Patent Document

BACKGROUND 
       [0001]    The present invention relates to the fabrication of semiconductor devices on a semiconductor on insulator (SOI) substrate, and more particularly, to the fabrication of semiconductor devices on an extremely thin SOI substrate with improved isolation and a thin buried oxide layer. 
         [0002]    Extremely thin SOI substrates (ETSOI), also known as fully depleted SOI (FDSOI), rely on an ultra-thin semiconductor layer (for example, silicon) on a buried oxide layer. “Fully-depleted” means that the conducting channel of the transistor is depleted of charge by the time the transistor turns on which can only occur in SOI technologies because in bulk silicon there is an almost infinite source of charge available that cannot be depleted. The performance advantage of fully-depleted transistors comes from the fact that when there is no charge in the channel, the entire gate voltage is applied to create a conducting channel. 
         [0003]    ETSOI is a viable device option for extending CMOS scaling. The device characteristics of ETSOI can be tuned by doping and/or applying back gate bias which enables device tuning and/or multiple threshold voltages (V T ). 
         [0004]    A challenge for enabling the back gate doping and biasing is the isolation. 
       BRIEF SUMMARY 
       [0005]    The various advantages and purposes of the exemplary embodiments as described above and hereafter are achieved by providing, according to a first aspect of the exemplary embodiments, an SOI structure. The SOI structure includes a semiconductor on insulator (SOI) substrate including a top semiconductor layer, an intermediate buried oxide (BOX) layer and a bottom substrate; at least two wells in the bottom substrate; a deep trench isolation (DTI) separating said two wells, the DTI having a top portion extending through the BOX layer and top semiconductor layer and a bottom portion within the bottom substrate wherein the bottom portion has a width that is larger than a width of the top portion; and at least two semiconductor devices in the semiconductor layer located over one of the wells, the at least two semiconductor devices being separated by a shallow trench isolation (STI) within the top semiconductor layer. 
         [0006]    According to a second aspect of the exemplary embodiments, there is provided a method of forming an SOI structure. The method includes providing a semiconductor on insulator (SOI) substrate having an SOI layer, an intermediate buried oxide (BOX) layer and a bottom substrate; patterning the SOI layer to form first and second openings in the SOI layer; extending the first openings into the bottom substrate; enlarging the first openings within the bottom substrate; filling the first and second openings with an insulator material to form deep trench isolations (DTIs) from the first openings and shallow trench isolations (STIs) from the second openings; implanting in the bottom substrate between the DTIs to form wells; and forming semiconductor devices in the SOI layer between the DTIs with each semiconductor device being separated from an adjacent semiconductor device by an STI. 
     
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         [0007]    The features of the exemplary embodiments believed to be novel and the elements characteristic of the exemplary embodiments are set forth with particularity in the appended claims. The Figures are for illustration purposes only and are not drawn to scale. The exemplary embodiments, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which: 
           [0008]      FIGS. 1A to 1G  illustrate a first exemplary embodiment in which:
         FIG. 1A  illustrates an SOI substrate used in the exemplary embodiment:     FIG. 1B  illustrates the patterning of the SOI layer;     FIG. 1C  illustrates the extending of the DTI trench into the substrate;     FIG. 1D  illustrates the filling of the DTI and STI trenches;     FIG. 1E  illustrates the forming of N-type and P-type wells in the substrate;     FIG. 1F  illustrates the forming of NFETs and PFETs in the SOI layer;     FIG. 1G  illustrates the forming of an interlevel dielectric and well contacts.       
 
           [0016]      FIGS. 2A to 2H  illustrate a second exemplary embodiment in which:
         FIG. 2A  illustrates an SOI substrate used in the exemplary embodiment:     FIG. 2B  illustrates the patterning of the SOI layer;     FIG. 2C  illustrates the forming of spacers;     FIG. 2D  illustrates the extending of the DTI trenches into the substrate;     FIG. 2E  illustrates the enlarging of the DTI trenches;     FIG. 2F  illustrates the filling of the DTI and STI trenches;     FIG. 2G  illustrates the forming of N-type and P-type wells in the substrate;       
 
           [0024]      FIG. 2H  illustrates the forming of NFETs and PFETs in the SOI layer, the forming of an interlevel dielectric and well contacts. 
