DEVICE WITH ALTERNATE COMPLEMENTARY CHANNELS AND FABRICATION METHOD THEREOF

A device comprises a gate structure, n-type source/drain features, p-type source/drain features, an NFET channel, and a PFET channel. The gate structure is over a substrate. The n-type source/drain features are on opposite first and second sides of the gate structure, respectively. The p-type source/drain features are on opposite third and fourth sides of the gate structure, respectively. The NFET channel extends within the gate structure and connects the n-type source/drain features. The PFET channel extends within the gate structure and connects the p-type source/drain features. The NFET channel and the PFET channel are vertically spaced apart by the gate structure.

BACKGROUND

A transistor is an element that is utilized extensively in semiconductor devices. There may be thousands of transistors on a single integrated circuit (IC) in some applications, for example. One common type of transistor used in semiconductor device fabrication is a metal oxide semiconductor field effect transistor (MOSFET). Two transistors may be coupled together to form an inverter.

DETAILED DESCRIPTION

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. As used herein, “around,” “about,” “approximately,” or “substantially” may generally mean within 20 percent, or within 10 percent, or within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the term “around,” “about,” “approximately,” or “substantially” can be inferred if not expressly stated. One skilled in the art will realize, however, that the values or ranges recited throughout the description are merely examples, and may be reduced with the down-scaling of the integrated circuits.

FIG.1is a schematic circuit diagram of an example complementary metal-oxide-semiconductor (CMOS) inverter100in accordance with some embodiments of the present disclosure. The example inverter100includes a p-type field effect transistor (PFET)102and an n-type field effect transistor (NFET)108coupled together. When the input voltage, Vin, to the inverter100is low, the p-type transistor102turns on, charges up a load capacitance104, and the output goes to a gate drive106, VDD. Alternatively, when Vinis high, the n-type transistor108turns on, discharges the load capacitance, and the output node goes to ground110(e.g., Vss). In this manner, the inverter100is able to perform the logic swing for digital processing. Because a CMOS inverter100includes two transistors formed on a same level height on wafer, it is challenging for scaling down footprint of inverters100. Therefore, embodiments of the present disclosure are directed to a new structure of inverter having PFET channels and NFET channels alternately arranged along a vertical direction, which in turn reduces the footprint of inverters.

FIGS.2A-19Care top views, perspective views, and cross-sectional views of intermediate stages in the manufacturing of an inverter in accordance with some embodiments of the present disclosure. The manufacturing process steps can be used to fabricate the inverter100as discussed with respect toFIG.1. It is understood that additional operations can be provided before, during, and after processes shown byFIGS.2A-19C, and some of the operations described below can be replaced or eliminated, for additional embodiments of the method. The order of the operations/processes may be interchangeable.

FIG.2Ais a top view of an intermediate stage in manufacturing of an inverter, andFIG.2Bis a cross-sectional view obtained from cut A-A′ inFIG.2A. InFIGS.2A and2B, a substrate200is illustrated. In some embodiments, the substrate200may be a semiconductor substrate, such as a bulk semiconductor substrate, a semiconductor-oninsulator (SOI) substrate, a multi-layered or gradient substrate, or the like. The substrate200may include a semiconductor material, such as an elemental semiconductor including Si and Ge; a compound or alloy semiconductor including SiC, SiGe, GeSn, GaAs, GaP, GaAsP, AlInAs, AlGaAs, GaInAs, InAs, GaInP, InP, InSb, GaInAsP; a combination thereof, or the like. The substrate200may be doped or substantially un-doped. In a specific example, the substrate200is a bulk silicon substrate, which may be a wafer.

FIGS.2A and2Balso illustrate a layer stack LS formed over the substrate200. The layer stack LS may include one or more buffer layers201formed on the substrate200. The buffer layer201can serve to gradually change the lattice constant from that of the substrate200to that of the epitaxial layers in the layer stack LS. The buffer layer201may be formed from epitaxially grown single crystalline semiconductor materials such as, but not limited to Si, Ge, GeSn, SiGe, GaAs, InSb, GaP, GaSb, InAlAs, InGaAs, GaSbP, GaAsSb, GaN, GaP, and InP. In some embodiments, the substrate200is made of Si, the buffer layer201is made of germanium. The buffer layer201is epitaxially grown on the substrate200by one or more epitaxy or epitaxial (epi) processes. The epitaxy processes include CVD deposition techniques (e.g., vapor-phase epitaxy (VPE) and/or ultra-high vacuum CVD (UHV-CVD)), molecular beam epitaxy (MBE), and/or other suitable processes.

A first semiconductor layer (also referred to as sacrificial layer in this context)202A is formed over the buffer layer201. A second semiconductor layer (also referred to as NFET channel layer)204A is formed over the sacrificial layer202A. Another first semiconductor layer (sacrificial layer)202B is formed over the NFET channel layer204A. A third semiconductor layer (also referred to as PFET channel layer)206A is formed over the sacrificial layer202B. Another first semiconductor layer (sacrificial layer)202C is formed over the PFET channel layer206A. Another second semiconductor layer (NFET channel layer)204B is formed over the sacrificial layer202C. Another first semiconductor layer (sacrificial layer)202D is formed over the NFET channel layer204B. Another third semiconductor layer (PFET channel layer)206B is formed over the sacrificial layer202D.

In some embodiments, the first, second and third semiconductor layers are alternately stacked such that there are more than two layers each of the first, second and third semiconductor layers. The first semiconductor layers202A-202D (collectively referred to as first semiconductor layers202) will be removed in subsequent processing and thus are referred to as sacrificial layers. The second semiconductor layers204A and204B (collectively referred to as second semiconductor layers204) will become nanosheets, nanowires, nanoslabs or nanorings that connect n-type source/drain regions formed in subsequent processing, and will remain in a final IC product to serve as NEFT channel layers. The third semiconductor layers206A and206B (collectively referred to as third semiconductor layers206) will become nanosheets, nanowires, nanoslabs or nanorings that connect p-type source/drain regions formed in subsequent processing, and will remain in a final IC product to serve as PEFT channel layers.

In some embodiments, the number of NFET channel layers204is from 1 to 20, and the number of PFET channel layers206is from 1 to 20. In some embodiments, the number of NFET channel layers204is the same as the number of PFET channel layers206. In some embodiments, the number of NFET channel layers204is greater than the number of PFET channel layers206. In some embodiments, the number of NFET channel layers204is less than the number of PFET channel layers206. The number of NFET channel layers204and the number of PFET channel layers206can be selected to balance the current for the resultant inverter.

In some embodiments, the sacrificial layers202, the NFET channel layers204, and the PFET channel layers206are made of different materials selected from the group consisting of Si, Ge, Sn, SiGe, GeSn, Ge:B, SiGeSn, III-V compound, and combinations thereof. Because of the material difference, in subsequent processing, the NFET channel layers204can be selectively etched without substantially etching the sacrificial layers202and the PFET channels206, the PFET channel layers206can be selectively etched without substantially etching the sacrificial layers202and the NFET channel layers204, and the sacrificial layers202can be selectively etched without substantially etching the NFET channel layers204and the PFET channel layers206. In some embodiments, the sacrificial layers202are pure germanium (Ge) layers without Si or Sn.

In some embodiments, the lattice constant of the PFET channel layers206is greater than the lattice constant of the NFET channel layers204, and thus the PFET channel layers206have compressive strain and the NFET channel layers204have tensile strain. The compressive strain will increase hole mobility in the PFET channel layers206, and the tensile strain will increase electron mobility in the NFET channel layers204. In some embodiments, the NFET channel layers204are germanium silicon (GeSi) layers, and the PFET channel layers206are germanium tin (GeSn) layers. In some embodiments, the NFET channel layers204are boron-doped germanium (Ge:B) layers, and the PFET channel layers206are un-doped GeSi layers. In some embodiments, the NFET channel layers204are Si layers without Ge, and the PFET channel layers206are GeSi layers. In some embodiments, the NFET channel layers204are Ge layers without Sn, and the PFET channel layers206are un-doped GeSn layers.

