Patent Document

This application is a Section 371 National Stage Application of International Application No. PCT/ CN2010/074392, filed Jun. 24, 2010, not yet published in the international stage. which is based on, and claims priority from Chinese Patent Application Serial No. 200910235339.9, filed on Sep. 30, 2009, entitled “Semiconductor Device and Method for Manufacturing the Same”, the contents of which are incorporated herein by reference in their entirety. 
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present invention relates to a semiconductor device and a method for manufacturing the same, in particular, to an improved FinFET formed on a semiconductor-on-insulator (SOI) substrate. 
     2. Description of Prior Art 
     One important trend in the integrated circuits is scaling down of metal-oxide-semiconductor field effect transistors (MOSFETs) so as to achieve a high integration degree of devices and reduce a cost of manufacture. However, it is well known that short channel effect occurs with a reduced size of the MOSFET, due to which, when the size of the MOSFET is reduced, the gate of the MOSFET has a smaller effective length and actually controls less charges in a depletion region with an applied gate voltage. Consequently, the MOSFET has a reduced threshold voltage with a reduced channel length. 
     A conventional planar MOSFET has a tri-layer structure including a gate electrode, a semiconductor layer, and a gate dielectric sandwiched therebetween. A channel region is provided in the semiconductor layer below the gate electrode, and source/drain regions are provided in the semiconductor layer adjacent to and at two opposing sides of the channel region. A silicide layer may be provided on the source/drain regions and then coupled with source/drain electrodes through vias so as to reduce a parasitic resistance or a parasitic capacitance of the device. The planar MOSFET suffers from the short channel effect and has a threshold voltage fluctuating with variation of the channel length. 
     To suppress the short channel effect, U.S. Pat. No. 6,413,802 discloses a FinFET formed on a SOI substrate, comprising a channel region provided in a central portion of a fin of semiconductive material and source/drain regions provided at two ends of the fin. A gate electrode is provided at both sides of the channel region and surrounds the latter to provide for example a double gate FinFET. Inversion channels are induced at both sides of the fin. The channel region in the fin has a small thickness so that the whole channel region is controlled by the gate, as a result of which, the short channel effect is suppressed. 
     However, in a conventional FinFET, the gate is provided between and extends parallel to the source/drain regions. Since the distance between the source/drain regions and the gate is typically small sufficient for a capacitive couple introduced therebetween, the resultant device has a large parasitic resistance and capacitance. 
     Moreover, the capacitive coupling between the source/drain regions and the gate limits the freedom of device design. For example, if one attempts to reduce a parasitic resistance, a thickness of the source/drain regions should be increased. However, the source/drain regions having a larger thickness also means an increased coupling area between the source/drain regions and the gate, which in turn causes a parasitic capacitance to increase, or vice versa. Thus, one skilled person in the art can not reduce both of the parasitic resistance and the parasitic capacitance together in a conventional FinFET. 
     Consequently, the conventional FinFET has a delay due to a large value of the time constant RC and thus has a low switching speed. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide a semiconductor device which can suppress the short channel effect while reducing the parasitic resistance and capacitance. 
     Another object of the present invention is to provide a semiconductor device which has improved electrical properties due to the induced stress. 
     According to one aspect of the invention, there is provided a semiconductor device formed on a SOI substrate comprising a buried insulating layer and a semiconductor layer on the buried insulating layer, wherein a fin of semiconductive material having two opposing sides perpendicular to a main surface of the SOI substrate is provided in the semiconductor layer, said semiconductor device comprising: a source region and a drain region provided at two ends of the fin respectively; a channel region provided at a central portion of the fin; and a stack of gate dielectric and gate conductor provided at one side of the fin, where the gate conductor is isolated from the channel region by the gate dielectric, wherein the gate conductor extends away from the one side of the fin in a direction parallel to the main surface of the SOI substrate. 
