Different types of transistors may be formed in a semiconductor material. One type is the Fin-Field Effect Transistor. The active region of a Fin-FET includes a section having the shape of a ridge. A predetermined portion of that section is surrounded by the gate insulating material and the gate electrode. Thus the current path (the channel) is controlled by the gate electrode from two or more sides.
Fin-FETs may be manufactured as transistors in a semiconductor material on a SOI-substrate. Thus the active region is vertically limited by the underlying insulating material. Another possibility to form a Fin-FET includes defining an active region in a bulk semiconductor material, wherein the fin-portion, that is that section of the active area that has the shape of a ridge forms a part of the semiconductor material and is laterally delimited by an insulating material.
While defining the active region and forming the gate insulating material and the gate electrode are well known processes in manufacturing a Fin-FET, defining the source and the drain region in the active region is a process causing several difficulties. Especially methods for bringing in dopants into the fin-portion are desired, which do not cause lattice defects in the semiconductor material and which are not affected by small spaces between neighboring fin-portions.
For these and other reasons, there is a need for the present invention.
The accompanying drawings are included to provide a further understanding of embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and together with the description serve to explain principles of embodiments. Other embodiments and many of the intended advantages of embodiments will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.
In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
It is to be understood that the features of the various exemplary embodiments described herein may be combined with each other, unless specifically noted otherwise.
In one embodiment, the method of doping a fin may further include providing a first cover layer over a predetermined section of the fin before carrying out the gas-phase doping. The first cover layer prevents the semiconductor material of the predetermined section from being doped during the gas-phase doping or retards the entry of dopants into the semiconductor material of the predetermined section from the gas phase. The first cover layer may include any material, which is suited for preventing the predetermined section from an undesired doping during subsequent gas-phase doping. The first cover layer may for instance include Al2O3, SiN or TiN.
The dopant concentration within the semiconductor material of the fin may be higher than 1·1020 cm−3 after carrying out the gas-phase doping and may be defined by the process parameters of the gas-phase doping, like for instance gas pressure, temperature and time.
The difference between the maximum and the minimum of the dopant concentration within the semiconductor material of the fin not covered by a first cover layer may be less than or equal to factor 2. Accordingly, a very good homogeneity of dopant concentration may be accomplished.
In one embodiment, the described method may further include providing a second cover layer over the fin outside the predetermined section. The second cover layer may include any material, which is suited to retard the entry of dopants into the semiconductor material from the gas phase. It may include the same or other materials than the first cover layer. The diffusion coefficient of the dopants through the second cover layer is higher than the diffusion coefficient of the dopants through the first cover layer. This may be achieved by providing the second cover layer with a smaller thickness than the thickness of the first cover layer over the predetermined section, for instance if the same materials for the first and the second cover layer are used, or by using different materials for the first and the second cover layer. The second cover layer improves the homogeneity of the dopant concentration within the semiconductor material of the fin and allows to better control the amount of dopants within the semiconductor material.
In one embodiment, the described method may further include creating lattice imperfections within the fin before carrying out the gas-phase doping. The lattice imperfections enhance the diffusion of dopants within the semiconductor material. If lattice imperfections are created in the fin only outside a predetermined section covered by a cover layer, the difference between the enhanced diffusion outside the predetermined section and the intrinsic diffusion within the predetermined section limits the diffusion of dopants into the predetermined section, thus allowing to control the spatial distribution of the dopants.
The active region may be defined by patterning the semiconductor material, like for instance by etching. The active region includes a section having the shape of a ridge. This section is also called fin-portion. In the fin-portion, a current path or channel between a source region and a drain region of the transistor is to be formed, wherein the conductivity of the current path may be controlled by a gate electrode.
A first predetermined portion of the fin-portion is covered with a first cover layer (S12). The first predetermined portion includes at least that portion of the fin-portion, in which the current path is to be formed and to be controlled by the gate electrode of the transistor. The first cover layer may, for instance, include a gate insulating layer adjacent to the semiconductor material and a gate electrode adjacent to the gate insulating material. Nevertheless, the first cover layer may include any other material, which is suited for preventing an undesired doping of the first predetermined portion during subsequent processing. The first cover layer may for instance include Al2O3, SiN or TiN. Furthermore, the first cover layer may include a gate insulating layer, the gate electrode and a covering layer suited for preventing an undesired doping of the gate electrode during subsequent processing. The first cover layer covers the side portions and the upper portion of the first predetermined portion of the fin-portion. The first cover layer may be formed by any suited process, like for instance a CVD (Chemical vapour deposition) process or an ALD (Atomic layer deposition) process.
