Abstract:
This invention provides methods of forming a field-effect transistor in an integrated circuit using self-aligning technology on the basis of a sidewall spacer masking procedure, both for defining the device isolation features and the source and drain regions. The active region is defined after patterning the gate electrode by means of deposition and etch processes instead of overlay alignment technique. Thus, the present invention enables an increase of the integration density of semiconductor devices, a minimization of the parasitic capacitances in field-effect transistor devices, and a quicker manufacturing process.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to a method of producing a semiconductor device using sidewall spacers to obtain alignment of overlying device features. The present invention in particular relates to a method of producing a field-effect transistor using sidewall spacers on a semiconductor substrate for adjusting the position of an active region with respect to a gate electrode without realigning steps during the production process.  
           [0003]    2. Description of the Related Art  
           [0004]    The manufacturing process of integrated circuits involves the fabrication of numerous insulated gate field-effect transistors, such as metal-oxide semiconductor field-effect transistors (MOSFETs). In order to increase integration density and improve device performance, for instance, with respect to signal processing time and power consumption, feature sizes of the transistor structures are steadily decreasing. Most importantly, not only the gate length but also the length of the active region of the fabricated transistors needs to be reduced to comply with these requirements in order to reduce parasitic source and drain capacitances.  
           [0005]    Conventionally, device features are defined and delineated by lithographic techniques, in particular photolithography, preferably using a high numerical aperture lens and a deep ultraviolet (DUV) light source. Current DUV lithography reaches its resolution limit at a feature size of approximately 0.2 μm. Together with emerging gate length trim techniques, it is possible to reach device features in the sub-100 nm region. Such feature definition by lithography requires a plurality of process steps, each usually involving a resist mask technique. Overlay alignment of subsequent resist masks using special alignment features on the semiconductor substrate requires exact positioning of a mechanical stage supporting the substrate. Desirably, the overlay accuracy is considerably higher than the smallest feature size, preferably, at least one order of magnitude.  
           [0006]    However, mechanical alignment of the various resist mask layers necessary for production of a field-effect transistor (FET) structure having a gate length of approximately 0.1 μm is very difficult to achieve due to the mechanical nature of the overlay alignment process.  
           [0007]    To comply with the general requirements of mass production of semiconductor devices, any new technology must conserve the current standards of efficiency, reliability, and cost of already existing methods or provide improvements in this respect.  
           [0008]    As mentioned above, the formation of the active region relative to the gate electrode is a critical step in the manufacturing process of a field-effect transistor. The gate length dimension, i.e., the lateral extension of the gate electrode between the source region and drain region of the field-effect transistor, is commonly known as critical dimension of the gate. This critical dimension is desirably reduced to sizes approaching or even exceeding the resolution limit of the optical imaging systems used for patterning the device features. In a field-effect transistor such as a MOSFET, the gate is used to control an underlying channel formed in the semiconductor substrate between source region and drain region. Channel, source region, and drain region are formed in, on, or over a semiconductor substrate which is doped inversely to the drain and source regions. The gate electrode is separated from the channel, the source region, and the drain region, by a thin insulating layer, generally by an oxide layer. Additionally, device insulation features are necessary to ensure electrical isolation between neighboring field-effect transistors in integrated circuits.  
           [0009]    During operation of such a MOSFET, a voltage is supplied to the gate electrode in order to create an electric field between the gate electrode and the source and drain regions affecting conductivity in the channel region of the substrate. Besides the desired transistor current control function, the gate electrode, the gate insulation layer, and the regions underlying the gate insulation layer, also act as a capacitor generating a parasitic capacitance. The amount of this parasitic capacitance depends on the feature size of the gate electrode. Most commonly in integrated circuit applications, the transistors are operated in a switching mode with clock frequencies currently as high as 400 to 500 MHz. In this operation mode, the gate capacitor has to be continuously charged and discharged, which significantly affects signal performance and power consumption of the device.  
           [0010]    Moreover, the electric field between the source region and the drain region generates an additional parasitic capacitance. The amount of this additional parasitic capacitance depends on the sizes of the source region and of the drain region. This additional parasitic capacitance also significantly affects signal performance and power consumption of the semiconductor device. Decreasing sizes of the source region and of the drain region will reduce the additional parasitic capacitance. Decreasing source and drain regions, however, require difficult aligning steps during the photolithography for patterning the gate electrode, and, thus, lead to a deterioration of device characteristics due to an unavoidable misalignment of the gate electrode with respect to the source and drain regions because of the mechanical nature of the alignment step.  
