The present invention relates to a semiconductor device and a method for fabricating the semiconductor device, and more particularly to a compound semiconductor epitaxial structure and a method for fabricating the compound semiconductor epitaxial structure.
With the technological advances of the communication equipment and other electronic equipment, the operating speed of the semiconductor device becomes faster and faster. For increasing the mobility of electrons and holes in the semiconductor device, compound semiconductor epitaxial structures are widely used in a variety of semiconductor applications. For example, the compound semiconductor epitaxial structure may be used in the fabrication of a metal-oxide-semiconductor field-effect transistor (MOSFET).
Because the lattice constant of the silicon germanium epitaxial material is larger than that of the monocrystalline silicon substrate, a compressive stress may be applied to the channel region between the source region and the drain region in order to enhance the carrier mobility. As a consequence, the silicon germanium epitaxial material is conventionally used to form a silicon germanium epitaxial structure. The silicon germanium epitaxial structure serves as the major component of the source/drain regions of the transistor in order to enhance the device performance of the semiconductor device.
However, it is found that a germanium agglomeration phenomenon is generated during the silicide process of fabricating the silicon germanium epitaxial structure. Moreover, since the lattice constant of silicon is different from that of germanium, the interfacial lattice mismatch between the silicon germanium epitaxial structure and the silicon substrate, and between the silicon germanium epitaxial structure and other material layers formed on the silicon germanium epitaxial structure in the subsequent processes will result in a delamination problem.
Therefore, there is a need of providing an advanced method for fabricating the compound semiconductor epitaxial structure in order to eliminate the above drawbacks and increase the performance of the semiconductor device.
In accordance with an aspect, the present invention provides a method for fabricating a compound semiconductor epitaxial structure. The method includes the following steps. Firstly, a first compound epitaxial layer is formed on a substrate. Then, a continuous epitaxial deposition process is performed to form a second compound epitaxial layer on the first compound epitaxial layer, so that the second compound epitaxial layer has a linearly-decreased concentration gradient of metal. Afterwards, a semiconductor material layer is formed on the second compound epitaxial layer.
In an embodiment, the first compound epitaxial layer has a metal concentration greater than or equal to an initial concentration of the linearly-decreased concentration gradient of metal.
In an embodiment, during the step of performing the continuous epitaxial deposition process to form the second compound epitaxial layer, the flow rate of a metal-containing reactive gas is controlled to be linearly decreased. In an embodiment, the formation of the second compound epitaxial layer further comprises steps of keeping the flow rates of the metal-containing reactive gas constant for a predetermined interval of time.
In an embodiment, the first compound epitaxial layer is a silicon germanium bulk layer, and the metal-containing reactive gas comprises a germane gas.
In an embodiment, during the step of performing the continuous epitaxial deposition process to form the second compound epitaxial layer, a mass flow controller is used to adjust the flow rates of the germane gas, a hydrogen chloride gas and a diborane gas, so that the flow rate of the germane gas is linearly decreased or is kept constant for a predetermined interval of time.
In an embodiment, the first compound epitaxial layer is further boron-doped.
In an embodiment, before the first compound epitaxial layer is formed, the method further includes a step of forming an undoped silicon germanium layer on the substrate.
In an embodiment, the undoped silicon germanium layer has a linearly-increased concentration gradient of germanium.
In an embodiment, during the step of forming the undoped silicon germanium layer, a mass flow controller is used to adjust the flow rates of the germane gas and a hydrogen chloride gas, so that the flow rate of the germane gas is linearly increased or is kept constant for a predetermined interval of time.
In an embodiment, the step of forming the first compound epitaxial layer and the step of forming the second compound epitaxial layer are carried out at the same temperature.
In accordance with another aspect, the present invention provides a compound semiconductor epitaxial structure. The compound semiconductor epitaxial structure includes a substrate, a first compound epitaxial layer, a second compound epitaxial layer, and a semiconductor material layer. The first compound epitaxial layer is formed on a substrate. The second compound epitaxial layer is formed on the first compound epitaxial layer, wherein the second compound epitaxial layer has a linearly-decreased concentration gradient of metal. The semiconductor material layer is formed on the second compound epitaxial layer.