     According to another aspect of the invention, there is provided a method for manufacturing a semiconductor device, comprising steps of: a) providing a fin of semiconductive material in a semiconductor layer of a SOI substrate by a self-alignment process, the fin having two opposing sides perpendicular to the main surface of the SOI substrate; b) providing a stack of gate dielectric and gate conductor on one side of the fin, the gate conductor extending away from the one side of the fin in a direction parallel to the main surface of the SOI substrate; c) doping the semiconductor material of the fin at its two ends so as to provide a source region and a drain region respectively; and d) providing a channel region at a central portion of the fin. 
     It should be noted that the inventive semiconductor device includes a fin of semiconductive material but has a structure different from the conventional FinFET, because it&#39;s gate is provided at only one side of the fin and extends away from the one side of the fin. As a comparison, the conventional FinFET typically has a double gate structure which surrounds a channel region at the central portion of fin. Moreover, in the present invention, the source/drain regions are provided at two ends of the fin and extend in a direction opposite to the direction in which the gate extends. 
     Since in the inventive semiconductor device the gate does not extend between the source/drain regions parallel to the source/drain regions, there is no capacitive coupling between the source/drain regions and the gate. Thus, the inventive semiconductor device has a reduced parasitic capacitance. Meanwhile, the inventive semiconductor device allows a reduced parasitic resistance by providing source/drain regions having a relatively larger thickness. 
     The inventive semiconductive device also allows further suppression of the parasitic effect relevant with the parasitic capacitance and the parasitic resistance by providing extensions adjacent to the channel region in the fin so as to decrease a length of electrical conduction of the charge carriers. 
     Moreover, the inventive semiconductive device can have an increased switching speed by providing stressors for the source/drain regions so as to induce stress in the channel region. 
     For the purpose of effectively controlling the short channel effect, the channel region is provided with self-aligned process and has a small thickness, for example in the range of 5-40 nm. Preferably, a supper steep retrograde well (SSRW) is used so as to decrease the thickness of the channel region. Even in a case where the gate is provide at only one side of the fin, the gate can completely control the channel region and suppress the short channel effect. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A and 1B  are a perspective view and a top view respectively of a structure of a semiconductor device according to an embodiment of the present invention, wherein the top view shows lines A-A′,  1 - 1 ′ and  2 - 2 ′ for taking cross sections of the following figures; 
         FIGS. 2-9  are cross-sectional views of the structure of the semiconductor device at various stages of fabrication process according to an embodiment of the present invention, taken along line A-A′ and for illustrating the process steps of forming a fin and a gate. 
         FIGS. 10-16  are cross-sectional views of the structure of the semiconductor device at various stages of the subsequent fabrication process according to an embodiment of the present invention, taken along line  1 - 1 ′ and for illustrating the process steps of forming source/drain regions. 
         FIGS. 17-21  are cross-sectional views of the structure of the semiconductor device at various stages of the subsequent fabrication process according to an embodiment of the present invention, taken along line A-A′ and for illustrating the process steps of forming a channel region. 
         FIGS. 22A ,  22 B,  23 A and  238  are cross-sectional views of the structure of the semiconductor device at various stages of the subsequent fabrication process according to an embodiment of the present invention, taken along line A-A′ for  FIGS. 22A and 23A , line  2 - 2 ′ for  FIGS. 22B and 23B , and for illustrating the process steps of forming a silicide layer on the source/drain regions and the gate. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to same elements throughout. The figures are not drawn to scale, for the sake of clarity. 
     It should be understood that when one layer or region is referred to as being “above” or “on” another layer or region in the description of device structure, it can be directly above or on the other layer or region, or other layers or regions may be is intervened therebetween. Moreover, if the device in the figures is turned over, the layer or region will be “under” or “below” the other layer or region. 
     In contrast, when one layer is referred to as being “directly on” or “on and adjacent to” another layer or region, there are not intervening layers or regions present. 