Next a source region and a drain region in the active region are provided, wherein this process includes carrying out a gas-phase doping process (S13). Gas-phase doping is a doping process wherein dopants are provided from a gaseous source and diffuse into a substrate, in this case the semiconductor material of the active region. At least that portions of the source and the drain region formed within the fin-portion are provided by the gas-phase doping. Portions of the source and the drain region outside the fin-portion may be provided using other doping processes, like for instance ion-implantation or selective doped epitaxy, but may be provided using gas-phase doping as well.
Accordingly, source and drain regions may be provided without destroying or deteriorating the lattice structure of the semiconductor material of the active region in the fin-portion. Furthermore, the doping process is not affected by geometrical limitations like for instance a plurality of neighboring fin-portions arranged with a small distance to each other, like it is the case for doping by ion implantation, for instance through shadowing effects.
A gate electrode 24 is formed above a first predetermined portion of the fin-like portion 23. The gate electrode 24 may include an electrically conductive material, like for instance a heavily doped semiconductor material or a metal, or a layer stack of electrically conductive materials. Spacers 25 formed of an insulating material may be arranged at the side portions of the gate electrode 24. The spacer 25 may insulate the electrically conductive material of the gate electrode 24 from the fin-like portion 23 at side portions, and an insulating material may be arranged between the fin-like portion 23 and the gate electrode 24, wherein the insulating material may form the gate insulator of the transistor 10. The gate electrode 24 is configured to control the conductivity of the semiconductor material 20 in a channel region of the transistor 10 arranged in the first predetermined portion of the section 23. The channel region is arranged between a source and a drain region of the transistor 10, wherein the source region includes the first or the second doped region 21, 22 and wherein the drain region includes the other doped region 21, 22. The source and the drain region may extend into the fin-like portion 23 except the first predetermined portion covered by the gate electrode 24.
Nevertheless, a plurality of individual fin-like portions 23 may be formed between the first and the second doped portion 21, 22, forming a plurality of channels. The gate electrode 24 and the insulating material may be formed at first predetermined portions of a plurality of individual fin-like portions 23. Furthermore, the gate electrode 24 and/or the insulating material of individual fin-like portions 23 may form a common gate electrode 24 and a common insulating material for a plurality of individual fin-like portions 23, respectively.
Next, a first cover layer 51 may be formed above the semiconductor material 20, the first cover layer 51 covering at least a first predetermined portion of the section 23. The first cover layer 51 may include different materials or a layer stack of different materials. It may for instance cover other layers formed on top of the semiconductor material 20 within the first predetermined portion, like for instance a gate insulating material, a gate electrode material or a spacer material. The lateral extension of the first cover layer 51 may be larger than the lateral extension of other layers formed on top of the semiconductor material 20 within the first predetermined portion. Furthermore, the cover layer 51 may cover other portions of the active area 201 as well, like for instance portions outside the section 23. Nevertheless, different cover layers having different materials or having different thicknesses may be formed above different portions of the active area 201.
The cover layer 51 may have a thickness of more than or equal to 2 nm. The cover layer may have a thickness of less than or equal to 5 nm. The thickness should be sufficient to prevent diffusion of dopants into the covered semiconductor material 20. Furthermore, the cover layer 51 may serve as a stress liner, inducing a predetermined stress, for instance a tensile stress, into the underlying semiconductor material 20, thereby changing the charge carrier mobility. A SiN layer, for instance, induces a tensile stress. Nevertheless, other materials, like for instance other semiconductor nitrides or oxides, may induce a stress into the underlying materials. In this case the thickness of the cover layer 51 should be larger than 20 nm. It may be smaller than 50 nm, wherein the thickness is limited by the lateral space of the section 23 to neighboring sections 23 or to other neighboring structures.
As described with respect to
A gas-phase doping (GPD-) process is carried out to form doped regions within the active region 201. The GPD-process may use AsH3 or PH3 as gases providing dopants for n-type doping or BH3 as gas providing dopants for p-type doping. Nevertheless, other gases providing dopants may be used. The molecules of the doping gas dissociate at surfaces being exposed to the gas thereby releasing dopants. The dopants may diffuse into the semiconductor material not being covered by the first cover layer 51. The cover layer 51 limits the diffusion of dopants such that the conduction type of the underlying material is not changed. A first and a second doped region 21, 22 are formed within the semiconductor material 20 in that portions which are not covered by the cover layer 51. The resulting structure is illustrated in
The GPD-process may be carried out by temperatures between 400° C. and 900° C., for example between 600° C. and 700° C., for a predetermined time period, like for instance 30 minutes. The GPD-process may be carried out as a batch process in a tube for a plurality of carriers including the semiconductor material 20 or may be carried out as a single carrier process in a respective tool. The thermal budget, that is the time-temperature effect on the semiconductor material, may be limited by the rounding effect of hydrogen, which may be contained in the gas, on the semiconductor material. This is for instance of concern, if silicon is used as the semiconductor material formed on an insulating material, like it is the case for a SOI-substrate.
