The present disclosure relates in general to semiconductor devices and manufacturing processes and more particularly to a semiconductor structure with an improved channel stack and method for fabrication thereof.
Field effect transistors are typically manufactured on a semiconductor substrate that is doped to contain mobile electric charge carriers. When incorporated into a semiconductor substrate lattice as a result of an activation process, dopant atoms can be either electron donors or acceptors. An activated donor atom donates weakly bound valence electrons to the material, creating excess negative charge carriers. These weakly bound electrons can move about in the semiconductor substrate lattice relatively freely, facilitating conduction in the presence of an electric field applied by a gate terminal. Similarly, an activated acceptor produces a mobile positive charge carrier known as a hole. Semiconductors doped with donor impurities are called n-type, while those doped with acceptor impurities are known as p-type. Common n-type donor atoms used in conjunction with silicon semiconductor substrates include arsenic, phosphorus, and antimony.
The dopant implant or in-situ dopant growth parameters used for semiconductor substrate doping of the doped layers beneath the gate are key to optimum performance of the FET device with respect to important parameters, such as threshold voltage or channel mobility. However, limitations in implant tools, required thermal processing conditions, and variations in materials or process can easily result in unwanted diffusion of dopant materials away from the initial implanted position, decreasing performance or even preventing reliable transistor operation. This is particularly true when co-dopant implant processes are used, since different dopant types have different solid diffusion constants and respond differently to process conditions.
Cost effective electronic manufacturing requires transistor structures and manufacturing processes that are reliable at nanometer scales, and that do not require expensive or unavailable tools or process control conditions. While it is difficult to balance the many variables that control transistor electrical performance, finding suitable transistor dopant structures and manufacturing technique that result in acceptable electrical characteristics such as charge carrier mobility and threshold voltage levels are a key aspect of such commercially useful transistors.
From the foregoing, it may be appreciated by those of skill in the art that a need has arisen for a technique to fabricate improved transistor devices that provides threshold voltage control and improved operational performance by creating a number of precisely doped layers beneath an undoped (intrinsic) channel layer that can be epitaxially grown on the doped layers. These doped layers and/or intrinsic channel layer can be formed as blanket layers that extend across multiple transistors, and can be later modified by shallow trench isolation or the like to separate transistors into blocks or individual elements. In accordance with the following disclosure, there is provided a doped semiconductor structure with an improved channel stack and method for fabrication thereof that substantially eliminates or greatly reduces disadvantages and problems associated with conventional transistor device design.
According to an embodiment of the disclosure, a method for fabricating a semiconductor structure with a channel stack is provided that includes forming a screening layer under a gate of a transistor element, forming a threshold voltage control layer on the screening layer of the transistor element, and forming an epitaxial channel layer on the threshold control layer of the transistor element. The screening layer for the PMOS transistor element includes antimony as a dopant material that may be inserted into the structure prior to or after formation of the epitaxial channel layer. As disclosed in greater detail in the specification, the concentration and type of single dopant or co-dopants atoms selected, the dopant implant or in-situ growth conditions, and the particular doping profiles, anneal profiles and transistor structure are all selected to maintain a device that is more reliable than conventional transistors.
Embodiments of the present disclosure may enjoy some, all, or none of these advantages. Other technical advantages may be readily apparent to one skilled in the art from the following figures, description, and claims.
For a more complete understanding of the present disclosure, reference is made to the following description taken in conjunction with the accompanying drawings, wherein like reference numerals represent like parts, in which:
Several approaches may be utilized to build a transistor element with a channel stack having a screening layer to screen the charges on the gate, a threshold voltage control layer to adjust the threshold voltage for the transistor element, and an intrinsic channel for high mobility and reduced random dopant fluctuation performance. Each approach has various advantages and disadvantages. In general, two tradeoffs are considered when building transistor elements on a semiconductor die, the number of steps in the process (relating to manufacturing costs) and channel formation (relating to transistor performance). The fewer masking steps and total steps required to build a design translates into a lower cost to build. Forming the channel later in the thermal cycle of the manufacturing process facilitates controlling the channel doping profile and avoiding unwanted contaminants from diffusing into the channel from other parts of the transistor design.
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Though not shown, a shallow trench isolation first process may be performed on P+ substrate 301 and P− silicon epitaxy layer 302 similar to that shown and described above with respect to
Formation of the screening layer and the threshold voltage control layer may be performed in different ways in each of the processes provided above. The screening layer may be formed through ion implantation into the p-well region, through in-situ deposition or growth of doped material, or through intrinsic silicon epitaxial growth followed by ion implantation. The threshold voltage control layer may be formed through in-situ deposition or growth of doped material or through intrinsic silicon epitaxial growth followed by ion implantation. The channel layer is formed through intrinsic silicon epitaxial growth.
