1. Field of the Invention
The invention relates generally to bipolar transistors. More particularly, the invention relates to bipolar transistors with enhanced performance.
2. Description of the Related Art
In addition to field effect transistors, resistors, diodes and capacitors, semiconductor circuits also often include bipolar transistors. Bipolar transistors are desirable within semiconductor circuits insofar as bipolar transistors may often be fabricated to provide semiconductor circuits with enhanced speed.
Although bipolar transistors provide performance advantages within semiconductor circuits, they are not entirely without problems. Bipolar transistors are generally more difficult to fabricate, thus bipolar transistors typically require a more complex manufacturing process in comparison with field effect transistors. Given the complexity of such a manufacturing process, bipolar transistors often require an enhanced thermal budget in comparison with field effect transistor manufacturing processes. An enhanced thermal budget, in turn, often leads to an enhanced probability for detrimental effects, such as, for example, undesirable dopant diffusion effects.
Of the possible methods for fabricating bipolar transistors, self-aligned methods are generally desirable. Self-aligned methods for fabricating bipolar transistors are generally characterized by alignment of an emitter region to a base region absent the use of a photolithographic process that provides a photolithographic offset. Self-aligned bipolar transistors enjoy performance advantages in comparison with bipolar transistors that are fabricated using non-self-aligned methods. In particular, self-aligned bipolar transistors typically have higher oscillation frequencies, reduced parasitic base resistance and reduced noise in comparison with bipolar transistors that are fabricated using non-self-aligned methods.
Self-aligned bipolar transistor structures and methods for fabrication thereof are known in the semiconductor fabrication art.
For example, Okita, in U.S. Pat. No. 5,234,844, teaches a self-aligned bipolar transistor structure and method for fabrication thereof for use in an ultrahigh speed integrated circuit. Within this prior art reference, the self-aligned bipolar transistor structure has a substantially coaxial symmetric structure.
In addition, Inoue et al., in “Self-Aligned Complementary Bipolar Transistors Fabricated with a Selective-Oxidation Mask,” IEEE Trans. on Electron Devices, Vol. 34(10), 1987, pp. 2146-52 teaches a self-aligned bipolar transistor that uses a 2-μm epitaxial layer and a non-LOCOS trench isolation. Within this prior art reference, active base and emitter regions are formed by ion implantation through a silicon nitride layer.
Desirable are additional self-aligned bipolar transistor structures and methods for fabrication thereof that provide self-aligned bipolar transistors with enhanced performance and ease of manufacturing.
The invention provides a semiconductor structure comprising a self-aligned bipolar transistor, and methods for fabricating the semiconductor structure.
A semiconductor structure in accordance with the invention includes a semiconductor substrate that includes a collector region and an intrinsic base surface region located above and contacting the collector region. The semiconductor structure also includes a vertical spacer layer located above the semiconductor substrate. The vertical spacer layer has an aperture therein aligned above the intrinsic base surface region. The aperture has a horizontal spacer layer located embedded within and aligned within a sidewall of the aperture. The semiconductor structure also includes an emitter layer located within the aperture and contacting the intrinsic base surface region.
A method for fabricating a semiconductor structure in accordance with the invention includes implanting an extrinsic base region located laterally connected to an intrinsic base surface region within a semiconductor substrate. The implantation is performed with an ion implantation mask layer disposed on a screen dielectric layer disposed on the semiconductor substrate. The semiconductor substrate includes the intrinsic base surface region located beneath the ion implantation mask layer and a collector region located beneath the intrinsic base surface region. This method also includes selectively depositing a vertical spacer layer upon the screen dielectric layer adjoining the ion implantation mask layer after implanting the extrinsic base region. This method also includes stripping the ion implantation mask layer from the screen dielectric layer to yield an aperture within the vertical spacer layer. The screen dielectric layer is exposed at the base of the aperture. This method also includes removing the screen dielectric layer at the base of the aperture. Finally, this method includes forming an emitter layer into the aperture and contacting the intrinsic base surface region.
