The present invention relates to semiconductor process technology and devices. In particular, the present invention relates to a method for modulating the effective work function of a gate electrode in a MOSFET device and the MOSFET device obtained by said method.
In the quest for CMOS scaling, alternative gate dielectrics exhibiting reduced leakage compared to the conventional SiO2-based materials are required. High-k gate dielectric films are being considered and, in particular, Hf-based gate dielectrics materials. However, severe limitations remain in the integration of conventional poly-Si gate electrodes with a high-k dielectric, such as HfO2. Indeed, despite improved leakage currents when using thin HfO2 films, problems are still observed, such as low yield and poor threshold voltage control.
In case of polysilicon on SiO2, the threshold voltage (Vt) of transistors can be tuned by doping the polycrystalline silicon (i.e., N or P type dopants). The doping of the poly-Si modifies the Fermi-level (FL) of the polysilicon, thus achieving the desired Vt for nMOS or pMOS. With the introduction of metal gates (in particular to avoid poly depletion effects), tuning by doping is no longer possible (since the FL of a metal gate electrode is set by the intrinsic workfunction of the metal or metallic compound used). Different solutions have been proposed to solve this problem of Vt control.
A first approach relates to the use of fully-silicided gates (FUSI gates) with the eventual addition of dopants that pile up at the interface. Partly because of diffusion of the siliciding species through the dielectric, this process is known to generate further problems with high-k dielectrics, such as HfO2 dielectric. Moreover, it is difficult to control the silicidation process up to the interface between the gate electrode and the gate dielectric.
In a second approach, the gate electrode composition and deposition chemistry is changed to achieve the desired work function and thus the desired Vt. But very few candidates can meet the requirements in terms of stability, compatibility, etc., having regard to the different thermal and chemical treatments applied.
In a third approach, the whole dielectric material is changed to achieve the desired band alignment. Similarly, very few candidates can meet the requirements in terms of performance, mobility, leakage, reliability, etc.
Hence, there is a need for a method for manufacturing MOSFET devices in which the effective work function and the threshold voltage of the metal gate electrode of each transistor type can be controlled in an easy, reproducible and efficient way.
The present invention is based on the surprising discovery that the electrostatic potential at the interface between the gate electrode and the gate dielectric of a MOSFET device can be controlled by introducing one or more interfacial layer(s) of a dielectric material, at the monolayer(s) level (i.e., preferably two monolayers), between the gate electrode and the gate dielectric.
The present invention relates to a MOSFET device comprising, between a semiconductor substrate and a gate electrode:
Said dielectric material of said interfacial layer is different from said gate dielectric material it contacts for forming the interface with the gate electrode. Said interfacial layer of a dielectric material preferably consists of less than about 10 monolayers, preferably of less than 5 monolayers, more preferably of one, two or three monolayer(s). Preferably, said at least one layer of dielectric material comprises (or consists of) any suitable high-k (i.e., k>3.9) material. Preferably, said at least one layer of dielectric material comprises (or consists of) hafnium-oxide, more particularly comprises (or consists of) HfO2.
Said interfacial layer can comprise (or consist of) any of Ca, Li, Mg, Lu Nd, Fr, Ra, (Na,K), Cs, Rb, Ba, Sr, La, Y, Zr, Ru, W based oxides, preferably comprises (or consists of) a La containing high-k material, more preferably comprises (or consists of) a La containing HfO2 high-k material, such as La2Hf2O7. Said interfacial layer can also comprise (or consist of) dysprosium oxide, scandium oxide or dysprosium scandate.
Preferably, said gate electrode comprises (or consists of) a metal gate electrode. Said metal gate electrode can comprise (or consist of) W, Ta, Pt and/or Mo, preferably TiN, TaN and/or Ru.
