METHOD OF FORMING A METAL SEMICONDUCTOR FIELD EFFECT TRANSISTOR

Abstract: A metal silicon field effect transistor and the meth­ od of producing such a transistor whereby all of the elements of the transistor are defined by a single masking step. These elements include the channel of the field effects transistor as well as the source and drain regions therefor and also the gate which completes the transistor. The transistor is formed by depositing a doped polysilicon layer on the surface of the semi­ conductor substrate, depositing an oxide layer thereover and opening a via in the insulating layer and the doped polysilicon layer to expose the silicon substrate. The channel is formed by ion implant through the via thus opened. The doped polysilicon layer serves as a diffusant source for the formation of the source and drain regions of the transistor which regions are defined by the via. The via then serves to define the area where the gate is to be formed in contact with the substrate region containing the channel.

Description: BACKGROUND OF THE INVENTION Field of Invention This invention relates to the method of forming a metal semiconductor field effect transistor and the product formed thereby. More particularly, this invention relates to the method of forming such a field effect transistor having a self-aligned gate. Description of the Prior Art A metal semiconductor field effect transistor, MESFET, differs from a traditional device such as a junction field effect transistor, JFET, and the metal oxide semiconductor field effect transistor, MOSFET. With a standard MOSPET, an oxide insulative layer separates the transistor gate from the semiconductor substrate between the source and drain of the transistor. In the JFET, the gate is in contact with the substrate, which, however, has nevertheless been appropriately doped so that a PN junction is formed. In a MESFET, the gate makes direct contact with the silicon substrate so as to form a Schottky diode by a metal-silicon #nterface. In the JFET, the PN junction ls a minority arriver device while in the MESPET, the Schottky diode s a majority carrier device. In the MESFET and JFET devices, the current conduction is within the bulk of the silicon substrate. While in a WIOSFET, the current conduction is along the axide-silicon interface. htith the conventional methods of the prior art for forming a XIESFET, the source and drain areas are first created by diffusion or implant, the channel agio is then implanted and an oxide layer deposited thereover. A via is then opened through the oxide to the silicon substrate between the source and drain areas. The metal gate is then formed in the via whDcc is of a sufficiently small dimension to make certain that the gate does not make ohmic contact with either the drain or source areas as such contact would short out the gate. The alignment of the gate, then, is critical which in turn requires that more space be allowed for the gate. This in turn diminishes the packing density of the circuit. A particular example of this process is disclosed in the Buiatti, Patent No. 4,048,712. It is then an object of the present invention to provlde an improved method of forming a metal silicon field effect transistor. It is another object of the present invention to provide a metal silicon field effect transistor having reduced space requirements. It is stlll another object of the present invention to provide an improved metal silicon field effect transistor having a self-aligned gate. BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects, advantages and features of the present invention will become more readily apparent to those skilled in the art when taken in conjunction with the foilowing specification and drawings wherein: Figure 1 is a cross-section of a prior art MESFET; Figure 2 is a cross-section of a device created by the present invention during its fabrication; and Figure 3 is a cross-section of a MESFET of the present invention in its completed form. SUN9tARY OF THE INVENTION In order to accomplish the above-identified objects, the present invention is directed toward a metal silicon field effect transistor and the method of producing such a transistor whereby ail of the elements of the transistor are defined by a single masking step. These elements include the channel of the field effect transistor as well as the source and drain regions therefor and also the gate which complets the transistor. The transistor is formed by depositing a doped polysilicon layer on the surface of the semiconductoi substrate, depositing an oxide layer thereover and opening a via in the insulating layer and the doped polysilicon iyer to expose the silicon substrate. The channel is formed by ion implant through the via thus opened. The doped polysilicon layer serves as a diffusant source for the formation of the source and drain regions of the transistor which regions are defined by the via. The via then serves to define the area where the gate is to be formed in contact with the substrate region containing the channel. A feature then of the present invent resides in depositing a doped polysilicon layer on the surface of the semiconductor substrate, depositing an oxide layer thereover and opening a via in the insulating layer and the doped polysilicon layer to expose the silicon substrate; forming a channel by ion implant through the via thus opened, employing the doped polysilicon layer as a diffusant source for the formation of the source and drain regions of the transistor which regions are defined by the via, and employing the via to define the area where the gate is to be formed in contact with the substrate region containing the channel. A second feature of the present invention resides in the manner in which the via is formed by undercutting the insulating layer to insure that the polysilicon layer does not make contact with the gate metal. GENERAL DESCRIPTION OF THE INVENTION A prior art structure and the method of mlking such a structure will now be described in relation to Figure 1. As sho