     Some particular details of the invention will be described, such as an exemplary structure, material, dimension, process step and fabricating method of the device, for a better understanding of the present invention. Nevertheless, it is understood by one skilled person in the art that these details are not always essential for but can be varied in a specific implementation of the invention 
     Unless the context clearly indicates otherwise, each part of the semiconductor device can be made of material(s) well-known to one skilled person in the art. As an initial structure, a SOI substrate can be for example silicon-on-insulator substrate, silicon germanium-on-insulator substrate, or multilayer semiconductor-on-insulator substrate. The multilayer semiconductor includes for example group-III-V semiconductor, such as GaAs, InP, GaN, SiC. A gate conductor can be for example a metal layer, a doped polysilicon layer, or a multilayer gate conductor including a metal layer and a doped polysilicon layer. The metal layer is made of one selected from a group consisting of TaC, TiN, TaTbN, TaErN, TaYbN, TaSiN, HfSiN, MoSiN, RuTax, NiTax, MoNx, TiSiN, TiCN, TaAlC, TiAlN, TaN, PtSix, Ni3Si, Pt, Ru, Ir, Mo, HfRu, RuOx, and their combinations. A gate dielectric is made of SiO 2  or other dielectric insulation material which has a dielectric constant larger than that of SiO 2 , such as an oxide, a nitride, an oxynitride, a silicate, an aluminate, and a titanate. The oxide includes for example SiO 2 , HfO 2 , ZrO 2 , Al 2 O 3 , TiO 2 , La 2 O 3 . The nitride includes for example Si 3 N 4 . The silicate includes for example HfSiOx. The aluminate includes for example LaAlO 3 . The titanate includes for example SrTiO 3 . The oxynitride includes for example SiON. Moreover, the gate dielectric can be made of those developed in the future, besides the above known materials. 
       FIGS. 1A and 1B  are perspective and top views respectively of a structure of a semiconductor device according to an embodiment of the present invention. Lines A-A′,  1 - 1 ′ and  2 - 2 ′ in  FIG. 1B  indicate where the following cross-sectional views are taken. Specifically, line A-A′ is perpendicular to a length direction of a channel region and through a gate, line  1 - 1 ′ is parallel to the length direction of the channel region and through the channel region, and line  2 - 2 ′ is also parallel to the length direction of the channel region but through an insulating filler between source/drain regions. 
     Referring to  FIGS. 1A and 1B , a semiconductor device  100  is formed in a semiconductor layer of a SOI substrate, which comprises a channel region  11  at a central portion of a fin of semiconductive material, a source region  12  and a drain region  13  at two ends of the fin respectively, a stack of a gate  15  and a gate dielectric  14  disposed adjacent to one side of the fin, and an insulating filler  18  for filling a trench at the other side of the fin. 
     The channel region at the central portion of the fin has relatively small thickness, for example in a range of about 5-40 nm. The thickness of the channel region is approximately equal to that of the conventional FinFET and provided with a similar self-aligned process. 
     The inventor has found that the gate at one side of the fin, instead of a double gate configuration, can still control the whole channel region and thus suppress the short channel effect if the thickness of the channel region is set to be in the above range. 
     Preferably, the semiconductor device further includes stressors  16 ,  17  which apply stress to the source region  12  and the drain region  13  respectively. The stressors  16 ,  17  contact the source region  12  and the drain region  13  respectively, with a contact area as large as possible so that a contact resistance between the stressors  16 ,  17  and the source region  12  and the drain region  13  can be minimized. As shown in  FIGS. 1A and 1B , the source region  12  and the drain region  13  include trenches where the stressors  16 ,  17  are disposed with one side and a bottom thereof in contact with the source region  12  and the drain region  13 . 
     The stressors  16 ,  17  are made of a material inducing a stress in the channel region, which has beneficial effect on electrical property of the transistor. In a case of an n-type MOSFET, the stressors  16 ,  17  should apply tensile stress towards the channel region in a direction parallel to the source and drain regions so as to maximize mobility of electrons which function as charge carriers. On the other hand, in a case of a p-type MOSFET, the stressors  16 ,  17  should apply compressive stress towards the channel region in a direction parallel to the source and drain is regions so as to maximize mobility of holes which function as charge carriers. 
