Patent Publication Number: US-2022216113-A1

Title: Method for manufacturing metal oxide semiconductor transistor

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the priority benefit of Taiwan application serial no. 11010000, filed on Jan. 4, 2021. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification. 
     BACKGROUND 
     Technical Field 
     The disclosure relates to a method for manufacturing a semiconductor device, and, more particularly, to a method for manufacturing a metal oxide semiconductor transistor. 
     Description of Related Art 
     With the increase in the integration of metal oxide semiconductor (MOS) devices, it is generally necessary to follow the scale-down design rule according to the manufacturing method for an integrated circuit device to reduce the size of a circuit structure device. In the conventional process for manufacturing a metal oxide semiconductor (MOS) transistor, it is common to add a lightly doped drain (LDD) region between the channel region and each source/drain region to reduce the hot electron effect. However, the high-concentration LDD end often overlaps with the gate electrode layer after annealing and heat treatments are performed. As a result, an abnormal bias voltage may easily occur and the performance may easily deteriorate in the device. 
     Forming a compensation spacer is one of the solutions to the above issue. A conventional process to form a compensation spacer is to form a spacer material layer on the gate structure, and then an etch-back process is performed to form a compensation spacer on the sidewall of the gate structure. However, due to the over-etching in the etch-back process, the height of the spacer is lower (lower than the height of the top surface of the gate structure), while the width of the spacer is also reduced. The smaller width and insufficient height of the spacer directly affect the range of the ion implantation region. Specifically, when the height of the spacer is insufficient, the spacer cannot block ions from being implanted. As a result, ions are still implanted to the region below the spacer, which results in a shift of the ion implantation region defined in advance. 
     SUMMARY 
     The embodiments of the disclosure provide a method for manufacturing a metal oxide semiconductor capable of effectively blocking ion implantation below a spacer. 
     An embodiment of the disclosure provides a method for manufacturing a metal oxide semiconductor, including the following steps. A gate stack structure and a hardmask layer on the gate stack structure are sequentially formed on a substrate. A first spacer is formed on a sidewall of the gate stack structure and a sidewall of the hardmask layer. A photoresist layer is formed on a sidewall of the first spacer. A top surface of the photoresist layer is higher than a top surface of the gate stack structure. The hardmask layer and a portion of the first spacer are removed to expose the top surface of the gate stack structure. A top surface of the remaining first spacer is higher than the top surface of the gate stack structure surface. The photoresist layer is removed. A second spacer is formed on a sidewall of the remaining first spacer. A top surface of the second spacer is higher than the top surface of the gate stack structure. 
     In an embodiment of the disclosure, before the photoresist layer is formed, the method further includes that a first doped region is formed in the substrate. The first doped region is adjacent to the sidewall of the first spacer. 
     In an embodiment of the disclosure, the first doped region is a lightly doped drain region. 
     In an embodiment of the disclosure, a method for forming a photoresist layer may include the following steps. A photoresist material layer is formed on the substrate to cover the substrate, the first spacer, and the hardmask layer. A portion of the photoresist material layer is removed to expose a top surface of the hardmask layer and a portion of the sidewall of the first spacer, and form the photoresist layer. 
     In an embodiment of the disclosure, a material of the photoresist material layer is, for example, a carbon-based material or a polymer material. 
     In an embodiment of the disclosure, a material of the hardmask layer is, for example, silicon oxide or silicon oxynitride. 
     In an embodiment of the disclosure, a material of the first spacer is, for example, silicon oxide, silicon nitride, or silicon oxynitride. 
     In an embodiment of the disclosure, the first spacer includes a first sub-spacer and a second sub-spacer. The first spacer is formed on the sidewall of the gate stack structure, and the second sub-spacer is formed on a sidewall of the first sub-spacer. 
     In an embodiment of the disclosure, a material of the first sub-spacer is, for example, silicon oxide or silicon oxynitride. 
     In an embodiment of the disclosure, a material of the second sub-spacer is, for example, silicon nitride. 