           [0025]      FIGS. 3A to 3H  illustrate a third exemplary embodiment in which:
         FIG. 3A  illustrates an SOI substrate used in the exemplary embodiment:     FIG. 3B  illustrates the patterning of the SOI layer;     FIG. 3C  illustrates the conformal deposition of spacer material;     FIG. 3D  illustrates the forming of spacers and the extending of the DTI trenches into the substrate;     FIG. 3E  illustrates the enlarging of the DTI trenches;     FIG. 3F  illustrates the filling of the DTI and STI trenches;     FIG. 3G  illustrates the forming of N-type and P-type wells in the substrate;     FIG. 3H  illustrates the forming of NFETs and PFETs in the SOI layer, the forming of an interlevel dielectric and well contacts.       
 
           [0034]      FIGS. 4A to 4H  illustrate a fourth exemplary embodiment in which:
         FIG. 4A  illustrates an SOI substrate used in the exemplary embodiment:     FIG. 4B  illustrates the patterning of the SOI and BOX layers;     FIG. 4C  illustrates the forming of spacers;     FIG. 4D  illustrates the extending of the DTI trenches into the substrate;     FIG. 4E  illustrates the enlarging of the DTI trenches;     FIG. 4F  illustrates the filling of the DTI and STI trenches;     FIG. 4G  illustrates the forming of N-type and P-type wells in the substrate;     FIG. 4H  illustrates the forming of NFETs and PFETs in the SOI layer, the forming of an interlevel dielectric and well contacts.       
 
           [0043]      FIGS. 5A to 5H  illustrate a fifth exemplary embodiment in which:
         FIG. 5A  illustrates an SOI substrate used in the exemplary embodiment:     FIG. 5B  illustrates the patterning of the SOI and BOX layers;     FIG. 5C  illustrates the conformal deposition of spacer material;     FIG. 5D  illustrates the forming of spacers and the extending of the DTI trenches into the substrate;     FIG. 5E  illustrates the enlarging of the DTI trenches;     FIG. 5F  illustrates the filling of the DTI and STI trenches;     FIG. 5G  illustrates the forming of N-type and P-type wells in the substrate;     FIG. 5H  illustrates the forming of NFETs and PFETs in the SOI layer, the forming of an interlevel dielectric and well contacts.       
 
       
    
    
     DETAILED DESCRIPTION 
       [0052]    In order to tune the V T  of N-type field effect transistor (NFET) and P-type field effect transistor (PFET) devices in ETSOI architecture, doping and/or back gate bias may be applied. Devices sharing the common back-gate bias may be isolated from the rest of the chip by deep-trench isolation. Within the deep-trench isolation region the individual devices may be separated from each other using shallow-trench isolation. 
         [0053]    Accordingly, the present exemplary embodiments provide a structure and a method for forming an ETSOI circuit with a deep trench isolation for interwell (well to well) isolation and a shallow trench isolation for intrawell (within the same well) isolation. The lower portion of the deep trench isolation below the buried oxide layer may be enlarged to improve isolation and enhance process window, for example, to improve overlay tolerance. 
         [0054]    The present invention relates to the fabrication of a circuit on a semiconductor on insulator (SOI) substrate which includes an SOI layer (for example, silicon), a buried oxide (BOX) layer and a bottom substrate, usually silicon. In exemplary embodiments, the SOI substrate is an extremely thin SOI substrate wherein the SOI layer has a thickness of about 3 to 15 nanometers. In further exemplary embodiments, the BOX layer is a thin BOX layer having a thickness of about 10 to 140 nanometers. This is compared to a typical SOI substrate having an SOI layer with a thickness of about 40-100 nanometers and a BOX layer with a thickness of about 150 nanometers or higher. 
         [0055]    The SOI circuit includes deep trench isolation (DTI) for well-to-well isolation and a shallow trench isolation for isolation within the same well. The lower portion of the DTI below the BOX layer is enlarged to improve isolation and enhance the process window such as by improving overlay tolerance. 
