Patent Document

FIELD OF INVENTION 
       [0001]    The field of invention relates generally to semiconductor devices, and, more importantly, to dual work function gate structures. 
       BACKGROUND 
       [0002]      FIGS. 1 and 2  provide pertinent details concerning complementary semiconductor device technologies such as CMOS.  FIG. 1  shows energy band diagrams for the MOS structure of both an NMOS device and a PMOS device at equilibrium. According to the approach of  FIG. 1  (which is a common approach), both devices are designed such that, at equilibrium, the Fermi level at the high K dielectric  102 _N/NMOS P-well  103 _N interface and the Fermi level at the high K dielectric  102 _P/PMOS N-well  103 _P interface is approximately halfway between the conduction band (Ec) and valence band (Ev). Here, equilibrium essentially corresponds to an “off” device and setting the Fermi level halfway between Ec and Ev keeps the device in its least conductive state (because the conduction band is largely devoid of free electrons and valence band is largely devoid of free holes). 
         [0003]    In order to set the Fermi level halfway between Ec and Ev as described above, specific gate metal materials are chosen that induce the proper amount of band bending in the NMOS P-well  103 _N and PMOS N-well  103 _P. Notably, in order to achieve the desired band bending, the material used for the NMOS gate  101 _N typically has a smaller work function  104 _N than the material used for the PMOS gate  104 _P (that is, the PMOS work function  104 _P is typically larger than the NMOS work function  104 _N). 
         [0004]      FIG. 2  shows the devices of  FIG. 1  in the active rather than off state. In the case of the NMOS device, a positive gate-to-source voltage essentially causes additional band bending that places the conduction band beneath the Fermi level at the dielectric/well interface  205 _N. When the conduction band Ec is beneath the Fermi level, free electrons are plentiful. Thus, a conductive channel is formed at interface  205 _N which corresponds to an “on” device. Likewise, in the case of PMOS device, a negative gate-to-source voltage essentially causes additional band bending that places the valence band above the Fermi level at the dielectric/well interface  205 _P. When the valence band Ev is above the Fermi level, free holes are plentiful. Thus, a conductive channel is formed at interface  205 _P which corresponds to an “on” device. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which: 
           [0006]      FIG. 1  show conventional NMOS and PMOS devices at equilibrium; 
           [0007]      FIG. 2  show conventional NMOS and PMOS devices in an active mode; 
           [0008]      FIGS. 3   a  and  3   b  show band diagrams along the channel of a conventional NMOS device; 
           [0009]      FIGS. 4   a  and  4   b  show band diagrams along the channel of an improved NMOS device; 
           [0010]      FIGS. 5   a  and  5   b  show band bending diagrams along the channel of an improved PMOS device; 
           [0011]      FIGS. 6   a  through  6   f  show a conventional dual metal gate manufacturing process; 
           [0012]      FIGS. 7   a  through  7   f  show a dual metal gate manufacturing process capable of manufacturing the improved devices of  FIGS. 4   a,b  and  5   a,b;    
           [0013]      FIG. 8   a  shows an embodiment of an asymmetric NMOS and PMOS devices each having a dual metal gate; 
           [0014]      FIG. 8   b  shows an embodiment of a vertical drain NMOS (VDNMOS) device having a dual metal gate; 
           [0015]      FIG. 8   c  shows an embodiment of a laterally diffused MOS (LDMOS) device having a dual metal gate. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0016]      FIGS. 3   a  and  3   b  show band diagrams along the channel of the NMOS device described with respect to  FIGS. 1 and 2   a .  FIG. 3   a  corresponds to the “off” device and  FIG. 3   b  corresponds to the “on” device. Referring to  FIG. 3   a , the presence of n+ source/drain extensions causes band bending  301  within the P-well. When gate lengths were longer in previous device generations, band bending  301  represented only a small fraction of the energy band profile within the P well beneath the gate. However, with continued gate length reductions, band bending  301  represents a larger and larger percentage of the energy band profile beneath the gate, and, the effects of band bending  301  are becoming increasingly noticeable. For instance, the presence of band bending  301  is believed to contribute to a reduced threshold voltage. 