     In an embodiment of the disclosure, forming the second spacer includes the following steps. A spacer material layer is conformally formed on the substrate, the first spacer, and the gate stack structure by performing an atomic layer deposition (ALD) process or a plasma enhanced ALD process. A portion of the spacer material layer is removed to expose the top surface of the gate stack structure. 
     In an embodiment of the disclosure, a material of the second spacer is, for example, silicon nitride. 
     In an embodiment of the disclosure, the method further includes that a second doped region is formed in the substrate. The second doped region is adjacent to a sidewall of the second spacer. 
     In an embodiment of the disclosure, the second doped region may be a source/drain region. 
     The disclosure provides a metal oxide semiconductor transistor including a substrate, a gate stack structure, a first spacer, and a second spacer. The gate stack structure is disposed on the substrate. The first spacer is disposed on a sidewall of the gate stack structure. The second spacer is disposed on a sidewall of the first spacer. A top surface of the second spacer is higher than a top surface of the gate stack structure. 
     In an embodiment of the disclosure, a top surface of the first spacer is higher than the top surface of the gate stack structure. 
     In an embodiment of the disclosure, the metal oxide semiconductor transistor further includes a first doped region disposed in the substrate and laterally adjacent to the sidewall of the first spacer. 
     In an embodiment of the disclosure, the metal oxide semiconductor transistor further includes a second doped region disposed in the substrate and laterally adjacent to a sidewall of the second spacer. 
     In an embodiment of the disclosure, a material of the first spacer is, for example, silicon oxide, silicon nitride, or silicon oxynitride. 
     In an embodiment of the disclosure, a material of the second spacer is, for example, silicon nitride. 
     Based on the above, in the metal oxide semiconductor transistor and the manufacturing method thereof according to the embodiments of the disclosure, by controlling the top surface of the photoresist layer to be higher than the top surface of the gate electrode layer, the height of the second spacer formed subsequently may be higher than the top surface of the gate electrode layer. Thus, the second spacer with a sufficient height may effectively block ions from being implanted into the substrate below the second spacer. Therefore, a process window shift occurring in the conventional ion implantation process due to an insufficient height of the spacer may be avoided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A to 1G  are schematic cross-sectional views of a manufacturing process of a metal oxide semiconductor transistor according to an embodiment of the disclosure. 
         FIG. 2  is a cross-sectional view of the metal oxide semiconductor transistor of  FIG. 1F  observed by using a transmission electron microscope (TEM). 
         FIG. 3A  is a cross-sectional view of a metal oxide semiconductor transistor having a compensation spacer according to the embodiment observed by using a TEM. 
         FIG. 3B  is a cross-sectional view of a metal oxide semiconductor transistor having a compensation spacer manufactured according to a conventional manufacturing process observed by using a TEM. 
     
    
    
     DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS 
     The following disclosure provides many different embodiments or examples for implementing different features of the provided subject matter. The specific examples of the elements and configuration described below are for the purpose of conveying the disclosure in a simplified manner. Of course, these are just examples and not configured to limit the disclosure. For example, in the following description, forming a second feature above a first feature or on a first feature may include an embodiment in which the second feature and the first feature are formed in direct contact, and may also include an embodiment in which an additional feature may be formed between the second feature and the first feature such that the second feature and the first feature may not be in direct contact. In addition, the same reference numerals and/or letters may refer to the same or similar parts in various embodiments of the disclosure. The repetition of the reference numerals is for simplicity and clarity, and does not denote the relationship between the various embodiments and/or configuration to be discussed. 
     In addition, in order to easily describe the relationship between one element or feature and another element or feature shown in the drawings, spatial relative terms such as “under”, “below”, “lower part”, “on”, “above”, “upper part”, and similar terms may be used in the present specification. In addition to the orientations depicted in the drawings, the spatial relative terms are intended to cover different orientations of elements in use or operation. The device may be otherwise oriented (rotated by 90 degrees or in other orientations), and the spatial relative terms used herein are interpreted accordingly. 
       FIGS. 1A to 1G  are schematic cross-sectional views of a manufacturing process of a metal oxide semiconductor transistor according to an embodiment of the disclosure. 
