Abstract:
A method includes growing a plurality of parallel mandrels on a surface of a semiconductor substrate, each mandrel having at least two laterally opposite sidewalls and a predetermined width. The method further includes forming a first type of spacers on the sidewalls of the mandrels, wherein the first type of spacers between two adjacent mandrels are separated by a gap. The predetermined mandrel width is adjusted to close the gap between the adjacent first type of spacers to form a second type of spacers. The mandrels are removed to form a first type of fins from the first type of spacers, and to form a second type of fins from spacers between two adjacent mandrels. The second type of fins are wider than the first type of fins.

Description:
[0001]    The present disclosure is related to the following commonly-assigned U.S. patent applications the entire disclosures of which are incorporated herein by reference: U.S. patent application Ser. No. 12/949,881 (Attorney Docket No. 24061.1573) filed on Nov. 19, 2010, entitled “Method for Forming Metrology Structures from Fins in Integrated Circuitry”; and U.S. patent application Ser. No. ______ (Attorney Docket No. 24061.1574) filed on Nov. ______, 2010, entitled “Devices and Method for Forming Fins in Integrated Circuitry.” 
     
    
     BACKGROUND 
       [0002]    The present disclosure relates generally to semiconductor manufacturing, and more particularly, to integrated circuit devices and methods for forming such devices. 
         [0003]    The semiconductor industry continues to have goals of higher density, higher performance, and lower cost. Scaling of device size has been a major tool user to reach these goals. However, scaling beyond the 100 nm process technology node has several difficulties associated with it, such as gate-oxide thickness, source and drain doping depths, and current density. These difficulties have resulted in new device structures to improve the existing metal oxide semiconductor field effect transistor (MOSFET) devices. Some of these new device structures include multi-gate MOSFET devices. A fin field effect transistor (FinFET) is a kind of multi-gate device which has a channel formed as a vertical fin. Multiple gates are formed over and along the sides of the vertical fin. A FinFET allows for a range of channel lengths and provides a broader process window for gate structures. FinFET devices typically include high aspect-ratio semiconductor fins in which the channel and source/drain regions for the transistor are formed. The increased surface area of the channel and source/drain regions in a FinFET results in faster, more reliable and better-controlled semiconductor transistor devices. These advantages have found many new applications in various types of semiconductor devices. 
         [0004]    A process for making a FinFET device uses stringent process control, including in the area of contact landing. For example, contact holes need to overlay with thin vertical fin channels or raised source/drain well-pick-up lines. Process control for contact landing gets even more difficult when horizontal and vertical gate lines co-exist in multi-gate FinFET structures. 
         [0005]    As such, there is need for improving fin structures and other aspects of FinFET integrated circuitry. 
       SUMMARY 
       [0006]    The present disclosure provides a method for forming fins in a semiconductor FinFET device. In one embodiment, the method includes growing a plurality of parallel mandrels on a surface of a semiconductor substrate, each mandrel having at least two laterally opposite sidewalls and a predetermined width. The method further includes forming a first type of spacers on the sidewalls of the mandrels, wherein the first type of spacers between two adjacent mandrels are separated by a gap. The predetermined mandrel width is adjusted to close the gap between the adjacent first type of spacers to form a second type of spacers. The mandrels are removed to form a first type of fins from the first type of spacers, and to form a second type of fins from spacers between two adjacent mandrels. The second type of fins are wider than the first type of fins. 
         [0007]    In another embodiment, the method includes forming a first, second, and third mandrel on a surface of a semiconductor substrate, each mandrel having at least two laterally opposite sidewalls and a first width. The first and second mandrels are adjacent to each other, the third mandrel is a distance away from either the first or second mandrel. The method further includes forming spacers on the sidewalls of all three mandrels, wherein the spacers between the first and second adjacent mandrels are separated by a gap. The first width is adjusted to close the gap between the spacers between the first and second adjacent mandrels. The mandrels are removed to form a first fin from the spacers between the first and second mandrels, and a second fin from a spacer of the third mandrel. 
         [0008]    The present disclosure also describes an integrated circuit device. In one embodiment, the device includes a substrate and first and second fins on the substrate. The first fin is about twice as wide as the second fin. The device also includes a gate dielectric layer on the first fin and a gate electrode on the gate dielectric layer. The gate electrode is in a direction perpendicular to a direction of the first fin. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. 