In an embodiment, the first compound epitaxial layer has a metal concentration greater than or equal to an initial concentration of the linearly-decreased concentration gradient of metal.
In an embodiment, the first compound epitaxial layer is a silicon germanium bulk layer, which contains 40 wt % of germanium and is doped with 25 wt % of boron, wherein the second compound epitaxial layer has a linearly-decreased concentration gradient of germanium.
In an embodiment, the compound semiconductor epitaxial structure further includes an undoped silicon germanium layer, wherein the undoped silicon germanium layer is arranged between the substrate and the first compound epitaxial layer. In an embodiment, the undoped silicon germanium layer has a linearly-increased concentration gradient of germanium.
In an embodiment, a top surface of the first compound epitaxial layer is higher than the substrate by a height difference.
In an embodiment, the height difference between the top surface of the first compound epitaxial layer and the substrate is in a range between 150 Å and 170 Å.
In an embodiment, the second compound epitaxial layer has a thickness smaller than 100 Å.
In an embodiment, the thickness of the second compound epitaxial layer is in a range between 30 Å and 100 Å.
The above objects and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed.
As previously described herein, the interfacial lattice mismatch may result in stress relaxation of the compound epitaxial structure and thereby reduce the device performance. For solving the above drawbacks, the present invention provides a compound semiconductor epitaxial structure and a method for fabricating the compound semiconductor epitaxial structure. The above and other objects, features and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings. An embodiment of a method for fabricating a metal-oxide-semiconductor field-effect transistor with a compound epitaxial structure in accordance with the present invention will be illustrated below.
The method for fabricating the metal-oxide-semiconductor field-effect transistor 10 comprises the following steps. Firstly, as shown in
In this embodiment, the substrate 101 is a silicon wafer. The gate structure 102 comprises a gate dielectric layer 102a and a gate conductor layer 102b. The gate dielectric layer 102a is formed on the surface 101a of the substrate 101. The gate conductor layer 102b is formed on the gate dielectric layer 102a. More preferably, a spacer 103 is formed on a sidewall of the gate structure 102. In addition, a gate cap layer 102c is formed over the gate conductor layer 102b.
Then, as shown in
Then, as shown in
In this embodiment, the content of germanium and the concentration of the boron dopant in the silicon germanium epitaxial layer 107 may be controlled by using a mass flow controller (MFC) to adjust the flow rates of the germane gas, the hydrogen chloride gas and the diborane gas. For example, by adjusting the flow rates of the germane gas, the hydrogen chloride gas and the diborane gas, the concentration and distribution of the boron dopant in the silicon germanium epitaxial layer 107 are correspondingly controlled. Consequently, the silicon germanium epitaxial layer 107 may contain 40 wt % of germanium and a linear gradient concentration of boron dopant varying with thickness thereof or otherwise contain a constant concentration of boron dopant. Alternatively, in some other embodiments of the present invention, a silane gas (SiH4) or a disilane gas (Si2H6) is used as the reactive gas in the above chemical vapor deposition process in order to replace the dichlorosilane gas.
In some other embodiments of the present invention, an undoped silicon germanium layer 108 is formed on an inner surface of the trench structure 106 before the silicon germanium epitaxial layer 107 is formed. The arrangement of the undoped silicon germanium layer 108 can inhibit external diffusion of the boron dopant to prevent serious problems due to boron diffusion. Consequently, the electrical punch-through effect and the short channel effect resulting from boron diffusion, which is a serious problem, will be avoided. The method of forming the undoped silicon germanium layer 108 is similar to the method of forming the silicon germanium epitaxial layer 107, except that the diborane gas is not used as the precursor reactive gas in forming the undoped silicon germanium layer 108. In this embodiment, the undoped silicon germanium layer 108 contains 25 wt % of germanium.
In some other embodiments, for improving the lattice mismatch between the substrate 101 and the silicon germanium epitaxial layer 107, a mass flow controller may be used to adjust the flow rates of the germane gas, the silane gas (the dichlorosilane gas or the disilane gas) and the hydrogen chloride gas during the process of forming the undoped silicon germanium layer 108. That is, the flow rate of the germane gas is linearly increased with the deposition time. Consequently, the undoped silicon germanium layer 108 has a linearly-increased concentration gradient of germanium varying with thickness thereof.
