Semiconductor devices are electronic components that exploit the electronic properties of semiconductor materials, such as silicon (Si), germanium (Ge), gallium arsenide (GaAs), and indium phosphide (InP). A field-effect transistor (FET) is a semiconductor device that includes three terminals: a gate, a source, and a drain. A FET uses an electric field applied by the gate to control the electrical conductivity of a channel through which charge carriers (e.g., electrons or holes) flow between the source and drain. In instances where the charge carriers are electrons, the FET is referred to as an n-channel device; and in instances where the charge carriers are holes, the FET is referred to as a p-channel device. Some FETs have a fourth terminal called the body or substrate, which can be used to bias the transistor. In addition, metal-oxide-semiconductor FETs (MOSFETs) include a gate dielectric between the gate and the channel. MOSFETs may also be known as metal-insulator-semiconductor FETs (MISFETSs) or insulated-gate FETs (IGFETs). Complementary MOS (CMOS) structures use a combination of p-channel MOSFET (PMOS) and n-channel MOSFET (NMOS) devices to implement logic gates and other digital circuits.
A FinFET is a MOSFET transistor built around a thin strip of semiconductor material (generally referred to as a fin). The conductive channel of the FinFET device resides on the outer portions of the fin adjacent to the gate dielectric. Specifically, current runs along/within both sidewalls of the fin (sides perpendicular to the substrate surface) as well as along the top of the fin (side parallel to the substrate surface). Because the conductive channel of such configurations includes three different planer regions of the fin (e.g., top and two sides), such a FinFET design is sometimes referred to as a tri-gate transistor. A gate-all-around (GAA) transistor is configured similarly to a fin-based transistor, but instead of a finned channel region, one or more channel bodies such as nanoribbons or nanowires extend between the source and the drain regions. In GAA transistors, the gate material wraps around each such body.
Scaling of integrated circuit structures, including GAA transistor devices or other types of transistor devices, results in high density of scaled interconnect features. One approach to circumvent congestion of frontside interconnects due to power and signal routing includes the use of a backside power and/or signal delivery. However, there remain a number of non-trivial challenges with respect to scaled interconnects.
FIGS. 3A1, 3A2, 3A3, 3B1, 3B2, 3B3, 3C, 3C2, 3C3, 3Ca, 3Cb, 3Cc, 3D1, 3D2, 3D3, 3Da, 3Db, 3Dc, 3E1, 3E2, 3E3, 3Ea, 3Eb, 3Ec, 3F1, 3F2, 3F3, 3F4, 3Fa, 3Fb, 3Fc, 3Fd, 3G1, 3G2, 3G3, 3G4, 3Ga, 3Gb, 3Gc, 3Gd, 3H1, 3H2, 3H3, 3H4, 3Ha, 3Hb, 3Hc, 3Hd, 3I1, 3I2, 3I3, 3I4, 3Ia, 3Ib, 3Ic, 3Id, 3Ie, 3If, 3Ig, 3Ih, 3J1, 3J2, 3J3, 3J4, 3Ja, 3Jb, 3Jc, 3Jd, 3K1, 3K2, 3K3, 3K4, 3Ka, 3Kb, 3Kc, and 3Kd collectively illustrate cross-sectional views of example integrated circuit structures in various stages of processing in accordance with the methodology of
As will be appreciated, the figures are not necessarily drawn to scale or intended to limit the present disclosure to the specific configurations shown. For instance, while some figures generally indicate perfectly straight lines, right angles, and smooth surfaces, an actual implementation of an integrated circuit structure may have less than perfect straight lines, right angles (e.g., some features may have tapered sidewalls and/or rounded corners), and some features may have surface topology or otherwise be non-smooth, given real world limitations of the processing equipment and techniques used. Likewise, while the thickness of a given first layer may appear to be similar in thickness to a second layer, in actuality that first layer may be thinner or thicker than the second layer; same goes for other layer or feature dimensions.
Microelectronic device structures including both frontside source or drain contacts, and backside source or drain contacts, and techniques for forming such frontside and backside source or drain contacts, are provided herein. The techniques are particularly useful in gate-all-around (GAA) transistor architectures such as nanowire and nanoribbon transistors, although they may also benefit other transistor topologies such as forksheet transistors or other transistors having epitaxial source and drain regions. Beneficially, trenches for backside source or drain contacts are formed from the frontside during source and drain processing, and sacrificial dielectric material is deposited within the trenches (e.g., within lower portions of the trenches, such as portions of the trenches extending within the sub-fin regions) from the frontside, e.g., during gate spacer deposition process. In an example, the sacrificial dielectric material and the gate spacer material comprise the same elemental constituents, and are elementally (and may also be compositionally) the same, as the sacrificial dielectric material is deposited during the gate spacer formation process. Subsequently, epitaxial (epi) source or drain regions are formed within the trenches and above the sacrificial dielectric material. Subsequently, if a backside source or drain contact is desired for a given source or drain region, the sacrificial material coupled to the given source or drain region is removed from the backside, and replaced with conductive material. On the other hand, if a given source or drain region has a frontside source or drain contact, the sacrificial material coupled to the backside of the second source or drain region is left in place. Thus, a given source or drain region may have a source or drain contact at its backside, or has dielectric material at its backside, where the dielectric material is elementally (and also may be compositionally) the same as the gate spacer material. In an example, the dielectric material and the gate spacer material comprise the same elemental constituents. Numerous configurations and variations will be apparent in light of this disclosure.