     It should be noted that the exemplary structure of the semiconductor device shown in  FIGS. 1A and 1B  includes stressors  16 ,  17  located in conduction paths between the source region  12  and a source contact (not shown), and between the drain region  13  and a drain contact (not shown). Thus, the stressors  16 ,  17  are also electrically conductive. For an n-type MOSFET, Si:C doped with As or P can be used as a material of the stressors. For a p-type MOSFET, SiGe doped with B can be used as a material of the stressors. 
     Additional layers and portions of the semiconductor device, which are disposed above the source region  12 , the drain region  13  and the gate  15 , are not shown in  FIGS. 1A and 1B , such as gate spacers, a silicide layer, a source contact, a drain contact, a gate contact, an interlayer insulator and vias formed therein, and a passivation layer. 
     In the following contents regarding the process steps of fabricating the semiconductor device, some of the above additional layers and portions related to the semiconductor device will be described, but detailed description of those additional layers or portions (for example a source contact, a drain contact, and a gate contact) well known to one skilled person are omitted. For simplicity, the structure of the semiconductor device having been subject to several relevant process steps may be shown in one figure. 
     Referring to  FIG. 2 , a method of manufacturing semiconductor device according to an embodiment of the present invention starts with an SOI wafer which is a stack of a bottom substrate  21 , a buried oxide layer (BOX)  22  and a top semiconductor layer  23 . 
     By a conventional deposition process, such as PVD, CVD, atomic layer deposition, sputtering and the like, a SiGe layer  24  which has a Ge content of about 5-15% and a thickness of about 3-20 nm and a Si layer  25  which has a thickness of about 30-100 nm are epitaxially grown in sequence on the SOI wafer. The Si layer  25  can be formed either in an independent deposition process or in-situ by using a Si target or a precursor in the same chamber after the SiGe layer  24  is epitaxially grown. 
     Then, a HfO 2  layer  26  which has a thickness of about 3-10 nm is formed on the Si layer  25  by atomic layer deposition or magnetron sputtering. 
     Referring to  FIG. 3 , by a conventional lithographical process including exposure and development steps, a photoresist pattern  27  in form of a stripe is formed on the HfO 2  layer  26 . 
     Referring to  FIG. 4 , with the photoresist pattern  27  as a mask, portions of the HfO 2  layer  26 , the Si layer  25 , and the SiGe layer  24  are selectively removed in sequence by dry etching such as ion beam milling, plasma etching, reactive ion etching, laser ablation and the like, so as to provide a stacked structure of the HfO 2  layer  26 , the Si layer  25 , and the SiGe layer  24  in a stripe pattern. 
     Two steps may be involved if the reactive ion etching is performed. At the first step, the portions of the HfO 2  layer  26  and the Si layer  25  are selectively removed with the SiGe layer  24  as a stop layer, by choosing a suitable gas in an etching atmosphere. At the second step, a portion of the SiGe layer  24  is further selectively removed with the top semiconductor layer  23  of the SOI substrate as a stop layer, by changing to another type of gas in the etching atmosphere. It is well known to one skilled person that one of the SiGe layer and the Si layer can be selectively removed by, controlling an etch selectivity with a different type of gas in an etching atmosphere being used in the reactive ion etching process. 
     Then, the photoresist pattern  27  is removed by ashing or dissolution with a solvent. A conformal thin oxide layer  28  which has a thickness of about 2-5 nm is formed on the stacked structure in the stripe pattern and on a exposed portion of the top semiconductor layer  23  of the SOI substrate. 
     The thin oxide layer can be formed by a conventional deposition process, such as PVD, CVD, atomic layer deposition, sputtering and the like. 
     Then, a conformal nitride layer is firstly formed and then has a portion thereof being removed so as to provide nitride spacers  29  which has a thickness of about 5-50 nm at both sides of the stacked structure comprising the HfO 2  layer  26 , the Si layer  25  and the SiGe layer  24 . 
