RELATED APPLICATIONThis application is a divisional of U.S. patent application Ser. No. 11/380,695, filed Apr. 28, 2006.
BACKGROUND1. Field of the Invention
The invention relates generally to mechanical stress within complementary metal oxide semiconductor (CMOS) structures. More particularly, the invention relates to structures and methods that provide mechanical stress within CMOS structures to enhance device performance and improve chip yield.
2. Description of the Related Art
CMOS structures comprise complementary mated pairs of field effect transistors of differing conductivity type. Due to the use of complementary mated pairs of differing conductivity type, CMOS structures also provide for reduced energy or power consumption.
A trend within CMOS fabrication is the use of stressed layers as a means to produce a mechanical stress or strain field within a channel region of a CMOS transistor. Certain types of mechanical stresses are desirable insofar as they introduce a stress into a semiconductor channel. Such a stress generally provides for enhanced charge carrier mobilities within a CMOS transistor. Complementary types of channel stress (i.e., tensile or compressive stress or strain in the direction of electrical current) enhance complementary types of charge carrier mobility (i.e., electron or hole) within complementary types of CMOS transistors (i.e., nFET or pFET).
Since mechanical stress is a significant factor that may considerably improve field effect transistor performance, CMOS structures and methods that provide for enhanced levels of mechanical stress within CMOS transistor channels are desirable.
Methods for improving charge carrier mobility within CMOS structures that include pFET and nFET devices are known in the semiconductor fabrication art. For example, En et al, in U.S. Pat. No. 6,573,172 teaches the use of a tensile stressed layer over a pFET device to provide a compressive stress of a pFET channel therein and a compressive stressed layer over an nFET device to cause a tensile stress of an nFET channel therein.
Since use of mechanical stress as a means to enhance charge carrier mobility is likely to continue within future generations of CMOS transistors, desirable are additional CMOS structures and methods for fabrication thereof that provide for charge carrier mobility enhancement incident to use of mechanical stress effects.
SUMMARY OF THE INVENTIONThe invention provides CMOS structures and methods for fabrication thereof wherein complementary transistors are covered with appropriate complementary stressed layers for purposes of providing a mechanical stress effect and enhancing a charge carrier mobility. The complementary stressed layers abut, but do not overlap at a location interposed between a pair of complementary transistors within the CMOS structure. In particular, the complementary stressed layers abut, and neither overlap, nor underlap, at a location over a source/drain region where a contact via is intended to be formed. When a silicide layer is located upon the source/drain region, absence of underlap or overlap of the complementary stressed layers provides for an enhanced manufacturing process window or improved chip yield, while avoiding overetching into the silicide layer or underetching into the complementary stressed layers.
The invention also provides an etching method for fabricating the CMOS structure. Within the etching method, at least one of a first stressed layer and a second stressed layer different from the first stressed layer that overlap and abut interposed between a first transistor and a second transistor is etched so that the first stressed layer and the second stressed layer abut, but do not overlap.
A CMOS structure in accordance with the invention includes a first transistor of a first polarity located laterally separated from a second transistor of a second polarity different from the first polarity over a semiconductor substrate. The CMOS structure also includes a first stressed layer having a first stress located over the first transistor and a second stressed layer having a second stress different from the first stress located over the second transistor. Within the CMOS structure, the first stressed layer and the second stressed layer abut and do not overlap.
A particular method for fabricating a CMOS structure in accordance with the invention includes forming a first transistor of a first polarity laterally separated from a second transistor of a second polarity different from the first polarity over a semiconductor substrate. The particular method also includes forming a first stressed layer having a first stress located over the first transistor and a second stressed layer having a second stress different from the first stress located over the second transistor. Within this particular method, the first stressed layer and the second stressed layer abut and overlap. This particular method also includes etching at least one of the first stressed layer and the second stressed layer so that the first stressed layer and the second stressed layer abut and do not overlap.