As noted above, there remain a number of non-trivial challenges with respect to scaled interconnects. For example, in addition to a frontside interconnect structure, a backside interconnect structure alleviates congestion and scaling issues with the frontside interconnect structure. To facilitate a backside interconnect structure, a source or drain region can have a frontside source or drain contact, or backside source or drain contact. However, processes to form backside source or drain contacts can damage or erode surrounding materials, such as a gate stack and/or a gate spacer, thereby impacting yield and performance.
Accordingly, techniques are provided herein to form an integrated circuit structure that includes first one or more source or drain regions having one or more backside source or drain contacts, and second one or more source or drain regions having one or more frontside source or drain contacts. Advantageously, trenches for backside source or drain contacts are formed from the frontside, and sacrificial dielectric material is deposited within the trenches (e.g., within lower portions of the trenches, such as portions of the trenches extending within the sub-fin regions) from the frontside, e.g., during gate spacer deposition process. Subsequently, epi source and drain regions are formed within the trenches and above the sacrificial dielectric material. Subsequently, if a backside source or drain contact is desired for a first source or drain region, the sacrificial material coupled to the first source or drain region is removed from the backside, and replaced with conductive material. The first source or drain contact is, thus, self-aligned to the first source or drain region. Additionally, the trench for the first source or drain contact is formed from the frontside, and the sacrificial dielectric material is also deposited from the frontside during the gate spacer deposition process, without causing any damage, or reduced damage, to surrounding material, thereby improving yield and performance.
In further detail, in one embodiment, during the source or drain trench formation process, the source or drain trench is extended deeper, e.g., within the sub-fin regions of the devices. Lower portions of the trenches are filled with dielectric material, e.g., when the gate spacers (also referred to as inner gate spacers, or cavity spacers) are formed. Accordingly, the dielectric material filling the lower portions of the trenches is the same as the gate spacer dielectric material (they are deposited during the same dielectric material deposition process). At least portions of the dielectric material occupying the lower portions of at least some of the trenches are later removed and replaced with conductive material to form backside source or drain contacts, and hence, the dielectric material occupying the lower portions of the trenches is referred as sacrificial dielectric material. Note, however, that in some instances, the sacrificial dielectric material may be left intact within the final integrated circuit structure.
After deposition of the sacrificial dielectric material within the trenches, further processing may commence, such as formation of source or drain regions, releasing of the nanoribbons (or other GAA channel configurations, such as nanowires or nanosheets), formation of the final replacement gate stack, and formation of a frontside interconnect structure. Note that each source or drain region is self-aligned with the corresponding sacrificial dielectric material at the bottom of the source or drain trench and below the source or drain region. In an example, one or more source or drain regions have frontside source or drain contacts coupled to the frontside interconnect structure.
Subsequently, the frontside of the wafer is bonded to a carrier wafer, so as to allow for access to the backside of the wafer. From the backside, the substrate is removed, and at least a portion of the sub-fin regions are removed and replaced with dielectric material. In one example, during the substrate removal process, if the prior formed source or drain trenches are deep enough (e.g., extend fully though the sub-fin regions), the sacrificial dielectric material within the trenches is exposed from the backside. In another example, during the substrate removal process, if the prior formed source or drain trenches are not deep enough (e.g., do not extend fully though the sub-fin regions), the sacrificial dielectric material is not exposed from the backside, and is still covered by a dielectric material used to replace the sub-fin regions.
Subsequently, a mask is patterned on the backside, where the mask has one or more openings above corresponding the sacrificial dielectric material, which is to be replaced with conductive materials, to form corresponding backside source or drain contacts. The mask may cover one or more other locations of the sacrificial material, with those location being coupled to source or drain regions having frontside source or drain contacts. For example, assume that the mask has an opening above a first sacrificial material coupled to a first source or drain region, and doesn't have an opening above a second sacrificial material coupled to a second source or drain region (where the second source or drain region may have a frontside source or drain contact). The first sacrificial material is removed from the backside through the opening within the mask, and subsequently replaced with a conductive material, to form a backside source or drain contact for the first source or drain region. On the other hand, the second sacrificial material coupled to the second source or drain region is not removed, because it is covered by the mask.
In an example in which the prior formed source or drain trenches are etched together and deep enough (e.g., are exposed through the backside during substrate removal), the backside surfaces of the backside source or drain contact for the first source or drain region and the second sacrificial material are substantially coplanar, such as within a tolerance of at most 5 nm, or at most 3 nm, or at most 2 nm, or at most 1 nm, for example, as will be described below. Some variances in trench depth may occur, due to factors such as the trench geometries and loading (similarly shaped and spaced trenches will tend to etch similarly, whereas differently shaped and spaced trenches may etch at different rates and thus have more divergent trench depths).
