FIELD-EFFECT TRANSISTORS WITH SELF-ALIGNED AND NON-SELF-ALIGNED CONTACT OPENINGS
Structures for a field-effect transistor and methods of forming a field-effect transistor. A sidewall spacer is arranged adjacent to a sidewall of a gate electrode, a source/drain region is arranged laterally adjacent to the sidewall spacer, and a contact is arranged over the source/drain region and laterally adjacent to the sidewall spacer. The contact is coupled with the source/drain region. A section of an interlayer dielectric layer is laterally arranged between the contact and the sidewall spacer.
The present invention relates to semiconductor device fabrication and integrated circuits and, more specifically, to structures for a field-effect transistor and methods of forming a field-effect transistor.
Device structures for a field-effect transistor generally include a body region, a source and a drain defined in the body region, and a gate electrode configured to switch carrier flow in a channel formed, during operation, in the body region. When a control voltage greater than a designated threshold voltage is applied to the gate electrode, carrier flow occurs in the channel between the source and drain to produce a device output current.
A self-aligned etching process may be used when forming contacts coupled with the source and drain of the field-effect transistor. The etching process removes dielectric material from locations over the semiconductor material constituting the source and drain. In a structure that includes both long-channel field-effect transistors and short channel field-effect transistors, the margin for shorting between the gate electrode and the source and drain contacts may be reduced by the removal of the dielectric material to expose the source and drain for contact formation.
Improved structures for a field-effect transistor and methods of forming a field-effect transistor are needed.
SUMMARYIn an embodiment, a structure includes a gate electrode, a sidewall spacer adjacent to a sidewall of the gate electrode, a source/drain region laterally adjacent to the sidewall spacer, and a contact arranged over the source/drain region. The contact, which is also arranged laterally adjacent to the sidewall spacer, is coupled with the source/drain region. The structure further includes an interlayer dielectric layer having a section laterally arranged between the contact and the sidewall spacer.
In an embodiment, a method includes forming a first section of an interlayer dielectric layer over a first source/drain region of a first field-effect transistor, and forming a second section of the interlayer dielectric layer over a second source/drain region of a second field effect transistor. The method further includes etching the first and second sections of the interlayer dielectric layer with an etching process that patterns the first section of the interlayer dielectric layer and that fully removes the second section of the interlayer dielectric layer.
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
The field-effect transistor 10 includes source/drain regions 16, a gate dielectric 18, and a gate electrode 20 that is separated from the semiconductor body 14 by the gate dielectric 18. Similarly, the field-effect transistor 12 includes source/drain regions 17, a gate dielectric 19, and a gate electrode 21 that is separated from the semiconductor body 14 by the gate dielectric 19. The gate dielectrics 18, 19 may be composed of one or more dielectric or insulating materials, such as silicon dioxide formed by oxidation or hafnium oxide deposited by atomic layer deposition. The gate electrodes 20, 21 may be composed of a conductor, such as doped polysilicon or one or more work function metals, deposited by chemical vapor deposition and/or atomic layer deposition. Sidewall spacers 22, 23 composed of a dielectric material, such as silicon nitride, may be provided adjacent to the sidewalls of the gate electrodes 20, 21. The sidewall spacers 22, 23 may be formed by depositing a conformal layer of the dielectric material with atomic layer deposition and anisotropically etching the deposited conformal layer. Gate caps 28, which may be composed of silicon nitride, are positioned over the gate electrodes 20, 21.
The source/drain regions 16 are laterally arranged on opposite sides of the gate electrode 20, and the source/drain regions 17 are laterally arranged on opposite sides of the gate electrode 21. As used herein, the term “source/drain region” means 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 16, 17 may be provided by the epitaxial growth of a semiconductor material following the formation of the gate electrodes 20, 21. The source/drain regions 16, 17 may contain an n-type dopant (e.g., phosphorus and/or arsenic) that provides n-type conductivity. Alternatively, the source/drain regions 16, 17 may contain a p-type dopant (e.g., boron) that provides p-type conductivity.