         [0056]    Referring to the Figures in more detail, and particularly referring to  FIGS. 1A to 1G , there is illustrated a first exemplary embodiment. In  FIG. 1A , an SOI substrate  100  is provided or manufactured. The SOI substrate  100  includes an SOI layer  102 , a BOX layer  104  and a bottom substrate  106 . In a preferred exemplary embodiment, the SOI layer  102  is an extremely thin SOI layer and the BOX layer  104  is a thin BOX layer. 
         [0057]    Referring now to  FIG. 1B , a pad film  108  may be formed over the SOI layer  102 . The pad film  108  is used for patterning the underlying SOI substrate  100  and may include a combination of pad oxide and a pad nitride. Thereafter, a photoresist  110  may be applied, exposed and developed to form openings  112 . Through an etching process, such as a conventional reactive ion etching (RIE) process, the openings  112  are extended through pad film  108  and the SOI layer  102  and stopping on the BOX layer  104 . 
         [0058]    Referring now to  FIG. 1C , the first photoresist  110  is conventionally stripped. A second photoresist  114  may be applied, exposed and developed to cover some of the openings  112 . Others of the openings  112  are left uncovered. The openings  112  that are left uncovered are referred to hereafter as DTI openings  116  and in a later step will be extended into the bottom substrate  106  and be filled to function as deep trench isolation (DTI). The openings that are covered by the resist  114  are referred to hereafter as STI openings  118  and in a later step will be filled to function as shallow trench isolation (STI). 
         [0059]    In a two-step etching process, the DTI openings  116  are extended into the bottom substrate  106  by etching through the box layer  104  and a portion of the bottom substrate  106 . It is noted that the DTI openings  116  are enlarged during the two-step etching process to form bottle-shaped openings  120  within the bottom substrate  106 . A polymeric residue  122  may be generated during the etching of the DTI openings  116 . The polymeric residue  122  may passivate the upper trench sidewall  124  while the lower trench is etched to form the bottle-shaped opening  120 . Any reactive ion etch (RIE) process that etches a silicon substrate is suitable for forming the bottle-shaped trench. For example, the process conditions for those two steps may have the same pressure (180 mTorr), same HBr flow rate (325 sccm), same NF3 flow rate (40 sccm), same high frequency power (450 W), but different O2 flow rate (30 sccm for the first step and 20 sccm for the second step), and different low frequency power (900 W for the first step and 1400 W for the second step. The polymeric residue  122  may result from a RIE byproduct such as silicon oxyfluoride (Si x O y F z ). 
         [0060]    The polymeric residue  122  may be stripped, for example, by oxygen plasma and the second resist  114  may be conventionally stripped. 
         [0061]    Referring now to  FIG. 1D , the DTI openings  116  and STI openings  118  may be filled with an electrically insulating material and then planarized by a conventional chemical-mechanical polishing process. In an exemplary embodiment, the DTI openings and STI openings  118  are filled with an oxide, such as silicon dioxide. There may also be a dielectric liner (for example, silicon nitride) on the walls and bottom of the DTI openings  116  and STI openings  118  prior to deposition of oxide fill. The dielectric liner, if present, may be conformally deposited prior to blanket deposition of the oxide. The DTI openings  116  filled with oxide are now referred to hereafter as deep trench isolation (or just DTI)  126  while the STI openings  118  filled with oxide are now referred to hereafter as shallow trench isolation (or just STI)  128 . 
         [0062]    Referring now to  FIG. 1E , the pad film  108  ( FIG. 1D ) is conventionally stripped which also removes an equally thick layer of oxide so that planarization by a process such as chemical-mechanical polishing may not be necessary. The bottom substrate  106  is implanted to form N wells  130  and P wells  132  which will form the back gate for semiconductor devices to be formed hereafter. The implantation may be a multiple-step process. A combination of low and high implantation energies may be used to achieve N and P wells  130 ,  132  that extend roughly 200 nanometers below the BOX (layer  104 ) bottom interface into the substrate layer  106 . The specie for the N wells  130  may be, for example, arsenic or phosphorus, while the implanted specie for the P wells  132  may be, for example, boron or born fluoride (BF 2 ). DTI  120  provides isolation of N wells  130  and P wells  132 . 
