Abstract:
Apparatuses, systems, and methods for tunneling MOSFETs (TFETs) using a self-aligned heterostructure source and isolated drain. TFETs that have an abrupt junction between source and drain regions have an increased probability of carrier direct tunneling (e.g., electrons and holes). The increased probability allows a higher achievable on current in TFETs having the abrupt junction.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present disclosure generally relates to semiconductor devices. More specifically, the present disclosure relates to tunneling field-effect transistors. 
     2. Description of the Related Art 
     Advances in the semiconductor industry have reduced the size of transistors in integrated circuits (ICs) to 45 nm. Continuing pressure to create smaller and more power efficient products will continue to reduce the transistor size to 32 nm and smaller. Decreases in transistor size lead to decreases in power supply voltage to the transistors and capacitance of the transistors. As the power supply voltage has decreased, the threshold voltage of the transistors in the ICs has also decreased. 
     Lower threshold voltages are difficult to obtain in conventional metal-oxide-semiconductor field-effect transistors (MOSFETs) because as the threshold voltage is reduced the ratio of on current to off current (Ion/Ioff) also decreases. The on current refers to the current through a MOSFET when a gate voltage applied is above the threshold voltage, and the off current refers to current through a MOSFET when a gate voltage applied is below the threshold voltage. 
     Tunneling field-effect transistors (TFETs) have improved Ion/Ioff ratios. Band-to-band tunneling in TFETs increases the achievable Ion allowing further reductions in threshold voltage, power supply voltage, and transistor size. A conventional TFET includes a drain region and a source region in a substrate layer and the drain region and the source region are doped with opposite carriers. For example, the drain region may be an n-doped region and the source region may be a p-doped region. A gate oxide is deposited on the substrate layer, and a gate electrode is deposited on the gate oxide. A gate voltage above the threshold voltage applied to the gate electrode switches the TFET from an off state to an on state. 
     SUMMARY OF THE INVENTION 
     A Tunneling Field Effect Transistor (TFET) is presented. In one embodiment, the apparatus includes an insulating layer, a first semiconductor layer on the insulating layer, a first doped region on the first semiconductor layer, and a second doped region on the first semiconductor layer. In some embodiments, the second doped region is separated from the first doped region. Additionally, some embodiments may include a second semiconductor layer on the first doped region, where the second semiconductor layer is coupled to the second doped region. Also, some embodiments may include a gate stack on the second semiconductor layer, where the gate stack is in complete contact with the second semiconductor layer. 
     In some embodiments, the gate stack may comprise a first dielectric layer and a first metal contact. The dielectric layer may be a high-k material. The first metal contact may be Tantalum Nitride (TaN). The first metal contact may also be a electrically conductive material such as polycrystalline silicon. In some embodiments, an insulating layer separates the first doped region and the second doped region. The insulating layer may include a semiconductor, a dielectric layer, an air gap, or a combination thereof. 
     In some embodiments, the first doped region comprises germanium (Ge). In some embodiments the first doped region is doped with a p-type dopant. The p-type dopant may be boron, aluminum and/or gallium. In some embodiments, the dopants can be incorporated in-situ during epitaxial growth. In some embodiments dopants can be incorporated via an implantation scheme including conventional ion-implant, plasma or through solid state diffusion (e.g. molecular layer diffusion). 
     In some embodiments, the second doped region comprises silicon (Si). In some embodiments, the second doped region is doped with an n-type dopant. The n-type dopant may be nitrogen, phosphorous, and/or arsenic. 
     In some embodiments, the TFET may further comprise a third doped region coupled to the first doped region. The third doped region may be Si. In some embodiments, the third doped region may be doped using a p-type dopant. The p-type dopant may be boron, aluminum and/or gallium. 
     Also presented is an Integrated Circuit (IC) device. The IC device may include a chip package configured to house an IC, at least one TFET disposed within the chip package, and a plurality of electrical interface pins coupled to the chip package and in communication with the IC. The electrical interface pins may be configured to conduct electrical signals. In some embodiments, the TFET includes an insulating layer, a first semiconductor layer on the insulating layer, a first doped region on the first semiconductor layer, and a second doped region on the first semiconductor layer. In some embodiments, the second doped region may be separated from the first doped region. In some embodiments, the TFET includes a second semiconductor layer on the first doped region, where the second semiconductor layer is coupled to the second doped region. Additionally, the TFET may include a gate stack on the second semiconductor layer, where the gate stack is in complete contact with the second semiconductor layer. 