In another example in which the prior formed source or drain trenches are not deep enough (e.g., are not exposed through the backside during substrate removal), the opening within the mask doesn't reveal the first sacrificial material (e.g., for being covered by the dielectric material that is used to replace the sub-fin regions). In such an example, the first sacrificial material replacement is performed using two removal processes through the opening within the mask: (i) a first removal process that removes the dielectric material covering the first sacrificial material, and (ii) a second removal process that removes the first sacrificial material. This results in a recess on the backside of the first source or drain region, where the recess has a stepped sidewall (e.g., see
The use of “group IV semiconductor material” (or “group IV material” or generally, “IV”) herein includes at least one group IV element (e.g., silicon, germanium, carbon, tin), such as silicon (Si), germanium (Ge), silicon-germanium (SiGe), and so forth. The use of “group III-V semiconductor material” (or “group III-V material” or generally, “III-V”) herein includes at least one group III element (e.g., aluminum, gallium, indium) and at least one group V element (e.g., nitrogen, phosphorus, arsenic, antimony, bismuth), such as gallium arsenide (GaAs), indium gallium arsenide (InGaAs), indium aluminum arsenide (InAlAs), gallium phosphide (GaP), gallium antimonide (GaSb), indium phosphide (InP), gallium nitride (GaN), and so forth. Note that group III may also be known as the boron group or IUPAC group 13, group IV may also be known as the carbon group or IUPAC group 14, and group V may also be known as the nitrogen family or IUPAC group 15, for example.
Materials that are “compositionally different” or “compositionally distinct” as used herein refers to two materials that have different chemical compositions. This compositional difference may be, for instance, by virtue of an element that is in one material but not the other (e.g., SiGe is compositionally different than silicon), or by way of one material having all the same elements as a second material but at least one of those elements is intentionally provided at a different concentration in one material relative to the other material (e.g., SiGe having 70 atomic percent germanium is compositionally different than from SiGe having 25 atomic percent germanium). In addition to such chemical composition diversity, the materials may also have distinct dopants (e.g., gallium and magnesium) or the same dopants but at differing concentrations. In still other embodiments, compositionally distinct materials may further refer to two materials that have different crystallographic orientations. For instance, (110) silicon is compositionally distinct or different from (100) silicon. Creating a stack of different orientations could be accomplished, for instance, with blanket wafer layer transfer. If two materials are elementally different, then one of the material has an element that is not in the other material. If two materials are elementally the same, then the two materials comprise the same elemental constituents.
Use of the techniques and structures provided herein may be detectable using tools such as electron microscopy including scanning/transmission electron microscopy (SEM/TEM), TEM electron energy loss spectroscopy (TEM-EELS), scanning transmission electron microscopy (STEM), nano-beam electron diffraction (NBD or NBED), and reflection electron microscopy (REM); composition mapping; x-ray crystallography or diffraction (XRD); energy-dispersive x-ray spectroscopy (EDX); secondary ion mass spectrometry (SIMS); time-of-flight SIMS (ToF-SIMS); atom probe imaging or tomography (APT); local electrode atom probe (LEAP) techniques; 3D tomography; or high resolution physical or chemical analysis, to name a few suitable example analytical tools. For example, such tools may be used to detect an integrated circuit structure including a device layer having some source and/or drain regions contacted with frontside contacts, and some source or drain regions contacted by backside contacts, wherein source/drain recesses extend into the subfin region even in non-backside contact regions where the recesses have their bottoms filled with dielectric material that is also used for the internal gate spacers. Moreover, if a given backside contact has its critical expanded, TEM-EELS, APT or SIMs may show etchant species next to the backside contact. Numerous configurations and variations will be apparent in light of this disclosure.
The cross-section view of
The devices within the device layer 150 are arranged in an array including a plurality of laterally adjacent devices. Accordingly, the devices, including the source or drain regions of the devices illustrated in
As illustrated in
As illustrated in
The frontside interconnect structure 101 comprises various back end of line (BEOL) metallization layers, such as a plurality of conductive interconnect features 124 within one or more layers 122 of dielectric material. Various such layers 122 of dielectric material may be separated by corresponding etch stop layers, although the etch stop layers are not illustrated in
Similarly, the backside interconnect structure 102 comprises various backside metallization layers, such as a plurality of conductive interconnect features 144 within one or more layers 142 of dielectric material. Various such layers 142 of dielectric material may be separated by corresponding etch stop layers, although the etch stop layers are not illustrated in
In an example, one or more of the devices included in the device layer 150 of the structure 100 each includes a corresponding channel layer comprising one or more bodies 103, where the one or more bodies comprise semiconductor material. The semiconductor bodies 103 included in the channel regions of the devices can vary in form, and in some examples described herein are in the form of nanoribbons. In particular, the channel region of each depicted devices in this example case includes a vertical stack of four nanoribbons 103 (see
Each device includes one or more source or drain regions 126. For ease of identification, in
The source and drain regions 126 can be any suitable semiconductor material and may include any dopant scheme. In an example, source or drain regions of a PMOS device can be PMOS source or drain regions that include, for example, group IV semiconductor materials such as silicon, germanium, SiGe, germanium tin (GeSn), SiGe alloyed with carbon (SiGe:C). Example p-type dopants include boron, gallium, indium, and aluminum. In an example, source or drain regions of a NMOS device can be NMOS source and drain regions that include, for example, silicon or group III-V semiconductor materials such as two or more of indium, aluminum, arsenic, phosphorus, gallium, and antimony, with some example compounds including but not limited to indium aluminum arsenide, indium arsenide phosphide, indium gallium arsenide, indium gallium arsenide phosphide, gallium antimonide, gallium aluminum antimonide, indium gallium antimonide, or indium gallium phosphide antimonide. In one specific embodiment, PMOS source and drain regions are boron-doped SiGe, and NMOS source and drain regions are phosphorus-doped silicon. In a more general sense, the source and drain regions can be any semiconductor material suitable for a given application.
