The metal-oxide-semiconductor transistor device according to the present invention may be an NMOS, a PMOS, or a CMOS transistor device.
In the CMOS transistor device 10, the semiconductor substrate generally comprises a silicon layer 12, such as silicon substrate or silicon-on-insulator (SOI) substrate, but not limited thereto. The insulation region 16 may be, for example, a shallow trench isolation comprising a material, such as silicon oxide, for electric insulation of the active region 13 surrounded by the insulation region 16. The active region 13 may comprise a P type well or an N type well, P type well 14 for an NMOS transistor device and N type well 15 for a PMOS transistor device. The active region 13 may comprise drain/source regions 26 and 27 or drain/source regions 28 and 29, formed respectively in the well 14 or 15 and the epitaxial layer 24 at two sides of the gate structure. In an NMOS transistor device, the drain/source regions 26 and 27 are doped with N type dopants. In a PMOS transistor device, the drain/source regions 28 and 29 are doped with P type dopants. The drain/source region may further comprise a lightly doped drain region. The epitaxial layer 24 is disposed above the active region 13 and under the gate structure, that is, between the well and the gate structure. It should be noted that the epitaxial layer does not cover the entire insulation region 16, but is selectively formed on the surface of the substrate having a crystal structure, and only a peripheral portion 24a laterally extends onto a peripheral portion of the insulation region 16.
In such structure clearly shown in
The gate structure may comprise a gate insulation layer 18 and a gate electrode layer 20. The gate insulation layer may comprise dielectric material such silicon oxide. The gate electrode layer may comprise a conductive material such as poly-silicon. The gate structure may further comprise a spacer 22 for forming a lightly doped extension region in the drain/source region. Thereafter, the spacer may be kept in the structure or removed. The gate structure may further comprise an L-shaped liner formed between the spacer and the gate electrode layer and semiconductor substrate (not shown).
The MOS transistor device according to the present invention has a structure characterized by the epitaxial layer between the gate structure and the active region of the semiconductor substrate and the peripheral portion of the epitaxial layer lateral extends onto a peripheral portion of the insulation region. Therefore, the channel width is increased.
It is known that drain current of a MOS transistor device can be calculated from the channel length (L) and the channel width (W), which are determined by the manufacturing process. When the transistor is operated in a saturation mode, the magnitude of Id is determined after the channel length and the channel width are determined, as shown by the equation as follows:
W: channel width
L: channel length
μ: mobility
Cox: capacitance
Vg: gate voltage
Vt: threshold voltage
Therefore, when the channel width is increased, the Id is increased. The structure of the MOS transistor device according to the present invention as described above is characterized by the structure with a selective epitaxial layer, such that the channel width is wider than that obtained by conventional techniques. Therefore, Id is improved as compared to Id obtained by the conventional techniques. When the MOS transistor device is manufactured according to the present invention, a formation of the selective epitaxial layer is performed in addition to the processes used in conventional manufacturing techniques. The formation of the selective epitaxial layer does not affect the conventional processes, but can further increase Id compared to that obtained from the conventional processes, to more increase the performance.
Furthermore, since the upper layer of the channel under the gate insulation layer comprises a pure epitaxial layer, the concentration of the dopants diffused thereto will be less as compared to the concentration of the dopants in semiconductor substrate caused by the un-avoided diffusion in the process. Therefore, the Vt is advantageously decreased and the Id can be increased.
The MOS transistor device based on such structure can be used in various MOS transistor devices, such as the MOS transistor device shown in
Please refer to
Referring to
In the method according to the present invention, the formation of the epitaxial layer is performed after the insulation region 16 is formed and the silicon nitride layer is removed to expose the silicon layer 12, and may be performed before and after the formation of well. The formation of the epitaxial layer is preferably performed immediately after the silicon layer 12 is exposed, to prevent the crystal structure of the silicon layer from damage affecting the quality of the epitaxial crystal. Please refer to
In a preferred embodiment according to the present invention, the silicon epitaxial layer is formed by a selective epitaxial growth using gasses comprising, for example, dichlorosilane (DCS), hydrochloride (HCl), and hydrogen, at a process temperature lower than 800° C., through, for example, a reduced pressure chemical vapor deposition (RPCVD). In another embodiment of the present invention, the gasses used in the selective epitaxial growth process may comprise for example silane (SiH4) and chloride (Cl2). Other process, such as MBE (molecular beam epitaxy) or UHVCVD (ultra high vacuum chemical vapor deposition) process, may be used to form a silicon epitaxial layer. In other embodiments of the present invention, an epitaxial layer comprising silicon and germanium may be formed using, for example, dichlorosilane (SiH2Cl2) and germane (GeH4) through a low pressure chemical vapor deposition at a temperature of, for example, 500 to 800° C. and under a low pressure. In other embodiments, an epitaxial layer comprising silicon and carbon may be formed using, for example, SiH4 and methylsilane (SiH3CH3) through a low pressure chemical vapor deposition at a temperature of, for example, 500 to 800° C. and under a low pressure. The epitaxial layer may be formed with dopants together during the epitaxial growth process or be lightly doped using an ion implantation after the epitaxial growth, to adjust the threshold voltage (Vt) of the MOS transistor device.