     In some embodiments, the first doped region is Ge. The first doped region may be doped with a p-type dopant. The p-type dopant may be boron, aluminum and/or gallium. In some embodiments, the second doped region may be Si. The second doped region may be doped with an n-type dopant. The n-type dopant of the second doped region may be nitrogen, phosphorous, and/or arsenic. 
     Method for manufacturing a semiconductor device is also presented. The methods in the disclosed embodiments substantially include the steps necessary to carry out the functions presented above with respect to the operation of the described apparatus and system. In some embodiments, the method includes forming a first semiconductor layer on an insulator, forming a first doped region on the first semiconductor layer, forming a second semiconductor region on the first doped region, and forming a gate stack on the second semiconductor layer, where the gate stack is in complete contact with the second semiconductor layer. Additionally, the method may include etching the second semiconductor layer and the first doped region adjacent to the gate stack, etching the first doped region under the gate stack, and forming a second doped region on the first semiconductor layer. 
     In some embodiments, forming the first doped region on the first semiconductor layer further comprises depositing germanium on the first semiconductor layer and doping the germanium with a p-type dopant. The first doped region may be epitaxially deposited onto the first semiconductor layer. The first doped region may be doped with boron, aluminum and/or gallium. 
     In some embodiments, forming the second semiconductor layer comprises depositing silicon onto the first doped region. The second semiconductor layer may be deposited epitaxially using ultra-high vacuum chemical vapor deposition (UHCVD) or molecular beam epitaxy (MBE). In some applications where leakage is not a significant concern, the second semiconductor layer may also be deposited in poly-crystalline form using low pressure chemical vapor deposition (LPCVD) or physical vapor deposition (PVD). 
     In some embodiments, etching the second semiconductor layer and the first doped region adjacent to the gate stack includes applying a mask layer over the first doped region, and performing an anisotropic etch to remove a portion of the second semiconductor layer and a portion of the first doped region. The mask layer may be a dielectric hardmask, or it may be a photoresist layer. In some embodiments, the second semiconductor layer and the first doped region may be etched right next to the gate stack. In some embodiments, a portion of the gate stack may be etched along with the second semiconductor region and the first doped region. 
     In some embodiments, etching the first doped region under the gate stack comprises performing an isotropic etch. Etching the first doped region may result in a gap next to the first doped region and under the second semiconductor region. 
     In some embodiments, forming a second doped region on the first semiconductor layer comprises depositing a semiconductor material. In some embodiments, the semiconductor material may be silicon. In some embodiments, the second doped region may be doped with an n-type dopant. The n-type dopant may be nitrogen, phosphorous, and/or arsenic. 
     The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically. 
     The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. 
     The term “substantially” and its variations are defined as being largely but not necessarily wholly what is specified as understood by one of ordinary skill in the art, and in one non-limiting embodiment “substantially” refers to ranges within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5% of what is specified. 
     The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a method or device that “comprises,” “has,” “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more elements. Likewise, a step of a method or an element of a device that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, a device or structure that is configured in a certain way is configured in at least that way, but may also be configured in ways that are not listed. 
     Other features and associated advantages will become apparent with reference to the following detailed description of specific embodiments in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein. 
         FIG. 1  is a schematic block diagram illustrating one embodiment of a TFET according to U.S. patent application Ser. No. 12/719,697, which is hereby incorporated by reference in its entirety. 
         FIG. 2  is a is a cross-sectional view illustrating an exemplary TFET according to one embodiment. 
         FIGS. 3A-3F  are cross-sectional views illustrating a method for manufacturing an exemplary TFET according to one embodiment. 
         FIG. 4  is a flow chart illustrating an exemplary manufacturing method for a TFET according to one embodiment. 
