Patent Description:
With the continuous pursuit for the reduction in size of semiconductor circuitry, it becomes increasingly difficult to physically align semiconductor devices in and/or at various integration levels. One such example includes the integration of buried power rails in a semiconductor substrate.

At current transistor node level, the critical dimension (CD) of buried power rail has become extremely small. In a process of forming nano through-silicon-via to land on the buried power rail, a bad or poor CD or overlay control may cause the nano through-silicon-via to be shorted to the substrate which normally directly surrounds the buried power rails. <CIT> describes a semiconductor device includes a substrate having a first surface and a second surface opposite to each other, and having an active region located on the first surface and defined by a first isolation region; a plurality of active fins arranged on the active region, extending in a first direction, and defined by a second isolation region having a second depth smaller than a first depth of the first isolation region; a buried conductive wiring in a trench adjacent to the plurality of active fins, and extending in a direction of the trench; a filling insulation portion in the trench, and having the buried conductive wiring therein; an interlayer insulation layer on the first and second isolation regions and on the buried conductive wiring; a contact structure penetrating the interlayer insulation layer, and contacting the buried conductive wiring; and a conductive through structure extending through the substrate from the second surface to the trench, and contacting the buried conductive wiring. <CIT> describes a semiconductor substrate, transistors, arranged in the vicinity of the surface of the semiconductor substrate, insulation layers for isolating the transistors, and lower power supply lines and an upper power supply line buried in the insulation layers for isolation.

According to an aspect of the present invention, there is provided a semiconductor structure. The semiconductor structure includes a substrate layer; and a buried power rail (BPR) embedded in the substrate layer, wherein the BPR is isolated from the substrate layer by an enlarged deep shallow-trench-isolation (STI) region. The enlarged deep STI region has a first width at near a top thereof and a second width at near a middle portion thereof, with the second width being larger than the first width.

Preferably, the present invention provides a semiconductor structure further including a nano through-silicon via (nTSV), with a bottom portion of the nTSV contacting a bottom portion of the BPR, where the bottom portion of the nTSV is fully surrounded by the enlarged deep STI region.

Preferably, the present invention provides a semiconductor structure, wherein the nTSV is embedded in the substrate layer and sidewalls of the TSV are fully surrounded by and isolated from the substrate layer by the enlarged deep STI region.

According to another aspect of the present invention, there is provided a method of forming a semiconductor structure. In one embodiment, the method includes providing a semiconductor substrate; forming first recesses in the semiconductor substrate; deepening and laterally widening the first recesses to form enlarged deep STI regions; filling the enlarged deep STI regions with a dielectric material; and forming at least one buried power rail (BPR) inside the dielectric material in the enlarged deep STI regions.

Preferably, the present invention provides a method further including flipping the semiconductor substrate upside down and forming a nano through-silicon via (nTSV) through at least a portion of the semiconductor substrate, wherein the nTSV contacts the at least one BPR.

Preferably, the present invention provides a method, wherein forming the nTSV further includes thinning down the semiconductor substrate to create a substrate layer and depositing an inter-level-dielectric (ILD) layer on top of the substrate layer.

Preferably, the present invention provides a method, wherein forming the nTSV further includes forming an nTSV opening through the ILD layer and the substrate layer to expose a bottom portion of the at least one BPR, via a patterning process, and filling the nTSV opening with one or more conductive materials to form the nTSV.

The present invention will be understood and appreciated more fully from the following detailed description of embodiments of present invention, taken in conjunction with accompanying drawings of which:.

It will be appreciated that for simplicity and clarity purpose, elements shown in the drawings have not necessarily been drawn to scale. Further, and if applicable, in various functional block diagrams, two connected devices and/or elements may not necessarily be illustrated as being connected. In some other instances, grouping of certain elements in a functional block diagram may be solely for the purpose of description and may not necessarily imply that they are in a single physical entity or they are embodied in a single physical entity.

In the below detailed description and the accompanying drawings, it is to be understood that various layers, structures, and regions shown in the drawings are both demonstrative and schematic illustrations that are not drawn to scale. In addition, for the ease of explanation, one or more layers, structures, and regions of a type commonly used to form semiconductor devices or structures may not be explicitly shown in a given drawing. This does not imply that any layers, structures, and regions not explicitly shown are omitted from the actual semiconductor structures. With respect to semiconductor processing steps, it is to be emphasized that the descriptions provided herein are not intended to encompass all of the processing steps that may be required to form a functional semiconductor integrated circuit device. Rather, certain processing steps that are commonly used in forming semiconductor devices, such as, for example, wet cleaning and annealing steps, are purposefully not described herein for economy of description.