In some cases, individual portions of an epitaxially formed source or drain region (also referred to as epi source or drain region) described above may include a multilayer structure, such as a germanium cap on a SiGe body, or a germanium body and a carbon-containing SiGe spacer or liner between the corresponding channel region and that germanium body. In any such cases, a portion of the epi source and drain regions may have a component that is graded in concentration, such as a graded germanium concentration to facilitate lattice matching, or a graded dopant concentration to facilitate low contact resistance. Any number of source and drain configurations can be used as will be appreciated, and the present disclosure is not intended to be limited to any particular such configurations.
Adjacent source or drain regions 126 (e.g., adjacent along the X axis direction of
Each source or drain region 126 has a corresponding source or drain contact (although in one example, a source or drain region may not have a corresponding source or drain contact, such as an example case where the source or drain region is not contacted). A source or drain contact for a given source or drain region may be from a frontside of the source or drain region 126 or a backside of the source or drain region, which are respectively referred to as a frontside source or drain contact, or a backside source or drain contact.
In one example, the structure 100 may have backside power and/or signal routing (such as backside power routing) using backside interconnect structure 102, as well as frontside power and/or signal routing (such as frontside signal routing) using frontside interconnect structure 101. In such an example, power to one or more devices of the device layer 150 may be delivered using backside source or drain contacts, and signals may be routed using frontside source or drain contacts. In such an example, one or more source regions may have corresponding backside source contacts for receiving power (as source region of a device may receive power), whereas one or more drain regions may have corresponding frontside drain contacts for routing signals, although the location of a source region and a drain region and positions of source or drain contacts thereof in a device may be interchanged.
Because the source or drain regions 126a and 126d have backside source or drain contacts 140a and 140d, the frontside of the source or drain regions 126a and 126d do not have any corresponding source or drain contacts. Accordingly, the frontside of the source or drain regions 126a and 126d are also covered with the above described layer 120 of dielectric material, as illustrated in
In one embodiment, the source or drain regions 126 that have frontside source or drain contacts (such as source or drain regions 126b, 126c having frontside source or drain contacts 125b, 125c, respectively) have a dielectric material 114 on its backside, as illustrated in
In one embodiment and as illustrated in
Note that as described below, trenches for the backside source or drain contacts 140a, 140d and the dielectric materials 114b, 114c are all formed from the frontside. Accordingly, each of the backside contacts 140a, 140d and the dielectric materials 114b, 114c are tapered. Accordingly, for each of these, a width of an upper surface is higher a width of the lower surface, e.g., by at least 10%, or at least 8%, or at least 5%, or at least 3%, or at least 2%, where the upper surface is towards the frontside and the lower surface is towards the backside. For example,
In one embodiment and as described below, each of the devices of the device layer 150 comprises gate spacers 110 that separates a corresponding source or drain region 126 from a corresponding gate electrode 112. In an example and as also described below with respect to method 200 of
Although not illustrated in
In one embodiment, the source or drain contacts 125, 140 comprise a conductive fill material, such as one or more of molybdenum (Mo), tungsten (W), cobalt (Co), titanium (Ti), vanadium (V), zirconium (Zr), Niobium (Nb), nickel (Ni), ruthenium (Ru), tantalum (Ta), titanium nitride (TiN), and/or vanadium nitride (VN), for example.
In one embodiment, in each device of the device layer 150, a gate structure wraps around each of the corresponding nanoribbons 103 in the corresponding channel region. The gate structures are visible in
The gate dielectric 128 may include a single material layer or multiple stacked material layers. The gate dielectric may include, for example, any suitable oxide (such as silicon dioxide), high-k dielectric material, and/or any other suitable material as will be apparent in light of this disclosure. Examples of high-k dielectric materials include, for instance, hafnium oxide, hafnium silicon oxide, lanthanum oxide, lanthanum aluminum oxide, zirconium oxide, zirconium silicon oxide, tantalum oxide, titanium oxide, barium strontium titanium oxide, barium titanium oxide, strontium titanium oxide, yttrium oxide, aluminum oxide, lead scandium tantalum oxide, and lead zinc niobate, to provide some examples. The high-k dielectric material (e.g., hafnium oxide) may be doped with an element to affect the threshold voltage of the given semiconductor device. According to some embodiments, the doping element used in gate dielectric 128 is lanthanum. In some embodiments, the gate dielectric can be annealed to improve its quality when high-k dielectric material is used. In some embodiments, the gate dielectric 128 includes a first layer (e.g., native oxide of nanoribbons, such as silicon dioxide or germanium oxide or SiGe-oxide) on the nanoribbons, and a second layer of high-k dielectric (e.g., hafnium oxide) on the first layer.