Another method for fabricating a CMOS structure includes forming a first transistor of a first polarity laterally separated from a second transistor of a second polarity different than the first polarity over a semiconductor substrate. This other method also includes forming a first stressed layer having a first stress located over the first transistor and a second stressed layer having a second stress different from the first stress located over the second transistor. Within this other method, the first stressed layer and the second stressed layer abut and overlap. This other method also includes further masking at least one of the first transistor and the second transistor to leave exposed at least the portion of the first stressed layer and the second stressed layer that abut and overlap. This other method also includes etching at least one of the first stressed layer and the second stressed layer so that the first stressed layer and the second stressed layer abut and do not overlap.
Within the disclosed invention the phrase “abut and do not overlap” is intended to describe a disposition and location of a first stressed layer and a second stressed layer that contact completely at end portions thereof. In addition, no portion of either the first stressed layer or the second stressed layer lies above the other of the first stressed layer or the second stressed layer.
BRIEF DESCRIPTION OF THE DRAWINGSThe objects, features and advantages of the invention are understood within the context of the Description of the Preferred Embodiments, as set forth below. The Description of the Preferred Embodiments is understood within the context of the accompanying drawings, which form a material part of this disclosure, wherein:
FIG. 1 toFIG. 9 show a series of schematic cross-sectional diagrams illustrating the results of progressive stages in fabricating a CMOS structure in accordance with an embodiment of the invention.
FIG. 10 toFIG. 12 show a series of schematic cross-sectional diagrams illustrating the results of progressive stages in fabricating a CMOS structure in accordance with another embodiment of the invention.
FIG. 13 toFIG. 15 show a series of schematic cross-sectional diagrams illustrating the results of progressive stages in fabricating a CMOS structure in accordance with yet another embodiment of the invention.
FIG. 16 toFIG. 18 show a series of schematic cross-sectional diagrams illustrating the results of progressive stages in fabricating a CMOS structure in accordance with still yet another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTThe invention, which provides CMOS structures and methods for fabrication thereof that include complementary stressed layers that abut and do not overlap, is described in further detail within the context of the description below. The description below is understood within the context of the drawings described above. Since the drawings are intended for illustrative purposes, they are not necessarily drawn to scale.
FIG. 1 toFIG. 9 show a series of schematic cross-sectional diagrams illustrating the results of progressive stages in fabricating a CMOS structure in accordance with an embodiment of the invention.
FIG. 1 shows asemiconductor substrate10 that comprises active regions separated by anisolation region12. A first transistor T1 is located upon one active region and a second transistor T2 is located upon an adjacent active region. Transistors T1 and T2 are of different polarity (i.e., conductivity type) and thus the doping type in each of active regions is different. The transistors T1 and T2 comprisegate dielectrics14 located upon the active regions of thesemiconductor substrate10.Gate electrodes16 are aligned upongate dielectrics14, although such alignment is not a requirement of the invention. Two part spacer layers18 (i.e. “L” or inverted “L” portions adjoininggate electrodes16 and spacer shaped portions nested therein)adjoin gate electrodes16 and are illustrated as mirroredspacer18 components although they are single components that surround eachindividual gate16. Source/drain regions20 are located within the active regions of the semiconductor substrate and separated by channel regions located beneath thegate electrodes16.Silicide layers22 are located upon source/drain regions20 andgate electrodes16.
Each of theforegoing semiconductor substrate10, layers and structures may comprise materials and have dimensions that are conventional in the semiconductor fabrication art. Each of theforegoing semiconductor substrate10, layers and structures may be formed using methods that are conventional in the semiconductor fabrication art.
Thesemiconductor substrate10 comprises a semiconductor material. Non-limiting examples of semiconductor materials from which may be comprised thesemiconductor substrate10 include silicon, germanium, silicon-germanium alloy, silicon carbide, silicon-germanium carbide alloy and compound semiconductor materials. Non-limiting examples of compound semiconductor materials include gallium arsenide, indium arsenide and indium phosphide semiconductor materials.
The embodiments and the invention contemplate that thesemiconductor substrate10 may comprise a bulk semiconductor substrate. Alternatively, the embodiment and the invention also contemplates that thesemiconductor substrate10 may comprise a semiconductor-on-insulator substrate. As a further alternative, the embodiments and the invention also contemplate that the semiconductor substrate may comprise a hybrid orientation substrate.