Another method for fabricating a semiconductor structure includes implanting, while using an ion implantation mask layer disposed upon a screen dielectric layer which is located upon a semiconductor substrate having an intrinsic base surface region located beneath the ion implantation mask layer and a collector region disposed beneath the intrinsic base surface region, an extrinsic base region located laterally connected to the intrinsic base region. This other method also includes selectively growing a vertical spacer layer upon the screen dielectric layer and encroaching upon the top surface of the adjoining ion implantation mask layer after implanting the extrinsic base region. This other method also includes etching the ion implantation mask layer from the screen dielectric layer to yield an aperture within the vertical spacer layer. The screen dielectric layer is exposed at the base of the aperture, and a horizontal spacer layer is located embedded within and aligned with a sidewall of the aperture. This other method also includes removing the screen dielectric layer at the base of the aperture. This other method also includes forming an emitter layer into the aperture and contacting the intrinsic base surface region.
The objects, features and advantages of the invention are understood within the context of the Description of the Preferred Embodiments, as set forth below. The Description of the Preferred Embodiments is understood within the context of the accompanying drawings, that form a material part of this disclosure, wherein:
The invention, which comprises a semiconductor structure comprising a bipolar transistor structure and methods for fabrication thereof, is described in further detail below within the context of the drawings described above. The drawings are intended for illustrative purposes only, and as such are not necessarily drawn to scale.
Each of the foregoing semiconductor substrate 10 and layers 12/14/16 located thereupon or thereover may comprise materials and have dimensions that are conventional in the semiconductor fabrication art. Each of the foregoing semiconductor substrate 10 and layers 12/14/16 located thereupon or thereover may be formed using methods that are conventional in the semiconductor fabrication art.
The semiconductor substrate 10 comprises a semiconductor material. Non-limiting examples of semiconductor materials include silicon, germanium, silicon-germanium alloy, silicon carbide, silicon-germanium carbide alloy and compound semiconductor materials. Non-limiting examples of compound semiconductor materials include gallium arsenide, indium arsenide and indium phosphide semiconductor materials. Typically, the semiconductor substrate 10 comprises a silicon semiconductor material. Typically, the silicon semiconductor material has a thickness from about 1 to about 3 mils.
The semiconductor substrate 10 may comprise a bulk semiconductor material. In the alternative, the semiconductor substrate 10 may comprise a semiconductor-on-insulator substrate or a hybrid orientation substrate. A semiconductor-on-insulator substrate comprises a base semiconductor substrate, a buried dielectric layer located thereupon and a surface semiconductor layer located further thereupon. A hybrid orientation substrate comprises multiple regions of different crystallographic orientations. Semiconductor-on-insulator substrates and hybrid orientation substrates may be formed using any of several methods. Non-limiting examples include laminating methods, layer transfer methods and separation by implantation of oxygen methods.
The semiconductor substrate 10 comprises in part a collector region within a bipolar transistor desired to be fabricated using the semiconductor structure whose schematic cross-sectional diagram is illustrated in
The intrinsic base region 12 has an epitaxial thickness of about 50 to about 3000 angstroms upon the semiconductor substrate 10. The intrinsic base region 12 also has a different or an opposite dopant polarity as compared to that of the semiconductor substrate 10 that serves as a collector region. An epitaxial chemical vapor deposition method is used for forming the intrinsic base region 12. The intrinsic base region 12 may comprise a different semiconductor material from the semiconductor material from which is comprised the semiconductor substrate 10. The intrinsic base region 12 may comprise a semiconductor material selected from the same group of semiconductor materials that are listed for the semiconductor substrate 10. Typically and preferably, the intrinsic base region 12 comprises a silicon-germanium alloy semiconductor material when the semiconductor substrate 10 comprises a silicon semiconductor material.
The screen dielectric layer 14 comprises a dielectric material. Non-limiting examples of suitable dielectric materials include oxides, nitrides and oxynitrides of silicon. Oxides, nitrides and oxynitrides of other elements are not excluded. The dielectric material may be formed using any of several methods. Non-limiting examples include thermal or plasma oxidation or nitridation methods, chemical vapor deposition methods and physical vapor deposition methods. Typically, the screen dielectric layer 14 comprises a thermal silicon oxide dielectric material that has a thickness from about 50 to about 500 angstroms upon the intrinsic base region 12.