Moreover, the same or similar reference numbers are used throughout the drawings to denote the same or similar features, elements, or structures, and thus, a detailed explanation of the same or similar features, elements, or structures may not be repeated for each of the drawings. It is to be understood that the terms "about" or "substantially" as used herein with regard to thicknesses, widths, percentages, ranges, etc., are meant to denote being close or approximate to, but not exactly. For example, the term "about" or "substantially" as used herein implies that a small margin of error may be present, such as <NUM>% or less than the stated amount. Likewise, the terms "on", "over", or "on top of" that are used herein to describe a positional relationship between two layers or structures are intended to be broadly construed and should not be interpreted as precluding the presence of one or more intervening layers or structures.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> that includes a semiconductor substrate <NUM>, and a plurality of sets of fins on top of semiconductor substrate <NUM>. Semiconductor substrate <NUM> may be a bulk silicon (Si) substrate, a bulk germanium (Ge) substrate, a silicon-on-insulator (SOI) substrate, a silicon-germanium-on-insulator (SiGeOI) substrate, or any other suitable substrates.

The plurality of sets of fins may include multiple sets of fins and in this application a set of fins may include one or more fins. A set of fins may be created to make one type of field-effect-transistors (FETs) such as, for example, a p-type FET or an n-type FET. Hereinafter, a set of fins may be referred to a fin-set, and a set of fins that is created to make a p-type FET may be referred to as a PFET fin-set and a set of fins that is created to make an n-type FET may be referred to as an NFET fin-set.

As is illustrated in <FIG>, semiconductor structure <NUM> may include a first fin-set <NUM>, a second fin-set <NUM>, a third fin-set <NUM>, and a fourth fin-set <NUM>. According to an embodiment, first fin-set <NUM> may be an NFET fin-set, second fin-set <NUM> may be a PFET fin-set, third fin-set <NUM> may be a PFET fin-set, and fourth fin-set <NUM> may be an NFET fin-set. Although not illustrated in <FIG>, it is further assumed here that there may be an NFET fin-set to the left of first fin-set <NUM> and an NFET fin-set to the right of fourth fin-set <NUM> as well.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> after forming a fin protecting liner <NUM> such as, for example, an oxide liner covering first, second, third, and fourth fin-set <NUM>, <NUM>, <NUM>, and <NUM>. In one embodiment, liner <NUM> may be a conformal liner and gaps between fins within a fin-set may be filled up by liner <NUM>. The embodiment also includes applying a mask layer <NUM>, such as an organic planarization layer (OPL), to cover and protect spaces between fin-sets for different types of FETs, while leave spaces open or uncovered between fin-sets for the same type of FETs. For example, the embodiment may include applying mask layer <NUM> to cover and protect spaces between first fin-set <NUM> and second fin-set <NUM> and between third fin-set <NUM> and fourth fin-set <NUM> and leave the space between second fin-set <NUM> and third fin-set <NUM>, the space left to first fin-set <NUM>, and the space right to fourth fin-set <NUM>, uncovered. The embodiment further includes etching semiconductor substrate <NUM> to create a first recesses <NUM>. First recesses <NUM> may be etched to have a depth around <NUM> to <NUM> such that sufficient areas directly underneath fin-sets may be preserved for the formation and functioning of transistors, and not be affected by later process of forming buried power rails. First recesses <NUM> may have a first width W1.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes forming additional liners <NUM> next to sidewalls of first recesses <NUM>, thereby protecting the sidewalls of first recesses <NUM> from subsequent etching process. Liners <NUM> may be, for example, low temperature silicon-nitride (SiN) liner. However embodiment of present invention is not limited in this aspect and other materials of liners may be used as well.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes performing etching further into semiconductor substrate <NUM> to deepen and widen first recesses <NUM> to create enlarged openings <NUM>, <NUM>, and <NUM> for forming enlarged deep STI regions in a later stage. For example, performing etching may include not only etching deep into semiconductor substrate <NUM> but also widening the etching in a horizontal direction, from the first width W1 of first recesses <NUM> (less the thickness of liner <NUM>) to a second width W2 of enlarged openings <NUM>, <NUM>, and <NUM> with W2 being larger than W1, such that enlarged deep STI regions may be formed later. In one embodiment, anisotropic dry etching may be performed using, for example, HBr, Cl<NUM>, He, followed with an isotropic wet etch with tetramethylammonium hydroxide (TMAH) to form the openings, and based on the type of etchants used and crystalline orientation of semiconductor substrate <NUM>, enlarged openings <NUM>, <NUM>, and <NUM> may be in a sigma shape, in a diamond shape, or in a hexagon shape. The horizontal widening may go beyond liners <NUM> into regions underneath the fin-sets such as, for example, underneath second fin-set <NUM> and third fin-set <NUM>. The enlarged openings <NUM>, <NUM>, and <NUM> may have the second width W2 at near the middle portion thereof larger than the first width W1 at near the top thereof that is near the top of semiconductor substrate <NUM>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes selectively removing liners <NUM> that cover the sidewalls of first recesses <NUM>, removing mask layer <NUM> between first fin-set <NUM> and second fin-set <NUM> and between third fin-set <NUM> and fourth fin-set <NUM>, and removing liners <NUM> that cover first, second, third, and fourth fin-set <NUM>, <NUM>, <NUM>, and <NUM> based on etch selectivity of respective materials to used etchants. The embodiment further includes subsequently filling enlarged openings <NUM>, <NUM>, and <NUM> with a dielectric material such as, for example, flowable oxide to create enlarged deep STI regions <NUM>, <NUM>, and <NUM>. The flowable oxide may be deposited through a chemical vapor deposition (CVD) process, followed by a steam annealing process, to fill the re-entrant shape of the openings. In doing so, enlarged deep STI regions <NUM>, <NUM>, and <NUM> may have a first width W1 at near a top thereof and a second width at near the middle portion thereof and the second width W2 is larger than the first width W1.