The resulting concentration of dopants within the semiconductor material may be controlled by the concentration and the pressure of the gas and the used temperature and the time of the GPD-process. The maximum concentration of dopants within the semiconductor material should be as high as possible, like for instance higher than 1·1020 cm−3.
Accordingly, a very good homogeneity of dopant concentration across the semiconductor material 20, especially within the section 23, may be accomplished. The difference between the maximum concentration at the surface of the semiconductor material and the minimum concentration found in the center of the section 23 may be around a factor 2 or may be less. Furthermore, no problems with shadowing effects of neighboring structures occur and the semiconductor material 20 will not get amorphous.
If a further thin cover layer is formed above the semiconductor material 20 of the section 23 as described above, the maximum dopant concentration and the homogeneity of the dopant concentration within the semiconductor material 20 may be controlled. The doping process may then be controlled rather by the diffusion coefficient of the dopants through the further thin cover layer than by the amount of dopants released from the gas.
In order to increase the diffusion of dopants into the semiconductor material and in order to limit the diffusion of dopants into the predetermined portion of section 23, which is covered by the cover layer 51, the diffusion coefficient of the dopants may be increased in the semiconductor material 20 outside the predetermined portion by creating additional, non-intrisic, lattice-defects like interstitials. For instance, a process inducing crystal damages or lattice imperfections may be carried out before carrying out the gas-phase doping. By way of example, an ion-implantation process with predetermined species may be carried out after covering the predetermined portion of the section 23 and before carrying out the gas-phase doping. The predetermined species, like for instance C, F, Si, Ge or dopants like As, P or B, create lattice imperfections within the active region 201 outside the predetermined portion. The lattice imperfections enhance the diffusion of dopants, whereas the diffusion of dopants is limited by the intrinsic diffusion coefficient in the predetermined portion having no additional lattice imperfections. The implanted species, like for instance C, may remain within the semiconductor material. The implanted species, like for instance F, may be implanted into a material lying beneath the semiconductor material 20, like for instance the insulating material 36 as illustrated in
A second cover layer 52 may be formed above second predetermined portions of the active region 201, as is illustrated by way of example in
In the example illustrated in
In the example illustrated in
Nevertheless, it is possible to form the second cover layer 52 and to carry out a further doping process before carrying out the first gas-phase doping process.
Furthermore, it is possible to carry out an additional process, like for instance a selective epitaxy process before carrying out the first gas-phase doping process. Such an epitaxy process is selective, since a layer growth takes place only on a monocrystalline semiconductor material. To put it more precisely, a selective epitaxy process illustrates a net growth rate larger than zero on a monocrystalline semiconductor material and a net growth rate equal to zero on other materials. As a consequence, the semiconductor material grows only on the monocrystalline surface regions.
The epitaxy process may include partially removing the semiconductor material 20 of the active region 201 and forming a semiconductor material at the place of the removed material. At least the first predetermined portion of the section 23, that is the channel, may be not removed. The semiconductor material 20 of the active region 201 outside the first predetermined portion may be removed partially and may be replaced by the new semiconductor material formed by the epitaxy process. The new semiconductor material may be formed by a doped epitaxy process, that is an epitaxy process using materials having dopants, and may have a predetermined conduction type, which may for instance be opposite to the conduction type of the removed semiconductor material 20. The new semiconductor material may be formed by an epitaxy process using materials not having dopants. The new semiconductor material may be the same semiconductor material as the original semiconductor material, like for instance silicon, or may be another semiconductor material, like for instance SiGe or Si:C, that is silicon containing carbon additive, for example at most 3 at-% carbon.
At least one second active region in a semiconductor material is defined (S72). The second active region includes a second section having the shape of a ridge. A plurality of second active regions each second active region having a second section having the shape of a ridge may be defined.
The semiconductor material may be the same for the first and the second active region and may be similar to the substrate defined above. Nevertheless, the semiconductor material of the first active region may be another than that of the second active region.
