Abstract:
A method forms fin structures for a semiconductor device. The method includes forming a first fin structure including a dielectric material and including a first side surface and a second side surface; forming a second fin structure adjacent the first side surface of the first fin structure; and forming a third fin structure adjacent the second side surface of the first fin structure. The second fin structure and the third fin structure are formed of a different material than the first fin structure.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to semiconductor manufacturing and, more particularly, to forming FinFET devices.  
         BACKGROUND OF THE INVENTION  
         [0002]    The escalating demands for high density and performance associated with ultra large scale integration semiconductor devices require design features, such as gate lengths, below 100 nanometers (nm), high reliability and increased manufacturing throughput. The reduction of design features below 100 nm challenges the limitations of conventional methodology.  
           [0003]    For example, when the gate length of conventional planar metal oxide semiconductor field effect transistors (MOSFETs) is scaled below 100 nm, problems associated with short channel effects, such as excessive leakage between the source and drain, become increasingly difficult to overcome. In addition, mobility degradation and a number of process issues also make it difficult to scale conventional MOSFETs to include increasingly smaller device features. New device structures are therefore being explored to improve FET performance and allow further device scaling.  
           [0004]    Double-gate MOSFETs represent new structures that have been considered as candidates for succeeding existing planar MOSFETs. In double-gate MOSFETs, two gates may be used to control short channel effects. A FinFET is a double-gate structure that exhibits good short channel behavior. A FinFET includes a channel formed in a vertical fin. The FinFET structure may also be fabricated using layout and process techniques similar to those used for conventional planar MOSFETs.  
         SUMMARY OF THE INVENTION  
         [0005]    Implementations consistent with the principles of the invention provide single-crystal silicon fin structures formed on opposite sides of a dielectric fin structure. The material for the dielectric fin structure is chosen such that a significant stress is induced in the single-crystal silicon material. Accordingly, enhanced mobility can be achieved.  
           [0006]    In accordance with the purpose of this invention as embodied and broadly described herein, a semiconductor device includes a first fin structure that comprises a dielectric material and includes a first side surface and a second side surface; a second fin structure that comprises a single-crystal silicon material and is formed adjacent to the first side surface of the first fin structure; a third fin structure that comprises the single-crystal silicon material and is formed adjacent to the second side surface of the first fin structure; a source region that is formed at one end of the first fin structure, the second fin structure, and the third fin structure; a drain region that is formed at an opposite end of the first fin structure, the second fin structure, and the third fin structure; and at least one gate.  
           [0007]    In another implementation consistent with the present invention, a method of manufacturing a semiconductor device that includes a substrate and a dielectric layer formed on the substrate is disclosed. The method includes etching the dielectric layer to form a first fin structure; depositing an amorphous silicon layer; etching the amorphous silicon layer to form a second fin structure adjacent a first side surface of the first fin structure and a third fin structure adjacent a second, opposite side surface of the first fin structure; depositing a metal layer on at least upper surfaces of the second fin structure and the third fin structure; performing a metal-induced crystallization operation to convert the amorphous silicon in the second and third fin structures to a single-crystal silicon material; forming a source region and a drain region; depositing a gate material over the first, second, and third fin structures; and patterning and etching the gate material to form at least one gate electrode.  
           [0008]    In yet another implementation consistent with the principles of the invention, a semiconductor device that includes a first fin structure, a second fin structure, and a third fin structure disclosed. The first and second fin structures include a single-crystal silicon material. The third fin structure is located between the first fin structure and the second fin structure and includes a dielectric material. The third fin structure causes stress to be induced in the single-crystal silicon material of the first fin structure and the second fin structure. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, explain the invention. In the drawings,  
         [0010]    [0010]FIG. 1 illustrates an exemplary process for forming fin structures for a FinFET device in an implementation consistent with the principles of the invention;  
         [0011]    [0011]FIGS. 2-9 illustrate exemplary views of a FinFET device fabricated according to the processing described in FIG. 1;  
         [0012]    [0012]FIGS. 10-15 illustrate exemplary views for forming multiple fin structures in an alternative implementation consistent with the principles of the invention; and  
         [0013]    [0013]FIGS. 16 and 17 illustrate exemplary views for creating a trench according to an alternative implementation consistent with the principles of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0014]    The following detailed description of implementations consistent with the present invention refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims their equivalents.  
         [0015]    Implementations consistent with the principles of the invention provide single-crystal silicon fin structures that are formed on opposite sides of a dielectric fin structure. The material for the dielectric fin structure is chosen such that a significant stress is induced in the single-crystal silicon material to enhance mobility.  
       Exemplary Processing  
       [0016]    [0016]FIG. 1 illustrates an exemplary process for forming fin structures for a FinFET device in an implementation consistent with the principles of the invention. FIGS. 2-9 illustrate exemplary views of a FinFET device fabricated according to the processing described in FIG. 1. The fabrication of one FinFET device will be described hereinafter. It will be appreciated, however, that the techniques described herein are equally applicable to forming more than one FinFET device.  