Here, it is to be noted that other suitable dielectric materials, in addition to flowable oxide, may be used as well in forming the enlarged deep STI regions <NUM>, <NUM>, and <NUM>. The dielectric material may be filled into the enlarged openings <NUM>, <NUM>, and <NUM>, in spaces between the sidewalls of first recesses <NUM> previously covered by liners <NUM>, and in spaces between and above first fin-set <NUM>, second fin-set <NUM>, third fin-set <NUM>, and fourth fin-set <NUM>. Embodiment then applies a chemical-mechanic-polishing (CMP) process to remove excessive dielectric material above the fins to polish down, for example, to the top of the fin hardmask.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes forming buried power rail trenches, filling the buried power rail trenches with metals, recessing the buried power rail metals, overfilling the recess with a dielectric, planarizing the dielectric, and recessing the dielectric to reveal the fins with buried power rail still being covered by the dielectric.

More specifically, using lithographic patterning process, buried power rail trenches may be made inside enlarged deep STI regions <NUM>, <NUM>, and <NUM> and the trenches may be subsequently filled with one or more conductive materials, such as tungsten (W), cobalt (Co), ruthenium (Ru), and/or copper (Cu) (with a thin adhesive metal liner, such as TiN), to form buried power rails <NUM>, <NUM>, and <NUM>. According to embodiments of present invention, the trenches (for forming buried power rails) may be created entirely inside enlarged deep STI regions <NUM>, <NUM>, and <NUM> and there is no part of the trenches that open directly to semiconductor substrate <NUM>. Thereafter, a dielectric liner such as, for example, a SiN liner may be optionally formed inside the trenches first before one or more conductive materials are used to fill up the openings to form buried power rails. For example, liners <NUM>, <NUM>, <NUM> may be formed lining the bottoms and sidewalls of the trenches and then metals, such as W, Co, Ru, and/or Cu with a thin adhesive metal liner such as TiN, may be used to fill the remaining trenches to form buried power rails <NUM>, <NUM>, and <NUM>. However, since buried power rails <NUM>, <NUM>, and <NUM> are now surrounded by dielectric materials of enlarged deep STI regions <NUM>, <NUM>, and <NUM>, liners <NUM>, <NUM>, and <NUM> may not be necessary. After the metal fill, the metals may be recessed, followed by dielectric overfill, planarization of the dielectric, and recess of the dielectric to reveal the active fins for further device fabrication.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes, after forming buried power rails <NUM>, <NUM>, and <NUM>, forming transistors such as NFETs and PFETs using the plurality of sets of fins by forming gates (not shown) and source/drain regions <NUM>, forming one or more via-to-BPR contact (VBPR) <NUM>, and forming source/drain contact layer <NUM> which may be a middle-of-line (MOL) layer. One or more back-end-of-line (BEOL) layers such as BEOL layers <NUM>/<NUM> and <NUM>/<NUM> may be subsequently formed on top of MOL layer <NUM>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes forming additional BEOL layers <NUM> on top of BEOL layer <NUM>, and subsequently wafer bonding a carrier wafer <NUM> on top of BEOL layers <NUM>. Carrier wafer <NUM> may be bonded to semiconductor structure <NUM>, for the ease of handling, such that semiconductor substrate <NUM> may be flipped upside down for further processing from the bottom of semiconductor substrate <NUM>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> which is an upside-down flipped semiconductor structure <NUM> illustrated in <FIG>. After flipping the semiconductor structure <NUM>, one embodiment of the method includes thinning down, such as through grinding, CMP, or other etching processes, semiconductor substrate <NUM> by a thickness <NUM> to create a substrate layer <NUM>. In one embodiment as being illustrated in <FIG>, the thinning down process may not expose a top surface of the enlarged deep STI regions <NUM>, <NUM>, and <NUM>. However, embodiment of present invention may include thinning down semiconductor substrate <NUM> to expose a top surface of or even into the enlarged deep STI regions <NUM>, <NUM>, and <NUM>, as being described below in more details with reference to <FIG>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes depositing an inter-level dielectric (ILD) layer <NUM> on top of the thinned down semiconductor substrate otherwise referred to herein as substrate layer <NUM>. The embodiment then includes performing a lithographic patterning process to create openings such as openings <NUM> and <NUM> for forming through-silicon-vias (TSVs). TSVs may have different sizes in diameter and in one embodiment the diameter of TSVs may be in the range of <NUM> to <NUM> nanometers. Such TSVs may be referred to as nano TSVs (nTSVs). Embodiments of present invention may create openings <NUM> and <NUM> for forming TSVs in general and in one embodiment for forming nTSVs.

