082b is lower than a
bottom surface of the epitaxy structures 172. In some other
embodiments, however, a bottom surface of the epitaxy structures
172 and a bottom surface of the top semiconductor fin 130 are
coplanar.
[0044] The epitaxy structures 172 and 174 may be formed using one
or more epitaxy or epitaxial (epi) processes, such that Si
features, SiGe features, and/or other suitable features can be
formed in a crystalline state on the recesses 232 and 234 of the
top semiconductor fin 130 and the semiconductor fin 109. In some
embodiments, the lattice constant of the epitaxy structures 172 and
174 are different from the lattice constant of the top
semiconductor fin 130 and the semiconductor fin 109, and the
epitaxy structures 172 and 174 are strained or stressed to enable
carrier mobility of the semiconductor device and enhance the device
performance. The epitaxy processes include CVD deposition
techniques (e.g., vapor-phase epitaxy (VPE) and/or ultra-high
vacuum CVD (UHV-CVD)), molecular beam epitaxy, and/or other
suitable processes. The epitaxy process may use gaseous and/or
liquid precursors, which interact with the composition of the
recesses 232 and 234 of the top semiconductor fin 130 and the
semiconductor fin 109 (e.g., silicon). Thus, a strained channel can
be achieved to increase carrier mobility and enhance device
performance. The epitaxy structures 172 and 174 may be in-situ
doped. The doping species include p-type dopants, such as boron or
BF.sub.2; n-type dopants, such as phosphorus or arsenic; and/or
other suitable dopants including combinations thereof. If the
epitaxy structures 172 and 174 are not in-situ doped, a second
implantation process (i.e., a junction implant process) is
performed to dope the epitaxy structures 172 and 174. One or more
annealing processes may be performed to activate the epitaxy
structures 172 and 174. The annealing processes include rapid
thermal annealing (RTA) and/or laser annealing processes.
[0045] Then, an interlayer dielectric (ILD) 170 is formed at outer
sides of the gate spacers 162 and 164 and on the top semiconductor
fin 130 and the semiconductor fin 109. The ILD 170 includes silicon
oxide, oxynitride or other suitable materials. The ILD 170 includes
a single layer or multiple layers. The ILD 170 is formed by a
suitable technique, such as CVD or ALD. A chemical mechanical
planarization (CMP) process may be applied to remove excessive ILD
170 and expose the top surface of the dummy gate electrodes 152 and
154 to a subsequent dummy gate removing process.
[0046] Reference is made to FIG. 17. FIG. 17 is a cross-sectional
view of the local semiconductor device 10. After the forming the
epitaxy structures 172 and 174 and the ILD 170, the dummy gate
electrodes 152 and 154 (see FIG. 16) are removed to form an opening
156 with the gate spacers 162 as its sidewall and an opening 158
with the gate spacers 164 as its sidewall. In some other
embodiments, the gate dielectrics 142 and 144 are removed as well.
Alternatively, in some embodiments, the dummy gate electrodes 152
and 154 are removed while the gate dielectrics 142 and 144 retains.
The dummy gate electrodes 152 and 154 (and the gate dielectrics 142
and 144) may be removed by dry etch, wet etch, or a combination of
dry and wet etch. For example, a wet etch process may include
exposure to a hydroxide containing solution (e.g., ammonium
hydroxide), deionized water, and/or other suitable etchant
solutions.
[0047] Reference is made to FIG. 18. FIG. 18 is a cross-sectional
view of the local semiconductor device 10. After the removing of
the dummy gate electrodes 152 and 154, metal gate electrodes 182
and 184 are respectively formed in the openings 156 and 158 (see
FIG. 17). The gate electrodes 182 and 184 are formed by the
deposition of aluminum or other conductive metal such as copper,
tungsten, or titanium. In some embodiments, depositing one of the
openings 162 and 164 includes depositing a work function layer
prior to depositing a metal fill layer. The gate dielectric 142 and
the gate electrode 182 can refer to as a gate structure 402, and
the gate dielectric 144 and the gate electrode 184 can refer to as
a gate structure 404.
[0048] As shown in FIG. 18, a first device 12 and a second device
14 are formed. The first device 12 includes the top semiconductor
fin 130, the first sidewall structure 1082a and the second sidewall
structure 1082b, the epitaxy structures 172, the gate structure 402
(or the gate structure 302 of FIG. 16), and the gate spacers 162.