In some embodiments, a thickness of each NFET channel layer204is smaller than a critical thickness of the epitaxial material of the NFET channel layer204, and a thickness of each PFET channel layer206is smaller than a critical thickness of the epitaxial material of the PFET channel layer206. As used herein, a “critical thickness” refers to a thickness that an epitaxial layer can keep to maintain the elastic strain energy below the energy of dislocation formation. When the film thickness is below the critical thickness, the elastically strained-layer is thermodynamically stable against dislocation formation. Because thickness of each NFET channel layer204is smaller than its critical thickness, and thickness of each PFET channel layer206is smaller than its critical thickness, the NFET channel layers204keep tensile-strained with no or negligible strain relaxation, and the PFET channel layers206keep compressive-strained with no or negligible strain relaxation. In some embodiments, the NFET channel layers204and PFET channel layers206each have a thickness in a range from about 1 nm to about 50 nm.

In some embodiments, the sacrificial layers202serve to define the spacing between adjacent two of the NFET channel layers204and PFET channel layers206. For example, the spacing between the NFET channel layer204A and the PFET channel layer206A can be adjusted by the sacrificial layer202B, the spacing between the NFET channel layer204B and the PFET channel layer206A can be adjusted by the sacrificial layer202C, and the spacing between the PFET channel layer206B and the NFET channel layer204B can be adjusted by the sacrificial layer202D. Therefore, the thickness of sacrificial layers202depends on a target distance between adjacent NFET channel and PFET channel. For example, the sacrificial layers202each have a thickness in a range from about 1 nm to about 50 nm.

The sacrificial layers202, the NFET channel layers204, and the PFET channel layers206may be formed by one or more epitaxy or epitaxial (epi) processes. The epitaxy processes include CVD deposition techniques (e.g., vapor-phase epitaxy (VPE) and/or ultra-high vacuum CVD (UHV-CVD)), molecular beam epitaxy (MBE), and/or other suitable processes.

FIG.3Ais a top view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.2A, andFIG.3Bis a cross-sectional view obtained from cut A-A′ or cut B-B′ inFIG.3A. InFIGS.3A and3B, a patterned mask208is formed over the topmost PFET channel layer206B. In some embodiments, the patterned mask208includes silicon nitride (Si3N4), silicon oxycarbide (SiOC), silicon oxide, the like, or combinations thereof. The patterned mask208may be formed by, for example, depositing a layer of mask material (e.g., silicon nitride) over the layer stack LS, coating a photoresist layer over the layer of mask material, patterning the photoresist layer into a photoresist mask by using a photolithography process, and etching the layer of mask material to form the patterned mask208by using the photoresist mask as an etch mask.

As illustrated in the top view ofFIG.3A, the patterned mask208has a cross-shaped pattern208M, a pair of X-directional linear patterns208X extending along X-direction at upper and lower ends of the cross-shaped pattern208M, and a pair of Y-directional linear patterns208Y extending along Y-direction at left and right ends of the cross-shaped pattern208M. The X-directional linear patterns208X correspond to top-view patterns of subsequently formed n-type source/drain regions. The Y-directional linear patterns208Y correspond to top-view patterns of subsequently formed p-type source/drain regions. In some embodiments, the cross angle θ of the cross-shaped pattern208M is in a range up to about 90 degrees.

FIG.3Cis a zoomed-in top view of the patterned mask208. The cross-shaped pattern208M has an X-directional width X1 at a boundary between the cross-shaped pattern208M and the X-directional linear pattern208X. The X-directional width X1 corresponds to channel width of subsequently formed NFET channels, and is in a range, e.g., from about 0.1 nm to about 100 µm. The cross-shaped pattern208M has a Y-directional width Y1 at a boundary between the cross-shaped pattern208M and the Y-directional linear pattern208X. The Y-directional width Y1 corresponds to channel width of subsequently formed PFET channels, and is in a range, e.g., from about 0.1 nm to about 100 µm. In some embodiments, the X-directional width X1 is the same as the Y-directional width Y1, and thus the subsequently formed NFET channels have a same channel width as the subsequently formed PFET channels. In some other embodiments, the X-directional width X1 is different from the Y-directional width Y1, and thus the subsequently formed NFET channels have a different channel width from the subsequently formed PFET channels. For example, when the X-directional width X1 is greater than the Y-directional width Y1, the subsequently formed NFET channels will have a larger channel width than the subsequently formed PFET channels; when the X-directional dimension X1 is less than the Y-directional dimension Y1, the subsequently formed NFET channels will have a smaller channel width than the subsequently formed PFET channels. Resultantly, the X-directional dimension X1 of the cross-shaped pattern208M can be selected to adjust NFET channel width and hence NFET gate length (Lg), and the Y-directional dimension Y1 of the cross-shaped pattern208M can be selected to adjust PFET channel width and hence PFET gate length (Lg), which in turn will aid in tuning currents of NFET and PFET.

InFIG.3C, the cross-shaped pattern208M of the patterned mask208has an X-directional length X2 extending from a first one of the Y-directional linear pattern208Y to a second one of the Y-directional linear pattern208Y. The X-directional length X2 of the cross-shaped pattern208M corresponds to channel length of subsequently formed PFET channels. The cross-shaped pattern208M of the patterned mask208has a Y-directional length Y2 extending from a first one of the X-directional linear pattern208X to a second one of the Y-directional linear pattern208X. The Y-directional length Y2 of the cross-shaped pattern208M corresponds to channel length of subsequently formed NFET channels. In the illustrated embodiment inFIG.3C, the cross-shaped pattern208M has X-directional width X1 same as Y-directional width Y1, and X-directional length X2 same as Y-directional length Y2. In some other embodiments, the cross-shaped pattern208M has different dimensions. For example, in another example of patterned mask208as illustrated inFIG.3D, the cross-shaped pattern208M has the Y-directional width Y1 greater than the X-directional width X1, and the X-directional length X2 less than the Y-directional length Y2. In such embodiments, the channel width of subsequently formed PFET channel structures (corresponding to Y-directional width Y1) is larger than the channel width of subsequently formed NFET channel structures (corresponding to X-directional width X1), and the channel length of the PFET channel structures (corresponding to the X-directional length X2) is shorter than the channel length of the NFET channel structures (corresponding to the Y-directional length Y2). The dimensions X1, X2, Y1 and Y2 can be selected to make sure that the total current of subsequently formed PFET and NFET is appropriate.

FIG.4Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.3A,FIG.4Bis a top view of the structure illustrated inFIG.4A, andFIG.4Cis a cross-sectional view obtained from cut A-A′ or cut B-B′ inFIG.4A. InFIGS.4A-4C, the layer stack is patterned into a patterned layer stack PS by one or more etching processes using the patterned mask208as an etch mask. The one or more etching processes may include wet etching processes, anisotropic dry etching processes, or combinations thereof, and may use one or more etchants that etch the sacrificial layers202, the NFET channel layers204, and the PFET channel layers206at a faster etch rate than etching the patterned mask208. The top-view pattern of patterned mask208is thus transferred to underlying layers, and hence each layer (including the buffer layer201, the sacrificial layers202, the NFET channel layers204, and the PFET channel layers206) in the resultant patterned stack PS inherits the top-view pattern of the patterned mask208, which includes a cross-shaped pattern PM, a pair of X-directional linear patterns PX at upper and lower ends of the cross-shaped pattern, and a pair of Y-directional linear patterns PY at left and right ends of the cross-shaped pattern, as previously described in detail with respect toFIGS.3C-3D. Therefore, the resultant patterned layer stack PS has Y-directional sidewalls SY extending along the Y-direction on left and right sides of the patterned stack PS, and X-directional sidewalls SX extending along the X-direction on upper and lower sides of the patterned stack PS, when viewed in a top view ofFIG.4B. Although the patterned stack PS illustrated inFIGS.4A-4Chas vertical sidewalls in cross-sectional view as illustrated inFIG.4C, the etching process may lead to tapered sidewalls in some other embodiments, such that each layer in the patterned stack PS has a width decreasing as a distance from the substrate200increases. In some embodiments, the sacrificial layers202, the NFET channel layers204and the PFET channel layers206in the patterned stack PS has a width (i.e., largest linear dimension from top view) in a range from about 1 nm to about 500 nm.

