Abstract:
Embodiments of methods and apparatus for a sacrificial oxide layer which enables spacer over-etch in multi-gate architectures are generally described herein. Other embodiments may be described and claimed.

Description:
FIELD OF THE INVENTION 
       [0001]    The field of invention relates generally to the field of semiconductor integrated circuit manufacturing and, more specifically but not exclusively, relates to CMOS (complementary metal oxide semiconductor) devices having a three-dimensional tri-gate fin body lacking spacers or dry etch damage on the side walls of the tri-gate fin body. 
       BACKGROUND INFORMATION 
       [0002]    In a conventional metal oxide semiconductor field effect transistor (MOSFET), the source, channel, and drain structures are constructed adjacent to each other within the same plane. The gate dielectric is formed on the channel area and the gate electrode is deposited on the gate dielectric. The transistor is controlled by applying a voltage to the gate electrode thereby allowing a current to flow through the channel between source and drain. 
         [0003]    An alternative to methods of building planar MOSFETs has been proposed to help alleviate some of the physical barriers to scaling down existing designs. The alternative method involves a construction of three dimensional MOSFETs, in the form of a multi-gate transistor such as a dual-gate field effect transistor (FinFET) or a tri-gate transistor, as a replacement for the conventional planar MOSFET. 
         [0004]    Three-dimensional transistor designs such as the dual-gate FinFET and the tri-gate transistor allow tighter packing of the same number of transistors on a semiconductor chip by using vertical or angled surfaces for the gates. A tri-gate device comprises three equal length gates situated on three exposed surfaces of a semiconductor body. 
         [0005]    An overall contact resistance of the tri-gate device is a function of a contact resistance contributed by the top gate and a contact resistance contributed by each of the two side gates. The contact resistance at each gate is determined in part by the contact area of the source and drain, materials used at the interface of the source and drain regions, such as a silicide layer, and the manner in which those materials interface. The silicide layer may be formed on the source and drain regions for the top and side gates of a multi-gate device to reduce the contact resistance, thereby increasing the transistor current. The contact resistance can increase when a portion of the silicide material is blocked or is otherwise prevented from contacting a source or drain region. 
         [0006]    Thus, there is a general need for maximizing the available contact area for the source drain regions in a multi-gate device. By increasing the area of contact in the source and drain regions and reducing the overall contact resistance, the transistor current for the multi-gate device can be increased. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified: 
           [0008]      FIG. 1  is a flowchart describing an embodiment of a fabrication process used to create a silicide layer on a top surface and a side surface of a tri-gate field effect transistor. 
           [0009]      FIG. 2  is an illustration of a cross-sectional view of a tri-gate field effect transistor after forming a dielectric layer for a spacer. 
           [0010]      FIG. 3  illustrates the transistor in  FIG. 2  after eroding a portion of the dielectric layer to expose a top surface of the semiconductor body. 
           [0011]      FIG. 4A  illustrates the transistor in  FIG. 3  after forming a sacrificial layer on the top surface of the semiconductor body. 
           [0012]      FIG. 4B  is a cross-sectional view of the transistor of  FIG. 4A  taken through section line  4 B- 4 B of  FIG. 4A . This view illustrates dielectric spacers formed on a front surface and a back surface of the semiconductor body. 
           [0013]      FIG. 5A  illustrates the transistor of  FIG. 4A  after eroding a portion of the dielectric layer to expose a side surface of the semiconductor body. 
           [0014]      FIG. 5B  is a cross-sectional view of the transistor of  FIG. 5A  taken through section line  5 B- 5 B of  FIG. 5A . This view illustrates the erosion of the dielectric spacers from the front surface and the back surface of the semiconductor body. 
           [0015]      FIG. 6  illustrates the transistor of  FIG. 5A  after eroding the sacrificial layer from the top surface of the semiconductor body. 
           [0016]      FIG. 7A  illustrates the transistor of  FIG. 6  after forming an epitaxial layer on a top surface and a side surface of the semiconductor body. 
           [0017]      FIG. 7B  is a cross-sectional view of the transistor of  FIG. 7A  taken through section line  7 B- 7 B of  FIG. 7A . This view illustrates the formation of the epitaxial layer on a front surface and a back surface of the semiconductor body. 
           [0018]      FIG. 7C  illustrates the transistor of  FIG. 6  after forming an alternate epitaxial layer on a top surface and a side surface of the semiconductor body. 
           [0019]      FIG. 7D  is a cross-sectional view of the transistor of  FIG. 7C  taken through section line  7 D- 7 D of  FIG. 7C . This view illustrates the formation of an alternate epitaxial layer on a front surface and a back surface of the semiconductor body. 
           [0020]      FIG. 8A  illustrates the transistor of  FIG. 7A  after forming a silicide layer on the epitaxial layer on the top surface and the side surface of the semiconductor body. 
           [0021]      FIG. 8B  is a cross-sectional view of the transistor of  FIG. 8A  taken through section line  8 B- 8 B of  FIG. 8A . This view illustrates the formation of a silicide layer on the epitaxial layer on the front surface and the back surface of the semiconductor body. 