     Referring to  FIG. 1A , a gate stack structure  110  and a hardmask layer  118  on the gate stack structure  110  are sequentially formed on a substrate  100 . The substrate  100  may be, for example, a semiconductor substrate, a semiconductor compound substrate, or a semiconductor over insulator (SOI) substrate, but the disclosure is not limited thereto. In  FIG. 1A , one gate stack structure  110  is illustrated, but the number of the gate stack structures  110  is merely an example for an illustrative purpose and the structure of the disclosure is not limited thereto. In an embodiment, the gate stack structure  110  may include a polysilicon gate structure or an alternative metal gate structure. In an embodiment, the gate stack structure  110  includes a gate dielectric layer  114  and a gate electrode layer  116  on the gate dielectric layer  114 . In an embodiment, a material of the gate dielectric layer  114  is, for example, silicon oxide, silicon oxynitride, silicon nitride, or a combination thereof. In an embodiment, a material of the gate dielectric layer  114  is, for example, a high-k dielectric material. In an embodiment, a material of the gate electrode layer  116  includes, for example, doped or undoped polysilicon or a metal-containing conductive material. In an embodiment, the metal-containing conductive material is, for example, aluminum (Al), copper (Cu), tungsten (W), cobalt (CO), titanium (Ti), tantalum (Ta), ruthenium (Ru), TiN, TiAl , TiAlN, TaN, TaC, NiSi, CoSi, or a combination thereof. In an embodiment, a material of the hardmask layer  118  includes , for example, silicon oxide or silicon oxynitride. 
     In an embodiment, the gate stack structure  110  and the hardmask layer  118  are formed through the following steps. A gate dielectric material layer (not shown), a gate electrode material layer (not shown), and a hardmask material layer (not shown) are sequentially formed on the substrate  100 . Next, the hardmask material layer, the gate electrode material layer, and the gate dielectric material layer are patterned to form the gate dielectric layer  114 , the gate electrode layer  116 , and the hardmask layer  118 . A process for forming the gate dielectric material layer includes, for example, thermal oxidation. A process for forming the gate electrode material layer includes, for example, chemical vapor deposition or physical vapor deposition. A process for forming the hardmask material layer includes, for example, chemical vapor deposition or physical vapor deposition. 
     Referring to  FIG. 1B , a first spacer  120  is formed on a sidewall of the gate stack structure  110  and a sidewall of the hardmask layer  118 . In an embodiment, the first spacer  120  may be a single-layer structure. A material of the first spacer  120  includes, for example, silicon oxide, silicon nitride, or silicon oxynitride. A process for forming the first spacer  120  includes, for example, forming a conformal spacer material layer (not shown) on the substrate  100 , and then removing a portion of the spacer material layer by performing anisotropic etching to form the first spacer  120  on the sidewall of the gate stack structure  110  and the sidewall of the hardmask layer  118 . 
     In an embodiment, the first spacer  120  may be a multilayer structure. The first spacer  120  may include a first sub-spacer  124  and a second sub-spacer  128 . The first sub-spacer  124  is formed on the opposite sidewalls of the gate stack structure  110  and the hardmask layer  118 , and the second sub-spacer  128  is formed on sidewalls of the first sub-spacer  124 . In an embodiment, a material of the first sub-spacer  124  includes, for example, silicon oxide or silicon oxynitride. A material of the second sub-spacer  128  includes, for example, silicon nitride. In an embodiment, a conformal oxide layer (not shown) may be first formed on the substrate  100 , and then a portion of the oxide layer may be removed by performing anisotropic etching to form the first sub-spacer  124  on the sidewalls of the gate stack structure  110  and the hardmask layer  118 . Next, a process for forming the second sub-spacer  128  includes, for example, forming a conformal nitride layer (not shown) on the substrate  100 , and then removing a portion of the nitride layer by performing anisotropic etching to form the second sub-spacer  128  on the sidewall of the first sub-spacer  124 . In an embodiment, the material of the first sub-spacer  124  and the material of the second sub-spacer  128  are different. In an embodiment, a thickness of the first sub-spacer  124  is less than a thickness of the second sub-spacer  128 , and the first sub-spacer  124  may be used as a liner. The first sub-spacer  124  may be configured to improve the adhesion and the stress, etc., between the second sub-spacer  128  and the gate stack structure  110 . 
