USE OF BAND EDGE GATE METALS AS SOURCE DRAIN CONTACTS
A method includes providing a semiconductor substrate having intentionally doped surface regions, the intentionally doped surface regions corresponding to locations of a source and a drain of a transistor; depositing a layer a band edge gate metal onto a gate insulator layer in a gate region of the transistor while simultaneously depositing the band edge gate metal onto the surface of the semiconductor substrate to be in contact with the intentionally doped surface regions; and depositing a layer of contact metal over the band edge gate metal in the gate region and in the locations of the source and the drain. The band edge gate metal in the source/drain regions reduces a Schottky barrier height of source/drain contacts of the transistor and serves to reduce contact resistance. A transistor fabricated in accordance with the method is also described.
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The exemplary embodiments of this invention relate generally to transistor devices and, more specifically, relate to complementary metal oxide semiconductor (CMOS) transistor devices and to the formation of source/drain (S/D) contacts for such devices.
BACKGROUNDContact resistance has become a dominating factor and consideration as transistor devices such as field effect transistor (FET) devices are scaled to smaller dimensions. There is a need to provide a process and a structure to reduce contact resistance (S/D contact resistance) that are compatible with existing processes and that are also cost effective.
SUMMARYIn a first aspect thereof the exemplary embodiments of this invention provide a method to fabricate a structure. The method comprises providing a semiconductor substrate having intentionally doped surface regions, the intentionally doped surface regions corresponding to locations of a source and a drain of a transistor; depositing a layer a band edge gate metal onto a gate insulator layer in a gate region of the transistor while simultaneously depositing the band edge gate metal onto the surface of the semiconductor substrate to be in contact with the intentionally doped surface regions; and depositing a layer of contact metal over the band edge gate metal in the gate region and in the locations of the source and the drain.
In another aspect thereof the exemplary embodiments of this invention provide a method to reduce a Schottky barrier height of source/drain contacts of a field effect transistor. The method comprises forming a gate stack comprising a gate insulator layer that overlies a surface of a semiconductor substrate; further forming the gate stack by depositing band edge gate metal on the gate insulator layer, while also depositing the band edge gate metal directly onto the surface of the semiconductor substrate at locations of the source/drain contacts; and further forming the gate stack by depositing contact metal over the band edge gate metal to form a gate contact and source/drain contacts.
In a still further aspect thereof the exemplary embodiments of this invention provide a device that comprises a gate stack formed over a channel in a semiconductor substrate. The gate stack comprises a layer of gate insulator material, a layer of gate metal overlying the layer of gate insulator material, and a layer of contact metal overlying the layer band edge gate metal. The device further comprises source and drain contacts adjacent to the channel. The source and drain contacts each comprise a layer of the gate metal that overlies and is in direct electrical contact with a doped region of the semiconductor substrate, and a layer of contact metal that overlies the layer of gate metal.
In accordance with an aspect of the exemplary embodiments of this invention gate metals are used as S/D contacts. The gate metal deposition can be by physical vapor deposition (PVD), chemical vapor deposition (CVD) or atomic layer deposition (ALD), as non-limiting examples of gate metal deposition processes. For an n-type FET (nFET) band edge (BE) gate metals include TiAl, TiAlN and TiN/Al/TiN as several non-limiting examples. For a p-type FET (pFET) the BE gate metals include thicker TiN, Re, Pt (and their carbides and nitrides) as several non-limiting examples.
The exemplary embodiments of this invention beneficially provide a BE gate metal as a S/D contact to reduce metal/Si contact resistance. By the use of these embodiments the need to provide a silicide can be eliminated. In addition there is a simplified process flow for fabricating metal contacts to the gate and the S/D, and a metal fill step can be simultaneously performed for the gate and the S/D.
The concept of a BE metal is conventionally referred to one of the conduction band edge (NMOS) or the valence band edge (PMOS) of the constituent semiconductor material. A goal is to reduce or minimize the Schottky barrier height, i.e., the difference between the metal workfunction and the semiconductor (e.g., Si) electron affinity.
It can be noted that the eWF (effective workfunction) on different gate dielectrics (for the gate) or directly on the Si is not the same as the vacuum WF. This is generally explained by the Fermi level pinning model. Different interfaces can have different pinning factors such that the eWF could vary on different dielectrics. However, there is still a correlation between the vacuum WF and the eWF: a higher WF metal exhibits a relatively higher eWF.
As considered herein a band edge gate metal (with the band edge eWF on high K) may no longer have a band edge eWF on the S/D depending on the pinning factor difference, but can still have an eWF that is closer to the band edge as compared to other metal choices.
For Silicon the conduction band edge Ec: 4.05 eV and the valence band edge Ev: 5.17 eV. The workfunctions for various metals are well characterized. Reference can be made, for example, to pages 18 and 19 of “Work Functions of the Transition Metals and Metal Silicides”, Timothy J. Drummond, Sandia National Laboratories, 1999 (SAN099-0391J).