         [0017]    Referring to  FIG. 3   b , the presence of the n+ drain extension causes sharp band bending  302  near/at the interface of the P well and the n+ drain extension. The sharp bending  302  corresponds to an extremely high electric field that is believed to be the cause of a number of problems associated with “hot carriers” such as substrate currents, avalanche breakdown, lowered energy barriers and threshold shifting. 
         [0018]      FIGS. 4   a  and  4   b  show a design for an NMOS device having improved band bending characteristics beneath the gate electrode as compared to the NMOS device of  FIGS. 3   a  and  3   b .  FIG. 4   a  shows the device in the off state and  FIG. 4   b  shows the device in the on state. 
         [0019]    Notably, the gate structure of the device can be viewed as having three sections: 1) outer sections  402   a  and  402   b ; and, 2) inner section  403 . In an embodiment, for an N type device as observed in  FIGS. 4   a  and  4   b , the outer sections  402   a  and  402   b  are composed of P type device gate metal, and, the inner section  403  is composed of N type device gate metal. Thus, outer sections  402   a ,  402   b  have a higher work function than inner section  403 . 
         [0020]    In this case, the effect of the higher work function material at the outer regions  402   a ,  402   b  of the gate have a similar effect as observed for the PMOS device of  FIG. 1 . That is, the higher work function material induces band bending that pulls the conduction and valence bands “up” relative to the Fermi level as compared to the levels observed in  FIG. 3   a . As such, the off device of  FIG. 4   a  has less band bending  401  at the P well/extension interface regions than the band bending  301  observed in the device of  FIG. 3   a . As a consequence, the threshold voltage reduction caused by the presence of the n+ source/drain extensions is practically eliminated or reduced. 
         [0021]    Similarly, referring to  FIG. 4   b , the upward pull on the valence and conduction bands induced by the higher work function material  402   b  causes less sharp band bending  404  at/near the P well/n+ drain extension in an on device as compared to the on device of  FIG. 3   b . The less sharp band bending  404  corresponds to a weaker electrical field which should reduce “hot carrier” effects. Band bending is also created at the P well/n+ source extension. As observed in  FIG. 4   b  a small barrier is created however this barrier may be minimized or eliminated with appropriate selection of doping levels and gate metal material. 
         [0022]      FIGS. 5   a  and  5   b  show a design for a PMOS device having improved band bending characteristics beneath the gate electrode as compared to prior art PMOS devices.  FIG. 5   a  shows the device in the off state and  FIG. 5   b  shows the device in the on state. 
         [0023]    Notably, the gate structure of the device can be viewed as having three sections: 1) outer sections  502   a  and  502   b ; and, 2) inner section  503 . In an embodiment, for a P type device as observed in  FIGS. 5   a  and  5   b , the outer sections  502   a  and  502   b  are composed of N type device gate metal, and, the inner section  503  is composed of P type device gate metal. Thus, outer sections  502   a ,  502   b  have a lower work function than inner section  503 . 
         [0024]    In this case, the effect of the lower work function material at the outer regions  502   a ,  502   b  of the gate have a similar effect as observed for the NMOS device of  FIG. 1 . That is, the lower work function material induces band bending that pulls the conduction and valence bands “down” relative to the Fermi level. As such, the off device of  FIG. 5   a  has less band bending  501  at the N well/extension interface regions than the corresponding band bending at the N well/extension interface regions in prior art (single gate metal) PMOS devices. As a consequence, the threshold voltage reduction caused by the presence of the p+ source/drain extensions is practically eliminated or reduced. 
         [0025]    Similarly, referring to  FIG. 5   b , the downward pull on the valence and conduction bands induced by the lower work function material  502 B causes less sharp band bending  504  at/near the N well/p+ drain extension in an on device as compared to a prior art (single gate metal) PMOS device. The less sharp band bending  504  corresponds to a weaker electrical field which should reduce “hot carrier” effects. Band bending is also created at the N well/p+ source extension. As observed in  FIG. 5   b  a small barrier is created however this barrier may be minimized or eliminated with appropriate selection of doping levels and gate metal material. 