         [0017]    With reference to FIGS. 1 and 2, processing may begin by forming a dielectric fin structure  210  on a substrate  200  of a semiconductor device (act  105 ). In one implementation, substrate  200  may comprise silicon. In alternative implementations consistent with the present invention, substrate  200  may comprise other semiconducting materials, such as germanium, or combinations of semiconducting materials, such as silicon-germanium. In another alternative, substrate  200  may include an insulator, such as an oxide layer, formed on a silicon or germanium substrate. Dielectric fin structure  210  may comprise a dielectric material that causes significant tensile stress (strain) in the dual fin structures that will be formed adjacent dielectric fin structure  210 . In one implementation, dielectric fin structure  210  may comprise an oxide or a nitride.  
         [0018]    Dielectric fin structure  210  may be formed in a conventional manner. For example, a dielectric material may be deposited over substrate  200  toga thickness ranging from about 200 Å to about 1000 Å. A mask may be formed over a portion of the dielectric material and the dielectric material may then be etched in a conventional manner, with the etching terminating on substrate  200  to form dielectric fin structure  210 . The resulting dielectric fin structure  210  may have a width ranging from about 100 Å to about 1000 Å.  
         [0019]    After forming dielectric fin structure  210 , an amorphous silicon layer  310  may be deposited on the semiconductor device, as illustrated in FIG. 3 (act  110 ). In one implementation consistent with the principles of the invention, amorphous silicon layer  310  may be deposited to a thickness ranging from about 100 Å to about 1000 Å.  
         [0020]    Amorphous silicon layer  310  may then be etched in a conventional manner, with the etching terminating at substrate  200  to form amorphous silicon spacer (fin) structures  410 , as illustrated in FIG. 4 (act  115 ). Each amorphous silicon fin structure  410  may have a height ranging from about 200 Å to about 1000 Å and a width ranging from about 100 Å to about 1000 Å.  
         [0021]    A dielectric layer  510  may be deposited on the semiconductor device, as illustrated in FIG. 5. (act  120 ). In one implementation consistent with the principles of the invention, dielectric layer  510  may be deposited to a thickness ranging from about 200 Å to about 1000 Å. Dielectric layer  510  may comprise an oxide or other dielectric materials.  
         [0022]    The semiconductor device may be polished via a chemical-mechanical polishing (CMP) (or other technique) to planarize the top surface of the semiconductor device such that the top surface of each of amorphous silicon fin structures  410  is exposed, as illustrated in FIG. 6 (act  120 ). During the CMP, a portion of the upper surface of dielectric fin structure  210  and amorphous silicon fin structures  410  may be removed so that the upper surface of each of amorphous silicon fin structures  410  is exposed. For example, after the CMP, the height of fins  210  and  410  may range from abou 5  150 Å to about 200 Å.  
         [0023]    A metal layer  710 , such as nickel, may be deposited on the semiconductor device, as illustrated in FIG. 7 (act  125 ). In one implementation, nickel layer  710  may be deposited to a thickness of about 20 Å.  
         [0024]    A metal-induced crystallization (MIC) operation may then be performed. The MIC operation may involve annealing nickel layer  710  at about 500° C. to about 550° C. for several hours, which acts to diffuse the nickel into the amorphous silicon to convert the amorphous silicon in fin structures  410  to single-crystal silicon  810 , as illustrated in FIG. 8 (act  130 ). As a result of the MIC operation, a thin layer of a nickel silicon (NiSi) compound  820  may formed between substrate  200  and single-crystal silicon fin structures  810 . In one implementation, the thickness of NiSi layer  820  may range from about 20 Å to about 200 Å.  
         [0025]    After single-crystal silicon fin structures  810  are formed, conventional FinFET fabrication processing can be utilized to complete the transistor (e.g., forming the source and drain regions), contacts, interconnects and inter-level dielectrics for the FinFET device. For example, dielectric layer  510  may be removed, a protective dielectric layer, such as a silicon nitride or silicon oxide may be formed on the top surface of fins  210  and  810 , followed by the formation of a gate dielectric on the side surfaces of single-crystal silicon fin structures  810 . Source/drain regions may then be formed at the respective ends of fins  210  and  810 , followed by formation of one or more gates. For example, a silicon layer, germanium layer, combinations of silicon and germanium or various metals may be used as the gate material. The gate material may then be patterned and etched to form the gate electrodes. For example, FIG. 9 illustrates an exemplary top view of the semiconductor device consistent with the principles of the invention after the source/drain regions and gate electrodes are formed. As illustrated, the semiconductor device includes a double-gate structure with fins  210  and  810 , source and drain regions  910  and  920 , and gate electrodes  930  and  940 .  