Sections 24 of an interlayer dielectric layer 35 are formed over the source/drain regions 16, and sections 25 of an interlayer dielectric layer 35 are formed over the source/drain regions 17. The sections 24, 25 of the interlayer dielectric layer 35 may be composed of a dielectric material, such as an oxide of silicon (e.g., silicon dioxide), that is deposited by chemical vapor deposition and planarized. Prior to depositing the interlayer dielectric layer 35, a contact etch-stop layer (CESL) 26 may be formed that provides a liner between the sections 24, 25 of the interlayer dielectric layer 35 and the source/drain regions 16, 17. The CESL 26 may be composed of a thin layer of a dielectric material, such as silicon nitride deposited by atomic layer deposition, characterized by etch selectivity relative to the dielectric material of the interlayer dielectric layer 35. The CESL 26 operates as an etch stop when the sections 24, 25 of the interlayer dielectric layer 35 are removed for contact formation.
A layer stack that includes a dielectric layer 30 and a sacrificial layer 32 is arranged over the field-effect transistors 10, 12 with the sacrificial layer 32 formed over the dielectric layer 30. The dielectric layer 30 may be composed of dielectric material, such as silicon dioxide, deposited by plasma-enhanced chemical vapor deposition using ozone and tetraethylorthosilicate (TEOS) as reactants, and the sacrificial layer 32 may be composed of amorphous carbon, or another inorganic material, deposited by plasma-enhanced chemical vapor deposition. The sacrificial layer 32 may have a thickness in a range of 50 nanometers to 150 nanometers. The layer stack may further include a dielectric layer 34 that is formed over the sacrificial layer 32 and another sacrificial layer 36 that is formed over the dielectric layer 34. The dielectric layer 34 may be composed of silicon carbon nitride (SiCN) deposited by chemical vapor deposition, and the sacrificial layer 36 may be composed of amorphous silicon, or another inorganic material, deposited by chemical vapor deposition. The dielectric layer 34 may function as an adhesion promoter between the sacrificial layer 32 and the sacrificial layer 36.
The layer stack including the sacrificial layers 32, 36 may be product of a process flow that relies on multiple lithography-etch processes and tone inversion. As shown in
A spin-on hardmask layer 38, a dielectric layer 40, and an anti-reflective coating 42 are arranged as components of a lithography stack formed over the layer stack with the spin-on hardmask layer 38 disposed directly on the upper sacrificial layer 36 and the dielectric layer 37. Resist shapes 44 of an etch mask 46 may be formed by lithography over the lithography stack. The etch mask 46 may include a layer of a light-sensitive material, such as an organic photoresist, applied by a spin coating process, pre-baked, exposed to light projected through a photomask, baked after exposure, and developed with a chemical developer to form the resist shapes 44. Each of the resist shapes 44 covers an area of nominally equal dimensions on the top surface of the lithography stack.
The individual resist shapes 44 of the etch mask 46 are separated by respective openings 48. The openings 48 have a given width dimension, W1, and the resist shapes 44 may be arranged to provide the openings 48 with a given pitch. The openings 48 are arranged over the field-effect transistor 12 and, in particular, are arranged directly over the sections 25 of the interlayer dielectric layer 35 that are arranged above the source/drain regions 17 of the field-effect transistor 12. The etch mask 46 is fully removed during lithography from the region over the field-effect transistor 10.
With reference to
With reference to
The resist shapes 44 function as sacrificial mandrels for the deposition of the conformal layer 49 and the subsequent formation of the sidewall spacers 50. The formation of the sidewall spacers 50 decreases the area of the lithography stack exposed between the resist shapes 44 by narrowing the openings 48 such that the width dimension, W2, is less than the width dimension, W1 (
With reference to
With reference to
With reference to
With reference to
Each of the openings 48 in the lower sacrificial layer 32 is arranged directly over one of the sections 25 of the interlayer dielectric layer 35. The width dimension, W2, of the openings 48 is preserved during the series of vertical transfers from the lithography stack to the lower sacrificial layer 32. The width dimension, W3, of sections 25 of the interlayer dielectric layer 35 is greater than the width dimension, W2, of the openings 48 in the lower sacrificial layer 32.