         [0026]    It is pertinent to point out that, although the terms “NMOS” and “PMOS” are used above in reference to  FIGS. 4   a,b  and  5   a,b  (which are typically understood to refer to N type Metal Oxide Semiconductor and P type Metal Oxide Semiconductor devices, respectively), for convenience, these terms should be understood to also apply to devices having a gate dielectric that is not technically an oxide. The terms “N type device” and “P type device” may also be utilized. Moreover, although the term “gate metal” is used above in reference to  FIGS. 4   a,b  and  5   a,b , the term “gate metal” should be understood to apply to gate materials that are not technically a metal (such as heavily doped polysilicon). The term “gate material”, “gate electrode”, “gate electrode material” and the like may also be utilized. Also, for convenience, the device diagrams do not depict well known device structures such as source/drain electrodes (which are understood to be electrically coupled to their respective source/drain extensions), metal gate fill material residing upon the depicted gate metal of a device, sidewall spacers, etc. 
         [0027]      FIGS. 6   a  through  6   f  show a prior art process for manufacturing NMOS and PMOS devices having different, respective gate metals.  FIG. 6   a  shows the NMOS and PMOS devices up through deposition of the gate dielectric  601   a,b . In  FIG. 6   b , the gate metal  602   a,b  for the NMOS device is deposited on the gate dielectric  601   a,b  of both devices. Then, as observed in  FIG. 6   c , photoresist  603   a,b  is coated on the wafer and patterned to form an opening  604  over the gate region of the PMOS device such that the NMOS gate metal  602   b  residing in the PMOS device is exposed. The NMOS gate material  602   a  over the NMOS device is covered with photoresist  603   a.    
         [0028]    As observed in  FIG. 6   d , the exposed NMOS gate metal  602   b  in the gate region of the PMOS device is etched away. The NMOS gate metal  602   a  in the gate region of the NMOS device is protected by the photoresist  603   a  during the etch. As observed in  FIG. 6E , the PMOS gate metal  605  is deposited over the gate dielectric of the PMOS device. The photoresist  603   a,b  is removed, as observed in  FIG. 6   f , leaving NMOS gate material  602   a  in the gate region of the NMOS device and PMOS gate material  605  in the region of the PMOS device. As observed in  FIG. 6   f , the manufactured devices only have one gate metal on the gate dielectric. 
         [0029]      FIGS. 7   a  through  7   f  shows a process that, by contrast, can manufacture devices having more than one gate material on the gate dielectric of a single device.  FIG. 7   a  shows the N type and P type devices up through deposition of the gate dielectric  701   a ,  701   b . In  FIG. 7   b , N type gate material  702   a,b  is deposited on the gate dielectric of both devices. As observed in  FIG. 7   c , photoresist  703   a,b  is coated on the wafer and patterned to form a pair of openings  704  over the gate edges of the N type device, and, a single opening  705  over the gate center of the P type device. Each of the openings expose underlying N type gate material  702   a,b . The exposed N type gate material  702   b  is then etched. The etch may be performed by a dry etch such as an HCl based or SF-6 based etch. 
         [0030]    When the exposed N type gate material is removed, P type gate material  706   a,b  is deposited in its place as observed in  FIG. 7   e . The photo resist is subsequently removed leaving devices having N and P type gate metal on a gate dielectric. 
         [0031]    Notably, in alternate approaches, P type gate material may be deposited before the N type gate material. In this case, the phororesist patterns are “switched” in comparison to  FIG. 7   b  (that is, the P type device will have a pair of openings and the N type device will have a single opening). 
         [0032]    The type of materials used for the gate material may vary from embodiment. As discussed above, according to one approach, the gate material used for a P type device (“P type gate material”) is deposited not only on the gate dielectric of a P type device but also on the gate dielectric of an N type device. Likewise, the gate material for an N type device (“N type gate material”) is deposited not only on the gate dielectric of an N type device but also on the gate dielectric of a P type device. Generally, as discussed above, the P type gate material has a higher work function than the N type gate material. Suitable gate materials may include but are not limited to polysilicon, tungsten, ruthenium, palladium, platinum, cobalt, nickel, hafnium, zirconium, titanium, tantalum, aluminum, titanium carbide, zirconium carbide, tantalum carbide, hafnium carbide, aluminum carbide, other metal carbides, metal nitrides, and metal oxides. As is known in the art, the gate materials may be deposited by various processes such as chemical vapor deposition or atomic layer deposition or sputtering. 
