1. Field of the Disclosure
The present disclosure generally relates to the formation of semiconductor devices and, more specifically, to various methods of forming nanowire devices with MIS (Metal-Insulator-Semiconductor) source/drain contacts and the resulting devices.
2. Description of the Related Art
The fabrication of advanced integrated circuits, such as CPUs (central processing units), storage devices, ASICs (application specific integrated circuits) and the like, requires the formation of a large number of circuit elements in a given chip area according to a specified circuit layout, wherein so-called metal oxide semiconductor field effect transistors (MOSFETs or FETs) represent one important type of circuit element that substantially determines performance of the integrated circuits. A FET is a planar device that typically includes a source region, a drain region, a channel region that is positioned between the source region and the drain region, and a gate structure positioned above the channel region. These elements are sometimes referred to as the source, drain, channel and gate, respectively. Current flow through the FET is controlled by controlling the voltage applied to the gate electrode. For example, for an NMOS device, if there is no voltage applied to the gate electrode, then there is no current flow through the NMOS device (ignoring undesirable leakage currents, which are relatively small). However, when an appropriate positive voltage is applied to the gate electrode, the channel region of the NMOS device becomes conductive, and electrical current is permitted to flow between the source region and the drain region through the conductive channel region.
To improve the operating speed of FETs, and to increase the density of FETs on an integrated circuit device, device designers have greatly reduced the physical size of FETs over the years. More specifically, the channel length of FETs has been significantly decreased, which has resulted in improving the switching speed of FETs. However, decreasing the channel length of a FET also decreases the distance between the source region and the drain region. In some cases, this decrease in the separation between the source and the drain makes it difficult to efficiently inhibit the electrical potential of the source region and prevent the channel from being adversely affected by the electrical potential of the drain. This is sometimes referred to as a short channel effect, wherein the characteristic of the FET as an active switch is degraded.
In contrast to a FET, which has a planar structure, there are so-called 3D devices, such as an illustrative FinFET device, which is a three-dimensional structure. More specifically, in a FinFET, a generally vertically positioned fin-shaped active area is formed, and a gate electrode encloses both sides and an upper surface of the fin-shaped active area to form a tri-gate structure so as to use a channel having a three-dimensional structure instead of a planar structure. In some cases, an insulating cap layer, e.g. silicon nitride, is positioned at the top of the fin and the FinFET device only has a dual-gate structure. Unlike a planar FET, in a FinFET device, a channel is formed perpendicular to a surface of the semiconducting substrate, which reduces the physical size of the semiconductor device. Also, in a FinFET, improved gate control leads to better short channel effects. When an appropriate voltage is applied to the gate electrode of a FinFET device, the surfaces (and the inner portion near the surface) of the fins, i.e., the substantially vertically oriented sidewalls and the top upper surface of the fin with inversion carriers, contributes to current conduction. In a FinFET device, the “channel-width” is approximately two times (2×) the vertical fin-height plus the width of the top surface of the fin, i.e., the fin width. Multiple fins can be formed in the same footprint as that of a planar transistor device. Accordingly, for a given plot space (or footprint), FinFETs tend to be able to generate significantly higher drive current than planar transistor devices. Additionally, the leakage current of FinFET devices after the device is turned “OFF” is significantly reduced as compared to the leakage current of planar FETs due to the superior gate electrostatic control of the “fin” channel on FinFET devices.
Another form of 3D semiconductor device employs so-called nanowire structures for the channel region of the device. There are several known techniques for forming such nanowire structures. As the name implies, at the completion of the fabrication process, the nanowire structures typically have a generally circular cross-sectional configuration. Nanowire devices are considered to be one option for solving the constant and continuous demand for semiconductor devices with smaller feature sizes. However, the manufacture of nanowire devices is a very complex process.
The gate structure 25 may include a variety of different materials and a variety of configurations. As shown, the gate structure 25 includes a gate insulation layer 25A, a gate electrode 25B and a gate cap layer 25C. A deposition or thermal growth process may be performed to form the gate insulation layer 25A, which may be made of silicon dioxide in one embodiment. Thereafter, the gate electrode 25B and the gate cap layer 25C may be deposited above the device 100, and the layers may be patterned using photolithographic and etching techniques. The gate electrode 25B may include a variety of materials, such as polysilicon or amorphous silicon. Finally, sidewall spacers 28 may be formed adjacent to the gate structure 25. The sidewall spacers 28 may be formed by depositing a layer of spacer material, such as silicon nitride, and thereafter performing an anisotropic etching process to define the spacers 28.
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Device manufacturers are under constant pressure to produce integrated circuit products with increased performance and lower production cost relative to previous device generations. Thus, device designers spend a great amount of time and effort to maximize device performance while seeking ways to reduce manufacturing costs and improve manufacturing reliability. The present disclosure is directed to various methods of forming nanowire devices with MIS (Metal-Insulator-Semiconductor) source/drain contacts and the resulting devices to realize such gains. Additionally, the methods and devices disclosed herein reduce or eliminate one or more of the problems identified above.
The following presents a simplified summary of the disclosure in order to provide a basic understanding of some aspects of the disclosure. This summary is not an exhaustive overview. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.
Generally, the present disclosure is directed to various methods of forming nanowire devices with MIS (Metal-Insulator-Semiconductor) source/drain contacts and the resulting devices. One illustrative device disclosed herein includes a gate structure and a nanowire channel structure positioned under the gate structure. The nanowire channel structure includes first and second end surfaces. A first insulating liner is positioned on the first end surface, and a second insulating liner is positioned on the second end surface. The device further includes a metal-containing source contact positioned on the first insulating liner and a metal-containing drain contact positioned on the second insulating liner.