     Continuing to refer to  FIG. 1B , a first doped region  126  is selectively formed in the substrate  100 . Specifically, the first doped region  126  is formed in the substrate  100  exposed on two sides of the gate stack structure  110 . A process for forming the first doped region  126  includes, for example, performing an ion implantation process by using the gate stack structure  110 , the hardmask layer  118 , and the first spacer  120  as a mask, so that the first doped region  126  is laterally formed in the substrate  100  adjacent to a sidewall of the first spacer  120 . An edge of the first doped region  126  is substantially aligned with the sidewall of the first spacer  120 . In an embodiment, the first doped region  126  is a lightly doped drain (LDD) region. 
     Referring to  FIG. 1C , a photoresist material layer  113  is formed on the substrate  100  to cover the substrate  100 , the first spacer  120 , and the hardmask layer  118 . In an embodiment, a material of the photoresist material layer  113  includes, for example, a carbon-based material or a polymer material. 
     Referring to  FIG. 1D , a portion of the photoresist material layer  113  is removed to expose a top surface of the hardmask layer  118  and form a photoresist layer  113   a  on the sidewall of the first spacer  120 . In an embodiment, after the portion of the photoresist material layer  113  is removed, a portion of the sidewall of the first spacer  120  is also exposed. In the embodiment, the remaining photoresist material layer  113  after being etched serves as the photoresist layer  113   a.  In an embodiment, a top surface of the photoresist layer  113   a  is higher than a top surface of the gate electrode layer  116  of the gate stack structure  110 . In the embodiment, a process for removing a portion of the photoresist material layer  113  includes, for example, an etch-back process. In an embodiment, an etching temperature is, for example, between 20° C. and 250° C. In an embodiment, CF 4 , O 2 , or a combination thereof may be used as the etching gas. A flow rate of CF 4  is, for example, between 5 sccm and 100 sccm, and a flow rate of O 2  is, for example, between 50 seem to 300 seem. In an embodiment, the photoresist material layer  113  is dry-etched by choosing a low temperature and a low flow rate. By doing so, the etching rate of the photoresist material layer may be effectively controlled. Specifically, a remaining height of the photoresist material layer may be controlled by adjusting the etching time, so that a top surface of the photoresist layer  113   a  formed accordingly is higher than a top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ). In this step, by controlling a distance d in which the top surface of the photoresist layer  113   a  is higher than the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ), a height of a second spacer  132   a  formed subsequently (see  FIG. 1G ) may be higher than the top surface of the gate electrode layer  116 . 
     Referring to  FIG. 1E , the hardmask layer  118  and a portion of the first spacer  120  are removed to expose the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ). In an embodiment, a process for removing the hardmask layer  118  and the portion of the first spacer  120  includes, for example, dry etching. In an embodiment, the hardmask layer  118  and the first spacer  120  are etched by using an etching gas or etchant having a higher etching selectivity for the hardmask layer  118  and the first spacer  120  than an etching selectivity for the photoresist layer  113   a.  In an embodiment, during the process of etching the hardmask layer  118  and the first spacer  120 , a portion of the photoresist layer  113   a  is also etched at the same time. After the first spacer  120  is etched, the remaining first spacer  120  forms a first spacer  120   a.  Since the top surface of the photoresist layer  113   a  is higher than the top surface of the gate electrode layer  116  before the hardmask layer  118  is removed, and the etching gas or etchant used in the embodiment has a higher etching selectivity for the hard mask layer  118  and the first spacer  120  than the etching selectivity for the photoresist layer  113   a,  the closer to the photoresist layer  113   a,  the slower the etching. Therefore, after the hardmask layer  118  is removed, the top surface of the photoresist layer  113   a  and a top surface of the first spacer  120   a  are higher than the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ). 