In some embodiments, the patterned stack PS is formed by anisotropic dry etching. Take plasma etching as an example of the anisotropic dry etching, the substrate200having the structure illustrated inFIGS.3A-3Bis loaded in to a plasma tool and exposed to a plasma environment generated by RF or microwave power in a gaseous mixture of one or more of chlorine-based gas (e.g., Cl2, SiCl4, or the like), a fluorine-based gas (such as CF4, SF6, CH2F2, CH3F, CHF3, or the like), and hydrogen bromide gas (HBr) for a duration time sufficient to expose the substrate200, while causing no or negligible loss in the patterned mask208. The plasma etching may be performed, by way of example and not limitation, at an RF power between about 1 and about 1000 Watts (e.g., 150 Watts). Once the etching process is complete, the patterned mask208can be removed by using a selective wet etching process using, for example, H3PO4or other suitable etchants that can selectively etch the nitride material of the patterned mask208.

FIG.5Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.4A,FIG.5Bis a top view of the structure illustrated inFIG.5A, andFIG.5Cis a cross-sectional view obtained from cut A-A′ or cut B-B′ inFIG.4A. InFIGS.5A-5C, dummy gate structure210is formed over the patterned stack PS. The dummy gate structure210have four sides respectively set back from the Y-directional linear patterns PY and the X-directional linear patterns PX, and thus the Y-directional linear patterns PY exposed by the dummy gate structure210can be replaced with p-type source/drain epitaxial structures in subsequent processing, and the X-directional linear patterns PX exposed by the dummy gate structure210can be replaced with n-type source/drain epitaxial structures in subsequent processing. Therefore, the Y-directional linear patterns PY can be interchangeably referred to as PFET source/drain regions in the patterned stack PS, and the X-directional linear patterns PX can be interchangeably referred to as NFET source/drain regions in the patterned stack PS. In some embodiments as illustrated inFIG.5B, the dummy gate structure210has a square top-view profile. In some other embodiments, the dummy gate structure210may have a rectangular top-view profile with a longest linear dimension in the X-direction or the Y-direction.

In some embodiments, the dummy gate structure210includes a dummy gate211which may be a conductive or non-conductive material and may be selected from a group including amorphous silicon, polycrystalline-silicon (polysilicon), polycrystalline silicon-germanium (poly-SiGe), metallic nitrides, metallic silicides, metallic oxides, and metals. The dummy gate211may be deposited by physical vapor deposition (PVD), CVD, sputter deposition, or the like. The dummy gate211can be formed by, for example, depositing a dummy gate material over the substrate200by using physical vapor deposition (PVD), CVD, sputter deposition, or the like, followed by planarizing the dummy gate material, such as by a chemical mechanical polish (CMP) process. Afterwards, the planarized dummy gate material is patterned by using suitable photolithography and etching techniques.

As illustrated inFIGS.5B and5C, gate spacers212are formed on sidewalls of the dummy gate211. In some embodiments of the spacer formation step, a spacer material layer is deposited on the substrate200. The spacer material layer may be a conformal layer that is subsequently etched back to form gate sidewall spacers. In the illustrated embodiment, a spacer material layer is disposed conformally on top and sidewalls of the dummy gate211. The spacer material layer may include a dielectric material such as silicon nitride, silicon oxide, silicon carbide, silicon oxynitride, SiCN films, silicon oxycarbide, SiOCN films, and/or combinations thereof. The spacer material layer may be formed by depositing a dielectric material over the dummy gate211using processes such as, CVD process, a subatmospheric CVD (SACVD) process, a flowable CVD process, an ALD process, a PVD process, or other suitable process. An anisotropic etching process is then performed on the deposited spacer material layer to expose portions of the patterned stack PS not covered by the dummy gate211(e.g., in PFET source/drain regions PY and NFET source/drain regions PX of the patterned stack PS). Portions of the spacer material layer directly above the dummy gate211may be completely removed by this anisotropic etching process. Portions of the spacer material layer on sidewalls of the dummy gate211may remain, forming gate sidewall spacers, which is denoted as the gate spacers212, for the sake of simplicity.

In some embodiments, as illustrated in the top view ofFIG.5B, four gate spacers212are respectively formed on four sides of the square-shaped dummy211. These gate spacers212are connected as a square ring-shaped spacer that encloses the square-shaped dummy gate211when viewed from a top view as illustrated inFIG.5B. Therefore, when viewed in a top view as illustrated inFIG.5B, the ring-shaped spacer212can separate the dummy gate211apart from the PFET source/drain regions PY on the left and right sides of the dummy gate211, and also separate the dummy gate211apart from the NFET source/drain regions PX on the upper and lower sides of the dummy gate211. It is understood that discussion about the square shape of the dummy gate structure and the square ring shape of the gate spacer are illustrative only, and other embodiments of the present disclosure may include a rectangular dummy gate structure and a rectangle ring-shaped spacer enclosing the rectangular dummy gate structure. The dummy gate211and its surrounding gate spacers212can be collectively referred to as a dummy gate structure210in this context. For the sake of simplicity and clarity, the dash lines indicating potential boundaries between the dummy gate211and gate spacers212are illustrated inFIGS.5B and5Conly, and will not be illustrated in figures about subsequent steps.

FIG.6Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.5A,FIG.6Bis a top view of the structure illustrated inFIG.6A,FIG.6Cis a cross-sectional view obtained from cut A-A′ inFIG.6A, andFIG.6Dis a cross-sectional view obtained from cut B-B′ inFIG.6A. InFIGS.6A-6D, the PFET source/drain regions PY in the patterned stack PS that extend laterally beyond the dummy gate structure210along X-direction are removed, for example, in an anisotropic etch step until the substrate200is exposed. The etching is performed using an etchant that attacks the patterned stack PS, and hardly attacks the dummy gate structure210. Stated differently, the dummy gate structure210has higher etch resistance to the etching process than that of the patterned stack PS. Accordingly, in the etching step, the height of dummy gate structure210is substantially not reduced. In some embodiments, the etching step is performed with an etch mask (e.g., photoresist mask and/or nitride mask) formed over the NFET source/drain regions PX, so as to allow the etching step etching the PFET source/drain regions PY, while leaving the NFET source/drain regions PX intact.

In some embodiments, removal of the PFET source/drain regions PY can be performed using anisotropic dry etching. Take plasma etching as an example of the anisotropic dry etching, the PFET source/drain regions PY can be etched by a plasma environment generated by RF or microwave power in a gaseous mixture of one or more of chlorine-based gas (e.g., Cl2, SiCl4, or the like), a fluorine-based gas (such as CF4, SF6, CH2F2, CH3F, CHF3, or the like), and hydrogen bromide gas (HBr) for a duration time sufficient to expose portions of the substrate200under the PFET source/drain regions PY. At this stage, because the PFET source/drain regions PY has been removed but the NFET source/drain regions PX remain in the patterned stack PS, each layer in the patterned stack PS has a longer dimension in Y-direction than in X-direction.

FIG.7Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.6A,FIG.7Bis a top view of the structure illustrated inFIG.7A,FIG.7Cis a cross-sectional view obtained from cut A-A′ inFIG.7A, andFIG.7Dis a cross-sectional view obtained from cut B-B′ inFIG.7A. InFIGS.7A-7D, Y-directional sidewalls of the NFET channel layers204exposed by the removal of PFET source/drain regions PY in the previous step are laterally recessed by suitable etching technique to form sidewall recesses R1between corresponding sacrificial layers202. Although sidewalls of the NFET channel layers204in the recesses R1are illustrated as being straight inFIG.7C, the sidewalls may be concave or convex. In some embodiments, the etching step is a selective etching step performed with an etch mask (e.g., photoresist mask and/or nitride mask) formed over the NFET source/drain regions PX, so that portions of the NFET channel layers204in the NFET source/drain regions PX remain substantially intact without being laterally recessed. Stated differently, the selective etching is performed to only the Y-directional sidewalls SY of the patterned stack PS by using a patterned mask that exposes the Y-directional sidewalls of the patterned stack PS only.