           [0011]    Due to the limitations of standard photolithography including mechanical alignment used to pattern and position the gate electrode within the active transistor region in which the drain and source have to be formed, advanced techniques for trimming the gate electrode will neither be translated into a decreasing size of the active region and, thus, into reduced source and drain regions, nor into reduced source and drain capacitances nor into an increased circuit-density.  
           [0012]    As the dimensions of the transistor significantly influence its electrical characteristics, when decreasing device dimensions it is important to provide a method of reliably and reproducibly forming and positioning device features and device insulation features in order to minimize variations in the electrical characteristics of integrated circuits.  
           [0013]    With reference to FIGS. 1 a - 1   c , an illustrative example of forming a field-effect transistor according to a typical prior art process will be described. It is to be noted that FIGS. 1 a - 1   c , as well as the following drawings in this application, are merely schematic depictions of the various stages in manufacturing the illustrative device under consideration. The skilled person will readily appreciate that the dimensions shown in the figures are not true to scale and that different portions or layers are not separated by sharp boundaries as portrayed in the drawings but may instead comprise continuous transitions. Furthermore, various process steps as described below may be performed differently depending on particular design requirements. Moreover, in this description, only the relevant steps and portions of the device necessary for the understanding of the present invention are considered.  
           [0014]    [0014]FIG. 1 a  shows a schematic cross-section of a field-effect transistor at a specific stage of a typical prior art manufacturing process. Within a silicon substrate  1 , shallow trenches  2 , e.g., made of silicon dioxide, are formed and define a transistor active region  3  in which a channel, a drain region and a source region will be formed. A gate insulation layer  4  is formed above the substrate  1 . The gate insulation layer  4  may be formed by a variety of techniques, e.g., thermal growth, chemical vapor deposition (CVD), etc., and it may be comprised of a variety of materials, e.g., an oxide, an oxynitride, silicon dioxide, etc.  
           [0015]    [0015]FIG. 1 b  shows a schematic cross-section of the field-effect transistor of FIG. 1 a  after formation of a layer of gate electrode material  5  above the gate insulation layer  4 . The layer of gate electrode material  5  may be formed from a variety of materials, e.g., polysilicon, a metal, etc., and it may be formed by a variety of techniques, e.g., CVD, low pressure chemical vapor deposition (LPCVD), sputter deposition, etc. Over the layer of gate electrode material  5 , a resist feature  6  is formed. The process steps involved in patterning a layer of resist (not shown) for producing the resist feature  6  are of common knowledge to the skilled person. These steps include the formation of the layer of resist by a spin-coating process, and the employment of short exposure wavelengths, such as wavelengths in the DUV range, while performing the required photolithography steps. Since these procedures are commonly known, the description thereof will be omitted.  
           [0016]    [0016]FIG. 1 c  shows a schematic cross-section of the field-effect transistor of FIG. 1 b  after conventional etching of the layer of gate electrode material  5  and after removing all remaining parts of resist feature  6 . As a result of these process steps, a gate electrode  7  is obtained. Lightly doped drain (LDD) regions  10  are then formed in the active region  3  by a shallow ion implantation with a low dose before the formation of sidewall spacers  8 . Next, the sidewall spacers  8  are formed adjacent the gate electrode  7 . Thereafter, source and drain regions  9  are formed by a deep ion implantation with a high dose. The implanted ions are electrically activated by rapid thermal annealing (RTA). In order to form the sidewall spacers  8  adjacent to the gate electrode  7 , silicon dioxide (SiO 2 ) was blanket deposited and subsequently anisotropically etched. According to the conventional fabrication process as described above, drain and source regions  9  are limited by lightly doped drain and source regions  10 , which connect to a channel  11 . The transverse dimension of the gate electrode  7  defines a critical dimension  12 , and the transverse dimension of the active region  3  defines a length dimension  13 .  
           [0017]    Since the source and drain regions  9  are defined by overlay alignment, i.e., mechanical alignment, in the various lithographic steps while forming the gate electrode, it is extremely difficult to decrease the length dimension  13  due to the mechanical nature of the alignment procedure. Therefore, advanced techniques for a desired down-sizing of the gate electrode  7  will not necessarily allow a corresponding scaling of the drain and source regions, and, thus, may not be translated into an increased circuit density or into reduced source and drain capacitances.  
           [0018]    In view of the above-mentioned problems, a need exists for an improved method for forming the source region, the drain region, and the gate electrode of field-effect transistors on semiconductor substrates and to precisely align the gate electrode within the active region.  