     In an embodiment, an end portion E 1  of the photoresist layer  113   a  and an end portion E 2  of the first spacer  120   a  are convex relative to an end portion E 3  of the gate electrode layer  116 . In an embodiment, the end portion E 1  of the photoresist layer  113   a  is convex relative to the end portion E 2  of the first spacer  120   a,  and the end portion E 2  of the first spacer  120   a  is convex relative to the end portion E 3  of the gate electrode layer  116 . In an embodiment, the end portion E 2  of the first spacer  120   a  has a substantially flat surface. In an embodiment, the end portion E 2  of the first spacer  120   a  has an inclined surface. Specifically, both the first sub-spacer  124  and the second sub-spacer  128  have inclined surfaces, and a top surface of the second sub-spacer  128  is higher than a top surface of the first sub-spacer  124 . More specifically, the first spacer  120   a  has a surface inclined toward the gate electrode layer  116  from a point in contact with the photoresist layer  113   a.    
     Referring to  FIG. 1F , the photoresist layer  113   a  is removed. A process for removing the photoresist layer  113   a  includes, for example, an ashing process. After the photoresist layer  113   a  is removed, the top surface of the first spacer  120   a  remains higher than the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ). Specifically, after the photoresist layer  113   a  is removed, the end portion E 2  of the first spacer  120   a  is still convex relative to the end portion E 3  of the gate electrode layer  116 .  FIG. 2  is a cross-sectional view of the metal oxide semiconductor transistor in  FIG. 1F  observed by using a transmission electron microscope (TEM). It can be seen from  FIG. 2  that the top surface of the first spacer  120   a  is higher than the top surface of the gate electrode layer  116 . 
     Next, continuing to refer to  FIG. 1F , a spacer material layer  132  is formed on the substrate  100 . The spacer material layer  132  is substantially conformally formed on the substrate  100 , the first spacer  120   a,  and the gate stack structure  110 . A process for forming the spacer material layer  132  includes, for example, atomic layer deposition (ALD) or plasma-enhanced ALD (PEALD). In an embodiment, a material of the spacer material layer  132  includes, for example, silicon nitride. 
     Since the top surface of the first spacer  120   a  is higher than the top surface of the gate stack structure  110  (i.e., the end portion E 2  of the first spacer  120   a  is convex relative to the end portion E 3  of the gate electrode layer  116 ), a height of the spacer material layer  132  in the region of the first spacer  120   a  is greater than a height of the spacer material layer  132  in the region of the gate electrode layer  116 . In an embodiment, the spacer material layer  132  forms a fang structure  134  at the top near the two ends of the first spacer  120   a.    
     Referring to  FIG. 1G , a portion of the spacer material layer  132  is removed to expose the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ) and form a second spacer  132   a  on a sidewall of the first spacer  120   a.  A process for removing the spacer material layer  132  includes, for example, dry etching. In the embodiment, a top surface of the second spacer  132   a  and the top surface of the first spacer  120   a  are higher than the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ). More specifically, a height from the top surface of the second spacer  132   a  to the substrate  100  and a height from the top surface of the first spacer  120   a  to the substrate  100  are greater than a height from the top surface of the gate stack structure  110  to the substrate  100 . 
     Next, continuing to refer to  FIG. 1G , a second doped region  136  is formed in the substrate  100 . Specifically, the second doped region  136  is formed in the substrate  100  on both sides of the gate stack structure  110  and the second spacer  132   a.  A process for forming the second doped area  136  includes, for example, performing an ion implantation process by using the gate stack structure  110 , the first spacer  120   a,  and the second spacer  132   a  as a mask, so that the second doped region  136  is laterally formed in the substrate  100  adjacent to a sidewall of the second spacer  132   a.  An edge of the second doped region  136  is substantially aligned with the sidewall of the second spacer  132   a.  In an embodiment, the ion implantation process is, for example, a heavy doping process. In an embodiment, the second doped region  136  is a source/drain region. So far, the manufacture of the metal oxide semiconductor transistor of the disclosure is completed. 
       FIG. 3A  is a cross-sectional view of a metal oxide semiconductor transistor having a compensation spacer according to the embodiment observed by using a TEM.  FIG. 3B  is a cross-sectional view of a metal oxide semiconductor transistor having a compensation spacer manufactured according to a conventional manufacturing process observed by using a TEM. 