In some embodiments where the NFET channel layers204are GeSi, and the PFET channel layers206are GeSn, the NFET channel layers204can be laterally etched by using a selective etching process that etches GeSi at a faster etch rate than etching GeSn. For example, the NFET channel layers204formed of GeSi can be selectively etched by a plasma etching using a plasma generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), wherein the etching conditions (e.g., flow rate of fluorine-based gas, plasma chamber temperature, and/or plasma chamber pressure) are tuned to etch GeSi at a faster etch rate than etching GeSn. By way of example, the GeSi selective etching step may be an isotropic dry etching process using CF4as a main precursor gas and performed at a flow rate of the using CF4gas in a range from about 1 standard cubic centimeters per minute (sccm) to about 100 sccm (e.g., 300 sccm), at RF power in a range from about 0 W to about 1000 W (e.g., 700 W), and at a pressure in a range from about 0 torr to about 300 torr (e.g., 350 mtorr).

In some embodiments where the NFET channel layers204are Ge:B, and the PFET channel layers206are un-doped GeSi or GeSn, the NFET channel layers204can be laterally etched by using a selective etching process that etches Ge:B at a faster etch rate than etching un-doped GeSi or GeSn. For example, the NFET channel layers204formed of Ge:B can be selectively etched by a plasma etching using plasmas generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), because the etch rate increases as boron concentration increases in the foregoing etching chemistry.

In some embodiments where the NFET channel layers204are Si, and the PFET channel layers206are GeSi, the NFET channel layers204can be laterally etched by using a selective etching process that etches Si at a faster etch rate than etching GeSi. For example, the NFET channel layers204formed of Si can be selectively etched by a plasma etching using a plasma generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), wherein the etching conditions (e.g., flow rate of fluorine-based gas, plasma chamber temperature, and/or plasma chamber pressure) are tuned to etch Si at a faster etch rate than etching GeSi. In some other embodiments, the NFET channel layers204formed of Si can be selectively etched by a wet etching process using tetramethylammonium hydroxide (TMAH) as the wet etchant.

In some embodiments where the NFET channel layers204are Ge, and the PFET channel layers206are GeSn, the NFET channel layers204can be laterally etched by using a selective etching process that etches Ge at a faster etch rate than etching GeSn. For example, the NFET channel layers204formed of Ge can be selectively etched by a plasma etching using a plasma generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), wherein the etching conditions (e.g., flow rate of fluorine-based gas, plasma chamber temperature, and/or plasma chamber pressure) are tuned to etch Ge at a faster etch rate than etching GeSn. By way of example, the Ge selective etching step may be an isotropic dry etching process using NF3as a main precursor gas and performed at a flow rate of the using NF3gas in a range from about 1 standard cubic centimeters per minute (sccm) to about 100 sccm (e.g., 7 sccm), at a chamber temperature in a range from about 0 degrees Centigrade to about 100 degrees Centigrade (e.g., 14 degrees Centigrade), and at a pressure in a range from about 1 torr to about 100 torr (e.g., 7 torr).

FIG.8Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.7A,FIG.8Bis a top view of the structure illustrated inFIG.8A,FIG.8Cis a cross-sectional view obtained from cut A-A′ inFIG.8A, andFIG.8Dis a cross-sectional view obtained from cut B-B′ inFIG.8A. InFIGS.8A-8D, after the NFET channel layers204are laterally recessed, PFET inner spacers214are formed in the sidewall recesses R1. The PFET inner spacers214act as isolation features between subsequently formed PFET source/drain epitaxial structures and NFET channel layers204.

Inner spacers214are formed from an inner spacer layer that is deposited by a conformal deposition process, such as CVD, ALD, or the like. The inner spacer layer may comprise a material such as silicon nitride or silicon oxynitride, although any suitable material, such as low-dielectric constant (low-k) materials having a k-value less than about 3.5, may be utilized. The inner spacer layer may then be anisotropically etched to form the inner spacers214. Although outer sidewalls of the inner spacers214are illustrated as being flush with sidewalls of the PFET channel layers206and sacrificial layers202, the outer sidewalls of the inner spacers214may extend beyond or be recessed from sidewalls of the PFET channel layers206and sacrificial layers202. Moreover, although the outer sidewalls of the inner spacers214are illustrated as being straight inFIGS.8A and8C, the outer sidewalls of the inner spacers214may be concave or convex. The inner spacer layer may be etched by an anisotropic etching process, such as RIE, NBE, or the like. In some embodiments, the inner spacers214has a thickness in a range from about 0.1 nm to about 50 nm.

FIG.9Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.8A,FIG.9Bis a top view of the structure illustrated inFIG.9A,FIG.9Cis a cross-sectional view obtained from cut A-A′ inFIG.9A, andFIG.9Dis a cross-sectional view obtained from cut B-B′ inFIG.9A. InFIGS.9A-9D, bottom dielectric isolation structures216are formed on the substrate200. In some embodiments, the bottom dielectric isolation structures216are localized to areas of previously removed PFET source/drain regions PY. In some other embodiments, the bottom dielectric isolation structures216cover all exposed areas of the substrate200. The bottom dielectric isolation structures216can serve to electrically isolate the subsequently formed p-type source/drain epitaxial structures from the underlying substrate200, which in turn will avoid unwanted leakage current in substrate200and hence unwanted shorting between source/drain epitaxial structures.

In some embodiments, the bottom dielectric isolation structures216may be an oxide, such as silicon oxide, a nitride, the like, or a combination thereof, and may be formed by a high density plasma chemical vapor deposition (HDP-CVD), a flowable CVD (FCVD) (e.g., a CVD-based material deposition in a remote plasma system and post curing to make it convert to another material, such as an oxide), the like, or combinations thereof. Other insulation materials formed by any acceptable process may be used. Once the dielectric material is deposited, the dielectric material can be selectively etched back to fall below the bottommost one of the PFET channel layers206, which in turn allows for epitaxially growing p-type source/drain structures from the exposed surfaces of the PFET channel layers206directly above the bottom dielectric isolation structures216. In some embodiments, the etched back dielectric material is patterned by using suitable photolithography and etching techniques to form bottom dielectric isolation structures216localized to the areas of previously removed PFET source/drain regions PY.

FIG.10Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.9A,FIG.10Bis a top view of the structure illustrated inFIG.10A,FIG.10Cis a cross-sectional view obtained from cut A-A′ inFIG.10A, andFIG.10Dis a cross-sectional view obtained from cut B-B′ inFIG.10A. It understood that the perspective view ofFIG.10Aand perspective views of following steps are depicted in a different viewing angle from the previous perspective views (e.g., 4A, 5A, 6A, 7A, 8A, and 9A) for the sake of clarity. InFIGS.10A-10D, p-type epitaxial source/drain structures218are formed on the previously removed PFET source/drain regions PY, and the PFET channel layers206continuously extend from a first one of the p-type epitaxial source/drain structures218to a second one of the p-type epitaxial source/drain structures218. In some embodiments, the p-type epitaxial source/drain structures218may exert compressive strain on the PFET channel layers206, thereby improving PFET device performance. The p-type epitaxial source/drain structures218are spaced apart along X-direction, with the dummy gate structure210there-between. In some embodiments, the p-type epitaxial source/drain structures218are spaced apart from the dummy gate structure210because the dummy gate structure210have opposite sidewalls laterally set back from the respective sidewalls of the PFET channel layer206. In some embodiments, the inner spacers214are used to separate the p-type epitaxial source/drain structures218from the NFET channel layers204by an appropriate lateral distance so that the p-type epitaxial source/drain structures218do not short out with the NFET channel layers204.