A semiconductor-on-insulator substrate comprises a base semiconductor substrate, a buried dielectric layer located thereupon and a surface semiconductor layer located further thereupon. A hybrid orientation substrate comprises a semiconductor substrate having multiple crystallographic orientations that may provide different crystallographic orientation channel regions for each transistor within a CMOS structure.
Semiconductor-on-insulator substrates and hybrid orientation substrates may be formed using any of several layer lamination methods and layer transfer methods. The foregoing substrates may also be formed using separation by implantation of oxygen (SIMOX) methods.
Theisolation region12 comprises a dielectric isolation material. The embodiments and the invention contemplate that isolation regions may comprise shallow trench isolation regions, deep trench isolation regions and, to a lesser extent, local oxidation of silicon isolation regions. The dielectric isolation material from which is comprised theisolation region12 may comprise an oxide, a nitride and/or an oxynitride of silicon. Oxides, nitrides and oxynitrides of other elements are not excluded as dielectric isolation materials. Dielectric isolation materials may be formed using methods including, but not limited to: thermal or plasma oxidation or nitridation methods, chemical vapor deposition methods and physical vapor deposition methods. Typically, theisolation region12 is formed at least in part from a silicon oxide dielectric isolation material that has a thickness from about 100 to about 50000 angstroms, where the thickness is highly dependent upon the use of a SOI or a bulk semiconductor substrate.
The gate dielectrics14 may comprise generally conventional gate dielectric materials having a dielectric constant from about 4 to about 20, measured in vacuum. Such generally conventional gate dielectric materials may include, but are not limited to: oxides, nitrides and oxynitrides of silicon. They may be formed using methods analogous or identical to those disclosed above with respect to forming theisolation region12. Alternatively, the gate dielectrics14 may also comprise generally higher dielectric constant dielectric materials having a dielectric constant from about 20 to at least about 100, also measured in a vacuum. These generally higher dielectric constant dielectric materials may include, but are not limited to: hafnium oxides, hafnium silicates, titanium oxides, lanthanum oxides, barium-strontium titantates (BSTs) and lead-zirconate titantates (PZTs). Typically, thegate dielectrics14 comprise a thermal silicon oxide gate dielectric material having a thickness from about 5 to about 70 angstroms.
Thegate electrodes18 comprise gate electrode conductor materials. Typical gate electrode conductor materials include certain metals, metal alloys, metal nitrides and metal suicides, as well as polysilicon materials. The gate electrode conductor materials may be formed using methods including, but not limited to: plating methods, chemical vapor deposition methods (including atomic layer chemical vapor deposition methods) and physical vapor deposition methods (including sputtering methods). Typically, thegate electrodes18 comprise a metal, metal silicide or polysilicon gate electrode conductor material having a thickness from about 500 to about 1500 angstroms.
As noted above, spacer layers18 are intended as two component structures comprising: (1) the illustrated “L” or invented “L:” shaped portions adjoining thegate electrodes16; in conjunction with, (2) the more traditional spacer shaped portions nested within the “L” shaped portions or the inverted “L” shaped portions. Each of the foregoing two component structures may comprise materials analogous, equivalent or identical to the materials from which are comprised theisolation region12. The “L” or inverted “L” shaped structures are typically deposited using a conformal layer deposition method. The spacer shaped portions are formed using a blanket layer deposition and anisotropic etchback method.
The source/drain regions20 are formed using a two step ion implantation method. A first step within the two step ion implantation method uses thegates16, absent thespacers18, as a mask to form extension regions into thesemiconductor substrate10. A second step within the two step ion implantation method uses thegates16 and thespacers18 as a mask to form conductor region portions of the source/drain regions20 into the semiconductor substrate. Thus, the source/drain regions20 comprise extension region components and conductor region components. Dopant concentrations within the source/drain regions20 range from about 1×1020to about 3×1021dopant atoms per cubic centimeter.
The silicide layers22 may comprise any of several metal silicide forming metals. Non-limiting examples of silicide forming metals include titanium, tungsten, nickel, cobalt, vanadium and molybdenum silicide forming metals. The silicide layers22 are typically formed using a self-aligned silicide (i.e., salicide) method that provides for: (1) a blanket metal silicide forming metal layer deposition; (2) a subsequent thermal annealing to provide for silicide formation in contact with silicon; and (3) a subsequent excess silicide forming metal layer stripping. Typically, each of the silicide layers22 has a thickness from about 50 to about 200 angstroms.