         SUMMARY OF THE INVENTION  
         [0019]    The present invention provides methods of forming a field-effect transistor in an integrated circuit using self-aligning technology on the basis of a gate electrode and sidewall spacer masking procedure both for forming the device isolation features and the source and drain regions.  
           [0020]    According to a first embodiment of the invention there is provided a method of forming a field-effect transistor in an integrated circuit comprising the steps of providing a semiconductor substrate having a surface, forming a gate electrode over the surface, the gate electrode having a gate width and sidewalls along its width direction, forming first sidewall spacers having a first lateral extension along the sidewalls of the gate electrode, removing portions of the semiconductor substrate adjacent the first sidewall spacers, using the first sidewall spacers as a masking material for defining trenches and an active region, and forming device insulation features at the trenches.  
           [0021]    According to a second embodiment of the invention there is provided a method of forming a field-effect transistor in an integrated circuit comprising the steps of providing a semiconductor substrate having a surface, forming a thin insulating layer over the surface, forming a gate electrode over the thin insulating layer, the gate electrode having a gate length direction and sidewalls along a gate width direction, forming a gate cover layer over the gate electrode and first sidewall spacers along the sidewalls of the gate electrode, the first sidewall spacers having a first lateral extension, masking and etching the gate cover layer and the first sidewall spacers so as to remove the first sidewall spacers along the gate length direction while maintaining the first sidewall spacers along the gate width direction, removing material of the semiconductor substrate adjacent the first sidewall spacers and the gate electrode, using the first sidewall spacers and the gate cover layer as a masking material for defining trenches and an active region, growing a thin thermal oxide film in the trenches for the benefit of trench corner rounding, filling the trenches with insulating material, polishing the insulating material back until the gate cover layer is exposed, etching the insulating material isotropically back, removing the gate cover layer and the first sidewall spacers, forming second sidewall spacers along the sidewalls of the gate electrode, the second sidewall spacers having a second lateral extension which is less than the first lateral extension, and forming source and drain regions in the active region.  
           [0022]    The present invention as outlined above enables one to fabricate a transistor device having reduced device dimensions, wherein the active region, as well as device insulation features, are aligned with respect to the gate electrode without any overlay steps. With the production method provided by this invention, the active region of a field-effect transistor may be tuned to minimum desired dimensions regardless of lithographic restrictions. Consequently, a drastically increasing circuit density and decreasing parasitic capacitances can be reached.  
           [0023]    This invention will enable a significant reduction of field-effect transistor dimensions in integrated circuits and, therefore, a significant cost reduction in manufacturing in semiconductor industries can be achieved. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0024]    Further advantages and objects of the present invention will become more apparent with the following detailed description when taken with reference to the accompanying drawings in which:  
         [0025]    [0025]FIGS. 1 a - 1   c  are schematic cross-sectional views of a semiconductor substrate in different process steps during production of a field-effect transistor according to the prior art;  
         [0026]    [0026]FIG. 2 a  is a schematic cross-sectional view of a semiconductor substrate after gate electrode formation, gate cover layer formation, and sidewall spacer formation during production of a field-effect transistor according to this invention;  
         [0027]    [0027]FIG. 2 b  is a schematic top view of the semiconductor substrate after forming a mask over said gate cover layer and said sidewall spacers during production of the field-effect transistor according to this invention;  
         [0028]    [0028]FIG. 2 c  is a schematic cross-sectional view of the semiconductor substrate after active region formation and mask removal during production of the field-effect transistor according to this invention;  
         [0029]    [0029]FIG. 2 d  is a schematic cross-sectional view of the semiconductor substrate after thermal oxide layer formation during production of the field-effect transistor according to this invention;  
         [0030]    [0030]FIG. 2 e  is a schematic cross-sectional view of the semiconductor substrate after trench filling with insulating material during production of the field-effect transistor according to this invention;  
         [0031]    [0031]FIG. 2 f  is a schematic cross-sectional view of the semiconductor substrate after polishing during production of the field-effect transistor according to this invention;  
         [0032]    [0032]FIG. 2 g  is a schematic cross-sectional view of the semiconductor substrate after isotropic etching the insulating material during production of the field-effect transistor according to this invention;  
         [0033]    [0033]FIG. 2 h  is a schematic cross-sectional view of the semiconductor substrate after sidewall spacer removal and gate cover layer removal during production of the field-effect transistor according to this invention; and  
         [0034]    [0034]FIG. 2 i  is a schematic cross-sectional view of the semiconductor substrate after completion of the field-effect transistor according to this invention.  