In some embodiments, the epitaxial source/drain structures218may include any acceptable material appropriate for PFET. For example, if the PFET channel layers206are Ge1-xSnx, the p-type epitaxial source/drain structures218may comprise materials exerting a compressive strain on the PFET channel layers206, such as Ge1-ySny, wherein y>x. In some embodiments, the epitaxial source/drain structures218include Si, Ge, Sn, Si1-xGex, Si1-x-yGexSny, III-V compound, or the like. In some embodiments, the epitaxial growth is performed with a patterned mask formed over the substrate200except for the target regions directly above bottom dielectric isolation structures216. As a result, the epitaxial growth takes place only on exposed surfaces of the PFET channel layers206and the sacrificial layers202that are exposed in the regions directly above the bottom dielectric isolation structures216, which in turn prevents the semiconductor layers in NFET source/drain regions PX from unwanted epitaxial growth. In some embodiments, the epitaxy growth may be performed using CVD deposition techniques (e.g., vapor-phase epitaxy (VPE) and/or ultra-high vacuum CVD (UHV-CVD)), molecular beam epitaxy (MBE), and/or other suitable processes. In some embodiments, the p-type epitaxial source/drain structures218each has a thickness in a range from about 1 nm to about 100 µm.

The p-type epitaxial structures218may be implanted with a p-type dopant (e.g., boron or gallium) to form p-type source/drain structures218, followed by an anneal process. The source/drain structures218may have an p-type impurity (e.g., boron or gallium) concentration of between about 1x1017atoms/cm3and about 1x1022atoms/cm3. In some embodiments, the p-type epitaxial structures218may be in situ doped with the p-type dopant during growth.

FIG.11Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.10A,FIG.11Bis a top view of the structure illustrated inFIG.11A,FIG.11Cis a cross-sectional view obtained from cut A-A′ inFIG.11A, andFIG.11Dis a cross-sectional view obtained from cut B-B′ inFIG.11A. InFIGS.11A-11D, the NFET source/drain regions PX in the patterned stack PS that extend laterally beyond the dummy gate structure210are removed, for example, in an anisotropic etch step until the substrate200is exposed. The etching is performed using an etchant that attacks the patterned stack PS, and hardly attacks the dummy gate structure210. Stated differently, the dummy gate structure210has higher etch resistance to the etching process than that of the patterned stack PS. Accordingly, in the etching step, the height of dummy gate structure210is substantially not reduced. In some embodiments, the etching step is performed with an etch mask (e.g., photoresist mask and/or nitride mask) formed over the p-type epitaxial source/drain structures218, so as to allow the etching step etching the NFET source/drain regions PX, while leaving the p-type epitaxial source/drain structures218intact.

In some embodiments, removal of the NFET source/drain regions PX can be performed using anisotropic dry etching. Take plasma etching as an example of the anisotropic dry etching, the NFET source/drain regions PX can be etched by a plasma environment generated by RF or microwave power in a gaseous mixture of one or more of chlorine-based gas (e.g., Cl2, SiCl4, or the like), a fluorine-based gas (such as CF4, SF6, CH2F2, CH3F, CHF3, or the like), and hydrogen bromide gas (HBr) for a duration time sufficient to expose portions of the substrate200under the NFET source/drain regions PX.

FIG.12Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.11A,FIG.12Bis a top view of the structure illustrated inFIG.12A,FIG.12Cis a cross-sectional view obtained from cut A-A′ inFIG.12A, andFIG.12Dis a cross-sectional view obtained from cut B-B′ inFIG.12A. InFIGS.12A-12D, X-directional sidewalls of the PFET channel layers206exposed by the removal of NFET source/drain regions PX in the previous step are laterally recessed by suitable etching technique to form sidewall recesses R2between corresponding sacrificial layers202. Although sidewalls of the PFET channel layers206in the recesses R2are illustrated as being straight inFIG.12D, the sidewalls may be concave or convex. In some embodiments, the etching step is a selective etching step performed with an etch mask (e.g., photoresist mask and/or nitride mask) formed over the p-type epitaxial source/drain structures218. More specifically, the selective etching is performed to only X-directional sidewalls SX of the patterned stack PS by using a patterned mask that exposes the X-directional sidewalls of the patterned stack PS only.

In some embodiments where the NFET channel layers204are GeSi, and the PFET channel layers206are GeSn, the PFET channel layers206can be laterally etched by using a selective etching process that etches GeSn at a faster etch rate than etching GeSi. For example, the PFET channel layers206formed of GeSn can be selectively etched by a plasma etching using a plasma generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), wherein the etching conditions (e.g., flow rate of fluorine-based gas, plasma chamber temperature, and/or plasma chamber pressure) are tuned to etch GeSn at a faster etch rate than etching GeSi. By way of example, the GeSn selective etching step may be an isotropic dry etching process using NF3as a main precursor gas and performed at a flow rate of the using NF3gas in a range from about 1 standard cubic centimeters per minute (sccm) to about 1000 sccm, at a chamber temperature in a range from about 0 degrees Centigrade to about 100 degrees Centigrade, and at a pressure in a range from about 1 torr to about 300 torr. As discussed previously about selectively etching NFET channel layers204formed from GeSi, the plasma etching using a fluorine-based gas can also be used to selectively etch GeSi. In that case, the GeSn selective etching process is performed at different process conditions (e.g., flow rate of fluorine-based gas, chamber temperature, and/or chamber pressure) than the GeSi selective etching process. Stated differently, process conditions can be tuned to selectively etch GeSn or GeSi.

In some embodiments where the NFET channel layers204are Ge:B, and the PFET channel layers206are un-doped GeSi or GeSn, the PFET channel layers206can be laterally etched by using a selective etching process that etches un-doped GeSi or GeSn at a faster etch rate than etching Ge:B. For example, the PFET channel layers206formed of un-doped GeSi or GeSn can be selectively etched by a plasma etching using a plasma generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), wherein the etching conditions (e.g., flow rate of fluorine-based gas, plasma chamber temperature, and/or plasma chamber pressure) are tuned to etch un-doped GeSi or GeSn at a faster etch rate than etching Ge:B. In some embodiments, the PFET channel layers206formed of GeSn or GeSi can be selectively etched by a wet etching process using hydrogen peroxide (H2O2) as the wet etchant, because the etch rate in H2O2etching decreases as boron concentration increases.

In some embodiments where the NFET channel layers204are Si, and the PFET channel layers206are GeSi, the PFET channel layers206can be laterally etched by using a selective etching process that etches GeSi at a faster etch rate than etching Si. For example, the PFET channel layers206formed of GeSi can be selectively etched by a plasma etching using a plasma generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), wherein the etching conditions (e.g., flow rate of fluorine-based gas, plasma chamber temperature, and/or plasma chamber pressure) are tuned to etch GeSi at a faster etch rate than etching Si. As discussed previously about selectively etching NFET channel layers204formed from Si, the plasma etching using a fluorine-based gas can also be used to selectively etch Si. In that case, the GeSi selective etching process is performed at different process conditions (e.g., flow rate of fluorine-based gas, chamber temperature, and/or chamber pressure) than the Si selective etching process. Stated differently, process conditions can be tuned to selectively etch GeSi or Si.

