The invention relates generally to semiconductor devices and integrated circuit fabrication and, in particular, to structures for a field-effect transistor and fabrication methods for forming a structure for a field-effect transistor.
Modern electronics achieve high levels of functionality in small and compact form factors by integrating multiple functions onto a single chip. A common fabrication process that allows high levels of integration at a relatively low cost is complementary metal-oxide-semiconductor (CMOS). CMOS processes build a combination of p-channel and n-channel metal-oxide-semiconductor field-effect transistors (MOSFETs) to implement logic gates and other types of digital circuits, as well as analog circuits. A field-effect transistor includes a gate electrode and source/drain regions between which a current can flow. A control voltage applied to the gate electrode controls the flow of current through a channel within the substrate between the source/drain regions.
Middle-of-line (MOL) processing includes the formation of gate contacts and source/drain contacts. A tie-off structure may be formed during middle-of-line MOL processing may be used to couple or “tie-off” a drain or source of a field-effect transistor to a dummy gate. The tie-off structure includes metallization formed in a MOL dielectric layer that couples the gate contact with one of the source/drain contacts of the field-effect transistor. Another way to couple the dummy gate to ground or power is to terminate one side of the active area at which the dummy gate is located, which prevents the dummy gate from forming a drain contact. This is known as a “diffusion break approach”. The diffusion break approach may use two dummy gates, one dummy gate on each side of the broken active area.
Improved structures for a field-effect transistor and fabrication methods for forming a structure for a field-effect transistor are needed.
In an embodiment of the invention, a method for forming a field-effect transistor includes forming a gate electrode, forming a source/drain region adjacent to a vertical sidewall of the gate electrode, and forming a conductive link coupling the vertical sidewall of the gate electrode with the source/drain region.
In an embodiment of the invention, a structure for a field-effect transistor includes a gate electrode, a source/drain region adjacent to a vertical sidewall of the gate electrode, and a conductive link coupling the vertical sidewall of the gate electrode with the source/drain region.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the embodiments of the invention.
With reference to
Gate structures 20, 22, 24 may be formed on the device layer 12. Each of the gate structures 20, 22, 24 includes a gate electrode 26 and a gate dielectric 28 arranged in a layer stack. The gate electrodes 26 may be comprised of a metal, a silicide, polycrystalline silicon (polysilicon), or combinations of these materials, deposited by physical vapor deposition (PVD), CVD, etc. The gate dielectrics 28 may be comprised of a dielectric or insulating material, such as silicon dioxide, a high-k dielectric material such as hafnium oxide, or layered combinations of these and other dielectric materials, deposited by CVD, atomic layer deposition (ALD), etc. The gate structures 20, 22, 24 may be formed by patterning the layer stack of their constituent materials with photolithography and etching.
Each of the gate structures 20, 22, 24 includes a top surface 30 and vertical sidewalls 32 that extend from the top surface 30 to the top surface of the device layer 12. A cap 33 comprised of a dielectric material, such as silicon nitride (Si3N4), is located on the top surface 30 of each of the gate structures 20, 22, 24. A conformal layer 34 is deposited on the device layer 12 and covers the top surface 30 and vertical sidewalls 32 of each of the gate structures 20, 22, 24. The conformal layer 34 may be comprised of a dielectric material, such as silicon nitride (Si3N4) deposited by CVD. The gate structures 20, 22, 24 may be dummy gate structures.