The second device 14 includes the semiconductor fin 109, the
epitaxy structures 174, the gate structure 404 (or the gate
structure 304 of FIG. 16), and the gate spacers 164. In the
embodiments where the first device 12 is p-channel
metal-oxide-semiconductor field-effect transistors (p-channel
MOSFETs), and the second device 14 is n-channel MOSFETs.
[0049] Reference is made to FIG. 19. FIG. 19 is a cross-sectional
view of the local semiconductor device 10. After the forming of the
metal gate electrodes 182 and 184, trenches 186 and 188 are formed
in the ILD 170. The trenches 186 expose the epitaxy structures 172,
and the trenches 188 expose the epitaxy structures 174. Metal such
as tungsten is then deposited into the trenches 186 and 188 down to
the epitaxy structures 172 and 174 to form source and drain
contacts 192 and 194. When formed, the source and drain contacts
192 and 194 are conductively coupled to the epitaxy structures 172
and 174.
[0050] According to some embodiments, the top semiconductor fin is
in contact with the first sidewall structure, the second sidewall
structure, and the bottom semiconductor fin, whereby enabling the
channel portion of the top semiconductor fin to improve fully
strain channel (FSC) due to the two opposite ends of the top
semiconductor fin strain with the first sidewall structure and the
second sidewall structure of the etched semiconductor fin
respectively, thus to improve performance of said two opposite
ends. As such, a stress relaxation occurring at the two opposite
ends of the top semiconductor fin reduces epitaxial defects, such
as, voids or dislocations, at an interface of the sidewall
structure and the top semiconductor fin. Further, the epitaxial
defects of the two opposite ends of the top semiconductor fin will
be reduced. Hence, the epitaxial quality of the channel portion of
top semiconductor fin will also be enhanced, such that the
performance of the channel portion will be improved.
[0051] According to some embodiments, a semiconductor device
includes a substrate, a bottom semiconductor fin, at least one
sidewall structure, a top semiconductor fin, and a gate structure.
The bottom semiconductor fin is disposed on the substrate. The
sidewall structure protrudes from the semiconductor fin. The top
semiconductor fin is disposed on the bottom semiconductor fin. The
top semiconductor fin includes a channel portion and at least one
source/drain portion. The source/drain portion is disposed between
the channel portion and the sidewall structure. The gate structure
covers the channel portion of the top semiconductor fin.
[0052] According to some embodiments, a semiconductor device
includes a substrate, a bottom semiconductor fin, atop
semiconductor fin, a first sidewall structure and a second sidewall
structure, and a gate structure. The bottom semiconductor fin is
disposed on the substrate and extending along a direction. The top
semiconductor fin is disposed on the bottom semiconductor fin. The
first sidewall structure and a second sidewall structure are
disposed on two opposite ends of the top semiconductor fin and
arranged in the direction, in which the top semiconductor fin is
made of a material that is different from that of the first
sidewall structure and the second sidewall structure. The gate
structure is disposed between the first sidewall structure and the
second sidewall structure and straddles across the top
semiconductor fin.
[0053] According to some embodiments, a method for manufacturing a
semiconductor device includes forming fin structure on a substrate;
forming an isolation material surrounding the fin structure;
removing a portion of the fin structure to form a bottom
semiconductor fin and sidewall structures over the bottom
semiconductor fin, in which the sidewall structures are in contact
with the isolation material, and the bottom semiconductor fin and
the sidewall structures define a trench therebetween; forming a top
semiconductor fin in the trench, between the sidewall structures,
and over the semiconductor fin; and forming a gate structure on the
top semiconductor fin.
[0054] The foregoing outlines features of several embodiments so
that those skilled in the art may better understand the aspects of
the present disclosure. Those skilled in the art should appreciate
that they may readily use the present disclosure as a basis for
designing or modifying other processes and structures for carrying
out the same purposes and/or achieving the same advantages of the
embodiments introduced herein. Those skilled in the art should also
realize that such equivalent constructions do not depart from the
spirit and scope of the present disclosure, and that they may make
various changes, substitutions, and alterations herein without
departing from the spirit and scope of the present disclosure.
* * * * *