FIG. 2 shows a first stressedlayer24 located upon the CMOS structure ofFIG. 1.FIG. 2 also shows anetch stop layer26 located upon the first stressedlayer24.
The first stressedlayer24 comprises a material that has a first stress intended to compliment and enhance performance of the first transistor T1. When the first transistor T1 is an nFET, the first stress is preferably a tensile stress that provides a tensile stress within the channel of the first transistor T1. Under those circumstances, an electron charge carrier mobility within the first transistor T1 is enhanced. Conversely, when the first transistor is a pFET, a compressive stress of an overlying layer is desirable for purposes of generating compressive channel stress that yields an enhanced hole mobility.
Within the instant embodiment, the first transistor T1 is preferably an nFET and the first stressedlayer24 preferably comprises a tensile stressed layer.
The first stressedlayer24 may comprise any of several stressed materials. Non-limiting examples includes nitrides and oxynitrides. Nitrides are particularly common stressed layer materials insofar as different magnitudes and types of stress may be introduced into a nitride layer material by using different deposition conditions for forming the nitride layer. Particular deposition conditions that affect nitride layer stress include a changing of the ratio of a low frequency plasma to a high frequency plasma at temperature range from 200° C. to 600° C.
Typically, the first stressedlayer24 comprises a nitride material that has a thickness from about 500 to about 1000 angstroms, although the invention is not limited to stressed layers comprising only nitride materials.
Theetch stop layer26 may comprise any of several etch stop materials. Etch stop materials will typically have a different composition from the first stressedlayer24. Typically, theetch stop layer26 comprises an oxide etch stop material when the first stressedlayer24 comprises a nitride material. Within the instant embodiment, theetch stop layer26 typically comprises a silicon oxide etch stop material that has a thickness from about 50 to about 300 angstroms. Theetch stop layer26 may be formed using methods analogous to the methods used for forming theisolation region12.
FIG. 3 shows ablock mask28 located upon theetch stop layer26 and covering the first transistor T1. Theblock mask28 may comprise any of several mask materials. Non-limiting examples include hard mask materials and photoresist mask materials. Photoresist mask materials are considerably more common. Non-limiting examples of photoresist mask materials include positive photoresist materials, negative photoresist materials and hybrid photoresist materials. Typically, theblock mask28 comprises a photoresist material having a thickness from about 1000 to about 5000 angstroms.
FIG. 4 shows the results of etching theetch stop layer26 and the first stressedlayer24 to form correspondingetch stop layer26′ and first stressedlayer24′, while using theblock mask28 as an etch mask. The foregoing etching is typically undertaken while using a plasma etchant, although neither the embodiment nor the invention is so limited. Wet chemical etchants, while generally less common, may also be used. Typically, the plasma etchant uses a fluorine containing etchant gas composition for etching each of theetch stop layer26 and the first stressedlayer24 when forming therefrom theetch stop layer26′ and the first stressedlayer24′. As is illustrated inFIG. 4, the etching also forms thespacers18′ from thespacers18.
FIG. 5 first shows the results of stripping theblock mask28 from the CMOS structure ofFIG. 4. Theblock mask28 may be stripped using methods and materials that are otherwise conventional in the semiconductor fabrication art. Included are wet chemical stripping methods and materials, dry plasma stripping methods and materials and aggregate stripping methods and materials thereof. Dry plasma stripping methods and materials are particularly common, but do not limit the invention.
FIG. 5 also shows a second stressedlayer30 located upon the semiconductor structure ofFIG. 4, subsequent to removing theblock mask28 therefrom.
The second stressedlayer30 has an appropriate stress engineered to promote enhanced performance (generally within the context of charge carrier mobility) of the second transistor T2. The second stressedlayer30 may comprise materials and have dimensions that are analogous, equivalent or identical to the materials and dimensions used for forming the first stressedlayer24 that is illustrated inFIG. 3. As is disclosed above, the first stressedlayer24 typically comprises a silicon nitride material whose stress (i.e., tensile or compressive) may be engineered incident to control of particular deposition conditions. The second stressedlayer30 thus also comprises a nitride material, but for which deposition conditions are selected to have a type of stress (i.e., tensile or compressive) typically opposite the first stressedlayer24.