In accordance with the embodiments of this invention, for a FET having a gate stack the use of the BE metal as a gate contact results in a reduction in the threshold voltage (Vt) of the FET. By applying the gate stack BE metal(s) to the S/D contacts the Schottky barrier height is reduced and current can more readily flow between the semiconductor material and the contact metal, which is manifested as a reduction in S/D resistance.
The presence of the BE gate metal on the S/D also beneficially implies that there is no need to form silicide. Silicide is conventionally used to reduce the interface contact resistance and to function as an adhesion of the CA metal to the substrate. In state-of-the-art FET devices, Nickel or Nickel-alloy silicides are typically used. It is known that the use of silicides can cause a yield loss due to metal diffusion into the substrate at typical processing temperatures (e.g., of about 300° C.) for silicide formation, especially through defects in substrates. The BE metals employed for fabricating the S/D contacts in accordance with the embodiments of this invention exhibit limited metal diffusion with no need of thermal treatment for silicide formation, thereby improving the yield.
The exemplary and non-limiting embodiments of this invention are described with reference to the process flow depicted in
The end result is that the CA is provided with a dual metal damascene comprising the layer of BE metal 26 in direct contact with the semiconductor substrate 10, and the Source or Drain implant region 12, and the overlying layer of CA metal 28. The layer of BE metal 26 in the CA in each type of transistor (nFET or pFET) is identical to the BE metal in the adjacent gate stack and can be deposited in the same process operation. The presence of the layer of BE metal 26 in the CA, in contact with the underlying semiconductor material of the S/D, reduces the Schottky barrier height and thus beneficially reduces S/D resistance. The disclosed processing beneficially eliminates the need to form a silicide.
It can be noted that the exemplary embodiments disclosed above assume the same BE gate metal in the gate stack and in the S/D contacts, however they do not have to be the same.
It is to be understood that the processes described by
For example, reference can be made to
However, in this embodiment the layer of gate dielectric layer 24 has been applied to the substrate 10 prior to the formation of the two dummy gate structures 16A, 16B. The gate dielectric layer 24 can be any suitable dielectric material that will not be affected by subsequent processing steps, and can comprise a layer of high-k material as discussed above. The thickness of the high-k dielectric layer 24 may be from about 1 nm to about 10 nm, with about 5 nm being one suitable value.
Processing then continues as described above with respect to
It is to be understood that although the exemplary embodiments discussed above with reference to
It is to be understood that in addition to fabricating transistor device contacts as discussed above, further aspects of the present invention include methods to form contacts for other devices or otherwise constructing integrated circuits with various analog and digital circuitry. In particular, integrated circuit dies can be fabricated with various devices such as a field-effect transistors, bipolar transistors, metal-oxide-semiconductor transistors, diodes, resistors, capacitors, inductors, etc., having contacts that are formed using methods as described herein. An integrated circuit in accordance with the present invention can be employed in applications, hardware, and/or electronic systems. Suitable hardware and systems in which such integrated circuits can be incorporated include, but are not limited to, personal computers, communication networks, electronic commerce systems, portable communications devices (e.g., cell phones), solid-state media storage devices, functional circuitry, etc. Systems and hardware incorporating such integrated circuits are considered part of this invention. Given the teachings of the exemplary embodiments of the invention provided herein, one of ordinary skill in the art will be able to contemplate other implementations and applications of the techniques of the invention.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural foams as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form 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 invention. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the concepts of this invention for various embodiments with various modifications as are suited to the particular use contemplated.
As such, various modifications and adaptations may become apparent to those skilled in the relevant arts in view of the foregoing description, when read in conjunction with the accompanying drawings and the appended claims As but some examples, the use of other similar or equivalent semiconductor fabrication processes, including material deposition processes and material removal processes may be used by those skilled in the art. Further, the exemplary embodiments are not intended to be limited to only those materials, metals, insulators, dopants, dopant concentrations, layer thicknesses and the like that were specifically disclosed above. Any and all such and similar modifications of the teachings of this invention will still fall within the scope of this invention.
Claims
1. A method to fabricate a structure, comprising:
- providing a semiconductor substrate having intentionally doped surface regions, the intentionally doped surface regions corresponding to locations of a source and a drain of a transistor;
- depositing a layer of a band edge gate metal directly onto a gate insulator layer in a gate region of the transistor while simultaneously depositing the band edge gate metal directly onto the surface of the semiconductor substrate to be in contact with the intentionally doped surface regions; and
- depositing a layer of contact metal directly onto the layer of band edge gate metal in the gate region and directly onto the band edge gate metal deposited in the locations of the source and the drain.
2. The method of claim 1, where the transistor is a p-type field effect transistor, where the intentionally doped surface regions are doped with a p-type dopant, and where the band edge gate metal is comprised of at least one of Pt, Ir, Pd, Rh, Co, Ni, Ru, Re, and heir alloys, carbides, and nitrides.