         [0026]    Source/drain regions  910  and  920  may then be doped with n-type or p-type impurities based on the particular end device requirements. In addition, sidewall spacers may optionally be formed prior to the source/drain ion implantation to control the location of the source/drain junctions based on the particular circuit requirements. Activation annealing may then be performed to activate source/drain regions  910  and  920 .  
         [0027]    The present invention has been described above as forming a number of fin structures. It should be understood that methods consistent with the present invention may be used to form any number of fins, based on the particular circuit requirements.  
         [0028]    Thus, in accordance with the principles of the invention, single-crystal silicon fin structures may be formed, having a dielectric fin structure located between the single-crystal silicon fin structures. The material for the dielectric fin structure may be chosen so as to induce a significant stress (strain) in the single-crystal silicon fin structures. As a result, enhanced mobility in the single-crystal silicon fin structures is achieved.  
       Other Implementations  
       [0029]    [0029]FIGS. 10-15 illustrate exemplary views for forming multiple fin structures in an alternative implementation consistent with the principles of the invention. With reference to FIG. 10, processing may begin with a semiconductor device that includes an oxide layer  1010  formed on a substrate  1000 . Substrate  1000  may comprise silicon or other semiconducting materials, such as germanium, or combinations of semiconducting materials, such as silicon-germanium. Oxide layer  1010  may have a height ranging from about 200 Å to about 1000 Å.  
         [0030]    Oxide layer  1010  may be etched to form a trench  1020 , as illustrated in FIG. 10. In one implementation, trench  1020  may have a width ranging from about 200 Å to about 2000 Å. Next, amorphous silicon may be deposited and etched to form amorphous silicon spacers  1110 , as illustrated in FIG. 11. Each of amorphous silicon spacers  1110  may have a width ranging from about 100 Å to about 1000 Å. A dielectric material  1210  may be deposited in the gap between amorphous silicon spacers  1110 , as illustrated in FIG. 12. The dielectric material may comprise an oxide or other dielectric materials.  
         [0031]    A layer of nickel  1310  may deposited on a top surface of amorphous silicon spacers  1110 , as illustrated in FIG. 13. The thickness of nickel layer  1310  may be about 20 Å. A MIC operation may then be performed. The MIC operation may involve annealing nickel layer  1310  at about 500° C. to about 550° C. for several hours to convert amorphous silicon spacers  1110  to single-crystal silicon fin structures  1410 , as illustrated in FIG. 14. As a result of the MIC operation, a thin layer of a nickel silicon (NiSi) compound  1420  may be formed between substrate  1000  and single-crystal silicon fin structures  1410 . In one implementation, the thickness of NiSi layer  1420  may range from about 20 Å to about 200 Å.  
         [0032]    Oxide layer  1010  may then be removed in a conventional manner, as illustrated in FIG. 15. Accordingly, a spacer-induced merged FET can be produced.  
         [0033]    In another implementation, spacers may be used to create a narrow trench that can provide a coupling effect between both sides of the trench. As illustrated in FIG. 16, a semiconductor device may include an oxide layer  1610  formed on a substrate (not shown) with a silicon layer  1620  formed thereon. A material, such as a silicon nitride or a silicon oxide, may be deposited and patterned to form hard masks  1640 . Next, a spacer material, such as SiN, SiO, or some other material, may be deposited and etched to form spacers  1630  on the side surfaces of hard masks  1640 . Silicon layer  1620  may then be etched using spacers  1630  and hard masks  1640  as masks to form a narrow trench  1710 , as illustrated in FIG. 17. Trench  1710  may have a width ranging from about 100 Å to about 1000 Å. Trench  1710  advantageously provides a coupling effect between fins  1620  located on both sides of trench  1710 .  
       Conclusion  
       [0034]    Implementations consistent with the principles of the invention provide single-crystal silicon fin structures that are formed on opposite sides of a dielectric fin structure. The material for the dielectric fin structure is chosen such that a significant stress is induced in the single-crystal silicon material. In this manner, enhanced mobility can be achieved.  
         [0035]    The foregoing description of exemplary embodiments of the present invention provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. For example, in the above descriptions, numerous specific details are set forth, such as specific materials, structures, chemicals, processes, etc., in order to provide a thorough understanding of the present invention. However, the present invention can be practiced without resorting to the details specifically set forth herein. In other instances, well known processing structures have not been described in detail, in order not to unnecessarily obscure the thrust of the present invention. In practicing the present invention, conventional deposition, photolithographic and etching techniques may be employed, and hence, the details of such techniques have not been set forth herein in detail.  
         [0036]    While a series of acts has been described with regard to FIG. 1, the order of the acts may be varied in other implementations consistent with the present invention. Moreover, non-dependent acts may be implemented in parallel.  
         [0037]    No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used.  
         [0038]    The scope of the invention is defined by the claims and their equivalents.