For example, during the process of depositing the undoped silicon germanium layer 108, the mass flow controller is used to control the flow rate of the germane gas to be linearly increased from 0 sccm (initial condition) to 270 sccm within 600 seconds of the operating time. Meanwhile the flow rates of the silane gas (dichlorosilane gas or disilane gas) and the hydrogen chloride gas may be also linearly increased with the operating time (see
In some embodiments, for increasing the germanium content in the undoped silicon germanium layer 108, after the flow rate of the germane gas is linearly increased for a period of time, the flow rate of the germane gas may be kept constant for a predetermined interval of time, and the linearly increased-constant flow rate pattern as described may be repeated as needed. Such that the germane concentration distribution of the undoped silicon germanium layer 108 can be controlled in a stepped increase mode with the thickness thereof, so as to enhance its stress effect. Meanwhile the flow rates of the silane gas (dichlorosilane gas or disilane gas) and the hydrogen chloride gas may be also controlled in a stepped increase mode with the deposition time (see
It should be appreciated that the flow rates of the germane gas, the silane gas (dichlorosilane gas or disilane gas) and the hydrogen chloride gas and the time intervals may be adjusted according to the distribution of the germanium concentration predetermined by the operators. And after the undoped silicon germanium layer 108 is formed, the process of depositing the undoped silicon germanium layer 108 may be continued by using the germane gas, the silane gas (dichlorosilane gas or disilane gas), the hydrogen chloride gas and the additional diborane gas as the precursor reactive gas to form the silicon germanium epitaxial layer 107 in situ.
After the silicon germanium epitaxial layer 107 is formed, as shown in
The method of forming the liner layer 109 is substantially similar to the method of forming the silicon germanium epitaxial layer 107, except that the germanium concentration distribution of the liner layer 109 is distinguished. In some embodiments, by using a mass flow controller to adjust the flow rates of the germane gas, the hydrogen chloride gas, the silane gas (dichlorosilane gas or disilane gas) and the diborane gas during the process of depositing the liner layer 109, the flow rate of the germane gas is linearly decreased with the deposition time. Consequently, a silicon germanium epitaxial liner layer having a thickness of 30˜100 Å and a linearly-decreased concentration gradient of germanium varying with thickness of the silicon germanium epitaxial liner layer is formed. In another embodiment, during the process of depositing the liner layer 109, the flow rate of the germane gas is linearly decreased from 270 sccm (initial) to 0 sccm within 200 seconds of the operating time. Meanwhile the flow rates of the hydrogen chloride gas, the diborane gas and the silane gas (dichlorosilane gas or disilane gas) may be also linearly decreased with the operating time or kept constant from the beginning. Preferably, the flow rates of the hydrogen chloride gas, the diborane gas and the silane gas (dichlorosilane gas or disilane gas) are linearly decreased along with the decreasing flow rate of the germane gas, such that, the growth rate of the liner layer 109 can be substantially kept constant, and the process can be controlled more easily. For example, during the process of depositing the liner layer 109, the flow rate of the diborane gas is linearly decreased from 60 sccm (initial) to 0 sccm within 200 seconds of the operating time (see
In some embodiments, for increasing the germanium content in the liner layer 109, after the flow rate of the germane gas is linearly decreased for a period of time, the flow rate of the germane gas may be kept constant for a predetermined interval of time, and the linearly decreased-constant flow rate pattern as described may be repeated. Such that the flow rate of the germane gas can be controlled in a stepped decrease mode with the deposition time. Meanwhile the flow rates of the diborane gas and the hydrogen chloride gas may be also controlled in a stepped decrease mode with the deposition time. In addition, to keep the liner layer 109 growing at a steady rate, the flow rates of the hydrogen chloride gas should be decreased or kept constant simultaneously with the variation of the flow rate of the germane gas. And in the present embodiment, the flow rates of the silane gas (dichlorosilane gas or disilane gas) is kept constant from the beginning (see
In this context, the in-situ process indicates that the silicon germanium epitaxial layer 107 and the liner layer 109 are produced in the same reaction chamber or the same processing machine. In some embodiments, the deposition temperature of forming the liner layer 109 is identical to the deposition temperature of forming the silicon germanium epitaxial layer 107. Alternatively, in some other embodiments, the undoped silicon germanium layer 108 and the silicon germanium epitaxial layer 107 and the liner layer 109 may be produced in-situ in the same reaction chamber or the same processing machine.