Within the context of the instant embodiment, the first stressedlayer24 preferably comprises a tensile stress from about 500 MPa to about 4 GPa (when the first transistor T1 is an nFET) and the second stressedlayer30 preferably a compressive stress from about −500 MPa to about −5 GPa (when the second transistor T2 is a pFET).
FIG. 6 shows ablock mask28′ located upon the second stressedlayer30 and covering the second transistor T2. Theblock mask28′ otherwise comprises materials and has dimensions analogous or equivalent to theblock mask28 that is illustrated inFIG. 3.
FIG. 7 shows the results of patterning the second stressedlayer30 to form a second stressedlayer30′, and subsequently stripping theblock mask28′ from the CMOS structure ofFIG. 6.
The second stressedlayer30 may be etched to form the second stressedlayer30, while using methods and materials analogous equivalent or identical to the methods and materials used for etching the first stressedlayer24 to from the first stressedlayer24′. Thesecond block mask28′ may be stripped using methods and materials analogous equivalent or identical to the methods and materials used for stripping thefirst block mask28.
As is illustrated within the schematic diagram ofFIG. 7, the first stressedlayer24′ and the second stressedlayer30′ abut and overlap.
FIG. 8 shows the results of etching theetch stop layer26′, the first stressedlayer24′ and the second stressedlayer30′ so that a resulting first stressedlayer24″ and a resulting second stressedlayer30″ abut and do not overlap, rather than abut and overlap. Also resulting from this etching is etch stop layers26″.
The foregoing etching may be undertaken using methods that are conventional in the semiconductor fabrication art. Non-limiting examples are plasma etch methods and sputter etch methods. Desirable are sputter etch methods that use argon or nitrogen sputter etchants. Such sputter etchants desirably have a tendency to etch more from top surfaces than lower surfaces of the first stressedlayer24′ and the second stressedlayer30′ when forming the first stressedlayer24″ and the second stressedlayer30″.
Within the context of the instant embodiment and the invention, the abutment of the first stressedlayer24″ with the second stressedlayer30″ absent overlap thereof provides for enhanced manufacturability. The enhanced manufacturability is desirable under circumstances where overlapped portions of the first stressedlayer24′ and the second stressedlayer30′ are located over a contact region portion of a source/drain region, particularly when the source/drain region has a silicide layer thereupon.
FIG. 9 shows the results of etching remaining portions of theetch stop layer26″ from the CMOS structure ofFIG. 8.FIG. 9 also shows acapping layer32 located upon the CMOS structure ofFIG. 8 after etching remaining portions of theetch stop layer26″. The remaining portions of theetch stop layer26″ may be etched using a wet chemical etchant or a dry plasma etchant.
Thecapping layer30 may comprise any of several capping materials. Included are oxides, nitrides and oxynitrides of silicon, as well as oxides, nitrides and oxynitrides of other elements. Thecapping layer32 preferably comprises a silicon nitride material having a thickness from about 50 to about 100 angstroms.
FIG. 9 shows a CMOS structure in accordance with a first embodiment of the invention. The CMOS structure comprises complementary first stressedlayer24″ located upon first transistor T1 and second stressedlayer30″ located upon second transistor T2. The complementary first stressedlayer24″ and second stressedlayer30″ abut, but do not overlap at a location interposed between the first transistor T1 and the second transistor T2.
Since the complementary first stressedlayer24″ and second stressedlayer30″ abut, but do not overlap, the CMOS structure that is illustrated inFIG. 9 provides for enhanced manufacturability. The enhanced manufacturability results from a nominally level surface provided by the first stressedlayer24″ and the second stressedlayer30″ so that a contact via may be efficiently etched reaching a source/drain region20 having asilicide layer22 thereupon while not damaging thesilicide layer22.
FIG. 10 toFIG. 12 show a series of schematic cross-sectional diagrams illustrating the results of progressive stages in fabricating a CMOS structure in accordance with another embodiment of the invention. This other embodiment of the invention comprises a second embodiment of the invention.