           [0010]      FIG. 1A  is a cross section of an array of mandrels and spacers used in FinFET devices.  FIG. 1B  illustrates the top view of the array of mandrels and spacers corresponding to  FIG. 1A .  FIG. 1C  is the top view of the array of fin structures resulted from the array of mandrels and spacers shown in  FIG. 1A  and  FIG. 1B . 
           [0011]      FIG. 2A  and  FIG. 2B  are cross section and top views of an array of parallel mandrels and spacers when merged spacer technique is applied, in accordance with certain embodiments of the present disclosure. 
           [0012]      FIG. 3A  and  FIG. 3B  are cross section and top views of an array of wider fin structures resulted from the array of mandrels and merged spacers shown in  FIG. 2A  and  FIG. 2B . 
           [0013]      FIG. 4A  is a top view of contact connections with an array of L-shaped and T-shaped spacers used in FinFET devices.  FIG. 4B  illustrates a cross sectional view of the contact connections with the L-shaped and T-shaped fin array, along the X-X′ cut line shown in  FIG. 4A . 
           [0014]      FIG. 5A  is a top view of contact connections with an array of L-shaped and T-shaped spacers used in FinFET devices when merged spacer technique is applied, and  FIG. 5B  is a cross sectional view of the contact connections with the L-shaped and T-shaped fin array, along the Y-Y′ line shown in  FIG. 5A , in accordance with some embodiments of the present disclosure. 
           [0015]      FIG. 6  compares a contact connection structure having a thin fin structure and another contact connection structure having a wider fin structure when merged spacer technique is applied, in accordance with some embodiments of the present disclosure. 
           [0016]      FIG. 7  compares an emitter ring of bipolar junction transistors (BJT) built on a thin fin structure and another emitter ring of BJT built on a broadened fin structure when merged spacer technique is applied, in accordance with various embodiments of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of the invention. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Various features may be arbitrarily drawn in different scales for simplicity and clarity. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. The specific embodiments discussed are merely illustrative and do not limit the scope of the invention. 
         [0018]    Fin field effect transistors (FinFETs) use a substantially rectangular fin structure which can be formed in several ways. In a first method, bulk silicon on a substrate is etched into rectangular fin shape by first depositing a hardmask layer on the bulk silicon. The hardmask forms a pattern covering the top of the fins. The bulk silicon is then etched to form trenches between the regions covered by the hardmask layer. The trenches are formed into shallow trench isolation (STI) features by depositing a dielectric material, usually silicon oxide, into the trench. The dielectric material is usually deposited in excess to completely cover the fins and optionally the hardmask layer if not already removed. The dielectric material is planarized down to the top surface of the fin/hardmask, and then etched to a level below the top of the fin so that a portion of the fin protrudes above the STI. 
         [0019]    In a second method, the STI features are formed first on bulk silicon material by depositing an STI layer and etching trenches into it. The bottoms of the trenches between the STI features are exposed bulk silicon. Silicon is then grown in the trenches to form the fins by using, for example, an epitaxial process. Once a desired fin height is reached, then the STI is etched to a level below the top of the fin to expose a portion of the fin. The bulk silicon material may be a silicon substrate or deposited silicon such as silicon-on-insulator (SOI) with a barrier oxide (BOX) layer between the SOI and the underlying silicon substrate. 
         [0020]    Both methods above use a photomask process at the desired fin dimension, often at or beyond the limit of the current photolithography technology. With the increasing demand to reduce device size, a variation of the first method was developed, in which elongated mandrels are used as a hardmask for etching into the bulk silicon, leaving thin spacers at both lateral sides of mandrel as fins after the mandrels are removed. The mandrel/spacer process is described in  FIG. 1A  and  FIG. 1B . 
         [0021]    Referring to  FIGS. 1A-1C , a semiconductor substrate  110 , such as a silicon substrate, or a silicon on oxide substrate. The substrate includes an array of mandrels. Mandrels  121 ,  122 ,  123 ,  124 , and  125  is formed by a photolithography and etch process. The mandrels are spaced at a pitch  101  and have a width  102 . A conformal spacer material is then deposited around each of the mandrels  121 ,  122 ,  123 ,  124 , and  125 , forming a spacer array. In the present embodiment, the spacer array is made of a hardmask material, and spacer sidewalls  131 ,  132   a ,  132   b ,  133   a ,  133   b ,  134   a ,  134   b ,  135   a ,  135   b , and  136  are thinner than the width of the mandrels  121 ,  122 ,  123 ,  124 , and  125 . In the present embodiment, the pitch and width of the mandrel array are selected such that facing sidewalls of a pair of adjacent mandrel structures are separated from each other at a distance on the order of the width  102  of a mandrel. As can be seen, mandrels  121 ,  122 ,  123 ,  124 , and  125  are sandwiched between spacer sidewalls  131  and  132   a ,  132   b  and  133   a ,  133   b  and  134   a ,  134   b  and  135   a ,  135   b  and  136  respectively. 