     Referring to  FIG. 5 , by a conventional lithographical process including exposure and development steps, a photoresist pattern  30  is formed on the structure shown in  FIG. 4  so as to mask the spacer at the left side of the stacked structure and its left portion. 
     Referring to  FIG. 6 , with the photoresist pattern  30  as a mask, the spacer at the right side of the stacked structure is removed by an isotropic etching process, such as conventional wet etching using a solution of etchant. 
     Alternatively, the spacer at the right side of the stacked structure can be removed in three steps. At the first step, with the photoresist pattern  30  as a mask, an angular implantation of Ge is performed so as to cause damages in the spacer at the right side of the stacked structure. At the second step, the photoresist pattern  30  is removed by ashing or dissolution with a solvent. At the third step, by wet etching or dry etching, the spacer at the right side is selectively removed relative to the spacer at the left side. 
     After the spacer at the right side of the stacked structure is removed, the portion of the thin oxide layer  28  that is exposed on the main surface of the semiconductor structure is selectively removed by choosing a suitable gas in an etching atmosphere for example in an reactive ion etching. Then, with the remaining portion of the thin oxide layer  28 , the spacer  29  at the left side of the stacked structure and the stacked structure comprising the HfO 2  layer  26 , the Si layer  25  and the SiGe layer  24  as a hard mask, an exposed portion of the top semiconductor layer of the SOI substrate is selectively removed by changing to another type of gas in the etching atmosphere for example in the reactive ion etching, so as to provide a fin  23 ′ of semiconductive material in a self-aligned manner. 
     Referring to  FIG. 7 , by CVD or atomic layer deposition for example, a conformal thin oxide (for example, HfO 2 ) layer  26 ′ which has a thickness of about 2-4 nm, a conformal metal (for example, TiN, which is a metal ceramic) layer  31  which has a thickness of about 3-10 nm, and a blanket polysilicon layer  32  are formed in sequence on the main surface of the semiconductor structure shown in  FIG. 6 . The conformal thin oxide layer  26 ′ will provide a gate dielectric, and the conformal metal layer  31  and the polysilicon layer  32  constitutes a multiplayer gate conductor. 
     Preferably, the polysilicon layer  32  can be in-situ doped so as to improve an electrical conductivity. 
     The polysilicon layer  32  covers the whole top of the semiconductor structure. Then, the polysilicon layer  32  is subjected to a planarization process such as chemical mechanical polishing (CMP). The CMP stops at the top of the metal layer of the multilayer gate conductor so as to provide a flat surface for the semiconductor structure. 
     Referring to  FIG. 8 , by wet etching or dry etching, a portion of the polysilicon layer  32  is selectively removed relative to the metal layer  31  so that the polysilicon layer  32  is etched back. Then, for example by CVD, a blanket oxide layer  33  is formed on the whole surface of the semiconductor structure. 
     The oxide layer  33  is subjected to CMP which stops at the top of the metal layer of the multilayer gate conductor so as to provide a flat surface for the semiconductor structure. Consequently, the oxide layer  33  fills the portion of the polysilicon layer  32  removed by etching back. 
     Then, for example by CVD, a nitride layer  34  is formed on the main surface of the semiconductor structure. 
     Referring to  FIG. 9 , by a conventional lithographical process including exposure and development steps, a photoresist pattern  35  in form of a stripe is formed for defining a gate region of the device, the multilayer gate conductor comprising the metal layer  31  and the polysilicon layer  32 . 
     Then, with the photoresist pattern  35  as a mask and the buried oxide layer (BOX)  22  of the SOI wafer as a stop layer, portions of the nitride layer  34 , the oxide layer  33 , the polysilicon layer  32 , the metal layer  31  and the thin oxide layer  26 ′ that are located outside of the fin  23 ′ are removed in sequence by dry etching, such as ion beam milling, plasma etching, reactive ion etching, laser ablation and the like. 