FIG. 10 shows a CMOS structure that derives from the CMOS structure ofFIG. 7 within the first embodiment. The CMOS structure ofFIG. 10 however shows ablocking layer34 located upon the CMOS structure ofFIG. 7. Ablock mask36 is located upon theblocking layer34 and covering the first transistor T1. Ablock mask36′ is located upon theblocking layer34 and covering the second transistor T2.
Theblocking layer34 preferably comprises an oxide material under circumstances where the first stressedlayer24 and the second stressedlayer30 comprise nitride materials. Theblocking layer34 may be formed using methods and materials analogous, equivalent or identical to the methods and materials used for forming theetch stop layer26. Typically, theblocking layer34 has a thickness from about 300 to about 500 angstroms.
The block masks36 and36′ may comprise any of several block mask materials that are disclosed above for the block masks28 and28′.
FIG. 11 shows the results of further processing of the CMOS structure ofFIG. 10.FIG. 11 shows the results of etching theblocking layer34 to form blockinglayers34′ that straddle the first transistor T1 and the second transistor T2. In so doing, an abutted and overlapped portion of the first stressedlayer24′ and the second stressedlayer30′ is exposed.FIG. 11 also shows the results of stripping the block masks36 and36′.
FIG. 12 shows the results of further processing of the CMOS structure ofFIG. 11.FIG. 12 shows the results of etching the first stressedlayer24′ and the second stressedlayer30′ to yield first stressedlayer24″ and second stressedlayer30″ that are abutted and do not overlap. The etching preferably uses a nitrogen or argon sputter etching as is disclosed above within the context of the first embodiment.
For reasons disclosed above within the context of the first embodiment, abutment absent overlap of the first stressedlayer24″ and the second stressedlayer30″ provides for enhanced manufacturability of the CMOS structure ofFIG. 12.
Within the second embodiment, the use of the blocking layers34′ also assist in preserving a full initial thicknesses of the first stressedlayer24″ and the second stressedlayer30″ at locations over the first transistor T1 and the second transistor T2. Thus, a full effect of stress from the first stressedlayer24″ and the second stressedlayer30″ is transmitted into respective semiconductor channels over which they are formed.
FIG. 13 toFIG. 15 show a series of schematic cross-sectional diagrams corresponding withFIG. 10 toFIG. 12, but where theblock mask36 is located over the first transistor T1 only, and not the second transistor T2.FIG. 13 toFIG. 15 comprise a third embodiment of the invention.
FIG. 16 toFIG. 18 show a series of schematic cross-sectional diagrams corresponding withFIG. 10 toFIG. 12 orFIG. 13 toFIG. 15, but where theblock mask36′ is located over the second transistor T2 only and not the first transistor T1.FIG. 16 toFIG. 18 comprise a fourth embodiment of the invention.
The processing for eitherFIG. 13 toFIG. 15 orFIG. 16 toFIG. 18 follows analogously from the processing ofFIG. 10 toFIG. 12. However, due to the presence of only asingle block mask36 or36′, only one of the first stressedlayer24″ (i.e.,FIG. 15) and the second stressedlayer30″ (i.e.,FIG. 18) has an initial thickness after sputter etching.
In each of the second embodiment of the invention that is illustrated inFIG. 10 toFIG. 12, the third embodiment of the invention that is illustrated inFIG. 13 toFIG. 15 and the fourth embodiment of the invention that is illustrated inFIG. 16 toFIG. 18, the first stressedlayer24′ that abuts and overlaps the second stressedlayer30′ are etched to form the first stressedlayer24″ and the second stressedlayer30″ that abut, but do not overlap.
In accordance with the first embodiment of the invention, the second embodiment, the third embodiment and the fourth embodiment provide for enhanced manufacturability of a CMOS structure due to the foregoing abutment absent overlap.
The preferred embodiments of the invention are illustrative of the invention rater than limiting of the invention. Revisions and modifications may be made to methods, materials, structures and dimensions of a CMOS structure or method for fabrication thereof in accordance with the preferred embodiments of the invention while still providing a CMOS structure in accordance with the invention, further in accordance with the accompanying claims.