In some embodiments where the NFET channel layers204are Ge, and the PFET channel layers206are GeSn, the PFET channel layers206can be laterally etched by using a selective etching process that etches GeSn at a faster etch rate than etching Ge. For example, the PFET channel layers206formed of GeSn can be selectively etched by a plasma etching using a plasma generated from a fluorine-based gas (such as CF4, NF3, or the like), an oxygen gas (e.g., O2), and/or a nitrogen gas (e.g., N2), wherein the etching conditions (e.g., flow rate of fluorine-based gas, plasma chamber temperature, and/or plasma chamber pressure) are tuned to etch GeSn at a faster etch rate than etching Ge. By way of example, the GeSn selective etching step may be an isotropic dry etching process using NF3as a main precursor gas and performed at a flow rate of the using NF3gas in a range from about 1 standard cubic centimeters per minute (sccm) to about 100 sccm, at a chamber temperature in a range from about 0 degrees Centigrade to about 100 degrees Centigrade, and at a pressure in a range from about 0 torr to about 300 torr. As discussed previously about selectively etching NFET channel layers204formed from Ge, the plasma etching using a fluorine-based gas can also be used to selectively etch Ge. In that case, the GeSn selective etching process is performed at different process conditions (e.g., flow rate of fluorine-based gas, chamber temperature, and/or chamber pressure) than the Ge selective etching process. Stated differently, process conditions can be tuned to selectively etch GeSn or Ge.

FIG.13Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.12A,FIG.13Bis a top view of the structure illustrated inFIG.13A,FIG.13Cis a cross-sectional view obtained from cut A-A′ inFIG.13A, andFIG.13Dis a cross-sectional view obtained from cut B-B′ inFIG.13A. InFIGS.13A-13D, after the PFET channel layers206are laterally recessed, NFET inner spacers220are formed in the sidewall recesses R2. The NFET inner spacers220act as isolation features between subsequently formed NFET source/drain epitaxial structures and PFET channel layers206.

NFET inner spacers220are formed from an inner spacer layer that is deposited by a conformal deposition process, such as CVD, ALD, or the like. The inner spacer layer may comprise a material such as silicon nitride or silicon oxynitride, although any suitable material, such as low-dielectric constant (low-k) materials having a k-value less than about 3.5, may be utilized. The inner spacer layer may then be anisotropically etched to form the inner spacers220. Although outer sidewalls of the inner spacers220are illustrated as being flush with sidewalls of the NFET channel layers204and sacrificial layers202as illustrated inFIG.13D, the outer sidewalls of the inner spacers220may extend beyond or be recessed from sidewalls of the NFET channel layers204and sacrificial layers202. Moreover, although the outer sidewalls of the inner spacers220are illustrated as being straight inFIGS.13A and13D, the outer sidewalls of the inner spacers220may be concave or convex. The inner spacer layer may be etched by an anisotropic etching process, such as RIE, NBE, or the like. In some embodiments, the inner spacers220have a thickness in a range from about 0.1 nm to about 500 nm.

FIG.14Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.13A,FIG.14Bis a top view of the structure illustrated inFIG.14A,FIG.14Cis a cross-sectional view obtained from cut A-A′ inFIG.14A, andFIG.14Dis a cross-sectional view obtained from cut B-B′ inFIG.14A. InFIGS.14A-14D, bottom dielectric isolation structures222are formed on the substrate200. In some embodiments, the bottom dielectric isolation structures222are localized to areas of previously removed NFET source/drain regions PX. In some other embodiments, the bottom dielectric isolation structures222cover all exposed areas of the substrate200. The bottom dielectric isolation structures222can serve to electrically isolate the subsequently formed n-type source/drain epitaxial structures from the underlying substrate200, which in turn will avoid unwanted leakage current in substrate200and hence unwanted shorting between source/drain epitaxial structures.

In some embodiments, the bottom dielectric isolation structures222may be an oxide, such as silicon oxide, a nitride, the like, or a combination thereof, and may be formed by a high density plasma chemical vapor deposition (HDP-CVD), a flowable CVD (FCVD) (e.g., a CVD-based material deposition in a remote plasma system and post curing to make it convert to another material, such as an oxide), the like, or combinations thereof. Other insulation materials formed by any acceptable process may be used. Once the dielectric material is deposited, the dielectric material can be selectively etched back to fall below the bottommost one of the NFET channel layers204, which in turn allows for epitaxially growing n-type source/drain structures from the exposed surfaces of the NFET channel layers204directly above the bottom dielectric isolation structures222. In some embodiments, the etched back dielectric material is patterned by using suitable photolithography and etching techniques to form bottom dielectric isolation structures222localized to the areas of previously removed NFET source/drain regions PX. In some embodiments, the bottom dielectric isolation structures222are formed from a same dielectric material as the bottom dielectric isolation structures216that serve to isolate the p-type epitaxial source/drain structures218from the substrate200.

FIG.15Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.14A,FIG.15Bis a top view of the structure illustrated inFIG.15A,FIG.15Cis a cross-sectional view obtained from cut A-A′ inFIG.15A, andFIG.15Dis a cross-sectional view obtained from cut B-B′ inFIG.15A. InFIGS.15A-15D, n-type epitaxial source/drain structures224are formed on the previously removed NFET source/drain regions PX, and the NFET channel layers204continuously extend from a first one of the n-type epitaxial source/drain structures224to a second one of the n-type epitaxial source/drain structures224. In some embodiments, the n-type epitaxial source/drain structures224may exert tensile strain on the NFET channel layers204, thereby improving NFET device performance. The n-type epitaxial source/drain structures224are spaced apart along Y-direction, with the dummy gate structure210there-between. In some embodiments, the n-type epitaxial source/drain structures224are spaced apart from the dummy gate structure210because the dummy gate structure210has sidewalls laterally set back from the respective sidewalls of the NFET channel layers204. In some embodiments, the inner spacers220are used to separate the n-type epitaxial source/drain structures224from the PFET channel layers206by an appropriate lateral distance so that the n-type epitaxial source/drain structures224do not short out with the PFET channel layers206.

In some embodiments, the epitaxial source/drain structures224may include any acceptable material appropriate for NFET. For example, the n-type epitaxial source/drain structures224may comprise phosphorous-doped silicon (SEP). In some embodiments, the epitaxial growth is performed with a patterned mask formed over the substrate200except for the regions directly above bottom dielectric isolation structures222. As a result, the epitaxial growth takes place only on exposed surfaces of the NFET channel layers204and the sacrificial layers202that are exposed in the regions directly above the bottom dielectric isolation structures222, which in turn prevents unwanted epitaxial growth taking place on other regions. In some embodiments, the epitaxy growth may be performed using CVD deposition techniques (e.g., vapor-phase epitaxy (VPE) and/or ultra-high vacuum CVD (UHV-CVD)), molecular beam epitaxy (MBE), and/or other suitable processes. In some embodiments, the n-type epitaxial structures224have a thickness in a range from about 1 nm to about 100 µm.

The n-type epitaxial structures224may be implanted with an n-type dopant (e.g., phosphorous or arsenic) to form n-type source/drain structures224, followed by an anneal process. The resultant source/drain structures224may have an n-type impurity (e.g., phosphorous or arsenic) concentration of between about 1x1017atoms/cm3and about 1x1022atoms/cm3. In some embodiments, the n-type epitaxial structures224may be in situ doped with the n-type dopant during growth.

FIG.16Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.15A,FIG.16Bis a top view of the structure illustrated inFIG.16A,FIG.16Cis a cross-sectional view obtained from cut A-A′ inFIG.16A, andFIG.16Dis a cross-sectional view obtained from cut B-B′ inFIG.16A. InFIGS.16A-16D, the dummy gate structure210is removed in one or more etching steps, so that a gate trench GT1 is formed in a space surrounded by the p-type epitaxial source/drain structures218and the n-type epitaxial source/drain structures224. In some embodiments, the dummy gate structure210is removed by an anisotropic dry etch process. For example, the etching process may include a dry etch process using reaction gas(es) that selectively etch the dummy gate structure210at a faster rate than etching other materials on the substrate200. In some embodiments, the dummy gate removal etching is performed with an etch mask (e.g., photoresist mask and/or nitride mask) formed over the p-type epitaxial source/drain structures218and the n-type epitaxial source/drain structures224, thus preventing unwanted damages on these source/drain structures. In some embodiments, an interlayer dielectric (ILD) is formed over the p-type epitaxial source/drain structures218and the n-type epitaxial source/drain structures224before the dummy gate removal step, and the ILD will not be removed and thus will remain in a final IC product.