         [0063]    Referring to  FIG. 1F , conventional field effect transistor (FET) devices may be formed in SOI layer  102 . For purposes of illustration and not limitation, over N well  130  are formed PFETs  134  and over P well  132  are formed NFETs  136 . It is also within the scope of the present invention for there to be NFETs over the N well  130  and PFETs over P well  132 . Separating the FET devices  134  or  136  is STI  128 . For example, PFETs  134  are separated by STI  128  while NFETs  136  are also separated by STI  128 . The PFETs  134  and NFETs  136  are shown as having a raised source/drain (RSD). 
         [0064]    Referring now to  FIG. 1G , an interlevel dielectric  142  has been applied over the nFETs  134  and pFETs  136 . Well contacts  138  may be formed to contact N wells  130  and well contacts  140  may be formed to contact P wells  132 . The well contacts  138 ,  140  enable the same or different back bias. Well contacts  138 ,  140  may be formed by masking the FET devices  134 ,  136 , etching through the interlevel dielectric  142 , STI  128  and BOX layer  104  and then filling with a metal such as tungsten. There may be a slight overetching into the substrate  106  to ensure good contact with the N wells  130  and P wells  132 . 
         [0065]    A second exemplary embodiment is illustrated in  FIGS. 2A to 2H . The second exemplary embodiment is similar to the first exemplary embodiment except for the formation of spacers after the first trench etch as will be described hereafter. 
         [0066]    Referring to  FIG. 2A , an SOI substrate  200  is provided or manufactured. The SOI substrate  200  includes an SOI layer  202 , a BOX layer  204  and a bottom substrate  206 . In exemplary embodiments, the SOI substrate is an extremely thin SOI substrate and may have a thin BOX layer as described previously. 
         [0067]    Referring now to  FIG. 2B , a pad film  208  may be formed over the SOI layer  202 . The pad film  208  and photoresist  210  may be used for forming openings  212  through the photoresist  210 , pad film  208  and SOI layer  202  as in the first exemplary embodiment. 
         [0068]    Referring now to  FIG. 2C , the first photoresist  210  is conventionally stripped. Thereafter, spacers  215  may be formed on the walls of the openings  212 . In an exemplary process, spacer material may be conformally deposited and then etched by a directional (anisotropic) reactive ion etching process to form the spacers  215 . The spacers  215  may be made from a material such as silicon oxide, silicon nitride, alumina or a high dielectric constant material such as hafnium oxide or hafnium silicate. The spacers  215  protect the SOI layer  202  in the upper part of the trench when the trench is enlarged in the bottom substrate  206 . 
         [0069]    Referring now to  FIG. 2D , a second photoresist  214  may be applied, exposed and developed to cover some of the openings  212 . Others of the openings  212  are left uncovered. The openings  212  that are left uncovered are referred to hereafter as DTI openings  216  and in a later step will be filled to function as deep trench isolation. The openings that are covered by the resist  214  are referred to hereafter as STI openings  218  and in a later step will be filled to function as shallow trench isolation. 
         [0070]    The DTI openings  216  are extended into the bottom substrate  206  by etching through the box layer  204  and a portion of the bottom substrate  206 . A directional RIE process may be used to extend the openings  216 . A RIE process similar to that in the first exemplary embodiment to extend the openings may be utilized here except that only the first step of the 2-step RIE process is used. In this exemplary embodiment, the DTI openings are extended in a first step and then enlarged as described hereafter in a second step. 
         [0071]    Referring to  FIG. 2E , the DTI openings  216  are enlarged in the bottom substrate  206  during the etching process to form bottle-shaped openings  220  within the bottom substrate  206 . The enlargement of the DTI openings  216  may be performed by a silicon etch process such as a wet etch by ammonia. The second photoresist  214  ( FIG. 2D ) may be conventionally stripped either before or after the formation of the bottle-shaped openings  220 . 