In an example, the gate electrodes 112 of the various devices of the device layer 150 may include any sufficiently conductive material, such as a metal, metal alloy, or doped polysilicon. The gate electrodes 112 may include a wide range of materials, such as polysilicon or various suitable metals or metal alloys, such as aluminum, tungsten, titanium, tantalum, copper, cobalt, molybdenum, titanium nitride, or tantalum nitride, for example.
In one embodiment, one or more work function materials (not illustrated in
Each of gate structures including the gate electrode 112 and the gate dielectric material 128 can be formed via gate-first or gate-last processing, and may include any number of suitable gate materials and configurations. Gate spacers 110 isolate the gate structures from contacting the corresponding source or drain regions. In one example the gate spacers 110 may be considered part of the gate structure, whereas in another example the gate spacers 110 may be considered external to the gate structure.
As described above, the dielectric materials 114 and the gate spacers 110 are deposited using the same deposition process. In an example, the dielectric materials 114 and the gate spacers 110 are elementally and/or compositionally same, and comprise the same elemental constituents. In such an example, the dielectric materials 114 and the gate spacers 110 comprise a nitride, oxide, carbide, oxycarbide, oxynitride, and/or oxycarbonitride, such as silicon nitride, silicon oxycarbonitride (SiOCN), or another dielectric material.
The semiconductor bodies 103 of the channel regions of the various devices, which in this case are nanoribbons, can be any number of semiconductor materials as well, such as group IV material (e.g., silicon, germanium, or SiGe) or group III-V materials (e.g., indium gallium arsenide). The semiconductor bodies 103 may be lightly doped, or undoped, and may be shaped or sculpted during the gate formation process, according to some embodiments. In some cases, semiconductor bodies 103 may be a multilayer structure, such as a SiGe body cladded with germanium, or a silicon body cladded with SiGe. Any number of channel configurations can be used.
The integrated circuit structure 170 of
In the structure 100 of
In an example, a sidewall of each of the backside source or drain contacts 180a, 180b have a step feature, such as a stepped sidewall. For example, referring to the backside source or drain contact 180a in
In an example, the substantially horizontal step section 183 of the source or drain contact 180a is substantially within the same plane as the lower surfaces of the dielectric materials 114b, 114c, with a tolerance of at most 5 nm, or at most 3 nm, or at most 2 nm, for example. Thus, a vertical height of the section 181 of the sidewall of the source or drain contact 180a and a vertical height of the dielectric materials 114b, 114c are substantially the same (e.g., represented by “h” in
Note that FIGS. 3A1, 3A2, 3A3, 3B1, 3B2, 3B3, 3C1, 3C2, 3C3, 3D1, 3D2, 3D3, 3E1, 3E2, 3E3, 3F1, 3F2, 3F3, 3F4, 3G1, 3G2, 3G3, 3G4, 3H1, 3H2, 3H3, 3H4, 3I1, 3I2, 3I3, 3I4, 3J1, 3J2, 3J3, 3J4, 3K1, 3K2, 3K3, and 3K4 collectively illustrate cross-sectional views of the integrated circuit structure 100 of
The cross-sectional views of FIGS. 3A1, 3B1, 3C1, 3Ca, 3D1, 3Da, 3E1, 3Ea, 3F1, 3Fa, 3G1, 3Ga, 3H1, 3Ha, 3I1, 3Ia, 3Ie, 3J1, 3Ja, 3K1, and 3Ka correspond to the cross-sectional views of
The cross-sectional views of FIGS. 3A2, 3B2, 3C2, 3Cb, 3D2, 3Db, 3E2, 3Eb, 3F2, 3Fb, 3G2, 3Gb, 3H2, 3Hb, 3I2, 3Ib, 3If, 3J2, 3Jb, 3K2, and 3Kb correspond to the cross-sectional views of
The cross-sectional views of FIGS. 3A3, 3B3, 3C3, 3Cc, 3D3, 3Dc, 3E3, 3Ec, 3F3, 3Fc, 3G3, 3Gc, 3H3, 3Hc, 3I3, 3Ic, 3Ig, 3J3, 3Jc, 3K3, and 3Kc correspond to the cross-sectional views of
The cross-sectional views of each of FIGS. 3F4, 3Fd, 3G4, 3Gd, 3H4, 3Hd, 3I4, 3Id, 3Ih, 3J4, 3Jd, 3K4, and 3Kd correspond to the cross-sectional views of
Referring to
In an example, the structure 100 or 170 of FIGS. 3A1-3A3 is formed using techniques to form such structures in GAA devices. In an example, the sacrificial material layers 303 comprises SiGe. The sacrificial material layer 303 is etch selective to the channel material layer 103, e.g., such that the sacrificial material layer 303 can be later etched and removed (e.g., during nanoribbon release process), without substantially etching the channel material layer 303. Individual ones of the sacrificial material layers 303 and the channel material layers 103 of the stack is formed using an appropriate deposition or epitaxial growth technique, such as chemical vapor deposition (CVD), physical vapor deposition (PVD), atomic layer deposition (ALD), vapor-phase epitaxy (VPE), molecular beam epitaxy (MBE), or liquid-phase epitaxy (LPE), for example. In one embodiment, etching the stack to define the fins can be performed using any suitable techniques for etching and defining fins. For example, regions to be processed into the fins are masked, followed by etching the surrounding regions to define the fins. For instance, an anisotropic etch proceeds substantially vertically through the upper fin portion to define isolation trenches between adjacent fins. In an example, the dummy gate structure 307 comprises dummy gate electrode, which may comprise poly-Si, for example. Also illustrated are isolation regions 104, such as shallow trench isolation (STI) regions 104 comprising dielectric material between adjacent sub-fins 105.