FIG.17Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.16A,FIG.17Bis a top view of the structure illustrated inFIG.17A,FIG.17Cis a cross-sectional view obtained from cut A-A′ inFIG.17A, andFIG.17Dis a cross-sectional view obtained from cut B-B′ inFIG.17A. InFIGS.17A-17D, the buffer layer201and sacrificial layers202are removed by a selective etching process, thus forming openings O1 each between adjacent two of the NFET channel layers204and PFET channel layers206and an opening O1 below a bottommost NFET channel layer204A. In this way, PFET channel layers206become suspended over the substrate200and connect the p-type source/drain structures218, and the NFET channel layers204also become suspended over the substrate200and connect the n-type source/drain structures224. The NFET channel layers204and PFET channel layers206are alternately arranged in the gate trench GT1 and spaced apart by the openings O1.

This step can be interchangeably referred to as a channel release process. At this interim processing step, the openings O1 may be filled with ambient environment conditions (e.g., air, nitrogen, etc). The selective etching process removes the material of the buffer layer201and sacrificial layers202(e.g., Ge) at a faster rate than or without substantially etching the material of the NFET channel layers204(e.g., GeSi) and PFET channel layers206(e.g., GeSn). By way of example, the Ge selective etching step may be an isotropic dry etching process using NF3as a main precursor gas and performed at a flow rate of the using NF3gas in a range from about 1 standard cubic centimeters per minute (sccm) to about 100 sccm (e.g., 7 sccm), at a chamber temperature in a range from about 0 degrees Centigrade to about 100 degrees Centigrade (e.g., 14 degrees Centigrade), and at a pressure in a range from about 1 torr to about 100 torr (e.g., 7 torr).

FIG.18Ais a perspective view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.17A,FIG.18Bis a top view of the structure illustrated inFIG.18A,FIG.18Cis a cross-sectional view obtained from cut A-A′ inFIG.18A, andFIG.18Dis a cross-sectional view obtained from cut B-B′ inFIG.18A. InFIGS.18A-18D, a replacement gate structure230is formed. The replacement gate structure230may be a high-k/metal gate stack, however other compositions are possible. The replacement gate structure230forms a gate associated with multi-channels provided by the NFET channel layers204, and also forms a gate associated with multi-channels provided by the PFET channel layers206. The replacement gate structure230thus serves as a final gate for both an NFET formed from the NFET channel layers204and a PFET formed from the PFET channel layers206. Stated differently, the NFET channel layers204and the PFET channel layers206share a same gate structure, and thus a gate terminal of the resultant NFET and a gate terminal of the resultant PFET are coupled together to serve as an inverter, which has a reduced footprint because of the overlapping NFET and PFET channel layers204and206.

The replacement gate structure230is formed within the gate trench GT1 and the openings O1 provided by the release of NFET and PFET channel layers204and206. In some embodiments, the replacement gate structure230includes a gate dielectric layer226formed over top and bottom surfaces of each of the NFET and PFET channel layers204and206, and a metal gate228formed over the gate dielectric layer226. In some embodiments, the gate dielectric layer226includes an interfacial layer (e.g., silicon oxide layer) and a high-k gate dielectric layer over the interfacial layer. High-k gate dielectrics, as used and described herein, include dielectric materials having a high dielectric constant, for example, greater than that of thermal silicon oxide (~3.9). The metal gate228includes one or more work function metal layers and a fill metal formed over the one or more work function metal layers. The one or more work function metal layers and the fill metal used within high-k/metal gate structure may include a metal, metal alloy, or metal silicide. Additionally, the formation of the high-k/metal gate stack may include depositions to form various gate materials, one or more liner layers, and one or more CMP processes to remove excessive gate materials. The gate dielectric layer226is illustrated in the top view ofFIG.18Band cross-sectional views ofFIGS.18C and18D, and not illustrated in the perspective view ofFIG.18Afor the sake of simplicity and clarity.

In some embodiments, the interfacial layer of the gate dielectric layer226may include a dielectric material such as silicon oxide (SiO2), HfSiO, or silicon oxynitride (SiON). The interfacial layer may be formed by chemical oxidation, thermal oxidation, atomic layer deposition (ALD), chemical vapor deposition (CVD), and/or other suitable method. The high-k dielectric layer of the gate dielectric layer226may include hafnium oxide (HfO2). Alternatively, the gate dielectric layer226may include other high-k dielectrics, such as hafnium silicon oxide (HfSiO), hafnium oxynitride (HfON), hafnium silicon oxynitride (HfSiON), hafnium tantalum oxide (HfTaO), hafnium titanium oxide (HfTiO), hafnium zirconium oxide (HfZrO), lanthanum oxide (La2O3), zirconium oxide (ZrO2), titanium oxide (TiO2), tantalum oxide (Ta2O5), yttrium oxide (Y2O3), strontium titanium oxide (SrTiO3, STO), barium titanium oxide (BaTiO3, BTO), barium zirconium oxide (BaZrO), hafnium lanthanum oxide (HfLaO), lanthanum silicon oxide (LaSiO), aluminum silicon oxide (AlSiO), aluminum oxide (Al2O3), silicon nitride (Si3N4), oxynitrides (SiON), and combinations thereof.

The metal gate228includes one or more n-type work function metal (N-metal) layers and/or one or more p-type work function metal (P-metal) layers. The n-type work function metals may exemplarily include, but are not limited to, titanium aluminide (TiAl), titanium aluminium nitride (TiAlN), carbo-nitride tantalum (TaCN), hafnium (Hf), zirconium (Zr), titanium (Ti), tantalum (Ta), aluminum (Al), tungsten (W), metal carbides (e.g., hafnium carbide (HfC), zirconium carbide (ZrC), titanium carbide (TiC), aluminum carbide (AlC), tungsten carbide (WC)), aluminides, and/or other suitable materials. The The p-type work function metals may exemplarily include, but are not limited to, titanium nitride (TiN), tungsten nitride (WN), tungsten (W), ruthenium (Ru), palladium (Pd), platinum (Pt), cobalt (Co), nickel (Ni), conductive metal oxides, and/or other suitable materials. The metal gate may further include a fill metal to fill remainder of the gate trench GT1 and openings O1. The fill metal may exemplarily include, but not limited to, tungsten, aluminum, copper, nickel, cobalt, titanium, tantalum, titanium nitride, tantalum nitride, tungsten nitride, nickel silicide, cobalt silicide, TaC, TaSiN, TaCN, TiAl, TiAlN, or other suitable materials.

FIG.19Ais a top view of an intermediate stage in manufacturing of the inverter that is subsequent to the stage shown inFIG.18A,FIG.19Bis a cross-sectional view obtained from cut A-A′ inFIG.19A, andFIG.19Cis a cross-sectional view obtained from cut B-B′ inFIG.19A. InFIGS.19A-19C, a gate contact232is formed over the replacement gate structure230, a common source/drain contact (e.g., common drain contact)234is formed over a first one of the p-type source/drain structures218(e.g., left one of the p-type source/drain structures218from top view inFIG.18B) and a first one of the n-type source/drain structures224(e.g., lower one of the n-type source/drain structures224from top view inFIG.18B), a PFET source/drain contact (e.g., PFET source contact)236is formed over a second one of the p-type source/drain structures218, and an NFET source/drain contact (e.g., NFET source contact)238is formed over a second one of the n-type source/drain structures224. The common source/drain contact234has a first portion234Y extending along Y-direction over the first one of the p-type source/drain structures218, and a second portion234X extending along X-direction over the first one of the n-type source/drain structures224. The first portion234Y connects to a left end of the second portion234X such that the common source/drain contact234has an L-shaped top-view profile. The PFET source/drain contact236is separated from the common source/drain contact234and is electrically coupled to Vdd, the NFET source/drain contact238is separated from the common source/drain contact234and is electrically coupled to ground (e.g., Vss), thereby forming an inverter. The contact236coupled to Vdd can be interchangeably referred to as a Vdd contact, and the contact238coupled to Vss can be interchangeably referred to as a Vss contact in some embodiments. As illustrated inFIGS.19A-19C, the inverter is formed from an NFET and a PFET that share a vertically overlapping area, which in turn will reduce the footprint of the inverter to, for example, about 0.006 µm2to about 0.007 µm2(e.g., about 0.0064 µm2).