A method for the manufacture of such a MOSFET device is provided. More particularly, a method of forming a gate in a MOSFET, FinFET or memory device, is provided, comprising the steps of:
In a method according to the invention, said interfacial layer can be deposited by means of Atomic Layer Deposition, by means of Chemical Vapor Deposition, preferably by means of Molecular Beam Epitaxy (MBE), more preferably by means of UltraHigh Vacuum MBE (UHV MBE). Preferably, a method according to the invention further comprises an annealing activation step, wherein the temperature applied can vary from about 700° C. to about 1100° C. Preferably, a method according to the invention further comprises FGA step. Preferably, said gate electrode forming step comprises depositing in-situ a gate electrode layer, which can be performed by sputtering.
A method according to the invention can be used in particular for modulating the effective work function of said metal gate electrode.
These as well as other aspects and advantages will become apparent to those of ordinary skill in the art by reading the following detailed description, with reference where appropriate to the accompanying drawings. Further, it is understood that this summary is merely an example and is not intended to limit the scope of the invention as claimed.
Presently preferred embodiments are described below in conjunction with the appended drawing figures, wherein like reference numerals refer to like elements in the various figures, and wherein:
In a MOSFET device, the interface between the gate dielectric and the gate critically determines the effective work function and thus, the MOSFET Vt.
A new MOSFET device is provided, comprising, between a semiconductor substrate and a gate electrode, a gate dielectric comprising (or consisting of) at least one layer of a dielectric material having (or for meeting) ((pre-)determined) mobility, leakage, and/or EOT specifications and, at the interface between said gate dielectric and said gate electrode, an interfacial layer of a dielectric material, different from the dielectric material of the gate dielectric it contacts, for modulating the effective work function of said metal gate.
By providing a chemical bond polarization layer (also referred to herein as “guest layer,” “interfacial layer,” “interlayer,” “interface polarization layer,” or as “dipole polarization layer”) at a monolayer (ML) level (i.e., one monolayer to about 10 monolayers, preferably one to about five monolayers, more preferably about 2 monolayers), the effective work function of the metal gate electrode can be modulated.
More particularly, by depositing an ultra-thin interfacial layer of dielectric material, e.g., by ALD deposition, or preferably in a ultrahigh vacuum (UHV) Molecular Beam Epitaxy (MBE) chamber, the electrostatics potential at the interface (between the gate dielectric and the gate electrode) is modified, offering means to control the work function.
In the context of the present invention, the term “monolayer” is meant to encompass the term “sub-monolayer” and refers to a layer one molecule thick, without necessarily implying, a uniform and/or total coverage of the surface concerned. Preferably, the term “monolayer” is meant to refer to a layer of sufficient amount of material to achieve full surface coverage, i.e., to achieve full closure of the film, such that no atom of the surface to be covered is exposed (left uncovered).
Said interfacial layer can comprise or consist of any suitable material used as dielectric material in MOSFET devices and is different from the gate dielectric material forming the interface (i.e., it contacts). In particular, said material can comprise or consist of SiO2, SiON, HfO2, HfSiO, HfZrO, HfZrSiO, HfZrSiON, HfSiON, Al2O3, HfAlOx, and possibly other Hf and Zr based dielectrics. Preferably, said interfacial layer comprises or consists of any of Ca, Li, Mg, Lu Nd, Fr, Ra (Na,K) based oxides, or Al2O3, or preferably any of Cs, or Rb, Ba, Sr, La, Y, Zr, Ru, W based oxides. More preferably, said interfacial layer comprises or consists of LaHfOx (lanthanum hafnium oxide), DyOx, ScOx, or DyScOx (dysprosium scandate). More preferably, said interfacial layer comprises or consists of La2Hf2O7.
Preferably, said interfacial layer consists of less than about 10 monolayers, preferably of less than 5 monolayers, more preferably consists of one, two or three monolayers. Preferably, said interfacial layer of dielectric material is submitted to a high temperature treatment, more particularly to a temperature higher than 700° C. or 800° C., preferably higher than 900° C., more preferably comprised between about 700° C. and about 1100° C. Said high temperature treatment can be applied during a period that can vary from few milliseconds to few minutes, preferably from (about) is to (about) 20 min.