An illustrative method disclosed herein includes forming a nanowire channel structure positioned under a gate structure, the nanowire channel structure including first and second end surfaces. The method further includes depositing a first insulating liner on the first end surface and depositing a second insulating liner on the second end surface. The method further includes forming a metal-containing source contact on the first insulating liner and forming a metal-containing drain contact on the second insulating liner.
Another illustrative method disclosed herein includes forming a sacrificial contact structure including one or more layers of insulation material. The method further includes forming an insulating material around the sacrificial contact structure and removing the sacrificial contact structure to form a contact opening within the insulating material. The method further includes depositing an insulating liner, within the contact opening, on an end surface of a nanowire channel structure. The method further includes forming a metal-containing contact on the insulating liner within the contact opening.
The disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
While the subject matter disclosed herein is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.
Certain terms are used throughout the disclosure to refer to particular components. However, different entities may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. The terms “including” and “comprising” are used herein an open-ended fashion, and thus mean “including, but not limited to.”
The present subject matter will now be described with reference to the attached figures. Various structures, systems, and devices are schematically depicted in the drawings for purposes of explanation only. The attached drawings are included to describe and explain illustrative examples of the present disclosure. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those in the industry. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those in the industry, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.
The present disclosure is directed to various methods of forming nanowire devices with MIS source/drain contacts and the resulting devices. As will be readily apparent, the present method is applicable to a variety of devices, including, but not limited to, logic devices, memory devices, etc., and the methods disclosed herein may be employed to form N-type or P-type semiconductor devices. With reference to the attached figures, various illustrative embodiments of the methods and devices disclosed herein will now be described in more detail.
In the depicted example, the device 200 will be disclosed in the context of using FinFET formation techniques. However, the present disclosure should not be considered to be limited to the examples depicted herein. The substrate may include a variety of configurations, such as the depicted bulk silicon configuration. The substrate may also include a silicon-on-insulator (SOI) configuration that includes a bulk silicon layer, a buried insulation layer, and an active layer, wherein semiconductor devices are formed in and above the active layer in various embodiments. Thus, the terms “substrate” or “semiconducting substrate” should be understood to cover all substrate configurations. The substrate may also be made of materials other than silicon.
Next, the illustrative gate structure 250 was formed above the layer 140. The illustrative gate structure 250 is intended to be representative in nature of any type of gate structure that may be formed on a nanowire device. In the depicted example, the gate structure 250 includes a gate insulation layer 250A, a gate electrode 250B and a gate cap layer 250C. A deposition process or thermal growth process may be performed to form the gate insulation layer 250A, which includes silicon dioxide in one embodiment. Thereafter, the material for the gate electrode 250B and the material for the gate cap layer 250C may be deposited above the device 200, and the layers may be patterned using known photolithographic and etching techniques. The gate electrode 250B may include a variety of, materials such as polysilicon or amorphous silicon. The gate cap layer 250C, the gate electrode 250B and the gate insulation layer 250A are sacrificial in nature as they will be removed at a later point during the formation of the device 200. Finally, the sidewall spacers 280 may be formed adjacent to the gate structure 250. The sidewall spacers 280 may be formed by depositing a layer of spacer material, such as silicon nitride, and thereafter performing an anisotropic etching process to define the spacers 280.
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Next, the layers 110 and 130 were selectively recessed by performing one or more etching processes such that they have a shorter length (in the channel length (current transport) direction of the device 200), than do the layers 120 and 140. In at least one embodiment, the layers 110 and 130 are recessed enough such that the ends of the recessed materials 110 and 130 are approximately aligned with the interface between the sidewall spacers 280 and the gate electrode 250B as viewed in cross-section. Thereafter, a layer of insulating material 300 was conformably deposited over the gate structure 250, the spacers 280, and the now-exposed buried insulation layer 103. Deposition of the layer of material 300 overfilled the recesses defined by the recessed layers 110, 130. Portions 300A were created in the former recesses. Portions 300A are positioned adjacent to the ends of the recessed layers 110, 130 and between the ends of the layers 120, 140. The portion of layer 300 over the buried insulation layer 103 is referred to as 300B. The layer portions 300B may have a thickness of about 2-5 nm in one embodiment. In various embodiments, the layer of material 300 may be formed from any of a variety of different materials, e.g., a low-k material (k value less than about 3.3), a nitride, etc.
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In general, as will be appreciated by those skilled in the art after a complete reading of the present application, in the novel nanowire device 200 disclosed herein, a raised epi source drain region was not formed so as to establish contact to the nanowire structures 120, 140 as was done using prior art processing techniques. Rather, in the novel device disclosed herein, the first end surface 350 and the second end surface 351 of each of the nanowires 120, 140 is conductively coupled to their respective contact 800, 900 with only the liner layer 700 being positioned therebetween. The end of the nanowires 120 and 140 are vertically separated from each other by a low-k material 300A (a material having a dielectric constant less than about 3.3). The source/drain contacts 800, 900 are separated from the first and second end surfaces 350 and 351 of the nanowire channel structure by the liner layer 700 (one for each contact). As such, the device 200 allows the nanowires 120 and 140 to conduct substantially evenly when compared to each other, and each has a low and similar access resistance. Also, the anchoring of nanowires 120 and 140 within the device 200 introduces little to no defects. The creation of nanowires 120 and 140 with similar characteristics allows for improved performance, reliability and predictability.
The particular embodiments disclosed above are illustrative only, as the disclosure may be modified and practiced in different but equivalent manners apparent to those having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the disclosure. Accordingly, the protection sought herein is as set forth in the claims below.