According to one embodiment of present invention, at least a bottom portion and a lower portion of openings <NUM> and <NUM> may be created entirely inside enlarged deep STI regions <NUM> and <NUM>. However, embodiments of present invention are not limited in this aspect and in one embodiment, as being described below in more details with reference to <FIG>, sidewalls of openings <NUM> and <NUM> may be entirely surrounded by the enlarged deep STI regions <NUM> and <NUM>. In <FIG>, as a non-limiting example, it is assumed that no opening (for forming TSV) is created in enlarged deep STI region <NUM>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes forming liners <NUM> and <NUM> of dielectric material, such as SiN, lining openings <NUM> and <NUM>. At the bottom of openings <NUM> and <NUM>, horizontal portions of the liner material of liner <NUM> and <NUM> may be subsequently removed by an anisotropic etch to expose a bottom portion of BPR <NUM> and BPR <NUM> for contact purpose. Conductive material such as, for example, W, Co, Ru, or Cu may then be used to fill openings <NUM> and <NUM> to form TSVs and more particularly nTSVs <NUM> and <NUM>. A bottom portion of nTSVs <NUM> and <NUM> contacts directly, at least partially, a bottom portion of BPR <NUM> and BPR <NUM>.

Here it is to be noted that because at least a bottom portion of openings <NUM> and <NUM> are created entirely inside enlarged deep STI regions <NUM> and <NUM>, a misalignment between, for example, BPR <NUM> and nTSV <NUM> may cause a part <NUM> of the bottom portion of nTSV <NUM> to be exposed to enlarged deep STI region <NUM>. Since enlarged deep STI region <NUM> is made of dielectric material such as flowable oxide, the misaligned part <NUM> of the bottom portion of nTSV <NUM> is still isolated from substrate layer <NUM>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to another embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> following the step illustrated in <FIG>. More particularly, one embodiment of the method includes flipping the semiconductor structure <NUM> in <FIG>upside down and performing a thinning process to semiconductor substrate <NUM> to remove a thickness <NUM> thereof, which is relatively thicker than that of thickness <NUM> illustrated in <FIG>, resulting in a thinner substrate layer <NUM>. The removal of the thickness <NUM> of semiconductor substrate <NUM> ensures that nTSVs formed in subsequent process steps to contact the BPRs are entirely surrounded by enlarged deep STI regions that are embedded in substrate layer <NUM>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes forming an ILD layer <NUM> on top of substrate layer <NUM>, and lithographically patterning one or more openings <NUM> and <NUM> for forming TSVs such as nTSVs. It is to be noted here that openings <NUM> and <NUM>, at least for the portions that are inside substrate layer <NUM>, are entirely surrounded by enlarged deep STI regions <NUM> and <NUM>.