         FIG. 5  is a block diagram illustrating implementation of an Integrated Circuit (IC) in a chip package according to one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Various features and advantageous details are explained more fully with reference to the nonlimiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well known starting materials, processing techniques, components, and equipment are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the invention, are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and/or rearrangements within the spirit and/or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure. 
       FIG. 1  illustrates a cross-sectional view of one embodiment of a Tunneling Field Effect Transistor (TFET), TFET  100 , as disclosed in U.S. patent application Ser. No. 12/719,697. A semiconductor layer  110  includes a drain region  120  and a source region  140 . The semiconductor layer  110  may be, for example, silicon, germanium, or III-V compound semiconductors. The regions  120 ,  140  are asymmetric, that is, the regions  120 ,  140  are doped with opposite carriers. For example, the drain region  120  may be n-doped with arsenic, and the source region  140  may be p-doped with boron. During an on state, current conducts substantially along a path illustrated by a line  146 . According to one embodiment, the regions  120 ,  140  may be heavily doped with a concentration of between 1×10 19  and 1×10 21  atoms/cm 3 . A gate stack  145  including a gate oxide  130  and a gate electrode  132  are on the semiconductor layer  110  and partially covering the regions  120 ,  140 . The gate oxide  130  may be, for example, high-K dielectrics, silicon oxide, hafnium silicon oxynitride (HfSiON), or other oxides, and the gate electrode  132  may be, for example, a metal or poly-silicon. Spacers  134  are deposited on the sides of the gate stack  145 . The spacers  134  may be, for example, silicon oxide, silicon nitride, high-K dielectrics, or other insulating materials. 
     A dielectric layer  122  is on the source region  140  and may be, for example, silicon oxide, silicon nitride, zirconium oxide, lanthanum oxide, aluminum oxide, or another dielectric material. According to one embodiment, the dielectric layer  122  is a dielectric with low permittivity and has a thickness between 5 and 50 Angstroms. A low permittivity compared with the permittivity of silicon (approx. 11.9) creates a large field drop across the dielectric layer  122  and enhances band alignment. A semiconductor layer  124  is on the dielectric layer  122  and doped with an opposite carrier of the source region  140 . The semiconductor layer  124  may be, for example, a poly-silicon layer or epitaxially grown silicon with thickness between 5 and 30 Angstroms. According to one embodiment, the drain region  120  may be n-doped and the semiconductor layer  124  may be p-doped. The dielectric layer  122  and the semiconductor layer  124  create an abrupt junction in the doping profile of the TFET  100 . The geometry of the abrupt junction enhances the electric field, allows direct tunneling, and creates a higher tunneling probability for carriers (e.g., holes and electrons). According to some embodiments, the semiconductor layer  124  may be absent, such that the dielectric layer  122  creates an abrupt junction without the semiconductor layer  124 . 
       FIG. 2  shows a cross-sectional view of one embodiment of a TFET as presently disclosed. A first semiconductor layer  204  is coupled to an insulator layer  202 . Coupled to the first semiconductor layer  204  is a first doped region  206  and a second doped region  208 . In this embodiment, the first doped region  206  is coupled to a third doped region  222 , which functions as the source, and the second doped region  208  functions as the drain. The semiconductor layer  204  may be, for example, silicon, germanium, or III-V compound semiconductors. The insulator layer  202  may be a buried oxide layer. 
     One aspect of this embodiment is that the first doped region  206  and the second doped region  208  are asymmetric. That is, the regions  206  and  208  are doped with opposite carriers. For example, the second doped region  208  may be n-doped with arsenic, and the first doped region  206  may be p-doped with boron. According to one embodiment, the regions  206  and  208  may be heavily doped with a concentration of between 1×10 19  and 1×10 21  atoms/cm 3 . 
     A gate stack  212  including a gate oxide  214 , a gate metal electrode  216 , and a gate semiconductor electrode  218  are on the second semiconductor layer  210 . The gate oxide  214  may be, for example, high-K dielectrics, silicon oxide, hafnium silicon oxynitride (HfSiON), or other oxides. The gate metal electrode  216  may be any metal nitride (including tantalum nitride and titanium nitride), metal carbide (such as TaC), or metal alloys. The gate semiconductor electrode  216  may be, for example, a metal or poly-silicon. Spacers  220  are deposited on the sides of the gate stack  212 . The spacers  220  may be, for example, silicon oxide, silicon nitride, high-K dielectrics, or other insulating materials. 