         [0072]    Referring now to  FIGS. 2F to 2H , processing of the SOI substrate  200  continues as in the first exemplary embodiment. That is, the DTI openings  216  and STI openings  218  may be filled and then planarized by a conventional chemical-mechanical polishing process as shown in  FIG. 2F  followed by stripping of the pad film  208  and implanting to form N wells  230  and P wells  232  as shown in  FIG. 2G . Thereafter, as shown in  FIG. 2H , conventional field effect transistor (FET) devices may be formed in SOI layer  202  separated by STI  228 . For purposes of illustration and not limitation, over N well  230  are formed pFETs  234  and over P well  232  are formed nFETs  236 . Interlevel dielectric  242  may be deposited and N well contacts  238  and P well contacts  240  may be formed. 
         [0073]    A third exemplary embodiment is illustrated in  FIGS. 3A to 3H . The third exemplary embodiment is similar to the first exemplary embodiment except for the formation of spacers after the first trench etch and the etching of the spacers occurring after the second lithography as will be described hereafter. 
         [0074]    Referring to  FIG. 3A , an SOI substrate  300  is provided or manufactured. The SOI substrate  300  includes an SOI layer  302 , a BOX layer  304  and a bottom substrate  306 . In exemplary embodiments, the SOI substrate is an extremely thin SOI substrate and may have a thin BOX layer as described previously. 
         [0075]    Referring now to  FIG. 3B , a pad film  308  may be formed over the SOI layer  302 . The pad film  308  and photoresist  310  may be used for forming openings  312  through the photoresist  310 , pad film  308  and SOI layer  302  as in the first exemplary embodiment. 
         [0076]    Referring now to  FIG. 3C , the first photoresist  310  is conventionally stripped. Thereafter, spacer material  315  may be conformally deposited everywhere so as to cover the walls and bottoms of the openings  312 . The spacer material may be a material such as silicon oxide, silicon nitride, alumina or a high dielectric constant material such as hafnium oxide or hafnium silicate. 
         [0077]    Referring now to  FIG. 3D , a second photoresist  314  may be applied, exposed and developed to cover some of the openings  312 . Others of the openings  312  are left uncovered. The openings  312  that are left uncovered are referred to hereafter as DTI openings  316  and in a later step will be filled to function as deep trench isolation. The openings that are covered by the resist  314  are referred to hereafter as STI openings  318  and in a later step will be filled to function as shallow trench isolation. 
         [0078]    Spacer material  315  within DTI openings  316  may be etched by a directional (anisotropic) reactive ion etching process to form the spacers  317 . The spacers  317  protect the SOI layer  302  in the upper part of the trench when the trench is enlarged in the bottom substrate  306 . The DTI openings  316  are extended into the bottom substrate  306  by a second directional reactive ion etching process (as described above in the second exemplary embodiment) through the box layer  304  and a portion of the bottom substrate  306 . 
         [0079]    Unetched spacer material  315  within STI openings  318  protected by the second photoresist  314  ensures a robust layer of spacer material  315  on the walls and bottom of the STI openings  318  and may help to prevent undesired electrical connection between the SOI layer  302  and the bottom substrate  306 . 
         [0080]    Referring to  FIG. 3E , the DTI openings  316  are enlarged in the bottom substrate  306  during the etching process to form bottle-shaped openings  320  within the bottom substrate  306 . The enlargement of the DTI openings  316  may be performed by a silicon etch process such as a wet etch by ammonia. The second photoresist  314  ( FIG. 3D ) may be conventionally stripped either before or after the formation of the bottle-shaped openings  320 . 
         [0081]    Referring now to  FIGS. 3F to 3H , processing of the SOI substrate  300  continues as in the first exemplary embodiment. That is, the DTI openings  316  and STI openings  318  may be filled and then planarized by a conventional chemical-mechanical polishing process as shown in  FIG. 3F  followed by stripping of the pad film  308  and implanting to form N wells  330  and P wells  332  as shown in  FIG. 3G . Thereafter, as shown in  FIG. 3H , conventional field effect transistor (FET) devices may be formed in SOI layer  302  separated by STI  328 . For purposes of illustration and not limitation, over N well  330  are formed pFETs  334  and over P well  332  are formed nFETs  336 . Interlevel dielectric  342  may be deposited and N well contacts  338  and P well contacts  340  may be formed. 