Since the epitaxial layer grows from a crystal structure layer by layer upwardly to get thicker, the crystal lattice formed will be similar to the lattice of the exposed semiconductor substrate. The insulation region 16, such as a shallow trench isolation, comprises amorphous oxide material, and does not offer a growth place for the epitaxial layer, and the epitaxial layer will not grow from it. Therefore, in the method according to the present invention, the selective epitaxial growth is performed entirely on the semiconductor substrate, and it is sufficient to perform the SEG once to conveniently obtain the epitaxial layer on the desired place of the semiconductor substrate. It is not necessary for the epitaxial growth to be performed in stages or using an assist of patterned masks. It is noted that, in the method according to the present invention, the epitaxial layer grows upwardly from the surface of the active region, as well as gradually grows in lateral direction from the sidewall of the just-obtained epitaxial layer, and thus the finally obtained epitaxial layer has a peripheral portion extending onto the surface of a peripheral portion of the insulation region 16. As such, the channel width of the transistor device is increased and the drain current can be improved.
After the epitaxial layer is formed, an anneal process may be further performed to recover the lattice in defect.
Thereafter, a doped well is formed to obtain a structure as shown in
Alternatively, the well is formed before the epitaxial layer is formed. As shown in
After the selective epitaxial layer is formed, elements, such as gate structures, may be formed on the epitaxial layer. Please refer to
After the gate structure is formed, source/drain regions may be formed in the epitaxial layer and the well at two sides of the gate structure. For example, a lightly doped drain (LDD) process may be performed. Please refer to
After forming the spacer 22, an ion implantation process is carried out to dope dopant species, such as N type dopant species (such as arsenic, antimony or phosphorous) for making an NMOS or P type dopant species (such as boron) for making a PMOS, into the silicon layer 12, thereby forming a source/drain regions 26, 27 of an NMOS device and a drain/source regions 28, 29 of a PMOS device. After the source/drain doping, the substrate may be subjected to an annealing and/or activation thermal process that is known in the art.
A metal silicide layer 25 may be further selectively formed on the exposed silicon surface of the gate electrode layer 20, the exposed source/drain regions 26, 27, 28, and 29. The process known as self-aligned silicide (salicide) process may be utilized to fabricate metal silicide layer, in which a source/drain region is first formed, a metal layer is formed on the source/drain region and the gate structure, and a rapid thermal process (RTP) is performed to react the metal layer with the silicon contained within the gate structure and the drain/source regions to form a metal silicide. The temperature for RTP may be between 700 and 1000° C.
The spacers 22 may be kept in the structure or removed. After the spacers 22 are removed, approximately L shaped liners are left. The liners are not limited to the L shape. A mild etching process may be performed to slightly etch the liner for reducing the thickness. In other embodiments, the liner may be completely stripped away.
Strained silicon or other semiconductor manufacturing techniques may be further performed. For example, a contact etch stop layer (CESL) 23, such as a conformal silicon nitride cap layer, may be formed on the semiconductor substrate. The CESL 32 may be deposited in a compressive-stressed status (for example, −0.1 Gpa to −3 Gpa) for a PMOS or in a tensile-stressed status (for example, 0.1 Gpa to 3 Gpa) for an NMOS to render the channel region a compressive strain or a tensile strain, to improve carrier mobility in the channel, and thus to improve the Id. The stress status of the CESL 23 may be accomplished by thermal treatment, UV radiation, plasma enhanced chemical vapor deposition, or other methods known to those skilled in the art.
In another embodiment of the method according to the present invention, an epitaxial layer is formed after the well is formed. In such case, the order of forming the insulation region and forming the well is not particularly limited. For example, the step 112 may be performed first to form a well, then the step 101 is performed to form an insulation region, and thereafter the step 113 is performed to form a selective epitaxial layer.
Accordingly, it is noted that in the method of manufacturing a MOS transistor device, the step of forming a selective epitaxial layer should be after the insulation region is formed and before the gate structure is formed.
The embodiment described above is one example of the method of the present invention and there are various modifications. For example, a MBE (molecular beam epitaxy) or UHVCVD (ultra high vacuum chemical vapor deposition) process may be used to replace the RPCVD, or SiH4 may be used to replace dichlorosilane.
The wafer number 24 having a selective epitaxial layer and an insulation region obtained from the embodiment described above is used to manufacture a high voltage P type MOS (HVT PMOS) transistor device and a HVT NMOS. The wafer number 12 without a selective epitaxial layer is used to manufacture a high voltage P type MOS (HVT PMOS) transistor device and a HVT NMOS. The transistor devices made from the wafers number 24 and number 12 are compared with each other. Both have a same channel length. With a same channel length (Ldrawn), under an voltage application of 1V, as shown in
All combinations and sub-combinations of the above-described features also belong to the present invention. Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.