therein, a substrate 10 is provided with source and drain areas 11 and 12 which are formed by N+ dopants, e.g. phosphorus or arsenic, respectively. The channel area 13 is forned with N- dopants, e.g. phosphorus or arsenic. An oxide layer (not shogun) is then provided to cover the entire surface and the via is opened therein to form the area cf gate 14 which is then formed. Metal gate 14 is in contact with the channel region 50 that when a voltage is applied thereto it will change the potential or depletion region 16. Conductors to apply the appropriate voltages are then provided to make contact with source and drain areas 11 and 12 and the surface is passivated to form a complet device. A particular problem with such a device is that of aligning gate 14 between the respective source and drain regions il and 12. If gate 14 makes contact with either such region, it will form an ohmic contact and gate 14 will be shorted to either the source or drain region. Therefore, there is a critical alignment problem with the prior art MESFET devices. Furthermore, because of the tolerances that must be allowed for this alignment, the gate area requires an extra area which in turn decreases the packing density of the circuit. This extra area in turn degrades the electrical characteristics of the device in that there is a higher source-drain series resistance created as indicated schematically in Figure 1 as resistances 15. Thus, the separation {eetween the gate and the drain or source is dependent 4 on the minimum masking alignments. The manner in which the present invention oercomes the disadvantages of the prior art will now be described in relation to Figures 2 and 3. As illustrated in Figure 2, a doped polysilicon conductor 27, e.g. arsenic or phosphorus is deposited on substrate 20 and is then covered with insulator 28. The polysilicon conductor is use# both as a diffusant source, as will be more thorougly described belon, and also as part of the interconnect structure Insulator 28 and conductor 27 are masked and etched to form via 29 in insulator 28 and also to undercut conductor 27 as illustrated in Figure 2 at 29A. in this manner, via 29 and insulator 28 serves to self-align both the channel region and the gate as will be further described below. N channel area 23 is then formed by impîanting through via 29. A second layer is then deposited in the via such that it fills in the exposed edges of conductor 27 in a manner not shown. Referring now to Figure 3, a high temperature step, e.g. at approximately 8000 or 9000 C, is now performed to cause the N+ dopants of doped conductor e 37 to diffuse into substrate 30 thus forming source and drain areas 31 and 32, respectively. At this time channel region 33 also diffuses outwnrdly. The second insulator (not shown) is then etched in the preferential manner, such as by a plasma etch or implanting the insulator regions parallel to the wafer surface, then performing a chemical etch to preferentially remove the insulator. The result is to expose that portion of the substrate with which a Schottky diode is to be formed. The structure in Figure 3 is completed by the formation of platlnum silicide region 39 to create the Schottky diode and then the deposition of titaniumtungsten layer 40 and finally aluminum layer 41. Pl,tinum silicide region 39 is formed by covering the entre layer with a pîatinum layer, portions of which are then sintered within each of vias 29 of Figure 2 by an anneal process. During this sintering, the platinum reacts with the silicon substrate to form platinum silicide region 39. Also, during this anneal operation, a thin oxide layer (not shown) is formed over the platinum silicide. After the anneal operation, the wafer is exposed to a hot aqua regia solution to etch away the platinum not covered by the thin oxide layer which does protect the platinum silicide region. As was indicated above, a titanium-tungsten layer 40 is then formed as was indicated above to make contact with platinum silicide region 39 and aluminum layer 41 is then deposited thereover. The purpose of the titanium-tunsten layer is to prevent aluminum layer 41 from penetrating into the platinum silicide. Pure tungsten can also be used for this purpose. The titanium-tunsten and aluminum structures are then patterned simultaneously and the resultant structure is as illustrated in Figure 3. Additional interconnect structures are then provided and the circuit is complet The self-alignment method of the present invention serves a number of functions. The opening ot¯the via in the insulating layer 28 and the doped polysilicon layer 27 of Figure 2 serves to define both the channel region 23 of Figure 2 as well as the subsequent source and drain regions 31 and 32 of Figure 3 which are created by the diffusing step where doped polysilicon layer 37 serves as the diffusant source. This via in insulating layer 38 of Figure 3 in turn serves to align the gate structure with channel structure 33. Because of the manner in which insulating layer 38 was undercut during the process, source and drain areas 31 and 32 can then be created very close to the gate structure location while insuring there will not be any ohmic contact herebetween. EPILOGUE A metal silicon field effect transistor and the method of forming suc a transistor has been described, which transistor is characterized by the reduced area required on the substrate for the formation thereof as well as an increased packing density of the circuit employing such devices. The device is also characterized by having a reduced channel resistance because of the reduced area required between the source and drain to accommodate the gate. These features are accomplished while insuring that the gate does not make ohmic contact with either the source or drain areas of the transistor. While only one erbodiment of the present invention has been described, it will be envident to to one skilled In the art that changes and modifications can be made therein without departing from the spirit and scope of the invention as claimed.