         [0082]    A fourth exemplary embodiment is illustrated in  FIGS. 4A to 4H . The fourth exemplary embodiment is similar to the first exemplary embodiment except for the etching of the SOI layers and the BOX layer during the first trench etch and for the formation of spacers after the first trench etch. 
         [0083]    Referring to  FIG. 4A , an SOI substrate  400  is provided or manufactured. The SOI substrate  400  includes an SOI layer  402 , a BOX layer  404  and a bottom substrate  406 . In exemplary embodiments, the SOI substrate is an extremely thin SOI substrate and may have a thin BOX layer as described previously. 
         [0084]    Referring now to  FIG. 4B , a pad film  408  may be formed over the SOI layer  402 . The pad film  408  and photoresist  410  may be used for forming openings  412  through the photoresist  410 , pad film  408  and SOI layer  402  as in the first exemplary embodiment. However, in this fourth exemplary embodiment, the openings  412  are further extended through the BOX layer  404 . There may also be a slight overetch into the bottom substrate  406  to ensure that the BOX layer  404  is completely etched through. 
         [0085]    Referring now to  FIG. 4C , the first photoresist  410  is conventionally stripped. Thereafter, spacers  415  may be formed on the walls of the openings  412 . Spacer material may be conformally deposited and then etched by a directional (anisotropic) reactive ion etching process to form the spacers  415 . The spacers may be made from a material such as silicon oxide, silicon nitride, alumina or a high dielectric constant material such as hafnium oxide or hafnium silicate. The spacers  415  protect the SOI layer  402  and BOX layer  404  in the upper part of the trench when the trench is enlarged in the bottom substrate  406 . 
         [0086]    Referring now to  FIG. 4D , a second photoresist  414  may be applied, exposed and developed to cover some of the openings  412 . Others of the openings  412  are left uncovered. The openings  412  that are left uncovered are referred to hereafter as DTI openings  416  and in a later step will be filled to function as deep trench isolation. The openings that are covered by the resist  414  are referred to hereafter as STI openings  418  and in a later step will be filled to function as shallow trench isolation. 
         [0087]    The DTI openings  416  are extended into the bottom substrate  406  by a directional reactive ion etching process (as described above in the second exemplary embodiment) through a portion of the bottom substrate  406 . 
         [0088]    Referring to  FIG. 4E , the DTI openings  416  are enlarged in the bottom substrate  406  during the etching process to form bottle-shaped openings  420  within the bottom substrate  406 . The enlargement of the DTI openings  416  may be performed by a silicon etch process such as a wet etch by ammonia. The second photoresist  414  ( FIG. 4D ) may be conventionally stripped either before or after the formation of the bottle-shaped openings  420 . 
         [0089]    Referring now to  FIGS. 4F to 4H , processing of the SOI substrate  400  continues as in the first exemplary embodiment. That is, the DTI openings  416  and STI openings  418  may be filled and then planarized by a conventional chemical-mechanical polishing process as shown in  FIG. 4F  followed by stripping of the pad film  408  and implanting to form N wells  430  and P wells  432  as shown in  FIG. 4G . Thereafter, as shown in  FIG. 4H , conventional field effect transistor (FET) devices may be formed in SOI layer  402  separated by STI  428 . For purposes of illustration and not limitation, over N well  430  are formed pFETs  434  and over P well  432  are formed nFETs  436 . Interlevel dielectric  442  may be deposited and N well contacts  438  and P well contacts  440  may be formed. 
         [0090]    A fifth exemplary embodiment is illustrated in  FIGS. 5A to 5H . The fifth exemplary embodiment is similar to the first exemplary embodiment except for the etching of the SOI layers and the BOX layer during the first trench etch, the formation of spacers after the first trench etch and the etching of the spacers occurring after the second lithography as will be described hereafter. 
         [0091]    Referring to  FIG. 5A , an SOI substrate  500  is provided or manufactured. The SOI substrate  500  includes an SOI layer  502 , a BOX layer  504  and a bottom substrate  506 . In exemplary embodiments, the SOI substrate is an extremely thin SOI substrate and may have a thin BOX layer as described previously. 