The active regions may be defined by patterning the semiconductor material, like for instance by etching. Each active region includes at least one section having the shape of a ridge. These sections are also called fin-portions. In the fin-portions, a current path or channel between a source region and a drain region of a transistor is to be formed, wherein the conductivity of the current path may be controlled by a gate electrode. At least one active region may include a plurality of fin-portions.
A first cover layer may be formed above the semiconductor material of a first predetermined portion of the first section, and a second cover layer may be formed above the semiconductor material of a first predetermined portion of the second section (S73). The first and the second cover layer may include the same materials and/or may have the same thickness. The first predetermined portions of the first and the second section include that part of the first and the second section, where the channel is to be formed. The first and the second cover layer may be formed as described above. Nevertheless, the first and the second cover layer may include different materials and/or may have different thicknesses.
Next, a source and a drain region in the first active region are provided, wherein this process includes carrying out a first gas-phase doping (S74). The source and the drain region may be provided as described above.
Next, a source and a drain region are provided in the second active region (S75). This may be accomplished by carrying out a process including a gas-phase doping or by carrying out another process, like for example a selective epitaxy process using materials having dopants.
The second transistor includes a second active region 802 defined in a second semiconductor material. The second semiconductor material may be the same or a different material like the first semiconductor material. The second active region 802 includes a source and a drain region 85, 86 and a second section 87 having the shape of a ridge. The second transistor includes a second gate electrode 88 formed above a predetermined portion of the section 87. A second gate insulator material is arranged between the semiconductor material of the section 87 and the second gate electrode 88. The second gate insulator material may be the same as the first gate insulator material or may be a different material. Spacers (not illustrated) may be arranged at the sides of the gate electrode 88. The source and the drain region of the first active area 801 may have the same or a different conduction type like the source and the drain region of the second active area 802. The source and the drain region 81, 82 and/or the section 83 of the first active area 801 may have the same dimensions as the source and the drain region 85, 86 and the section 87 of the second active area 802, respectively.
The source and the drain region 81, 82 of the first transistor are provided in the first active area 801 by carrying out a process having a first gas-phase doping process as described above. The first gas-phase doping process uses a gas having dopants of an desired conduction type. The process for providing the source and the drain region 81, 82 may further include other doping processes as described above. The resulting structure is illustrated in
Next, the third cover layer 93 may be partially removed, for instance by a wet or a dry etching process, and a fourth cover layer 94 is formed above the first active region 801. If the second cover layer 92 is not yet formed, it is formed above a first predetermined portion of the section 87. If the third cover layer 93 is not removed from the first predetermined portion of the section 87, it may serve as the second cover layer 92. A sixth cover layer (not illustrated) may be formed above the second active area 802. The sixth cover layer may be formed at least above the section 87 outside the second predetermined portion. The sixth cover layer may include the same material as the second cover layer 92 or may include other materials. It retards the diffusion of dopants into the semiconductor material as described with respect to
The source and the drain region 85, 86 of the second transistor are provided by a process which may include a second gas-phase doping process or may include another doping process, like for instance a selective epitaxy process using materials having dopants. The resulting structure is illustrated in
The fourth cover layer 94 may be removed subsequently. The first and the second cover layer 91, 92 may be removed or may remain above the first predetermined portions as well as the fifth and the sixth cover layer. At least one of the cover layers may be configured to induce a predetermined stress into the underlying semiconductor material.
The third and the fourth cover layer may be formed of the same materials and/or with the same thicknesses as the first and the second cover layer, respectively. Nevertheless, they may be formed of other materials or with other thicknesses, as long as they prevent an undesired doping or processing of the underlying regions.
As described above, a conduction type of the source and the drain region 81, 82 of the first transistor may be a first conduction type which may be different from a second conduction type of the source and the drain region 85, 86 of the second transistor. The first conduction type may be n-type, and the second conduction type may be p-type.
The transistor fabricated by the described method may be a SOI-FinFet, a local SOI/bulk-FinFet or a bulk-FinFet. The integrated circuit fabricated by the described method may for instance be a DRAM with a high current flow per area or a capacitor-less DRAM or another memory device or a logic circuitry or a processor. The fabricated transistors or integrated circuits may be used in low-leakage devices, logic devices, high-voltage devices, high-speed devices, low-standby-power devices or battery-operated or mobile systems, like for instance in a mobile RAM.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adoption or variations of the specific embodiments discussed herein. Therefore it is intended that this invention be limited only by the claims and the equivalents thereof.