Next, as shown in
In some embodiments of the present invention, the process of depositing liner layer 109 may be continued by using the silane gas (dichlorosilane gas or disilane gas), the hydrogen chloride gas and the diborane gas as the precursor reactive gas to form the cap layer 110 in situ. As shown in
As previously described in the background of the invention, because of the interfacial lattice mismatch between adjacent layers of the multilayered silicon germanium epitaxial liner structure, the compressive stress is readily relaxed. According to the embodiments of the present invention, since the liner layer 109 is a single-layered structure whose germanium concentration is linearly decreased with thickness thereof, the problem due to lattice mismatch between adjacent silicon germanium epitaxial liner layers will be eliminated. As a result, the stress relaxation problem of the silicon germanium epitaxial structure will be minimized.
For better understanding of the features and advantages of the liner layer 109, a series of tests are performed in order to compare several comparison examples with the compound semiconductor epitaxial structure 100 of
In the compound semiconductor epitaxial structure 100, the silicon germanium epitaxial liner layer 109 has a linearly-decreased concentration gradient of germanium varying with thickness thereof. In the compound semiconductor epitaxial structure 200, the silicon germanium epitaxial liner layer 209 is a single-layered structure having a fixed germanium concentration (e.g. 25 wt %). Whereas, the compound semiconductor epitaxial structure 300 has a first silicon germanium epitaxial liner layer 309a containing 30 wt % of germanium and a second silicon germanium epitaxial liner layer 309b containing 8 wt % of germanium. For clarification and brevity, identical components of the metal-oxide-semiconductor field-effect transistors 10, 20 and 30 are designated by identical numeral references.
The results of the strain and relaxation tests demonstrate that the relaxation percentages for the compound semiconductor epitaxial structures 100, 200 and 300 are respectively 0.43%, 17.01% and 19.82% relative to the silicon germanium epitaxial structure without the liner layer. It is found that the liner layer 109 whose germanium concentration is linearly decreased with thickness thereof is effective in solving the delamination problem resulting from the lattice mismatch between the compound semiconductor epitaxial structure 100 and other material layers. Moreover, the stress relaxation problem of the silicon germanium epitaxial structure resulted from the multilayered silicon germanium epitaxial liner structure will be minimized.
Furthermore, since the liner layer 109 is produced by dynamically adjusting the concentration of the deposition gas and performing a single continuous epitaxial deposition process, the pre-cleaning and pumping & purging process necessary to be performed during the time period between individual processes of forming the silicon germanium epitaxial liner layers 309a and 309b as shown in
From the above description, the embodiments of present invention provide a compound semiconductor epitaxial structure and a method for fabricating the compound semiconductor epitaxial structure. Firstly, a first compound epitaxial layer is formed in a substrate. Then, by dynamically adjusting the concentration of the deposition gas and performing a single continuous epitaxial deposition process, a second compound epitaxial layer is formed on the first compound epitaxial layer. Consequently, the second compound epitaxial layer has a linearly-decreased concentration gradient of metal. Then, a semiconductor material layer is formed on the second compound epitaxial layer. Since the interfacial lattice mismatch between the compound epitaxial layers is reduced, the stress relaxation problem of the compound epitaxial structure will be minimized and the device performance of the MOSFET will be enhanced.
While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. Such that, the material of forming the compound semiconductor epitaxial structure is not limited to the silicon germanium epitaxial material, and the application of the compound semiconductor epitaxial structure is not limited to the metal-oxide-semiconductor field-effect transistor. For example, the compound semiconductor epitaxial structure can be applied by a fin field effect transistor (FINFET). On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
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