         [0092]    Referring now to  FIG. 5B , a pad film  508  may be formed over the SOI layer  502 . The pad film  508  and photoresist  510  may be used for forming openings  512  through the photoresist  510 , pad film  508  and SOI layer  502  as in the first exemplary embodiment. However, in this fifth exemplary embodiment, the openings  512  are further extended through the BOX layer  504 . There may also be a slight overetch into the bottom substrate  506  to ensure that the BOX layer  504  is completely etched through. 
         [0093]    Referring now to  FIG. 5C , the first photoresist  510  is conventionally stripped. Thereafter, spacer material  515  may be conformally deposited everywhere so as to cover the walls and bottoms the openings  512 . The spacer, material may be a material such as silicon oxide, silicon nitride, alumina or a high dielectric constant material such as hafnium oxide or hafnium silicate. 
         [0094]    Referring now to  FIG. 5D , a second photoresist  514  may be applied, exposed and developed to cover some of the openings  512 . Others of the openings  512  are left uncovered. The openings  512  that are left uncovered are referred to hereafter as DTI openings  516  and in a later step will be filled to function as deep trench isolation. The openings that are covered by the resist  514  are referred to hereafter as STI openings  518  and in a later step will be filled to function as shallow trench isolation. 
         [0095]    Spacer material  515  within DTI openings  516  may be etched by a directional (anisotropic) reactive ion etching process to form the spacers  517 . The spacers  517  protect the SOI layer  502  and BOX layer  504  in the upper part of the trench when the trench is enlarged in the bottom substrate  506 . The DTI openings  516  are extended into the bottom substrate  506  in a second directional reactive ion etching process (as described above in the second exemplary embodiment) by etching through a portion of the bottom substrate  506 . 
         [0096]    Unetched spacer material  515  within STI openings  518  protected by the second photoresist  514  ensures a robust layer of spacer material  515  on the walls and bottom of the STI openings  518  and may help to prevent undesired electrical connection between the SOI layer  502  and the bottom substrate  506 . 
         [0097]    Referring to  FIG. 5E , the DTI openings  516  are enlarged in the bottom substrate  506  during the etching process to form bottle-shaped openings  520  within the bottom substrate  506 . The enlargement of the DTI openings  516  may be performed by a silicon etch process such as a wet etch by ammonia. The second photoresist  514  ( FIG. 5D ) may be conventionally stripped either before or after the formation of the bottle-shaped openings  520 . 
         [0098]    Referring now to  FIGS. 5F to 5H , processing of the SOI substrate  500  continues as in the first exemplary embodiment. That is, the DTI openings  516  and STI openings  518  may be filled and then planarized by a conventional chemical-mechanical polishing process as shown in  FIG. 5F  followed by stripping of the pad film  508  and implanting to form N wells  530  and P wells  532  as shown in  FIG. 5G . Thereafter, as shown in  FIG. 5H , conventional field effect transistor (FET) devices may be formed in SOI layer  502  separated by STI  528 . For purposes of illustration and not limitation, over N well  530  are formed pFETs  534  and over P well  532  are formed nFETs  536 . Interlevel dielectric  542  may be deposited and N well contacts  538  and P well contacts  540  may be formed. 
         [0099]    After the processing described in  FIGS. 1A to 1G ,  2 A to  2 H,  3 A to  3 H,  4 A to  4 H and  5 A to  5 H, further conventional processing to form contacts and back end of the line wiring layers may proceed hereafter to form a semiconductor device such as a MOSFET. It is to be understood that the semiconductor structures shown in  FIGS. 1A to 1G ,  2 A to  2 H,  3 A to  3 H,  4 A to  4 H and  5 A to  5 H form only a part of a MOSFET and that there will be a plurality of such semiconductor structures in the finished MOSFET. 
         [0100]    It will be apparent to those skilled in the art having regard to this disclosure that other modifications of the exemplary embodiments beyond those embodiments specifically described here may be made without departing from the spirit of the invention. Accordingly, such modifications are considered within the scope of the invention as limited solely by the appended claims.

Technology Category: 5