     A second semiconductor layer  210  is on the first doped region  206  and is coupled to the second doped region  208 . The second semiconductor layer  210  may be, for example, a poly-silicon layer or epitaxially grown silicon with thickness between about 5 and 30 Angstroms. According to one embodiment, the second doped region  208  may be n-doped and the first doped region  206  may be p-doped. The second semiconductor layer  210  creates an abrupt junction in the doping profile of the TFET  200 . The abrupt junction enhances the electric field, allows direct tunneling, and creates a higher tunneling probability for carriers (e.g., holes and electrons). 
     One aspect of this embodiment is that the gate oxide  214  is in complete contact with the second semiconductor layer  210 . As used herein, the term complete contact means that substantially the entire bottom surface of the gate oxide  214  is in direct contact with the top surface of the second semiconductor layer  210 . A large contact area between the gate oxide and the tunneling front of the second semiconductor layer  210  may maximize band-to-band tunneling and increase transistor efficiency. 
     Between the first doped region  206  and the second doped region  208  there is a separation  224 . The separation  224  may be an air gap or it may be filled with a dielectric or undoped semiconductor. The separation  224  may decrease the leakage of current when the transistor is in the off state by decreasing the parasitic conduction path between the first doped region  206  and the second doped region  208 . 
     TFET  200  may also include a third doped region  222  that is coupled to the first doped region  206 . The third doped region  222  is typically where the source connection is made on the TFET. The third doped region  222  may be configured to maximize electrical conduction between the second doped region  206  and the third doped region  222 . The third doped region  222  may be silicon, germanium, or III-V compound semiconductors and may be p-doped with boron. Spacers  220  are coupled to the gate stack  212 . Spacers  220  are typically made of insulating dielectrics and are used to prevent electrical shorts between the third doped region  222  and the gate stack  212 . 
     During typical operation, a voltage on the gate semiconductor electrode  216  will place the TFET  200  into an on state. During an on state, current conducts substantially along the path  226 . The current travels from the third doped region  222 , through the first doped region  206 , through the second semiconductor layer  210 , and through the region  208 . 
     One method for manufacturing an exemplary TFET according to one embodiment is illustrated in the cross-sectional views of  FIGS. 3A-3F  and the flow chart of  FIG. 4 . A flow chart  400  starts at block  410  with semiconductor deposition. Turning to  FIG. 3A , a cross-sectional view illustrating a partially complete TFET according to one embodiment is shown. A first semiconductor layer  304  is deposited on an insulator layer  302 . The first semiconductor layer  304  may be, for example, silicon. In some embodiments, a starting material such as Si on BOX can be purchased commercially. Insulator layer  302  may be buried oxide or any semi-insulating large band-gap semiconductor. Next, another semiconductor, that will eventually become the first doped region  306 , may be deposited onto the first semiconductor layer  302 . Block  415  of flowchart  400  shows the step of dopant implantation  415 , which may be used to create first doped region  206 . A dopant may be implanted into the semiconductor above semiconductor layer  304 , creating the first doped region  306 . First doped region  306  may be silicon, germanium, or III-V compound semiconductors and may be p-doped with boron. 
     Block  420  of flow chart  400  shows another step of semiconductor deposition. In this step  420 , a second semiconductor layer  310  may be deposited onto the first doped region  306 . The second semiconductor layer  310  may be silicon, germanium, or III-V compound semiconductors. 
     The flow chart  400  continues to block  425  with gate stack formation. Turning now to  FIG. 3B , a cross-sectional view illustrating a partially complete TFET after gate stack formation is shown. A gate oxide  314  may be deposited onto the second semiconductor layer  310 , followed by a gate electrode  316 , and a gate electrode  318 . The gate oxide  312  may be, for example, high-K dielectrics, silicon oxide, or other oxides. The gate electrode  316  and the gate electrode  318  may be, for example, tantalum nitride and poly-silicon, respectively. The gate oxide  314 , the gate electrode  316 , and the gate electrode  318  are patterned into a gate stack  312 . The flow chart  400  continues to block  430  with spacer formation. Spacers  320  are deposited and etched back to substantially cover sides of the gate stack  312 . 
     Flow chart  400  continues to block  435  with mask deposition and an anisotropic etch. Turning to  FIG. 3C  a first mask layer  322 , and a second mask layer may be deposited on to the structure. The first mask layer, for example, may be a dielectric. The second mask layer  324  may be a photoresist layer. The masks  322 ,  324  may also comprise a hardmask such as silicon nitride. After the masks  322 ,  324  have been deposited, an anisotropic etch may be performed adjacent to the gate stack. As shown in  FIG. 3C , a portion of the second insulating layer  310  and a portion of the first doped region  306  may be etched away adjacent to the gate stack. It is this etch that may form the TFET with a self-aligned heterostructure. One method of performing the anisotroopic etch is a reactive ion etch. 
     Flow chart  400  continues to block  440 , which describes an isotropic etch and mask stripping. Turning to  FIG. 3D , the isotropic etch of block  440  removes an additional portion of second doped region  306  from under the gate stack formation. The isotropic etch may be accomplished, for example, using a reactive ion etch or a wet etching. Next, in block  445 , the masks  322  and  324  may be stripped from the structure using conventional plasma ashing and isotropic wet etching of mask  322 . 
     Flow chart  400  continues to block  450  where a semiconductor is deposited onto the structure and doped, forming the second doped region  326 , as shown in  FIG. 3E . The second doped region  325  may be silicon, germanium, or III-V compound semiconductors and may be n-doped with arsenic. The second doped region  325  may also undergo an activation anneal. One aspect of this embodiment is the separation  328  between the first doped region  306  and second doped region  326 . The separation  328  may be an air gap, filled with a dielectric or undoped semiconductor, or a combination thereof. The separation  328  may reduce the parasitic conduction path, and consequently the leakage current, between the first doped region  306  and the second doped region  326 . 
     Flow chart  400  continues to block  455 , where contacts may be formed over the first doped region  306  and the second doped region  326 . In this embodiment, nickel (Ni) may be deposited onto the first doped region  306  to form the source contact  330 . Ni may also be deposited onto the second doped region  326  to form the drain contact  332 . Ni may be deposited using self-aligned salicidation, where Ni only forms over exposed Si. In typical operation, the TFET will be in an on state when voltage is applied to the gate electrode  318 . Current will then typically flow from the source contact  330 , through the first doped region  306 , tunnel through the second semiconductor layer  310 , through the second doped region  326  and finally to the drain contact  332 . 
     One beneficial aspect of the current disclosure over the prior art is that it allows for the proper incorporation of a self-aligned heterostructure source with a conventional CMOS process flow without incurring high leakage current and reducing parasitic conduction paths. This process can be carried out without using advanced processes such as laser or flash annealing. Also, the process allows for low-temperature processing with a pre-formed source and a dopant-segregated silicided drain. 
     Turning to  FIG. 5 , a schematic diagram of an Integrated Circuit (IC) device  502  is shown. The chip package  504  houses the transistors that are inside at position  508 . The package has interface pins  506  that allow the IC to be electrically coupled to other circuitry. The pins may be made of metal such as nickel. The blowout  508  shows a TFET  528  inside the chip package  504 . TFET  528  comprises a source contact  510 , a gate contact  512 , and a drain contact  514 . Each of these electrodes  510 ,  512 ,  514  may then be connected through wires or traces  530  with other parts of the integrated circuit  516 ,  518 ,  520 ,  522 ,  524 , and  526 . The electrodes  510 ,  512 ,  514  may also be connected to a package pin  506 . 
     The schematic flow chart diagram  400  is generally set forth as logical flow chart diagram. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagram, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown. 
     All of the methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the apparatus and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. In addition, modifications may be made to the disclosed apparatus and components may be eliminated or substituted for the components described herein where the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention as defined by the appended claims.