     The metal oxide semiconductor transistor in  FIG. 3A  is a metal oxide semiconductor transistor with a compensation spacer manufactured according to the manufacturing process of the embodiment (as in  FIGS. 1A to 1G ).  FIG. 3B  is a metal oxide semiconductor transistor with a compensation spacer manufactured by using a conventional manufacturing process. 
     Specifically, in the conventional manufacturing process, since the photoresist material layer of the embodiment is not formed before the second spacer (i.e., the compensation spacer) is formed, during the subsequent etch-back process of the spacer material layer, a height of the second spacer layer  132   a  is lower than the top surface of the gate electrode layer  116  due to over-etching. However, the height of the second spacer layer  132   a  of the embodiment (see  FIG. 3A ) is higher than the top surface of the gate electrode layer  116 . 
     In the conventional process of forming a doped region, due to the insufficient height of the spacer (as in  3 B, equal to or even lower than the height of a gate), a dopant is still implanted in the substrate below the spacer, which serves as a mask, during the ion implantation process. As a result, a process window shift occurs. However, in the embodiment (as in  3 A), by forming a spacer higher than the gate on a sidewall of the gate, a sufficiently high spacer may effectively block ions from being implanted into the substrate below the spacer. Thus, a metal oxide semiconductor transistor with favorable electrical performance may be manufactured. 
     Hereinafter, a structure of the metal oxide semiconductor transistor according to an embodiment of the disclosure will be described with reference to  FIG. 1G . In addition, although the method for manufacturing the metal oxide semiconductor transistor of the embodiment is described by taking the above method as an example, the method for forming the metal oxide semiconductor transistor of the disclosure is not limited thereto. 
     Referring to  FIG. 1G , the metal oxide semiconductor transistor includes the substrate  100 , the gate stack structure  110 , the first spacer  120   a,  the second spacer  132   a,  the first doped region  126 , and the second doped region  136 . The gate stack structure  110  is disposed on the substrate  100 . The gate stack structure  110  includes the gate dielectric layer  114  and the gate electrode layer  116  on the gate dielectric  114 . The first spacer  120   a  is disposed on the sidewall of the gate stack structure  110 . In an embodiment, the top surface of the first spacer  120   a  is higher than the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ). The first doped region  126  is disposed in the substrate  100  and laterally adjacent to a sidewall of the first spacer  120   a.  In an embodiment, the edge of the first doped region  126  is substantially aligned with the sidewall of the first spacer  120   a.  The second spacer  132   a  is disposed on the sidewall of the first spacer  120   a.  In an embodiment, the top surface of the second spacer  132   a  is higher than the top surface of the gate stack structure  110  (i.e., the top surface of the gate electrode layer  116 ). The second doped region  136  is disposed in the substrate  100  and laterally adjacent to the sidewall of the second spacer  132   a.  In an embodiment, the edge of the second doped region  136  is substantially aligned with the sidewall of the second spacer  132   a.    
     In the embodiment, the spacer manufactured by the process in  FIGS. 1A to 1G  may ensure that the spacer has a sufficient height. Therefore, the process window shift encountered in the conventional ion implantation process due to the insufficient spacer height may be avoided. 
     Based on the above, in the metal oxide semiconductor transistor and the manufacturing method thereof according to the embodiments of the disclosure, by controlling the top surface of the photoresist layer to be higher than the top surface of the gate electrode layer, the height of the second spacer formed subsequently may be higher than the top surface of the gate electrode layer. Thus, the second spacer with a sufficient height may effectively block ions from being implanted into the substrate below the second spacer. Therefore, a manufacturing window shift occurring in the conventional ion implantation process due to an insufficient height of the spacer may be avoided. 
     Although the disclosure has been described with reference to the above embodiments, they are not intended to limit the disclosure. It will be apparent to one of ordinary skill in the art that modifications to the described embodiments may be made without departing from the spirit and the scope of the disclosure. Accordingly, the scope of the disclosure will be defined by the attached claims and their equivalents and not by the above detailed descriptions.