         [0035]    While the present invention is described with reference to the embodiment as illustrated in the following detailed description as well as in the drawings, it should be understood that the following detailed description as well as the drawings are not intended to limit the present invention to the particular embodiment disclosed, but rather the described embodiment merely exemplifies the various aspects of the present invention, the scope of which is defined by the appended claims. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]    Further advantages and objects of the present invention will become more apparent with the following detailed description and the appended claims. Furthermore, it is to be noted that although the present invention is described with reference to the embodiments as illustrated in the following detailed description, it should be noted that the following detailed description is not intended to limit the present invention to the particular embodiments disclosed, but rather the described embodiment merely exemplifies the various aspects of the present invention, the scope of which is defined by the appended claims.  
         [0037]    With reference to FIGS. 2 a - 2   i , an illustrative example of forming a field-effect transistor according to one embodiment of the present invention will be described. FIG. 2 a  shows a schematic cross-section of a field-effect transistor at a specific stage of a manufacturing process according to the present invention. The structure shown in FIG. 2 a  includes a gate insulation layer  102 , comprised of, for example, silicon dioxide (SiO 2 ), formed over a semiconductor substrate  101 , comprised of Si, Ge, or the like, a gate electrode  103  having a gate length  105  and formed above the gate insulation layer  102 , a gate cover layer  104  positioned over the gate electrode  103 , and a sidewall spacer  106  formed around the sidewalls of the gate electrode  103  and the gate cover layer  104 . The sidewall spacer  106  and the gate cover layer  104  may preferably be comprised of a material such as silicon nitride (SiN) that can selectively be etched with respect to the semiconductor material of the substrate.  
         [0038]    The process steps involved in patterning a resist (not shown) for producing the gate electrode  103 , the gate cover layer  104 , and the sidewall spacers  106  are of common knowledge to the skilled person, and usually include the employment of short exposure wavelengths, such as wavelengths in the DUV range, while performing the required photolithography steps. According to the anisotropic etching necessary for formation of the sidewall spacers  106 , due to a relation of sidewall height to spacer thickness at the bottom, depending on the slope of the sidewall spacers  106 , their lateral extension can be determined by the thickness of the gate cover layer  104 . Hence, by increasing the sidewall height, substantially thicker sidewall spacers  106  can be formed, employing a standard anisotropic etch process for sidewall spacer formation, which otherwise is commonly known, so that the detailed description thereof will be omitted.  
         [0039]    [0039]FIG. 2 b  shows a schematic top view of the field-effect transistor of FIG. 2 a  after deposition of a mask  107  over the gate cover layer  104 , over the sidewall spacers  106 , and over the thin gate insulation layer  102 . The deposition of this mask  107  is made such that both end caps  108  of the gate cover layer  104 , and, therefore, both end caps of the gate electrode  103 , and all remaining parts of the sidewall spacers  106  around the end caps  108 , are exposed. All the exposed parts have to be selectively removed until the thin gate insulation layer  102  is exposed (not shown) resulting in two opposing sidewall spacers  106  in both directions of the gate length  105 .  
         [0040]    [0040]FIG. 2 c  shows a schematic cross-section of the field-effect transistor of FIG. 2 b  after conventional etching all parts of the thin gate insulation layer  102 , as well as the substrate  101 , which are not covered with the gate cover layer  104  or the sidewall spacers  106 , and thereby forming trenches  109 . These trenches  109  are needed for shallow trench isolations (STIs), as described below.  
         [0041]    [0041]FIG. 2 d  shows a schematic cross-section of the field-effect transistor of FIG. 2 c  after growing a thin thermal oxide layer  110 , which is of benefit to trench corner rounding.  
         [0042]    [0042]FIG. 2 e  shows a schematic cross-section of the field-effect transistor of FIG. 2 d  after an insulating material layer  111 , comprised of, for example, silicon dioxide (SiO 2 ), is formed over the field-effect transistor depicted in FIG. 2 d . This covering step, including overfilling, is needed for a secure filling of the trenches  109  for the shallow trench isolations (STIs) with necessary insulating material.  
         [0043]    [0043]FIG. 2 f  shows a schematic cross-section of the field-effect transistor of FIG. 2 e  after polishing said insulation layer  111  to a plane level  112 . This polishing process is executed until just a top part of the gate cover layer  104  is exposed.  
         [0044]    [0044]FIG. 2 g  shows a schematic cross-section of the field-effect transistor of FIG. 2 f  after isotropically etching the insulation layer  111 . This etching process results in completed shallow trench isolations (STIs)  113  with a top surface  114  that is located above the gate insulation layer  102  for the benefit of a reduced probability of shorts to the drain and source regions to be formed. Such shorts may occur due to the relatively small overlap of the end caps  108  with the shallow trench isolations  113 . Preferably, the top surface  114  is located above the gate insulation by at least an amount that ensures compensation for oxide consumption of the shallow trench isolation  113  during subsequent process steps.  