         [0022]    The mandrels  121 ,  122 ,  123 ,  124 , and  125  between the spacers are then removed in a subsequent etching operation to leave just the spacers behind, now referred to as fin structures. It is understood that the fin structures can be used as a hardmask for etching the silicon layers below, forming additional fin structures. Using the mandrel/spacer method, the fin structures  131 ,  132   a ,  132   b ,  133   a ,  133   b ,  134   a ,  134   b ,  135   a ,  135   b , and  136  are very thin and close together, and can be formed without a difficult lithography process. Thus formed fin structures have a width  152  at a pitch  151  ( FIG. 1C ), which can be half the mandrel pitch  101 . For example, the mandrel pitch varies from 20 nm to 200 nm, the mandrel width varies from 10 nm to 100 nm, and the fin width varies from 5 nm to 80 nm. The vertical fin structures are the building blocks for forming gate channels for double, triple, and multiple gate transistors in a FinFET process. 
         [0023]    It may further be a desire to form fin structures of different widths. For example, a number of circuit components may use various lateral dimensions for various vertical structures, which may benefit from multi-sized fin structures. Furthermore, it may be desired for the fin structures formed in the above mandrel and spacer process to provide relatively large contact landing areas on the top surface of a connection line. In addition, it may be desired to improve well-pick-up in source and drain structures, as well as improved emitter efficiency in bipolar junction transistor (BJT) integrated circuits. 
         [0024]    A modification of the above-described method is discussed below to achieve one or more of the above-listed desires. It is further desired for the modification to maintain the fin density within the confines of existing transistor structures. Furthermore, it may be undesirable to require new photomasks to be made, especially for an existing product. Hence, it is desired to avoid creating new photomasks, and form FinFETs within the confines of the existing transistor structures so that layouts of other layers are not affected. 
         [0025]    Referring now to  FIGS. 2A-2B , a method of making fin structures in a semiconductor substrate  210 , such as a silicon substrate or silicon on oxide substrate is provided. For the sake of reference, this method will be referred to as the spacer-merging process. An array of mandrels  221 ,  222 ,  223 ,  224 , and  225  is formed by a photolithography and etch process. Based on device requirement for a specific fin dimension, the mandrel array is designed to have a pitch  201  and a width  202  that are appropriate to form the desired fins. A conformal spacer material is then deposited around the mandrels  221 ,  222 ,  223 ,  224 , and  225 . The conformal spacer array is usually made of a hardmask material. In addition, spacer sidewalls  231 ,  232   a ,  232   b ,  233   a ,  233   b ,  234   a ,  234   b ,  235   a ,  235   b , and  236  are thinner than the width of the mandrels  221 ,  222 ,  223 ,  224 , and  225 . The pitch and width of the mandrel array can be designed such that nearby facing sidewalls of a pair of adjacent mandrel structures actually touch and merge into one structure. As shown in  FIG. 2B , mandrels  221 ,  222 ,  223 ,  224 , and  225  are sandwiched between spacer sidewalls  231  and  232   a ,  232   b  and  233   a ,  233   b  and  234   a ,  234   b  and  235   a ,  235   b  and  236 , respectively. Facing sidewalls  232   a  and  232   b ,  233   a  and  233   b ,  234   a  and  234   b , and  235   a  and  235   b  are located very closely to each other, or are touching each other respectively. 
         [0026]    Now referring to  FIGS. 3A-3B , the mandrel material between the spacers is then removed in a subsequent etching operation to leave just the spacers behind, which are now referred to as the desired fin structures. The fin structures  232 ,  233 ,  234 , and  235  are formed from joining the nearby spacers  232   a  and  232   b ,  233   a  and  233   b ,  234   a , and  234   b  respectively. As shown in  FIG. 3B  the thus formed fins  232 ,  233 ,  234 , and  235  have a wider width  252  at a pitch  251 , which is the same as the mandrel pitch  201 . At the same time, fin structures  231  and  236  are not merged with other spacers; therefore fin structures  231  and  236  have their fin width unchanged. The pitch  251  is changed within the allowed range by the device layouts in the full process. For example, the mandrel pitch may vary from 20 nm to 200 nm, its width may vary from 10 nm to 100 nm, and the fin width varies from 5 nm to 180 nm. The wider vertical fin structures can be used for forming connector lines for well-pick-ups, for contact landing pads in Fin IC circuits, for BJT emitter channels, and other applications that desire wider fins. 