In the embodiment illustrated inFIGS.19A-19C, the number of NFET channel layers204is the same as the number of PFET channel layers206. However, in some other embodiments, the NFET channel layers and the PFET channel layers may have different number so as to balance the current in the inverter. For example, inFIGS.20A and20B, the inverter includes a single NFET channel layer204and three PFET channel layers206above the NFET channel layer204. This inverter can be fabricated using similar steps as illustrated inFIGS.2A-19C, except that in the layer stack formation step as illustrated inFIGS.2A-2B, the epitaxy growth is modified to form a single NFET channel layers and three PFET channel layers above the NFET channel layer. Alternatively, as illustrated inFIGS.21A and21B, the inverter includes three NFET channel layers204and a single PFET channel layer206above the NFET channel layers204. This inverter can be fabricated using similar steps as illustrated inFIGS.2A-19C, except that in the layer stack formation step as illustrated inFIGS.2A-2B, the epitaxy growth is modified to form three NFET channel layers and one PFET channel layer above the NFET channel layers. Alternatively, as illustrated inFIGS.22A and22B, the inverter includes alternate three PFET channel layers206and two NFET channel layers204. This inverter can be fabricated using similar steps as illustrated inFIGS.2A-19C, except that in the layer stack formation step as illustrated inFIGS.2A-2B, the epitaxy growth is modified to alternately grow three PFET channel layers and two NFET channel layers.

Based on the above discussions, it can be seen that the present disclosure in various embodiments offers advantages. It is understood, however, that other embodiments may offer additional advantages, and not all advantages are necessarily disclosed herein, and that no particular advantage is required for all embodiments. One advantage is that the inverter has a reduced footprint because NFET and PFET of the inverter share an overlapping area and a single gate structure. Another advantage is that the vertical spacing between the NFET channel layer and the PFET channel layer can be easily controlled by a thickness of the sacrificial layer formed between the NFET channel layer and the PFET channel layer. Another advantage is that the number of PFET channel layer and the number of NFET channel layer can be selected to balance the current of invertor. Another advantage is that the cross-shaped pattern of the stack of NFET channel layers and PFET channel layers can serve to adjust NFET gate length and PFET gate length, thereby optimizing total currents of the NFET and PFET. Another advantage is that the vertically stacked NFET and PFET can be fabricated simultaneously in same front-end-of-line (FEOL) processing, and thus the thermal budges of the NFET and PFET are the same.

In some embodiments, a method comprises forming a first semiconductor layer on a substrate and a second semiconductor layer above the first semiconductor layer, the first and second semiconductor layers having first sidewalls extending along a first direction, and second sidewalls extending along a second direction different from the first direction; forming first inner spacers on the first sidewalls of the first semiconductor layer; forming p-type source/drain structures on the first sidewalls of the second semiconductor layer; forming second inner spacers on the second sidewalls of the second semiconductor layer; forming n-type source/drain structures on the second sidewalls of the first semiconductor layer; and forming a gate structure at least partially between the first and second semiconductor layers. In some embodiments, the second semiconductor layer is formed of a different material than the first semiconductor layer. In some embodiments, the first semiconductor layer has tensile strain, and the second semiconductor layer has compressive strain. In some embodiments, the method further comprises prior to forming the first inner spacers, etching the first sidewalls of the first semiconductor layer such that the first sidewalls of the first semiconductor layer are laterally set back from the first sidewalls of the second semiconductor layer. In some embodiments, the method further comprises prior to forming the second inner spacers, etching the second sidewalls of the second semiconductor layer such that the second sidewalls of the second semiconductor layer are laterally set back from the second sidewalls of the first semiconductor layer. In some embodiments, the method further comprises after forming the first inner spacers, forming bottom dielectric isolation structures on the substrate, wherein the p-type source/drain structures are respectively formed on the bottom dielectric isolation structures. In some embodiments, the method further comprises after forming the second inner spacers, forming bottom dielectric isolation structures on the substrate, wherein the n-type source/drain structures are respectively formed on the bottom dielectric isolation structures. In some embodiments, the method further comprises forming a third semiconductor layer over the first semiconductor layer before forming the second semiconductor layer, and after the p-type source/drain structures and the n-type source/drain structures are formed, removing the third semiconductor layer to form an opening between the first and second semiconductor layers, wherein the gate structure is formed at least partially in the opening between the first and second semiconductor layers. In some embodiments, the method further comprises forming a common source/drain contact electrically connecting one of the p-type source/drain structures and one of the n-type source/drain structures. In some embodiments, the common source/drain contact has an L-shaped top view profile.

In some embodiments, a method comprises forming a layer stack on a substrate, the layer stack comprising an NFET channel layer, a PFET channel layer, and a sacrificial layer between the NFET channel layer and the PFET channel layer; performing a first selective etching process to opposite first sidewalls of the layer stack, wherein the first selective etching process etches the NFET channel layer at a faster etch rate than etching the PFET channel layer; after performing the first selective etching process, forming p-type epitaxial structures on the first sidewalls of the layer stack; performing a second selective etching process to opposite second sidewalls of the layer stack, wherein the second selective etching process etches the PFET channel layer at a faster etch rate than etching the NFET channel layer; after performing the second selective etching process, forming n-type epitaxial structures on the second sidewalls of the layer stack; and replacing the sacrificial layer with a gate structure. In some embodiments, the method further comprises after performing the first selective etching process and before forming the p-type epitaxial structures, forming inner spacers on the first sidewalls of the layer stack, wherein the inner spacers are localized to the NFET channel layer. In some embodiments, the method further comprises after performing the second selective etching process and before forming the n-type epitaxial structures, forming inner spacers on the second sidewalls of the layer stack, wherein the inner spacers are localized to the PFET channel layer. In some embodiments, replacing the sacrificial layer with the gate structure comprises performing a third selective etching process to remove the sacrificial layer, leaving an opening between the PFET channel layer and the NFET channel layer; and forming the gate structure at least partially in the opening between the PFET channel layer and the NFET channel layer.

In some embodiments, a device comprises a gate structure, n-type source/drain features, p-type source/drain features, an NFET channel, and a PFET channel. The gate structure is over a substrate. The n-type source/drain features and p-type source/drain features are disposed around the gate structure. From a top view, the gate structure has a quadrilateral profile, the n-type source/drain features are respectively at opposite first and second sides of the quadrilateral profile of the gate structure, and the p-type source/drain features are respectively at opposite third and fourth sides of the quadrilateral profile of the gate structure. The NFET channel extends within the gate structure and connects the n-type source/drain features. The PFET channel extends within the gate structure and connects the p-type source/drain features. The NFET channel and the PFET channel are vertically spaced apart by the gate structure. In some embodiments, the device further comprises a first inner spacer separating the NFET channel from a first one of the p-type source/drain features, and a second inner spacer separating the NFET channel from a second one of the p-type source/drain features. In some embodiments, the device further comprises a third inner spacer separating the PFET channel from a first one of the n-type source/drain features, and a fourth inner spacer separating the PFET channel from a second one of the n-type source/drain features. The first and second inner spacers are spaced apart along a first direction, and the third and fourth inner spacers are spaced apart along a second direction different from the first direction. In some embodiments, the device further comprises a common source/drain contact electrically connecting one of the p-type source/drain features and one of the n-type source/drain features, and the common source/drain contact has an L-shaped top view profile. In some embodiments, the device further comprises a Vdd contact over one of the p-type source/drain features, and a Vss contact over one of the n-type source/drain features. From a top view the Vdd contact and the Vss contact extend along different directions.