         [0045]    [0045]FIG. 2 h  shows a schematic cross-section of the field-effect transistor of FIG. 2 g  after removing the gate cover layer  104  and the sidewall spacers  106 . The shallow trench isolations (STIs)  113  define an active region  115  with a length dimension  116  in the substrate  101 . The length dimension  116  is defined by the length dimension  105  of the gate electrode and the bottom thickness of the sidewall spacers  106 . That is, both the length and the location of the active region are determined by well-controllable deposition and etching processes without the necessity of any additional (mechanical) aligning steps. This will hereinafter also be referred to as self-aligned. Moreover, since the length and the location of the active region with respect to the gate electrode are related to the gate length, a down-scaling of the gate length may also be translated in a corresponding down-scaling of the active region. Furthermore, for a given gate length, the length dimension of the active region may be controlled by adjusting the thickness of the sidewall spacers so that a length of the drain and source regions may be controlled in accordance to design requirements irrespective from the channel length (gate length).  
         [0046]    Finally, FIG. 2 i  shows a schematic cross-section of the field-effect transistor of FIG. 2 h  after conventional device processing is performed to complete the field-effect transistor. Lightly doped drain (LDD) and source regions  119  were formed in the active region  115  by a shallow ion implantation with a low dose. The implanted ions are diffused by rapid thermal annealing (RTA) so as to partially extend in the area below the thin gate oxide layer  102 . Silicon dioxide (SiO 2 ), or other similar material, was blanket deposited and subsequently anisotropically etched in order to form sidewall spacers  117  adjacent to the gate electrode  103  and to the lightly doped drain and source regions  119 . Thereafter, source and drain regions  118  are completed by a deep ion implantation with a high dose. The source and drain regions  118  are limited by the lightly doped drain and source regions  119 , which connect to a channel  120 .  
         [0047]    After the formation of the gate electrode  103 , the gate insulation layer  102 , the active region  115 , and the shallow trench isolations (STIs)  113 , manufacturing of the field-effect transistor is continued by commonly known standard techniques. Since these techniques are known to the skilled person, the production steps for these standard techniques are not described in this description.  
         [0048]    The present invention provides a method of forming a field-effect transistor in an integrated circuit, wherein the source region and the drain region are self-aligned with respect to the gate electrode, i.e., the gate electrode is substantially centrally positioned within the active region without the need of a separate aligning step. Additionally, the transistor length, particularly the source length and the drain length, can be reduced, regardless of the critical dimension of the gate electrode. Hence, the source and drain lengths may be optimized in conformity with design requirements so as to significantly reduce the parasitic capacitances as well as the circuit-density. Therefore, the overall product performance is improved and the production costs are reduced.  
         [0049]    Due to the self-alignment technique of the shallow trench isolations (STIs)  113  and of the active region  115  relative to the gate electrode  103  as described above, the length dimension  116  of the active region  115  may be tuned to minimum desired dimensions without lithographic processing and therefore without lithographic restrictions. Thus, the production of field-effect transistors according to the present invention requires less masks as compared to conventional processing for the benefit lower production cost.  
         [0050]    According to a modification of the above-described embodiment of the present invention, the first sidewall spacers  106  are formed without the gate cover layer  104  over the gate electrode  103 . In order to achieve sidewall spacers  106  of sufficient bottom thickness for defining the active region  115 , the process for depositing the spacer material and/or the anisotropic etch process for forming the sidewall spacers  106  is accordingly adjusted to lead to spacer flanks of a shallower slope so as to achieve a greater thickness to height ratio of the sidewall spacers  106 . Since anisotropic etching and depositing of material layers are well-controllable within a range of few nm to several μm, any desired bottom thickness is adjustable so that corresponding drain and source lengths may be manufactured.  
         [0051]    According to another modification of the above-described embodiment of the present invention, the sidewall spacers  106  are not removed after the formation of the active region  115 . In this case, the sidewall spacers  106  are trimmed, e.g., by an etch process, yielding sidewall spacers  117  having a shorter lateral extension than the sidewall spacers  106 . Afterwards, the lightly doped drain and source regions  119  will be formed in the active region  115  under said sidewall spacers  117  by diffusion of ions or by oblique ion implantation with a low dose. Thereafter, source and drain regions  118  are formed by a deep ion implantation with a high dose. The remaining production steps according to the above-mentioned embodiment describing the drawings remain the same.  
         [0052]    The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.