           [0022]      FIG. 8C  illustrates the transistor of  FIG. 7C  after forming a silicide layer on an alternate epitaxial layer on the top surface and the side surface of the semiconductor body. 
           [0023]      FIG. 8D  is a cross-sectional view of the transistor of  FIG. 8C  taken through section line  8 D- 8 D of  FIG. 8C . This view illustrates the formation of a silicide layer on an alternate epitaxial layer on the front surface and the back surface of the semiconductor body. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Embodiments of methods and apparatus for a three-dimensional multi-gate transistor device with a dielectric spacer adjacent to a gate electrode and a silicide layer on a top surface and a side surface of a semiconductor body are described herein. In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. 
         [0025]    Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
         [0026]    One embodiment for how a three-dimensional multi-gate transistor device with a dielectric spacer adjacent to a gate electrode and a silicide layer on the top and side surfaces of a semiconductor body may be formed is described in  FIG. 1 . The process may be initiated (element  100 ) by depositing a dielectric layer on a top surface and at least one side surface of a semiconductor body. The dielectric layer may comprise a nitride layer such as silicon nitride, titanium nitride, or silicon oxynitride, but the embodiment is not so limited. The dielectric layer may be deposited using methods known to persons having ordinary skill in the art, such as plasma enhanced chemical vapor deposition (PECVD), high density chemical vapor deposition (HDCVD), or sputtering, but the embodiment is not so limited. The semiconductor body may be formed, for example, from a monocrystalline substrate or from a silicon-on-insulator (SOI) layer. 
         [0027]    The dielectric layer is then eroded (element  102 ) to expose the top surface of the semiconductor body. In one embodiment, the dielectric layer may be eroded by a dry-etch process using sulfur hexafluoride (SF6) or a fluorinated hydrocarbon (CHxFy) gas in a magnetically enhanced reactive ion etching (MERIE) or an electron cyclotron resonance (ECR) chamber or tool. The dry-etch process may be terminated by using a timing mechanism or by sensing a silicon layer on the top surface of the semiconductor body. However, the dielectric material may also be eroded using a wet-etch process, or an ion milling process. In one embodiment, the wet-etch process may comprise a hydrofluoric acid (HF) or a hot phosphoric acid (H3PO4) solution. 
         [0028]    After eroding the dielectric layer, a sacrificial layer (element  104 ) is formed on the top surface of the semiconductor body. The sacrificial layer, or protective layer, is formed to protect the top surface of the semiconductor body during subsequent processing. In one embodiment, the sacrificial masking layer may be an oxide layer formed using a chemical vapor deposition (CVD) chamber, but the embodiment is not so limited. The dielectric layer is then further eroded (element  106 ) to expose at least one side surface of the semiconductor body. In one embodiment, the dielectric layer may be eroded by a dry-etch process using sulfur hexafluoride (SF6) or a fluorinated hydrocarbon (CHxFy) gas in a MERIE or an ECR chamber or tool. 
         [0029]    The sacrificial layer is eroded (element  108 ) to expose a top surface of the semiconductor body. The sacrificial layer may be eroded using a wet-etch process or a dry-etch process that selectively etches the sacrificial layer while leaving remaining structures largely intact. In one embodiment, the wet-etch process may comprise an HF or a buffered HF solution. At least one side surface and a top surface of the semiconductor body is exposed and a dielectric spacer remains adjacent to a gate electrode on the semiconductor body following the erosion of the sacrificial layer. The semiconductor body is then thickened by forming an epitaxial layer (element  110 ) on the top and at least one side surface of the semiconductor body. Typically, the epitaxial layer will form in areas where monocrystalline silicon is exposed. 
         [0030]    In one embodiment, a silicide layer may be formed (element  112 ) on the exposed epitaxial layer using a physical vapor deposition (PVD) or a chemical vapor deposition (CVD) technique and a subsequent high temperature step, although the scope of the invention is not limited in this respect. 
         [0031]    The method for how a three-dimensional multi-gate transistor device with a dielectric spacer adjacent to a gate electrode and a silicide layer on the top and side surfaces of a semiconductor body may be formed is illustrated in  FIG. 2  through  FIG. 8D .  FIG. 2  illustrates a cross-sectional view of a tri-gate field effect transistor comprising a semiconductor body  200  and a gate electrode comprising a thin gate dielectric layer  220 , a conductive layer  230 , and a hard mask layer  240 . The thin gate dielectric layer  220  may comprise a silicon oxide, or alternatively, a high-k dielectric layer such as lanthanum oxide, tantalum oxide, titanium oxide, hafnium oxide, zirconium oxide, lead-zirconate-titanate (PZT), barium-strontium-titanate (BST), or aluminum oxide. In one embodiment, the high-k dielectric layer is between 15 angstroms and 30 angstroms in thickness, although these values for the dielectric layer are not limiting. The conductive layer  230  may comprise doped or un-doped polysilicon, or a metal film such as tungsten, tantalum, titanium and/or nitrides and alloys thereof as the conductive path for the gate electrode. The hard mask layer  240  may comprise a silicon dioxide, silicon nitride, or silicon oxynitride layer, but the embodiment is not limited to these materials. A dielectric layer  210  may be deposited on the tri-gate field effect transistor. The dielectric layer  210  may comprise silicon nitride, silicon oxynitride, or silicon carbide, but the embodiment is not so limited. 