Materials used for the screening layers for the PMOS transistor elements in each fabrication process may include arsenic, phosphorous, and/or antimony. When arsenic is used for the PMOS transistor elements, ion implantation of the arsenic is performed prior to epitaxial growth of the channel layer (and also prior to epitaxial growth of the threshold voltage control layer where this process step is performed). To prevent diffusion of screening layer material, a material that has a lower diffusion characteristic may be used. For a PMOS transistor element, antimony diffuses less than arsenic in the thermal cycles of the fabrication process. The use of antimony solves a problem of diffusion of the material in the screening layer into the epitaxial channel layer.
Another manner in which the leakage current for antimony can be reduced is to decrease the thickness or otherwise have a smaller thickness for the epitaxial channel layer of the PMOS transistor element as compared to the NMOS transistor element.
Reduction in epitaxial channel layer thickness, though achievable, may be costly to implement into the fabrication process. Though techniques have been discussed above that provide an ability to obtain differing epitaxial channel layer thicknesses, such techniques still result in additional steps being performed in the fabrication process. A technique to avoid reducing the thickness of the epitaxial channel layer for an antimony screen implant is to implant the antimony screen after the epitaxial channel layer for the PMOS transistor element is grown. The reduced straggle and diffusion of antimony compared to arsenic makes it possible to achieve an acceptable doping profile using this implant after epi technique. This technique can be integrated into a full CMOS process and the processes discussed above by implanting or otherwise forming the screening layer for the NMOS transistor element before epitaxial growth of the channel layer, forming the channel layer through intrinsic silicon epitaxial growth, and then implanting the screening layer for the PMOS transistor element through the epitaxial channel layer.
Another alternative process is to use a dual implant with antimony and a faster diffusing n-type dopant such as arsenic, both done before the deposition or other formation of the epitaxial channel layer. Diffusion of the arsenic into the threshold voltage control layer will increase the threshold voltage and decrease the leakage current as compared to antimony only. The arsenic implant energy would typically be the same as or less than the antimony implant energy. The dopant concentration of the arsenic may be chosen to give a doping profile peak concentration the same as or less than that of the antimony dopant concentration. Though disclosed as an antimony screening layer and an arsenic threshold voltage control layer, it may be desirable to have an arsenic screening layer and an antimony threshold voltage control layer.
It may be useful to perform an anneal step, following the antimony implant to improve the activation of the antimony dopant. This anneal step would typically be in the range of 950° C. to 1050° C. with a duration from several milliseconds to several seconds. It may also be useful to perform an anneal step following the arsenic implant before formation of the epitaxial channel layer. This anneal step would typically be in the range of 800° C. to 1000° C. with a duration from several milliseconds to several seconds.
The antimony profile is essentially unchanged by the anneals. The arsenic anneal has the effect of reducing arsenic diffusion into the subsequently formed epitaxial channel layer. Higher anneal temperatures and longer anneal durations are more effective in suppressing arsenic diffusion into the epitaxial channel layer while lower anneal temperatures and shorter anneal durations allow more diffusion. Thus, the anneal temperature and time can be used to set the threshold voltage by controlling the diffusion of arsenic. This arsenic anneal step can be done in conjunction with the antimony anneal step or as a single anneal without an antimony anneal. The epitaxial channel layer may then be deposited after the anneal.
Another alternative process is to implant or otherwise form the screening layer with antimony prior to formation of the epitaxial channel layer and then implant antimony following formation of the epitaxial channel layer. This process can be performed to adjust the threshold voltage of the PMOS transistor element. FIGURE shows a simulated doping profile where antimony is implanted with an energy of 20 keV at a doping concentration of 1.5e13 atoms/cm2 before deposition of the epitaxial channel layer followed by an antimony implant with an energy of 30 keV at a doping concentration of 1.0e13 atoms/cm2 after deposition of a 20 nm epitaxial channel layer.
The epitaxial thickness of 20 nm used in
Although the present disclosure has been described in detail with reference to a particular embodiment, it should be understood that various other changes, substitutions, and alterations may be made hereto without departing from the spirit and scope of the appended claims. For example, though not shown, a body tap to the well regions of the transistor elements may be formed in order to provide further control of threshold voltage. Although the present disclosure includes a description with reference to a specific ordering of processes, other process sequencing may be followed and other incidental process steps may be performed to achieve the end result discussed herein. Moreover, process steps shown in one set of figures may also be incorporated into another set of figures as desired.
Numerous other changes, substitutions, variations, alterations, and modifications may be ascertained by those skilled in the art and it is intended that the present disclosure encompass all such changes, substitutions, variations, alterations, and modifications as falling within the spirit and scope of the appended claims. Moreover, the present disclosure is not intended to be limited in any way by any statement in the specification that is not otherwise reflected in the appended claims.
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