Referring again to the method 200 of
Referring again to the method 200 of
Note that FIGS. 3C1, 3C2, and 3C3 are for formation of the structure 100, while
As illustrated in FIG. 3C3, the source or drain trenches 314a, 314b, 314c, 314d are etched deeper, so as to extend within the sub-fin area, such that portions of the source or drain trenches 314a, 314b, 314c, 314d extending within the sub-fin 105 have a height of h1. In contrast, as illustrated in
So, depending on the process used, the source or drain trenches may be extended deeper within the sub-fin area 105 (e.g., up to a height of h1, see FIG. 3C3), or less deep within the sub-fin area 105 (e.g., up to a height of h2, see
Note that sections of the sub-fins are also etched during the process 212, such that the source or drain trenches extend into the sub-fin. In contrast, in general GAA devices, the source or drain trenches may not extend to such depths. For example, in FIG. 3C3, a portion of each of the trenches 314a, 314b, 314c, 314 are laterally between two sub-fin areas of two adjacent devices. Similarly, in FIG. 3C1, the sections of the sub-fins are removed, to form the trenches 314 between the isolation regions 104. The trenches are etched deeper, e.g., to facilitate formation of backside source or drain contacts, as described below. In an example, sections of the spacer 110 above the isolation region may be preserved, as illustrated in FIG. 3C1.
Referring again to the method 200 of
Note that a height of the dielectric materials 114a, 114b, 114c, 114d in FIG. 3D3 is more than a height of the dielectric materials 114a, 114b, 114c, 114d in
Referring again to the method 200 of
Note that the frontside source or drain contacts 125b and 125c are formed above the corresponding source or drain regions 126b and 126c, respectively, see FIGS. 3E3 and 3Ec. The source or drain trenches above the source or drain regions 126a and 126d are not opened, and hence, no frontside source or drain contacts are formed above the source or drain regions 126a, 126d. Also, each of the source or drain regions 126a, . . . , 126d has corresponding dielectric materials 114a, . . . , 114d, respectively, there below, as illustrated in FIGS. 3E3 and 3Ec. Each of the dielectric materials 114a, . . . , 114d is laterally between two sub-fins 105.
Referring again to the method 200 of
Note that the dielectric materials 114a, . . . , 114d are deeper in FIGS. 3F1-3F4, and hence, during the substrate 107 removal process, the lower surfaces of the dielectric materials 114a, . . . 114d are revealed in FIGS. 3F1, 3F2, 3F3, and 3F4. In contrast, the dielectric materials 114a, . . . 114d is less deep in
Because the wafer is flipped, the backside is above the frontside in the orientations of FIGS. 3F1, 3F2, and 3F3, and 3Fa, 3Fb, and 3Fc. The substrate is removed, for example with a mechanical polish process, or a chemical mechanical polish (CMP) process, or an etch process.
Referring again to the method 200 of
Referring again to the method 200 of
In contrast, in
The mask 320 may be of any appropriate type, and may include one or more layers (such as a tri-layer mask). The mask 320 comprises titanium nitride (TiN), tungsten doped carbide, or a carbon based hard mask, for example. The mask 320 defines openings for backside source or drain contacts.
Referring again to the method 200 of
In FIGS. 3I1-3I4, the dielectric material 114a, 114d exposed through the openings within the mask 320 are removed, e.g., etched, to form recesses 324. Note that the recesses 324 are self-aligned to the corresponding source or drain regions 126. For example, the recess 324a is self-aligned to the corresponding source or drain region 126a, and the recess 324b is self-aligned to the corresponding source or drain region 126b. This consequently results in the later formed source or drain contacts 140a, 140b being self-aligned to the source or drain regions 126a, 126d, respectively.
In
Thus, subsequent to process 236, one or more source or drain regions are now exposed from the backside. For example, FIGS. 3I3 and 3Ig illustrate dielectric material 114a being removed, resulting in recess 324a, and hence, the source or drain region 126a being exposed from the backside through the recess 324a. Similarly, FIGS. 3I3 and 3Ig also illustrate dielectric material 114d being removed, resulting in recess 324d, and hence, the source or drain region 126d being exposed from the backside through the recess 324d. The source or drain regions 126b, 126c are covered by the dielectric materials 114b, 114c, respectively, as the dielectric materials 114b, 114c are not removed for being covered by the mask 320. Note that the etch process may round off some of the surrounding dielectric material, such as dielectric material 106.
Referring again to the method 200 of
Referring again to the method 200 of
Note that the processes in method 200 are shown in a particular order for ease of description. However, one or more of the processes may be performed in a different order or may not be performed at all (and thus be optional), in accordance with some embodiments. Numerous variations on method 200 and the techniques described herein will be apparent in light of this disclosure.
Depending on its applications, computing system 1000 may include one or more other components that may or may not be physically and electrically coupled to the motherboard 1002. These other components may include, but are not limited to, volatile memory (e.g., DRAM), non-volatile memory (e.g., ROM), a graphics processor, a digital signal processor, a crypto processor, a chipset, an antenna, a display, a touchscreen display, a touchscreen controller, a battery, an audio codec, a video codec, a power amplifier, a global positioning system (GPS) device, a compass, an accelerometer, a gyroscope, a speaker, a camera, and a mass storage device (such as hard disk drive, compact disk (CD), digital versatile disk (DVD), and so forth). Any of the components included in computing system 1000 may include one or more integrated circuit structures or devices formed using the disclosed techniques in accordance with an example embodiment. In some embodiments, multiple functions can be integrated into one or more chips (e.g., for instance, note that the communication chip 1006 can be part of or otherwise integrated into the processor 1004).
The communication chip 1006 enables wireless communications for the transfer of data to and from the computing system 1000. The term “wireless” and its derivatives may be used to describe circuits, devices, systems, methods, techniques, communications channels, etc., that may communicate data through the use of modulated electromagnetic radiation through a non-solid medium. The term does not imply that the associated devices do not contain any wires, although in some embodiments they might not. The communication chip 1006 may implement any of a number of wireless standards or protocols, including, but not limited to, Wi-Fi (IEEE 802.11 family), WiMAX (IEEE 802.16 family), IEEE 802.20, long term evolution (LTE), Ev-DO, HSPA+, HSDPA+, HSUPA+, EDGE, GSM, GPRS, CDMA, TDMA, DECT, Bluetooth, derivatives thereof, as well as any other wireless protocols that are designated as 3G, 4G, 5G, and beyond. The computing system 1000 may include a plurality of communication chips 1006. For instance, a first communication chip 1006 may be dedicated to shorter range wireless communications such as Wi-Fi and Bluetooth and a second communication chip 1006 may be dedicated to longer range wireless communications such as GPS, EDGE, GPRS, CDMA, WiMAX, LTE, Ev-DO, and others.
The processor 1004 of the computing system 1000 includes an integrated circuit die packaged within the processor 1004. In some embodiments, the integrated circuit die of the processor includes onboard circuitry that is implemented with one or more integrated circuit structures or devices formed using the disclosed techniques, as variously described herein. The term “processor” may refer to any device or portion of a device that processes, for instance, electronic data from registers and/or memory to transform that electronic data into other electronic data that may be stored in registers and/or memory.
The communication chip 1006 also may include an integrated circuit die packaged within the communication chip 1006. In accordance with some such example embodiments, the integrated circuit die of the communication chip includes one or more integrated circuit structures or devices formed using the disclosed techniques as variously described herein. As will be appreciated in light of this disclosure, note that multi-standard wireless capability may be integrated directly into the processor 1004 (e.g., where functionality of any chips 1006 is integrated into processor 1004, rather than having separate communication chips). Further note that processor 1004 may be a chip set having such wireless capability. In short, any number of processor 1004 and/or communication chips 1006 can be used. Likewise, any one chip or chip set can have multiple functions integrated therein.
In various implementations, the computing system 1000 may be a laptop, a netbook, a notebook, a smartphone, a tablet, a personal digital assistant (PDA), an ultra-mobile PC, a mobile phone, a desktop computer, a server, a printer, a scanner, a monitor, a set-top box, an entertainment control unit, a digital camera, a portable music player, a digital video recorder, or any other electronic device or system that processes data or employs one or more integrated circuit structures or devices formed using the disclosed techniques, as variously described herein. Note that reference to a computing system is intended to include computing devices, apparatuses, and other structures configured for computing or processing information.
The following examples pertain to further embodiments, from which numerous permutations and configurations will be apparent.
Example 1. An integrated circuit structure, comprising: a device layer comprising a plurality of devices, the plurality of devices including (i) a plurality of source and drain regions, (ii) a plurality of gate stacks, and (iii) a plurality of gate spacers, each gate spacer separating a corresponding source or drain region from a corresponding gate stack, the gate spacers comprising a first dielectric material; a first source or drain contact coupled to a frontside of a first source or drain region of the plurality of source and drain regions; a second dielectric material coupled to a backside of the first source or drain region; and a second source or drain contact coupled to a backside of a second source or drain region of the plurality of source and drain regions; wherein the first dielectric material and the second dielectric material comprise the same elemental constituents.
Example 2. The integrated circuit structure of example 1, wherein a lower surface of the second dielectric material and a lower surface of the second source or drain contact are coplanar with each other within a tolerance of at most 3 nanometers (nm), wherein the lower surfaces of the second dielectric material and the second source or drain contact face a backside interconnect structure.
Example 3. The integrated circuit structure of any one of examples 1-2, further comprising: a third source or drain contact coupled to a frontside of a third source or drain region of the plurality of source and drain regions; and a third dielectric material coupled to a backside of the third source or drain region, wherein lower surfaces of each of the second dielectric material, the second source or drain contact, and the third dielectric material are coplanar within a tolerance of at most 5 nanometers (nm).