         [0032]      FIG. 3  illustrates the transistor in  FIG. 2  after eroding a portion of the dielectric layer  210  to form a gate electrode spacer  310  and a semiconductor body spacer  320 , and exposing a top surface  330  of the semiconductor body  200 . In one embodiment, the dielectric layer  210  may be eroded to form the gate electrode spacer  310  and the semiconductor body spacer  320  using sulfur hexafluoride (SF6), oxygen (O2), carbon monoxide (CO), and argon (Ar), or a fluorinated hydrocarbon (CHxFy) gas in a MERIE or an ECR chamber or tool. 
         [0033]    Turning to  FIG. 4A , a sacrificial layer  410  is formed on the top surface  330  of the semiconductor body  200 . The sacrificial layer  410  is formed to protect the top surface  330  of the semiconductor body  200  during subsequent processing of the gate electrode spacer  310  and the semiconductor body spacer  320 . In one embodiment, the sacrificial layer  410  acts as a mask and may be an oxide layer formed using a chemical vapor deposition (CVD) chamber, a wet chemical passivation method, or through native oxide growth by exposure to an ambient environment, but the embodiment is not so limited. The illustration of  FIG. 4B , a cross-section through section line  4 B- 4 B of  FIG. 4A , shows that a front  420  and a back  430  of the semiconductor body  200  with the sacrificial layer  410  may have an adjacently positioned semiconductor body spacer  320 . 
         [0034]      FIG. 5A  illustrates the transistor of  FIG. 4A  after eroding a portion of the dielectric layer to expose a side surface  530  of the semiconductor body  200 . A sacrificial layer  520  may be minimally eroded during this process. A gate electrode spacer  510  may also be eroded during this process. In one embodiment, the sacrificial layer  520  and the gate electrode spacer may be eroded using sulfur hexafluoride (SF6) or a fluorocarbon (CxFy) gas in a MERIE or an ECR chamber or tool. The illustration of  FIG. 5B , a cross-section through section line  5 B- 5 B of  FIG. 5A , shows the semiconductor body  200  and sacrificial layer  520  with an exposed front surface  540 . 
         [0035]      FIG. 6  illustrates the transistor of  FIG. 5A  with a gate electrode spacer  510  after eroding the sacrificial layer  520  from a top surface of the semiconductor body  200 . The sacrificial layer  520  may be eroded using a wet-etch process or a dry-etch process. In one embodiment, the wet-etch process may comprise an HF or a buffered HF solution, although the scope of the invention is not limited in this respect. 
         [0036]    An epitaxial layer  710  is deposited adjacent to a gate electrode spacer  510  on a top surface and a side surface of the semiconductor body  200  after eroding the sacrificial layer  520 .  FIG. 7A  illustrates one embodiment of the transistor of  FIG. 6  after forming the epitaxial layer  710 .  FIG. 7C  illustrates another embodiment of the transistor of  FIG. 6  after forming an alternate epitaxial layer  710 . The illustration of  FIG. 7B , a cross-section through section line  7 B- 7 B of  FIG. 7A , shows an embodiment with an epitaxial layer  710  formed on a front and a back as well as the top of the semiconductor body  200 .  FIG. 7D  illustrates the structure of  FIG. 7B  with an alternate epitaxial layer  710 . The epitaxial layer  710  may be formed using a CVD chamber using a source gas such as silane, or by molecular beam epitaxy (MBE), though the invention is not limited in this respect. 
         [0037]    A silicide layer  810  is deposited adjacent to a gate electrode spacer  510  on a top surface and a side surface of the semiconductor body  200  and the epitaxial layer  710 .  FIG. 8A  illustrates one embodiment of the transistor of  FIG. 7A  after forming the silicide layer  810 .  FIG. 8C  illustrates another embodiment of the transistor of  FIG. 7C  after forming the silicide layer  810 .  FIG. 8B  is a cross-sectional illustration of section line  8 B- 8 B of  FIG. 7B , which shows one embodiment with a silicide layer  810  formed on a front and a back as well as the top of the semiconductor body  200  and the epitaxial layer  710 .  FIG. 8D  illustrates the structure of  FIG. 8B  with an alternate epitaxial layer  710 . The silicide layer  810  may be formed on the exposed epitaxial layer  710  by depositing a metal such as titanium (Ti), cobalt (Co), nickel (Ni), or platinum (Pt) using a physical vapor deposition (PVD) technique or a chemical vapor deposition (CVD) technique and a subsequent high temperature step, although the scope of the invention is not limited in this respect. 
         [0038]    The above description of illustrated embodiments of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. 
         [0039]    These modifications can be made to the invention in light of the above detailed description. The terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification and the drawings. Rather, the scope of the invention is to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation.