Abstract:
Tapered source and drain contacts for use in an epitaxial FinFET prevent short circuits and damage to parts of the FinFET during contact processing, thus improving device reliability. The inventive contacts feature tapered sidewalls and a pedestal where electrical contact is made to fins in the source and drain regions. The pedestal also provides greater contact area to the fins, which are augmented by extensions. Raised isolation regions define a valley around the fins. During source/drain contact formation, the valley is lined with a conformal barrier that also covers the fins themselves. The barrier protects underlying local oxide and adjacent isolation regions against gouging while forming the contact. The valley is filled with an amorphous silicon layer that protects the epitaxial fin material from damage during contact formation. A simple tapered structure is used for the gate contact.

Description:
BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    The present disclosure generally relates to FinFETs and, in particular, to lowering contact resistance in a FinFET, while reducing the probability of short circuits between adjacent contacts. 
         [0003]    2. Description of the Related Art 
         [0004]    Forming electrical contacts to the terminals of integrated circuit transistors becomes more challenging as the transistors become smaller and more complex. Nanoscale transistor designs such as fin field effect transistors (FinFETs) pose new challenges to circuit designers in positioning adjacent structures that are prone to developing short circuits. Because they tend to be intermittent, short circuits are more likely to cause reliability failures rather than functional test failures. Structures prone to developing short circuits include corners of metal interconnect lines and electrical contacts that are in close proximity to one another, especially when transistor dimensions are at or below 20 nm. To prevent short circuits between contacts, metal lines can be angled or corners can be rounded, for example. Alternatively, short circuit prevention can be provided for some structures by making changes in the fabrication process for conducting features. 
         [0005]    Controlling contact resistance poses another challenge to designers of nanoscale circuits. As the contact area shrinks, the associated contact resistance increases according to the relationship R=ρ c I/A, wherein A is the contact surface area at the point of contact through which current flows, I is the height of the contact in the direction of current flow, and ρ c  is the resistivity of the contact metal. Increases in contact resistance significantly degrade overall device performance. Thus, it is important to address and compensate for the increased contact resistance that occurs with each new technology generation by making changes in the transistor design, the contact design, or the transistor fabrication process. 
       BRIEF SUMMARY 
       [0006]    Tapered source and drain contacts for use in epitaxial transistors can reduce short circuits and prevent damage to neighboring regions during contact processing, thus improving device reliability. A high-reliability contact for use in nanoscale transistor designs features tapered sidewalls that spread out at the base of the contact to form an enlarged pedestal where electrical contact is made to fins in the source and drain regions. The pedestal provides greater contact area at the fins, thus reducing contact resistance. Raised isolation regions form a valley around the fins. 
         [0007]    During source/drain contact formation, the bottom and sides of the valley, and the fins themselves, are lined with a conformal silicon nitride barrier. Then, the valley is filled with an amorphous silicon layer. The silicon nitride barrier protects underlying local oxide and adjacent isolation regions against gouging while forming the contact. The amorphous silicon layer protects the epitaxial fin material from damage during contact formation. A simple tapered structure is used for the gate contact. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0008]    In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. 
           [0009]      FIG. 1  is a top plan view of an existing layout of electrical contacts for a FinFET, according to the prior art. 
           [0010]      FIG. 2  is a flow diagram summarizing a processing sequence for fabricating a FinFET with high-reliability, low-resistance contacts, according to one exemplary embodiment described herein. 
           [0011]      FIGS. 3A-6C  illustrate a process for forming an inventive semiconductor FinFET device having high-reliability, low-resistance contacts, according to one embodiment. 
           [0012]      FIGS. 3A-3C  show a one embodiment of a partially formed FinFET on a silicon substrate, the FinFET including fins, a dummy gate, and raised isolation regions. 
           [0013]      FIGS. 4A-4C  show one embodiment of a partially formed FinFET after carrying out a replacement metal gate process and following formation of un-merged epitaxial extensions. 
           [0014]      FIGS. 5A-5C  show one embodiment of a partially formed FinFET after forming source/drain contact openings. 
           [0015]      FIGS. 6A-6C  show one embodiment of a completed FinFET after the source/drain and gate contacts have been filled. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    In the following description, certain specific details are set forth in order to provide a thorough understanding of various aspects of the disclosed subject matter. However, the disclosed subject matter may be practiced without these specific details. In some instances, well-known structures and methods of semiconductor processing comprising embodiments of the subject matter disclosed herein have not been described in detail to avoid obscuring the descriptions of other aspects of the present disclosure. 
         [0017]    Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprise” and variations thereof, such as “comprises” and “comprising” are to be construed in an open, inclusive sense, that is, as “including, but not limited to.” 
         [0018]    Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more aspects of the present disclosure. 
         [0019]    Reference throughout the specification to integrated circuits is generally intended to include integrated circuit components built on semiconducting substrates, whether or not the components are coupled together into a circuit or able to be interconnected. Throughout the specification, the term “layer” is used in its broadest sense to include a thin film, a cap, or the like and one layer may be composed of multiple sub-layers. 
         [0020]    Reference throughout the specification to conventional thin film deposition techniques for depositing silicon nitride, silicon dioxide, metals, or similar materials include such processes as chemical vapor deposition (CVD), low-pressure chemical vapor deposition (LPCVD), metal organic chemical vapor deposition (MOCVD), plasma-enhanced chemical vapor deposition (PECVD), plasma vapor deposition (PVD), atomic layer deposition (ALD), molecular beam epitaxy (MBE), electroplating, electro-less plating, and the like. Specific embodiments are described herein with reference to examples of such processes. However, the present disclosure and the reference to certain deposition techniques should not be limited to those described. For example, in some circumstances, a description that references CVD may alternatively be done using PVD, or a description that specifies electroplating may alternatively be accomplished using electro-less plating. Furthermore, reference to conventional techniques of thin film formation may include growing a film in-situ. For example, in some embodiments, controlled growth of an oxide to a desired thickness can be achieved by exposing a silicon surface to oxygen gas or to moisture in a heated chamber. 
         [0021]    Reference throughout the specification to conventional photolithography techniques, known in the art of semiconductor fabrication for patterning various thin films, includes a spin-expose-develop process sequence typically followed by an etch process. Alternatively or additionally, photoresist can also be used to pattern a hard mask (e.g., a silicon nitride hard mask), which, in turn, can be used to pattern an underlying film. 
         [0022]    Reference throughout the specification to conventional etching techniques known in the art of semiconductor fabrication for selective removal of polysilicon, silicon nitride, silicon dioxide, metals, photoresist, polyimide, or similar materials includes such processes as wet chemical etching, reactive ion (plasma) etching (RIE), washing, wet cleaning, pre-cleaning, spray cleaning, chemical-mechanical planarization (CMP) and the like. Specific embodiments are described herein with reference to examples of such processes. However, the present disclosure and the reference to certain deposition techniques should not be limited to those described. In some instances, two such techniques may be interchangeable. For example, stripping photoresist may entail immersing a sample in a wet chemical bath or, alternatively, spraying wet chemicals directly onto the sample. 
         [0023]    Specific embodiments are described herein with reference to FinFETs that have been produced; however, the present disclosure and the reference to certain materials, dimensions, and the details and ordering of processing steps are exemplary and should not be limited to those shown. 
         [0024]    Turning now to the figures,  FIG. 1  shows a top plan view of an existing FinFET design  100  on a silicon substrate. The FinFET design  100  includes three fins  102 , a metal gate  104 , a gate contact  106 , and a source/drain contact  108 . The source/drain contact  108  forms an electrical connection to a region of epitaxial silicon that acts as a charge reservoir for the transistor. Portions of the fins  102  underlying the metal gate  104  serve as the current-carrying channels for the transistors. Portions of the fins  102  on either side of the metal gate  104  are coupled to source and drain regions underlying the source/drain contact  108 . The source/drain contact  108  bridges all of the fins  102 , and extends beyond the fins  102  to allow for some margin of error in alignment of a contact lithography mask for establishing a pattern of electrical contacts with respect to the fins  102 . Depending on the particular design layout, a gate contact corner  110  may be close enough to an adjacent source/drain contact corner  112  that there is a risk of a short circuit forming between the two contacts. For this reason the gate contact  106  is positioned as far away as possible from the fins  102 . Because the contacts are so closely spaced, the fins  102  are prone to damage during the contact etch process. 
         [0025]      FIG. 2  shows an exemplary sequence of steps in a method  120  of fabricating FinFETs having tapered source/drain contacts, according to one embodiment. The tapered source/drain contacts reduce the risk of a short circuit to the gate contact  106 . The process shown and described may make use of techniques for nanoscale fin formation, e.g., a self-aligned sidewall image transfer (SIT) process, and gate formation, e.g., a replacement metal gate process, which techniques are known and therefore are not explained herein in detail. 
         [0026]    The steps  122 - 140  for fabricating high-reliability, low-resistance FinFET contacts are described further below, with reference to  FIGS. 3A-6C . In each set of FIGS. A-C, A is a top plan view showing the FinFET gate electrode in a transverse orientation with respect to the fins; B is a cross-sectional schematic view at a cut line X-X through the gate region, along a particular fin; and C is a cross-sectional view at a cut line Y-Y through a source/drain region, across a plurality of fins, adjacent to the gate region. In accordance with convention, arrows on each cut line represent the direction of an observer&#39;s eye looking at the corresponding cut plane. 
         [0027]      FIGS. 3A-3C  show a partially formed FinFET  150  on a silicon substrate  151 , according to one embodiment. The partially formed FinFET  150  has raised isolation regions  152 , fins  154 , and a dummy gate  155 . 
         [0028]    At  122 , the raised isolation regions  152  are formed to define a valley  153  that will accommodate the FinFET  150 . The raised isolation regions  152  are made of SiO 2  and can be formed according to any suitable process known in the art of semiconductor fabrication. 
         [0029]    At  124 , the fins  154  are formed in the valley  153  by epitaxial growth extending about 40-60 nm from a surface of the silicon substrate  151 . Three elongated fins  154  are shown in the valley  153 , however more or fewer fins can be formed in the valley  153  in other embodiments. 
         [0030]    Alternatively, the fins  154  can be formed first at step  122 , and then at step  124  the valley  153  can be defined around the fins, according to another exemplary embodiment. For example, a full array of fins  154  initially can be patterned on the substrate  151  using a thin SiN hard mask. Then, spaces between the fins  154  are filled with oxide to cover the fins  154  completely, and the oxide is planarized to stop on the thin SiN hard mask. The oxide formation is then followed by formation of a thick SiN layer, in the range of about 30-40 nm. Next, the thick SiN layer is patterned using a standard photoresist mask to form a hard mask for the valley  153 . That is, the thick SiN layer is masked in the center to protect the underlying fins  154  that are to be retained, while the SiN layer is removed on either side of the valley  153 . At the same time that the SiN is removed, the extraneous fins can also be removed, along with non-active regions of the substrate  151  located outside the valley  153 , using an anisotropic, low selectivity etching process. The non-active regions outside the valley  153  are then over-filled with oxide to form the raised isolation regions  152 . The raised isolation regions  152  remain in place as the SiN protective mask overlying the valley  153  and the original thin SiN hard mask are removed together. The SiN can be removed by for example, a hot phosphoric acid wet etch that attacks SiN while leaving behind the SiO 2  raised isolation regions  152 . Finally, the oxide between the fins  154  is partially removed down to the surface of the valley  153 , revealing the retained fins  154 . The oxide removal step that reveals the fins  154  can be carried out using a isotropic etch that is highly selective to silicon, e,g, a hydrofluoric acid dip. Other embodiments in which fins are formed in a valley surrounded by isolation regions can be substituted for either one of the processing sequences described above with respect to steps  122  and  124 . 
         [0031]    At  126 , a gate electrode  155  is formed including a polysilicon gate  156 , a gate dielectric  157 , silicon nitride sidewall spacers  158 , and a silicon nitride cap  159 . The polysilicon gate  156  and the gate dielectric  157  are temporary layers that will be replaced during a subsequent step. 
         [0032]      FIGS. 4A-4C  show one embodiment of a partially formed FinFET  170  after carrying out a replacement metal gate process and following formation of un-merged epitaxial extensions. 
         [0033]    At  128 , epitaxial extensions  172  of the fins are formed in the source/drain regions by epitaxial growth outward from the fins  154 . The epitaxial extensions  172  can be made of, for example, doped silicon or silicon germanium to provide charge reservoirs for the device. The epitaxial extensions  172  have diamond-shaped profiles in the example shown, but in general, profiles of the epitaxial extensions  172  can have a variety of different shapes. For example, the epitaxial extensions  172  can be shaped like cubes, ovals, ellipsoids, prismatic shapes, shapes having a corrugated surface, or any number of acceptable shapes, and do not need to be diamond-shaped as shown in  FIG. 4C . The epitaxial extensions  172  do not merge together, but remain un-merged, or spaced apart from one another by a gap that is at least a few nm wide. In the gate region ( FIG. 4B ), epitaxial growth results in planar layers being formed on a top surface of the silicon substrate  151 . The epitaxial extension  172  serves to increase the electrical contact area to the fins by a factor of about 10-12. 
         [0034]    At  130 , a protective liner  174  is conformally deposited over the surface of the valley  153 , the epitaxial extensions  172 , and the raised isolation regions  152 . The liner  174  is made of silicon nitride (SiN), in the range of about 3-10 nm thick. In the gate region, the liner  174  conformally covers the planar layers and the gate electrode  155 . 
         [0035]    At  132 , the valley  153  is filled with amorphous silicon  176  to encapsulate the epitaxial extensions  172 . The amorphous silicon  176  is positioned so as to isolate the epitaxial extensions  172  from effects of the subsequent ILD etching process described below. The amorphous silicon  176  may not fill completely the regions between the epitaxial extensions  172 , leaving voids therein. Incomplete fill is acceptable because the amorphous silicon  176  is also a sacrificial layer. A top surface of the amorphous silicon  176  is then recessed below the liner  174  by about 10 nm. In the gate region ( FIG. 4B ) the amorphous silicon  176  forms a planar layer on top of the liner  174 . 
         [0036]    At  134 , a thick, insulating inter-layer dielectric (ILD)  180 , e.g., silicon dioxide (SiO 2 ) or a low-k ILD is formed in contact with the amorphous silicon  176  and the liner  174 . The ILD  180  is planarized, using the polysilicon gate  156  as a stop layer. During planarization, the cap  159  is removed, along with top portions of the sidewall spacers  158 . 
         [0037]    At  135 , the polysilicon gate  156  and the gate dielectric  157  are replaced by a metal gate  182  and a high-k gate dielectric  184 , respectively, according to a replacement metal gate process as is known in the art. The metal gate  182  can be made of tungsten (W), for example, or a metal stack including tungsten and a work function metal. 
         [0038]      FIGS. 5A-5C  show one embodiment of a partially formed FinFET  200  after forming source/drain contact openings  202 . Footprints of the source/drain and gate contact openings are indicated in  FIG. 6A  by dashed lines. The footprint areas are about 10-20 nm wide×50-100 nm long. 
         [0039]    At  136 , tapered contact openings  202  are formed using, for example, a two-step etch process: in a first step, a reactive ion etch (RIE) process etches the ILD  180  anisotropically, in a downward vertical direction, to form a tapered column having a top surface width  204 , a bottom surface width  206 , and sidewalls that slope inward from the top surface. The RIE for ILD removal is a high-power, mechanically harsh process that uses ion bombardment to eject chunks of the ILD  180 . In the inventive method, the RIE stops on the amorphous silicon  176  so as not to damage the epitaxial extensions  172 . The SiN liner  174  may further protect the epitaxial extensions  172  from damage during the contact etch process. 
         [0040]    The RIE can be followed by a second step that uses an isotropic etchant, e.g., a wet chemical etchant, to more gently remove the amorphous silicon. Thus is formed an enlarged pedestal opening  218  at the bottom of the tapered column, the enlarged pedestal opening  218  having a width that is wider than the top surface width  204 . The isotropic etchant attacks the amorphous silicon  176 , selective to the SiN liner  174  and the silicon nitride sidewall spacers  158 . In the gate region ( FIG. 5B ) the planar layer of amorphous silicon is removed, undercutting the ILD  180 . 
         [0041]    The electrical contact area provided by the epitaxial extensions  172  is about 10-15 times greater than the surface area of the fins without the extensions. The enlarged pedestal opening  218  will allow the electrical contact to access this larger surface area while maintaining a small footprint,  206 , on the contact mask. 
         [0042]      FIGS. 6A-6C  show one embodiment of a completed FinFET  230  after the source/drain and gate contacts have been filled. 
         [0043]    At  138 , the liner  174  is removed, for example, using a wet chemical etchant such as hot phosphoric acid that attacks SiN selective to both silicon and oxide. Thus, the liner  174  is gone in  FIGS. 6B and 6C , while the epitaxial extensions  172  and the ILD  180  remain intact. 
         [0044]    At  140 , the tapered source/drain contact openings  202  are filled with a contact metal to form a tapered source/drain contact structure. The contact metal can be, for example, copper, aluminum, tungsten, silver, titanium, titanium nitride, or any other metal, metal alloy, metal stack, or other combinations thereof suitable for interconnections among FinFET devices. A first layer of the contact metal can be a thin layer that reacts with the epitaxial extensions  172  to form a silicide as is known in the art. The contact metal fills the valley  153  and the contact openings  202  to form source/drain contacts  232 . A lower portion of the source/drain contacts  232  in the valley  153  forms a bottom pedestal  233 . Gate contacts  234  are formed in a similar manner, and can be tapered, and filled in the same step as the source/drain contacts  232 . The bottom pedestal  233  provides increased contact area to the epitaxial extensions  172 . But, by tapering the source/drain contacts  232  down to a depth below the gate contact  234 , the risk of creating a short circuit between the gate contact and the source/drain contact is reduced. 
         [0045]    The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments. 
         [0046]    It will be appreciated that, although specific embodiments of the present disclosure are described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the present disclosure. Accordingly, the present disclosure is not limited except as by the appended claims. 
         [0047]    These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.