The hard mask layer 16 (a portion of which eventually serves as an ion implantation mask layer) comprises a hard mask material. Non-limiting examples of hard mask materials include oxides, nitrides and oxynitrides of silicon. Similarly with the screen dielectric layer, oxides, nitrides and oxynitrides of other elements are not excluded. Typically, the hard mask layer 16 and the screen dielectric layer 14 will comprise different dielectric materials in order to provide desired etch selectivity when subsequently etching the hard mask layer 16 with respect to the screen dielectric layer 14. Thus, the hard mask layer 16 typically comprises a silicon nitride hard mask material or a silicon oxynitride hard mask material, when the screen dielectric layer 14 comprises a silicon oxide material. The hard mask material may in general be deposited using methods and materials analogous or equivalent to the methods and materials used for forming the dielectric material from which is comprised the screen dielectric layer 14. The hard mask layer 16 typically has a thickness from about 500 to about 2000 angstroms upon the screen dielectric layer 14.
The photoresist layer 18 may comprise any of several photoresist materials. Non-limiting examples include positive photoresist materials, negative photoresist materials and hybrid photoresist materials. Typically, the photoresist layer 18 has a thickness from about 3000 to about 10000 angstroms. Typically, the photoresist layer 18 results from spin coating, photoexposure and development methods that are otherwise generally conventional in the semiconductor fabrication art.
Selective dielectric deposition methods may commonly include, but are not limited to, liquid phase deposition methods. The methods may utilize a specific catalytic activity of an active surface for purposes of selective deposition upon that surface.
Within the context of the instant embodiment for selectively depositing a silicon oxide vertical spacer layer 22 upon a silicon oxide screen dielectric layer 14, a particular liquid phase deposition method uses a supersaturated solution of hydrofluorosilicic acid (i.e., H3SiF6) as a silicon oxide deposition source. The supersaturated solution of hydrofluorosilicic acid may be prepared by addition of aluminum or boric acid (i.e., H3BO3) to a saturated solution of hydrofluorosilicic acid until saturation of the boric acid. The saturated solution of hydrofluorosilicic acid may be prepared by addition of silicon dioxide (i.e., SiO2) to hydrofluoric acid (i.e., HF) until saturation of the silicon dioxide. Hydrolysis of the foregoing solutions may lead to a fluorinated deposited silicon oxide rather than a deposited silicon oxide. A fluorine content of up to about 10 atomic percent is contemplated within such a fluorinated deposited silicon oxide. Fluorinated deposited silicon oxide layers may also have superior electrical properties due to generally lower dielectric constants (i.e., about 2.5 to about 3.5) in comparison with non-fluorinated deposited silicon oxides (i.e., about 3.5 to about 4.0).
The supersaturated solution of hydrofluorosilicic acid may be prepared, and the liquid phase selective deposition may be undertaken, at a temperature from about 0° to about 35° C. The selective deposition may also be undertaken at a higher temperature while using simple immersion of an appropriately fabricated substrate in accordance with the embodiment into a supersaturated solution of hydrofluorosilicic acid (or a hydrolyzed supersaturated solution of hydrofluorosilicic acid). Additional details and description of a particular liquid phase epitaxy method may be found in U.S. Pat. No. 6,995,065, the disclosure of which is incorporated herein fully by reference.
Use of the foregoing selective deposition method for forming the vertical spacer layers 22 is desirable insofar as the vertical spacer layers 22 may be deposited at a generally lower temperature (i.e., in a range from about 0° to about 35° C.) that allows for a more limited thermal exposure and thus a more limited thermal budget when fabricating the semiconductor structure whose schematic plan-view diagram is illustrated in
As is illustrated in
In addition, the second embodiment of the invention also uses overgrowth of a pair of selectively deposited vertical spacer layers 22′″ upon a generally thinner hard mask layer 16′″ such that hard mask derived horizontal spacer layers 16″″ may be formed embedded within and aligned within the sidewalls of an aperture A2″ defined in part by vertical spacer layers 22′″. The aperture A2″ exposes a surface region of the intrinsic base region 12.
The preferred embodiments of the invention are illustrative of the invention rather than limiting of the invention. Revisions and modifications may be made to methods, materials, structures and dimensions of a semiconductor structure including a bipolar transistor in accordance with the preferred embodiments of the invention, while still providing a semiconductor structure including a bipolar transistor in accordance with the invention, further in accordance with the accompanying claims.