With reference to
In contrast, the etching of the sections 25 of the interlayer dielectric layer 35 is not self-aligned. Instead, the sections 25 of the interlayer dielectric layer 35 are directly patterned during the anisotropic etching process. Portions of the sections 25 of the interlayer dielectric layer 35 are masked by overlying portions of the lower sacrificial layer 32 and dielectric layer 30 during the etching process. The openings 48 extend through the sections 25 of the interlayer dielectric layer 35 to the sections of the CESL 26 over the source/drain regions 17.
The width difference between the openings 48 and the sections 25 of the interlayer dielectric layer 35 provides the residual portions of the sections 25 of the interlayer dielectric layer 35 remaining over the source/drain regions 17. The anisotropic etching process removes the materials of the sections 24, 25 of the interlayer dielectric layer 35 and the dielectric layer 30 selective to the materials of the sidewall spacers 22, 23, the CESL 26, and the gate caps 28. In an embodiment, the anisotropic etching process may be selected to remove silicon dioxide selective to silicon nitride. The remainder of the dielectric layer 30 may be removed by the anisotropic etching process. The residual portions of the sections 25 of the interlayer dielectric layer 35 and the sidewall spacers 22, 23 have approximately equal heights.
With reference to
The residual portions of the sections 25 of the interlayer dielectric layer 35 are arranged between the contacts 54 and the CESL 26 and sidewall spacers 23 adjacent to the gate electrodes 21 of the field-effect transistor 12. In contrast, the contacts 52 are in direct contact with the CESL 26 covering the sidewall spacers 22 of the field-effect transistor 10 due to the full removal of the sections 24 of the interlayer dielectric layer 35.
With reference to
With reference to
The methods as described above are used in the fabrication of integrated circuit chips. The resulting integrated circuit chips can be distributed by the fabricator in raw wafer form (e.g., as a single wafer that has multiple unpackaged chips), as a bare die, or in a packaged form. The chip may be integrated with other chips, discrete circuit elements, and/or other signal processing devices as part of either an intermediate product or an end product. The end product can be any product that includes integrated circuit chips, such as computer products having a central processor or smartphones.
References herein to terms modified by language of approximation, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. The language of approximation may correspond to the precision of an instrument used to measure the value and, unless otherwise dependent on the precision of the instrument, may indicate +/−10% of the stated value(s).
References herein to terms such as “vertical”, “horizontal”, etc. are made by way of example, and not by way of limitation, to establish a frame of reference. The term “horizontal” as used herein is defined as a plane parallel to a conventional plane of a semiconductor substrate, regardless of its actual three-dimensional spatial orientation. The terms “vertical” and “normal” refer to a direction perpendicular to the horizontal, as just defined. The term “lateral” refers to a direction within the horizontal plane.
A feature “connected” or “coupled” to or with another feature may be directly connected or coupled to or with the other feature or, instead, one or more intervening features may be present. A feature may be “directly connected” or “directly coupled” to or with another feature if intervening features are absent. A feature may be “indirectly connected” or “indirectly coupled” to or with another feature if at least one intervening feature is present. A feature “on” or “contacting” another feature may be directly on or in direct contact with the other feature or, instead, one or more intervening features may be present. A feature may be “directly on” or “in direct contact with” another feature if intervening features are absent. A feature may be “indirectly on” or “in indirect contact with” another feature if at least one intervening feature 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.
Claims
1-8. (canceled)
9. A method comprising:
- forming a first section of an interlayer dielectric layer over a first source/drain region of a first field-effect transistor;
- forming a second section of the interlayer dielectric layer over a second source/drain region of a second field-effect transistor;
- forming a first sacrificial layer over the first section and the second section of the interlayer dielectric layer;
- forming a second sacrificial layer over the first sacrificial layer;
- forming a first mandrel and a second mandrel on the second sacrificial layer, wherein the second mandrel is separated from the first mandrel by a gap that is arranged over the first section of the interlayer dielectric layer;
- forming a first sidewall spacer on the first mandrel and a second sidewall spacer on the second mandrel that narrow the gap;
- transferring a first pattern that includes the first mandrel, the second mandrel, the first sidewall spacer, and the second sidewall spacer to the second sacrificial layer with a first etching process such that the second sacrificial layer includes a first opening over the first section of the interlayer dielectric layer at a location of the gap;
- transferring the first pattern from the second sacrificial layer to the first sacrificial layer with a second etching process such that the first sacrificial layer includes a second opening over the first section of the interlayer dielectric layer at a location of the first opening; and
- etching the first section and the second section of the interlayer dielectric layer with a third etching process that transfers the first pattern from the first sacrificial layer to the first section of the interlayer dielectric layer and that fully removes the second section of the interlayer dielectric layer, wherein a third opening is formed in the first section of the interlayer dielectric layer at a location of the second opening in the first sacrificial layer.
10-16. (canceled)
17. The method of claim 9 wherein the first sacrificial layer is comprised of amorphous carbon, and the second sacrificial layer is comprised of amorphous silicon.
18. The method of claim 9 further comprising:
- before forming the first mandrel and the second mandrel, patterning the second sacrificial layer with a fourth etching process to form a first second pattern including a section and a trench arranged over a third section of the interlayer dielectric layer; and
- depositing a layer of image reverse material in the trench to form a third pattern that is complementary to the first second pattern.
19-20. (canceled)
21. The method of claim 9 further comprising:
- removing the first mandrel, the second mandrel, the first sidewall spacer, and the second sidewall spacer following the first etching process.
22. The method of claim 9 further comprising:
- forming a first gate electrode of the first field-effect transistor; and
- forming a third sidewall spacer adjacent to a sidewall of the first gate electrode,
- wherein the first source/drain region is laterally adjacent to the third sidewall spacer, the first section of the interlayer dielectric layer is positioned over the first source/drain region, and the third opening extends through the first section of the interlayer dielectric layer to the first source/drain region.
23. The method of claim 22 further comprising:
- forming a first contact arranged over the first source/drain region and laterally adjacent to the first sidewall spacer,
- wherein the first contact is coupled with the first source/drain region, and a portion of the first section of the interlayer dielectric layer is positioned between the first contact and the first sidewall spacer.
24. The method of claim 23 wherein the first contact is physically and electrically coupled in direct contact with the first source/drain region.
25. The method of claim 23 wherein the first sidewall spacer and the portion of the interlayer dielectric layer have approximately equal heights.
26. The method of claim 22 further comprising:
- forming a second gate electrode of the second field-effect transistor;
- forming a fourth sidewall spacer adjacent to a sidewall of the second gate electrode; and
- forming a second contact arranged over the second source/drain region and laterally adjacent to the fourth sidewall spacer,
- wherein the second section of the interlayer dielectric layer is fully removed from over the second source/drain region before forming the second contact.
27. The method of claim 9 wherein the first field-effect transistor is a long-channel field-effect transistor, and the second field-effect transistor is a short-channel field-effect transistor.
28. The method of claim 9 wherein forming the first mandrel and the second mandrel on the second sacrificial layer comprises:
- applying a photoresist by a spin coating process; and
- patterning the photoresist to form a first resist shape providing the first mandrel and a second resist shape providing the second mandrel.
Type: Application
Filed: Apr 17, 2019
Publication Date: Oct 22, 2020
Inventors: Michael Aquilino (Gansevoort, NY), Daniel Jaeger (Saratoga Springs, NY), Naved Siddiqui (Malta, NY), Jessica Dechene (Watervliet, NY), Daniel J. Dechene (Watervliet, NY), Shreesh Narasimha (Charlotte, NC), Natalia Borjemscaia (Greensboro, NC)
Application Number: 16/386,363