         [0033]    Although efficiency in terms of the number process steps is achieved when P type gate material is deposited on both P type and N type devices and N type gate material is deposited on both N type devices and P type devices—alternate approaches may use a gate metal that is used on only one of the devices (N type or P type) to engineer the desired band bending. Those of ordinary skill will be able to determine the application and materials when such an approach is warranted. 
         [0034]    Also, in an embodiment, the gate lengths of the devices are longer than the minimum gate length that is achievable with the manufacturing process. For instance, in a logic process, typically, the smallest manufactured feature of the logic transistors is the gate length. Thus, devices having gate structures as described herein have longer gate lengths than the logic transistors (because multiple features are formed on a single gate as discussed above rather than a single, smallest manufactured feature as in the case of a logic transistor). For instance, according to one implementation, devices having gate structures as described herein are used to implement higher voltage analog and/or mixed signal circuits. Such devices may be integrated on the same semiconductor device having logic transistors with minimum feature gate lengths. For example, a System on Chip (SOC) having digital components (e.g., processing core, memory, etc.) and analog/mixed signal components (e.g., amplifiers, I/O drivers, etc.)) may use devices having gate structures as described herein for the analog/mixed signal components. 
         [0035]    It is also pertinent to point out that although the examples discussed above show strict alignment of the outer gate edge metal with the underlying source/drain extension tips, such an approach is merely exemplary. The positioning of the boundary between the inner gate metal and the outer gate metal of a dual gate metal structure may vary so long as appropriate band bending is achieved. Moreover, as is indicated by  FIG. 8   a  (discussed in more detail immediately below), some device designs may have different outer edge gate material on only one of the edges—e.g., only on the source side or only on the drain side. For example, a device design that is mostly concerned with hot carrier effects may choose to place different outer edge gate material on the drain side of the gate but not the source side of the gate. Likewise, a device design that is less concerned about hot carrier effects and more concerned about a substantially non flat energy band structure beneath the source end of the gate may choose to only add different gate material on the source side of the gate and not the drain side of the gate. 
         [0036]    Further still, although the examples discussed above indicate that, in cases where different outer edge gate material exists at both the source and the drain the same gate material is used at both edges, alternative device designs may exist where the pair of outer edge gate materials are different as between themselves. For instance, a first outer edge gate material may be used at the source side of the gate to control the height of the barrier beneath the source side of the gate (observed in  FIG. 4   b ), and, a second outer edge gate material—that is different than the gate material used on the source side—may be used at the drain side to diminish the electric field between the well and the drain junction. 
         [0037]      FIGS. 8   a  through  8   c  show various kinds of transistors that may be formed with dual metal gate structures as described herein.  FIG. 8   a  shows an N type asymmetrical device and a P type asymmetrical device. Notably, these devices only contain a different outer edge metal near the drain side and not the source side (specifically, the P type gate metal for the N type device, and, the N type gate metal for the P type device). As such, these devices only attempt to impart band bending that reduces the electric field near the well/drain extension. 
         [0038]      FIG. 8   b  shows a Vertical Drain NMOS device (VDNMOS) device having a dual metal gate structure. As is known in the art, a VDNMOS device addresses the problem of a high electric field between the well and drain junction by inserting insulation material  801  beneath the drain edge of the gate. This insertion of a trench  801  creates a high resistance path from the extrinsic drain contact to the gate edge, thereby decreasing the electric field at the region under the gate. In addition, the highly doped drain implants and tips are prevented from encroaching under the gate, which also reduces the peak electric field. These reductions in the field translate to lower carrier energies, and enhanced device reliability. 
         [0039]      FIG. 8   c  shows a laterally diffused MOS (LDMOS) device having a dual metal gate structure. As is known in the art, an LDMOS device addresses the problem of having a high electric field between the well and drain junction by extending the drain extension (DEX) beneath a field plate  802 . A field plate  802  acts to spread the field over a larger drain distance, effectively lowering the peak field and enhancing the device lifetime through reduction of hot carrier effects. 
         [0040]    In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.

Technology Category: 5