<FIG> is a demonstrative illustration of cross-sectional view of a semiconductor structure during a process of a method of manufacturing thereof according to one embodiment of present invention. More specifically, <FIG> illustrates a semiconductor structure <NUM> and one embodiment of the method includes performing metallization by filling openings <NUM> and <NUM> with one or more conductive materials such as, W, Co, Ru, and/or Cu, to form TSVs such as nTSVs <NUM> and <NUM>. Contrast to nTSVs <NUM> and <NUM> illustrated in <FIG>, since openings <NUM> and <NUM> are embedded in substrate layer <NUM> but separated and isolated from substrate layer <NUM> by enlarged deep STI regions <NUM> and <NUM>, no dielectric liner such as SiN liner is needed to prevent nTSVs <NUM> and <NUM> from contacting or shorting substrate layer <NUM>. For example, according to embodiment of present invention, when nTSV <NUM> is misaligned with BPR <NUM>, as an illustrative example shown in <FIG>, a bottom of nTSV <NUM> is covered by enlarged deep STI region <NUM>. In the meantime, since sidewalls <NUM> of nTSV <NUM> are fully surrounded by enlarged deep STI region <NUM> as well, they are prevented from shorting or contacting substrate layer <NUM>.

<FIG> is a demonstrative illustration of a flow-chart of a method of manufacturing a semiconductor structure according to embodiments of present invention. The embodiment includes (<NUM>) forming first recesses in a semiconductor substrate between semiconductor device regions such as between two NFET regions or between two PFET regions; (<NUM>) deepening and widening the first recesses to create enlarged openings and subsequently filling the enlarged openings with a dielectric material to form enlarged deep STI regions; (<NUM>) forming buried power rails in the enlarged deep STI regions embedded in the semiconductor substrate; and (<NUM>) forming transistors such as NFETs and PFETs and associated MOL layer and BEOL layers on top the transistors and wafer bonding a carrier wafer onto a top of the BEOL layers.

Embodiments of present invention further include (<NUM>) flipping the semiconductor substrate upside down and thinning down a thickness of the semiconductor substrate to create a substrate layer with the thinning process, in one embodiment, exposing the enlarged deep STI regions; (<NUM>) creating nano through-silicon-via (nTSV) openings in the enlarged deep STI regions with at least a bottom portion of the openings being surrounded by the enlarged deep STI regions. This nTSV creation process may be made by first depositing an inter-level-dielectric (ILD) layer on top of the substrate layer, planarizing the ILD layer, and patterning the nTSV openings through a lithographic patterning and etching process. In one embodiment, sidewalls of the nTSV openings are not fully surrounded by the enlarged deep STI regions, and the embodiment may include (<NUM>) lining the nTSV openings with a dielectric liner. Embodiments of present invention may further include (<NUM>) metallizing the nTSV openings with conductive material to contact the buried power rails.

Integrated circuit dies can be fabricated with various devices such as field-effect transistors, bipolar transistors metal-oxide-semiconductor transistors, diodes, capacitors, inductors, etc. An integrated circuit in accordance with the present invention can be employed in applications, hardware, and/or electronic systems. Suitable hardware and systems for implementing the invention may include, but are not limited to, personal computers, communication networks, electronic commerce systems, portable communications devices (e.g., cell phones), solid-state media storage devices, functional circuitry, etc. Systems and hardware incorporating such integrated circuits are considered part of the embodiments described herein. Given the teachings of the invention provided herein, one of ordinary skill in the art will be able to contemplate other implementations and applications of the techniques of the invention.

Although exemplary embodiments have been described herein with reference to the accompanying figures, it is to be understood that the invention is defined by the appended claims.

In some embodiments, the above-described techniques are used in connection with manufacture of semiconductor integrated circuit devices that illustratively include, by way of non-limiting example, CMOS devices, MOSFET devices, and/or FinFET devices, and/or other types of semiconductor integrated circuit devices that incorporate or otherwise utilize CMOS, MOSFET, and/or FinFET technology.

Claim 1:
A semiconductor structure comprising:
a substrate layer (<NUM>); and
a buried power rail (BPR) (<NUM>, <NUM>) embedded in a deep shallow-trench-isolation (STI) region (<NUM>, <NUM>, <NUM>) inside the substrate layer,
wherein the BPR is isolated from the substrate layer by the deep STI region,
wherein the deep STI region has a first width at near a top thereof and a second width at near a middle portion thereof, wherein the second width being larger than the first width.