3. The method of claim 1, where the transistor is an n-type field effect transistor, where the intentionally doped surface regions are doped with an n-type dopant, and where the band edge gate metal is comprised of at least one of Al, Ti, Er, Yb, Ta, and their alloys, carbides, and nitrides.
4. The method of claim 1, where the gate insulator layer is comprised of a high dielectric constant gate insulator material.
5. The method of claim 1, where the gate region is formed by a replacement gate process that removes a dummy gate material leaving a gate opening in a dielectric material to expose an underlying surface of the substrate, further comprising forming openings in the dielectric material at locations of the source and the drain, masking the openings in the dielectric material at the locations of the source and the drain; depositing gate insulator material into the gate opening while preventing with the mask the deposition of the gate insulator material into the openings in the dielectric material at the locations of the source and the drain; removing the mask, depositing the band edge gate metal directly onto the gate insulator material in the gate opening and into the openings in the dielectric material at the locations of the source and the drain; and depositing the layer of contact metal over the band edge gate metal.
6. The method of claim 5, further comprising removing excess band edge gate metal and contact metal and planarizing a top surface of the structure.
7. The method of claim 1, where the gate region is formed by a gate-first process that removes a dummy gate material forming a gate opening that exposes an underlying surface of the gate insulator layer within the gate opening, further comprising depositing the band edge gate metal directly onto the gate insulator layer in the gate opening and into openings in the dielectric material at the locations of the source and the drain; and depositing the layer of contact metal over the band edge gate metal.
8. A method to reduce a Schottky barrier height of source/drain contacts of a field effect transistor, comprising:
- forming a gate stack comprising a gate insulator layer that overlies a surface of a semiconductor substrate;
- further forming the gate stack by depositing band edge gate metal directly onto the gate insulator layer, while also depositing the band edge gate metal directly onto the surface of the semiconductor substrate at locations of the source/drain contacts; and
- further forming the gate stack by depositing contact metal directly onto the deposited band edge gate metal to form a gate contact and source/drain contacts.
9. The method of claim 8, where depositing the band edge gate metal on the gate insulator layer and also onto the surface of the semiconductor substrate simultaneously deposits the same band edge gate metal on the gate insulator layer and also onto the surface of the semiconductor substrate.
10. The method of claim 8, where depositing the contact metal is performed by blanket depositing the contact metal over the band edge metal.
11. The method of claim 8, where the field effect transistor is a p-type field effect transistor, where a surface region of the semiconductor substrate at the locations of the source/drain contacts is doped with a p-type dopant, and where the band edge gate metal is comprised of at least one of Pt, Ir, Pd, Rh, Co. Ni, Ru, Re, and their alloys, carbides, and nitrides.
12. The method of claim 8, where the field effect transistor is an n-type field effect transistor, where a surface region of the semiconductor substrate at the locations of the source/drain contacts is doped with an n-type dopant, and where the band edge gate metal is comprised of at least one of Al, Ti, Er, Yb, Ta, and their alloys, carbides, and nitrides.
13. The method of claim 8, where the gate insulator layer is comprised of a high dielectric constant gate insulator material.
14. The method of claim, where forming the gate stack comprises a replacement gate process that removes a dummy gate material leaving a gate opening in a dielectric material, and where the gate insulator layer is deposited in the gate opening subsequent to removing the dummy gate material.
15. The method of claim 8, where forming the gate stack comprises a replacement gate process that removes a dummy gate material leaving a gate opening in a dielectric material, and where the gate insulator layer is deposited prior to deposition of the dummy gate material and is exposed within the gate opening subsequent to removing the dummy gate material.
16.-20. (canceled)
21. The method of claim 1, where depositing the layer of band edge gate metal also deposits the layer of band edge gate metal upon sidewalls of openings formed in a layer of dielectric material at the locations of the source and drain of the transistor.
22. The method of claim 1, where depositing the layer of band edge gate metal also deposits the layer of band edge gate metal upon sidewalls of an opening formed in the gate region.
23. The method of claim 8, where depositing the layer of band edge gate metal also deposits the layer of band edge gate metal upon sidewalls of openings formed in a layer of dielectric material at the locations of the source/drain contacts.
24. The method of claim 8, where depositing the layer of band edge gate metal also deposits the layer of band edge gate metal upon sidewalls of an opening formed at a location of the gate stack.
Type: Application
Filed: Mar 15, 2012
Publication Date: Sep 19, 2013
Applicant: International Business Machines Corporation (Armonk, NY)
Inventors: Kisik Choi (Hopewell Junction, NY), Christian Lavoie (Ossining, NY), Paul M. Solomon (Yorktown Heights, NY), Bin Yang (Ossining, NY), Zhen Zhang (Ossining, NY)
Application Number: 13/421,276
International Classification: H01L 29/78 (20060101); H01L 21/283 (20060101);