In particular, said interfacial layer can comprise a metal element, the electro-negativity of which has to be sufficiently different from that of the metal element (if any) of the gate dielectric. Additionally it is preferred that the electro-negativity of the metal element of the guest dielectric (interfacial layer) is also sufficiently different from that of the metal element of the metal gate. More particularly, the electro-negativity difference between the metal in the guest dielectric and the metal in one of the surrounding materials (host dielectric or metallic gate) is larger than 0.05 Pauling units, preferably larger than 0.1 Pauling units, more preferably larger than 0.4 Pauling units.
For some materials, in particular those reacting with the adjacent layers, said interfacial layer may not be defined in terms of thickness.
Said gate dielectric can comprise or consist of at least one layer of a dielectric material. Preferably, said gate dielectric consists of one layer of a dielectric material. Said dielectric material can comprise or consist of SiO2, SiON, HfO2, HfSiO, HfZrO, HfZrSiO, HfZrSiON, HfSiON, Al2O3, HfAlOx, and possibly other Hf and Zr based dielectrics. More particularly, said dielectric material comprises (or consists of) any suitable high-k (i.e., k>3.9) material.
Preferably, said gate dielectric material comprises or consists of HfO2 or SiO2. Preferably, said gate electrode is a metal gate electrode (e.g., any metal gate electrode suitable for MOSFET devices). More particularly, said metal gate electrode can comprise or consist of W, Ta, Pt or Mo. More preferably, said metal gate electrode comprises or consists of TiN, TaN or Ru.
The present invention also relates to a new method for the manufacture of a MOSFET device according to the invention. In particular, a method of the invention can be used for modulating the effective work function of a gate electrode in a MOSFET device. More particularly, a method of the invention comprises the steps of:
In a method according to the invention, the material used for said interfacial layer is different from said gate dielectric material it contacts. Preferably, said interfacial layer consists of less than about 10 monolayers, preferably of less than 5 monolayers, more preferably of one, two or three monolayers.
Depending on the material used, said interfacial layer can be deposited by means of Chemical Vapor Deposition (CVD), by Atomic Layer Deposition (ALD), or preferably by means of Molecular Beam Epitaxy (MBE), and more preferably by means of UltraHigh Vacuum Molecular Beam Epitaxy (UHV MBE). More particularly, when said interfacial layer consists of DyOx, ScOx, or DyScOx, CVD or ALD can be used. When said interfacial layer consists of LaOx, WOx, or SrOx, the deposition can be performed by spinning followed by oxidation.
A method according to the invention can further comprise an annealing activation step (also referred to as a high temperature treatment). Preferably, the temperature is higher than about 700° C., 800° C., or 900° C.; and more particularly comprised between about 700° C. and about 1100° C. The high temperature treatment can be applied during a period of time varying between few milliseconds to few minutes, e.g., 1 ms to 20 min.
Preferably, a method according to the invention further comprises a Forming Gas Anneal (FGA) step.
In a method according to the invention, said gate electrode forming step preferably comprises (or consists of) depositing in-situ a gate electrode layer, more particularly by sputtering.
A method according to the invention can further comprise a capping step, whereby a capping layer is formed upon said gate electrode, such as a TiN capping layer.
In a method according to the invention, said gate electrode comprises (or consists of) a metal gate electrode.
The materials that can be use in a method according to the invention are those defined for a MOSFET of the invention.
Preferably, the gate material is deposited in-situ, after depositing said interfacial layer.
According to a preferred embodiment, the gate electrode is a metal gate electrode, preferably consisting of TaN, the gate dielectric consists of HfO2, and the interfacial layer consists of two monolayers of La2Hf2O7. Accordingly, in a preferred method of the invention, the gate electrode is a metal gate electrode, preferably consisting of TaN, the gate dielectric consists of HfO2, and the interfacial layer consists of two monolayers of La2Hf2O7.
A method of the invention can also be used for the manufacture of further devices such as FinFET devices or memory devices. Accordingly, FinFET and/or memory devices are also objects of the present invention.