Example 4. The integrated circuit structure of any one of examples 1-3, further comprising: a frontside interconnect structure coupled to the first source or drain contact; and a backside interconnect structure coupled to the second source or drain contact.
Example 5. The integrated circuit structure of any one of examples 1-4, wherein a device of the plurality of devices comprises: the first source or drain region, with the first source or drain contact coupled to the frontside of the first source or drain region; the second source or drain region, with the second source or drain contact coupled to the backside of the second source or drain region; and one or more bodies comprising semiconductor material laterally extending from the first source or drain region to the second source or drain region.
Example 6. The integrated circuit structure of example 5, wherein the device of the plurality of devices comprises: a gate stack of the plurality of gate stacks, the gate stack at least partially wrapped around the one or more bodies; and the gate spacers comprising the first dielectric material between the first source or drain region and the gate stack, and wrapped an end portion of each of the one or more bodies.
Example 7. The integrated circuit structure of any one of examples 5-6, wherein each of the bodies comprise one of a nanoribbon, a nanowire, or a nanosheet.
Example 8. The integrated circuit structure of any one of examples 1-7, wherein the second source or drain contact comprises: a stepped sidewall having a first section and a second section, wherein the first section is stepped inward of the second section of the sidewall so as to provide a step section of the stepped sidewall, the step section extending more in the horizontal direction than in the vertical direction.
Example 9. The integrated circuit structure of example 8, wherein: a lower surface of the first section and a lower surface of the second dielectric material are coplanar within a tolerance of at most 3 nanometers (nm), wherein the lower surfaces of the second dielectric material and the second source or drain contact faces a backside interconnect structure.
Example 10. The integrated circuit structure of any one of examples 1-9, wherein: at least a part of a lower surface of the second dielectric material facing a backside of the device layer is at a first horizontal plane; at least a part of a lower surface of the second source or drain contact facing the backside of the device layer is at a second horizontal plane; and the first horizontal plane and the second horizontal plane is separated by a vertical distance of at least 3 nanometers.
Example 11. An integrated circuit structure, comprising: a first source or drain region; a second source or drain region; one or more bodies comprising semiconductor material laterally extending from the first source or drain region to the second source or drain region; a gate electrode at least in part wrapped around the one or more bodies; a spacer comprising a first dielectric material and between the first source region and gate electrode; a source or drain contact coupled to a backside of the first source or drain region; and a second dielectric material coupled to a backside of the second source or drain region; wherein the first dielectric material and the second dielectric material comprise the same elemental constituents.
Example 12. The integrated circuit structure of example 11, wherein the source or drain contact is a first source or drain contact, and wherein the integrated circuit structure further comprises: a second source or drain contact coupled to a frontside of the second source or drain region.
Example 13. The integrated circuit structure of any one of examples 11-12, wherein a lower surface of the second dielectric material and a lower surface of the source or drain contact are coplanar within a tolerance of at most 3 nanometers (nm).
Example 14. The integrated circuit structure of any one of examples 11-13, wherein: at least a part of a lower surface of the second dielectric material facing a backside interconnect structure is at a first horizontal plane; at least a part of a lower surface of the source or drain contact facing the backside interconnect structure is at a second horizontal plane; and the first horizontal plane and the second horizontal plane is separated by a vertical distance of at least 3 nanometers.
Example 15. The integrated circuit structure of any one of examples 11-14, wherein each of the first and second dielectric materials comprises silicon, and one or more of oxygen, nitrogen, and carbon.
Example 16. A method comprising: forming a first source or drain trench and a second source or drain trench, wherein the first and second source or drain trenches extend within respective sub-fin regions, and wherein a first end of a body is exposed through the first source or drain trench, and a second end of the body is exposed through the second source or drain trench, the body comprising a semiconductor material; depositing a first dielectric material within the first source or drain trench, to form (i) a first gate spacer that wraps around the first end of the body, and (ii) a portion of the first dielectric material at a lower section of the first source or drain trench extending within the sub-fin region; depositing a second dielectric material within the second source or drain trench, to form (i) a second gate spacer that wraps around the second end of the body, and (ii) a portion of the second dielectric material at a lower section of the second source or drain trench extending within the sub-fin region; forming a first source or drain region within the first source or drain trench, and above the portion of the first dielectric material; and forming a second source or drain region within the second source or drain trench, and above the portion of the second dielectric material.
Example 17. The method of example 16, further comprising: forming a frontside source or drain contact coupled to the first source or drain region.
Example 18. The method of example 17, further comprising: removing, from a backside of the second source or drain region, the portion of the second dielectric material, to form a recess on the backside of the second source or drain region, without removing the portion of the first dielectric material; and depositing conductive material within the recess, so as to form a backside source or drain contact coupled to the second source or drain region.
Example 19. The method of example 18, wherein removing the portion of the second dielectric material comprises: patterning a mask on the backside of the second source or drain region, the mask having an opening above the portion of the second dielectric material, and the mask covering the portion of the first dielectric material; and removing, through the opening within the mask, the portion of the second dielectric material.
Example 20. The method of any one of examples 17-19, further comprising: forming a frontside interconnect structure coupled to the frontside source or drain contact; and forming a backside interconnect structure coupled to the backside source or drain contact.
The foregoing description of example embodiments of the present disclosure has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims appended hereto.