With reference to
Raised source/drain regions 38, 40, 42, 44 are formed adjacent to the vertical sidewalls 32 of the gate structures 20, 22, 24. As used herein, the term “source/drain region” refers to a doped region of semiconductor material that can function as either a source or a drain of a field-effect transistor. The source/drain regions 38, 40, 42, 44 may be formed by an epitaxial growth process that deposits sections of a semiconductor material, such as silicon germanium (SiGe), at the designated areas on the top surface of device layer 12 that were opened in the conformal layer 34. In an embodiment, the raised source/drain regions 38, 40, 42, 44 may be formed by a selective epitaxial growth process in which semiconductor material nucleates for epitaxial growth on semiconductor surfaces (e.g., the top surface of the device layer 12), but does not nucleate for epitaxial growth from insulator surfaces (e.g., the caps 33 and spacers 36). The gate structures 20, 22, 24 may function to self-align the semiconductor material of the source/drain regions 38, 40, 42, 44 during epitaxial growth. The constituent semiconductor material may be in situ doped during growth to impart a given conductivity type to the sections of semiconductor material. The semiconductor material of the raised source/drain regions 38, 40, 42, 44 may comprise an n-type dopant from Group V of the Periodic Table (e.g., phosphorus (P) or arsenic (As)) that is effective to impart n-channel conductivity.
With reference to
The spacer 36 associated with the gate structure 22, and that is exposed by the opening 50 in the etch mask 48, is etched using an etching process with an etch chemistry that removes the material of the spacer 36 selective to the materials of the source/drain region 42 and the gate electrode 26. Due to masking provided by the etch mask 48 during the performance of the etching process, the spacers 36 on the gate structures 20 and 24, as well as one of the spacers 36 on gate structure 22, are intact following the etching process. The exposed portion of the cap 33 on the gate electrode 26 of gate structure 22 is also etched by the etching process, and the etch chemistry removes the material of the cap 33 selective to the materials of the source/drain region 42 and the gate electrode 26.
The vertical sidewall 32 of the gate electrode 26 of gate structure 22 is exposed after the removal of the spacer 36. In the representative embodiment, the spacer 36 is completely removed so that the vertical sidewall 32 of the gate electrode 26 is fully exposed. The removal of the spacer 36 leaves an unfilled gap as an open space between one of the vertical sidewalls 32 of the gate electrode 26 of the gate structure 22 and the raised source/drain region 42. In an alternative embodiment and as diagrammatically shown in
With reference to
Sections 54 of the silicide layer 52 form on the top surfaces 30 of the gate electrodes 26 of gate structures 20 and 24. Sections 56 of the silicide layer 52 form on the top surfaces of the raised source/drain regions 38, 40, and 44. A section 58 of the silicide layer 52 is located on the top surface 30 of the gate electrode 26 of gate structure 22, the vertical sidewall 32 of the gate electrode 26 of gate structure 22, and the top surface 43 of the raised source/drain region 42. The recess or removal of the spacer 36 permits the section 58 of the silicide layer to form on the vertical sidewall 32 of the gate electrode 26 of gate structure 22. Section 58 includes one of the sections 54 on the top surface 30 of the gate electrode 26 of gate structure 22, one of the sections 56 on the top surface of the raised source/drain region 42, and an additional connecting section that provides a bridge between these sections 54 and 56. The section 58 of the silicide layer 52 forms a continuous conductive link between the gate electrode 26 of gate structure 22 and the raised source/drain region 42. This continuous conductive link shorts the gate electrode 26 and the raised source/drain region 42 such that these objects are at the same electrical potential during chip operation.
In the alternative embodiment in which the spacer 36 is recessed instead of removed, the section 58 of the silicide layer may bridge across the recessed top surface of the spacer 36 between the raised source/drain region 42 and the vertical sidewall 32 of the gate structure 22. The dielectric material of the spacer 36 does not support the formation of silicide, but the silicide layer 52 forming on the raised source/drain region 42 and the vertical sidewall 32 of the gate structure 22 may connect in the space above the recessed top surface of the spacer 35.
Middle-of-line (MOL) processing and back-end-of-line (BEOL) processing follows, which includes formation of contacts and wiring for the local interconnect structure overlying the field-effect transistors, and formation of dielectric layers, via plugs, and wiring for an interconnect structure coupled by the interconnect wiring with the field-effect transistors. One or all of the gate structures 20, 22, 24 may be dummy structures that are not contacted by MOL processing. After processing is completed, the SOI substrate 10 may be diced into multiple chips each including one or more integrated circuits.