High-k dielectrics featuring HfO2 or La2Hf2O7 (LHO) were considered. These dielectrics were deposited either by atomic layer deposition (using HfCl4 and H2O as chemical precursors) or by Molecular Beam Epitaxy on 200 mm-Si wafers. The 10 nm thick TaN metal gate (also referred to as MG) was deposited by sputtering, in- or ex situ, and capped with 70 nm TiN. Overlapping MOS Capacitors were processed in a conventional flow. MOSFETs were processed using an etched gate and encapsulating spacer. Several temperatures of activation anneal (high temperature treatment) were evaluated, followed by FGA (Forming Gas Anneal(ing)).
In some experiments, the effective WF was extracted using C-V measurements. This was done on capacitors where the high-k was deposited on a thick SiO2 whose thickness is varied by chemical etching (slant etch). Further measurement of the potential barrier between the gate electrode and the dielectric has been done using the internal photoemission (IPE). In the IPE experiment, an ultraviolet light source is used to excite electrons in the MG (see inset of
For HfO2 and LHO grown on (100) Si substrates, the IPE reveals the same energy barrier between the top of the Si valence band and the bottom of the oxide conduction band. This is illustrated by the IPE spectra shown in
In contrast to the Si/dielectric interface, the composition of the dielectric has a significant influence in the band alignment of the dielectric/MG interface. For the same integration scheme and TaN MG considered, the effective WF is 3.9 eV and 4.5 eV for respectively MBE LHO and MBE HfO2 (see
Since all the interactions responsible for eWF changes are limited to the interfacial layer between the MG and the dielectric, the eWF can be tuned by monolayer (ML) controlled deposition of a guest dielectric (interfacial layer) on top of a well known gate dielectric. This concept is illustrated in
Feasibility of eWF tunability is demonstrated in
Direct measurement of the energy barrier between the TaN Fermi Level and the oxide conduction band using IPE electrons proves the finding regarding the barrier lowering by the LHO interlayer. As shown in the Fowler plot of the IPE yield of
Referring to FIGS. 8 to 10, a La, Sr or W based oxide was deposited on SiO2 and HfO2 respectively by spin contamination form nitride based standard solutions. The depositions were tuned to deposit a metal dose of approximately 5e12 and 5e13 atoms/cm2 for each of the used species. Assuming only the metal would be present, a dose of 5e12 and 5e13 atoms/cm2 would correspond to a sub-monolayer and approximately a monolayer coverage. However, due to the fact that the considered species oxidize easily in air, and the volume of their oxides is bigger than that of the pure metals, the monolayer coverage is most likely reached with the 5e13 atoms/cm2 dose.
Natural oxidation of the considered species occurs (or at least is expected to occur) after deposition of the metal species.
The interfacial layers were combined with both ALD TiN and PVD TaN gates.
Effective WF extractions were based on the CV based method (VFB vs. EOT extrapolation) using a slant etched SiO2 (allowing the EOT variation in one wafer); that was or was not capped with HfO2 depending on the case considered. Effective WF extractions were both done after [520° C. FGA during 20 min] and [950° C., 30 s N2 anneal +520° C. FGA during 20 min].
In order to confirm the cause of this effective WF shift, the interface electrostatic potential between the high-k dielectric and the metal gate was calculated based on an atomic interface model, calculating the charge distribution in the interface region using the electronegativities of the involved elements. To model the guest capping oxide some of the metal elements of the host oxide (Si or Hf) are replaced by those of the guest oxide (Rb, Sr, Zr, Ru, Cd, Ba, La, Ce, Pr, W) in the upper atomic layers of the host oxide, as such forming an effective layer or sub-monolayer of the guest oxide.
These calculations indicate that an effective WF change can be obtained by changing both the guest dielectric as well as the amount of guest dielectric at the sub-monolayer to monolayer level (see FIGS. 11 to 14).
It should be understood that the illustrated embodiments are examples only and should not be taken as limiting the scope of the present invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.
Number | Date | Country | Kind |
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EP 06447071.9 | May 2006 | EP | regional |
The present patent application claims priority under 35 U.S.C. § 119(b) to EP 06447071.9, which was filed May 29, 2006. The full disclosure of EP 06447071.9 is incorporated herein by reference.