Claims: IS ISCLAIMED IS: 1. Method of forming a metal silicon field effect transistor, said method comprising the steps of forming an insulating layer over the surface of a silicon substrate; opening a via in said insulating layer to expose said substrate; implanting impurities of a given conductivi < through said via into said substrate; and depositing a metal layer in said via in electrical contact with said substrate. 2. A method according to Claim 1 wherein said metal layer formation includes: forming a platinum silicide region on said substrate in contact therewith; forming a first layer over said platinum silicide, which first layer is of a material selected from the group of tungsten and titanium-tungsten; and forming a second layer over said first layer which second layer is aluminum. 3 A method according to Claim I including the step of: depositing a polysilicon layer over said substrate surface prior to the formation of said insulating layer, said polysilicon being doped with impurities of the same conductivity as said implanted impurities; and opening a via in said polysilicon layer in alignment with said insulating layer via at the same time as said insulating layer via is opened. 4 A method according to Claim 3 including the step of: undercutting said insulating layer in the region of said via when said via is open; forming a second insulating layer in said via in contact with said silicon substrate and filin said undercut region; and opening a via in said second insulating layer to expose said silicon substrate. 5. A method according to Claim s including -the step of: heating said substrate and said polysilicon layer to a temperature efficient to cause said impurities in said polysilicon layer to diffuse irs said substrate to form source and drain areas for said field effect transistor, said source and cre,n areas having a higher concentration of said impurities than said implanted region of said substrate. 6 A me EhoA according to Claim 5 wheren: said channel area diffuses laterally during said heating steps. 7. A method according to Claim 5 wherein: said temperature is approximately 8000 C to 9000 C. 8. A metal silicon field effect transistor conprising: a silicon substrate; a polysilicon layer over said silicon substra said polysilicon layer containing impurities of one conductivity type; an insulating layer over said polysilicon lay said polysilicon layer and said insulating layer having vias opened therethrough to expose said silicon substrate, which vias are centered about the same axis; and a metal gate layer in said via in electrical contact with said silicon substrate; said silicon substrate having source and drain regions therein under said polysilicon layers exrept said vias which source and drain regions contain imparities of said one conductivity type; said silicon substrate also having a channel region under said vias which channel region is formed by ions implanted through said vias, said ions being of said one conductivity type but with a less Concentration than said source and drain regions. 9. A field effect transistor according to Claim 8 wherein said metal gate layer includes: a platinum silicide region in contact with said substrate; a first layer over said pla--inum silicide, which first layer is of a materai selected frorn the group of tunsten and titanium-tungsten an a second layer over said first layer which second layer is aluminum. 10. A field effect transistor according to Claim 8 wherein: said gate metal layer is isolated from said polysilicon layer by an insulating layer.

Inventors: ROESNER, BRUCE BOYD
Applicants: BURROUGHS CORPORATION (A DELAWARE CORPORATION)
Application year: 1982
Main classification: H01L21
IPC codes: H01L29, H01L21