The connection of the gate electrode 26 of gate structure 22 and the raised source/drain region 42 provides a tie-off structure that may be used for isolation purposes. The embodiments of the invention allow enable the formation of a gate-tie off construct without the usage of contact layers formed during MOL processing, which reduces MOL congestion. Silicide, which is a conductive alloy, promotes the connectivity between the gate electrode of the intended dummy gate structure and the source/drain region. The gate-tie off construct may be used in consecutive gate pitches without missing a critical poly pitch (CPP), which conserves cell area and prevents any compromise in the design rules for the contacts to other gate electrodes that are contacted by MOL contacts.
With reference to
The vertical sidewall 32 of the gate electrode 26 of gate structure 22 and the vertical sidewall 32 of the gate electrode 26 of gate structure 24 are exposed after the removal of the spacers 36. In the representative embodiment, the spacers 36 are completely removed so that the vertical sidewalls 32 of the gate electrodes 26 are fully exposed. The removal of the spacers 36 leaves unfilled gaps as open spaces between one of the vertical sidewalls 32 of the gate electrode 26 of the gate structure 22 and the raised source/drain region 42, as well as between one of the vertical sidewalls 32 of the gate electrode 26 of the gate structure 24 and the raised source/drain region 42. In an alternative embodiment and as diagrammatically shown in
With reference to
The continuous conductive link provided by the silicide layer section 58 shorts the gate electrodes 26 of the different gate structures 22, 24 and the raised source/drain region 42. However, the gate electrode 26 of additional gate structures, e.g., the gate electrode 26 of gate structure 20, may be linked along with the gate electrodes 26 of the gate structures 22, 24 and the raised source/drain region 44. To that end, the width of the opening 50 in the etch mask 48 may be further widened so that additional spacers 36 are removed. For example, the other spacer 36 on of gate structure 22 may be removed along with one of the spacers 36 of gate structure 20 such the conductive link provided by the silicide layer 52 links more than two gate electrodes 26 and multiple raised source/drain regions 40, 42.
With reference to
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The continuous conductive link provided by the sections 60, 62 comprised of the epitaxial semiconductor material of the raised source/drain region 42 shorts the gate electrodes 26 of the different gate structures 22, 24 and the raised source/drain region 42. However, the gate electrode 26 of additional gate structures, e.g., the gate electrode 26 of gate structure 20, may be linked along with the gate electrodes 26 of the gate structures 22, 24 and the raised source/drain region 44. To that end, the width of the opening 50 in the etch mask 48 may be further widened so that additional spacers 36 are removed. For example, the other spacer 36 on of gate structure 22 may be removed along with one of the spacers 36 of gate structure 20 such the conductive link provided by sections of the epitaxial semiconductor material of the raised source/drain regions 40, 42 links more than two gate electrodes 26 and multiple raised source/drain regions 40, 42.
References herein to terms such as “vertical”, “horizontal”, “lateral”, etc. are made by way of example, and not by way of limitation, to establish a frame of reference. Terms such as “horizontal” and “lateral” refer to a direction in a plane parallel to a top surface of a semiconductor substrate, regardless of its actual three-dimensional spatial orientation. Terms such as “vertical” and “normal” refer to a direction perpendicular to the “horizontal” and “lateral” direction. Terms such as “above” and “below” indicate positioning of elements or structures relative to each other and/or to the top surface of the semiconductor substrate as opposed to relative elevation.
A feature “connected” or “coupled” to or with another element may be directly connected or coupled to the other element or, instead, one or more intervening elements may be present. A feature may be “directly connected” or “directly coupled” to another element if intervening elements are absent. A feature may be “indirectly connected” or “indirectly coupled” to another element if at least one intervening element is present.
The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.