         [0027]    Referring to  FIGS. 4A-4B , an array of L-shaped and T-shaped spacers is provided. Horizontal fins  401 ,  402 ,  403  and vertical fins  404 ,  405 , and  406  are fabricated using a mandrel and spacer process similar to that in  FIG. 1A ,  FIG. 1B , and  FIG. 1C . Fin  404  is an L-shaped fin, and  405  and  406  are T-shaped fins according to their shapes in the layout. Contacts  421  and  422  are overlaid on fins  404  and  406  respectively. Fins  404  and  406  each form a contact landing surface  421   a  and  422   a  as shown in  FIG. 4B . The lateral dimension of fins  401 ,  402 , and  403  form gate channels for FinFETs, therefore they may be appropriate and do not need any changes. However, lateral dimension of connection line fins  404  and  406  are too thin for forming good contact landing. 
         [0028]    Referring to  FIGS. 5A-5B , another array of L-shaped and T-shaped spacers is provided. Horizontal fins  501 ,  502 ,  503  and vertical fins  504  and  505  are fabricated using the spacer-merging process. Fin  504  is an L-shaped fin and  505  is a T-shaped fin according to their shapes in the layout. Contacts  521  and  522  are overlaid on fins  504  and  505  respectively. Fins  504  and  505  are lines each forming a contact landing surface  521   a  and  522   a  as shown in  FIG. 5B . Block  550  in  FIG. 5A  is enlarged to illustrate an intermediate layout with a pair of adjacent mandrels  551  and  552  and their merged sidewall spacers  504   a  and  504   b  before contact  521  is overlaid on top. And  FIG. 5B  illustrates a cross sectional view of a contact connection with the array of L-shaped and T-shaped spacers, along the dashed Y-Y′ cut line in  FIG. 5A . Lateral dimension of fins  501 ,  502 , and  503  remain narrow to form gate channels for FinFETs. The lateral dimension of connection line fins  504  and  505  are doubled from single fins  504   a  and  504   b , resulting in improved contact landing areas to  521   a  and  522   a.    
         [0029]    Referring to  FIG. 6 , a contact connection structure  600  having a thin fin structure and a contact connection structure  650  having a wider fin structure are shown. The fin structures can be created using the merged spacer technique as discussed above. A narrower fin structure  601  forms connections with contacts  610 ,  611 ,  612 ,  613 , and  614 , where contact landings are limited by the lateral width of fin line  601 . However, contact connection structure  650  has a wider fin structure  651  to provide contact landing areas for contacts  660 ,  661 ,  662 ,  663 , and  664 . Block  651  in  FIG. 6  illustrates an intermediate layout with a pair of adjacent mandrels  655  and  656  and their merged spacers  651   a  and  651   b  before contacts  660 ,  661 ,  662 ,  663 , and  664  are overlaid on the top surface of line  651 . As a result, the lateral dimension of connection line fin  651  is doubled from the single fins  651   a  and  651   b  to form improved contact landing. 
         [0030]      FIG. 7  compares different emitter ring layouts of bipolar junction transistors (BJT) built according to the two methods discussed above. A bipolar junction transistor is a collector-base-emitter three-terminal transistor having a charge flow due to bidirectional diffusion of charge carriers across junctions from two regions of different charge concentrations. 
         [0031]    Layout  700 , formed by the method of  FIG. 1 , illustrates an emitter ring formed of four thin fin structure sides  710 ,  711 ,  712 , and  713 . Other transistor components built on the emitter ring are not shown. A BJT emitter is heavily doped to increase the emitter injection efficiency. For high current gain, most of the carriers injected into the emitter-base junction come from the emitter. Therefore, emitter injection currents  720 ,  721 ,  722 , and  723  in the integrated BJT circuits can be limited from the narrow emitter fins  710 ,  711 ,  712 , and  713  as fin dimension keeps on shrinking. 
         [0032]    In layout  750 , formed by the spacer-merging process, emitter injection currents  770 ,  771 ,  772 , and  773  in the integrated BJT circuits are largely increased from the broadened emitter fins  760 ,  761 ,  762 , and  763 . The wider fins  760 ,  761 ,  762 , and  763  are formed with the merged spacer technique described above. As a result of the wider emitter fins, BJT emitter efficiency is improved in  750 . 
         [0033]    Although the embodiments and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.