     Corresponding to the cross sectional view of the semiconductor structure along line A-A′ shown in  FIG. 9 ,  FIG. 10  shows the cross sectional view of the semiconductor structure along line  1 - 1 ′. In the etching step with the photoresist pattern  35  as a mask, a stack of the nitride layer  34 , the oxide layer  33 , the polysilicon layer  32 , the metal layer  31 , and the thin oxide layer  26 ′ is provided on the Si layer  25 . 
     Before or after the above etching step, an additional masking step and an additional etching step can be involved so as to remove portions of the fin  23 ′, the SiGe layer  24  and the Si layer  25  for defining a length of the fin.  FIG. 10  shows the dimension of the length of the fin  23 ′ in a horizontal direction after that. 
     Referring to  FIG. 11 , still with the photoresist pattern  35  as a mask, portions of the Si layer  25  and the SiGe layer  24  are selectively removed in sequence by dry is etching such as ion beam milling, plasma etching, reactive plasma etching, laser ablation and the like, which stops at the top of the fin  23 ′. Consequently, a stack  101  of layers including the nitride layer  34 , the oxide layer  33 , the polysilicon layer  32 , the metal layer  31 , the thin oxide layer  26 ′, the Si layer  25  and the SiGe layer  24  is provided on the fin  23 ′. 
     Referring to  FIG. 12 , the photoresist pattern  35  is removed by ashing or dissolution with a solvent. 
     Then, for example by CVD, a conformal oxide layer  36  which has a thickness of about 2-5 nm and a conformal nitride layer  37  which has a thickness of about 10-20 nm are formed, in sequence on the whole surface of the semiconductor structure. 
     By dry etching, such as ion beam milling, plasma etching, reactive ion etching, laser ablation and the like, a portion of the nitride layer  37  is removed, with the oxide layer  36  as a stop layer, so as to form nitride spacers  37  at both sides of the fin  23 ′ and the stack of layers  101  respectively. 
     Referring to  FIG. 13 , with the stack of layers  101  and the nitride spacers  37  as a hard mask, a portion of the oxide layer  36  exposed at the main surface and a portion of the semiconductive material of the fin  23 ′ are removed by dry etching, such as ion beam milling, plasma etching, reactive ion etching, laser ablation and the like, so as to provide trenches  38  at two ends of the fin  23 ′ in its length direction (i.e. a horizontal direction in the drawing). A thin layer of semiconductive material, which has a thickness of about 10 nm, remains at the bottom of the trenches  38 . 
     The etching step is performed in a self-aligned manner, where the size of the trenches  38  is defined by the oxide layer  36  and the nitride spacers  37 . 
       FIG. 14  shows an optional step of the manufacturing method according to some embodiments, in which an angular ion implantation is performed through the trenches  38  towards to the central portion of the fin  23 ′ so as to provide halos in channel or in the substrate below the channel (i.e. a halo implantation). As a dopant for an n-type MOSFET, B or BF 2  may be used. As a dopant for a p-type MOSFET, As or P may be used. 
       FIG. 15  shows an optional step of the manufacturing method according to some embodiments, in which an angular ion implantation is performed through the trenches  38  towards to the central portion of the fin  23 ′ so as to provide source/drain extensions (i.e. an extension implantation). As a dopant for an n-type MOSFET, As or P may be used. As a dopant for a p-type MOSFET, B or BF 2  may be used. 
     Compared with the halo implantation, the extension implantation uses a relatively small implantation angle and a relatively large implantation energy. Consequently, in the extension implantation, most of the implanted ions pass through the thin layer of semiconductive material at the bottom of the trenches  38  so that no amorphous phase occurs in the thin layer of semiconductive material. 
     Since the trenches  38  provide a window for ion implantation, and the nitride layer  34 , the oxide layer  36  and the nitride spacers  37  on the surface of the semiconductor structure provide a hard mask, the above extension implantation, halo implantation and the source/drain implantation can be performed in-situ, which reduces the number of masks needed and simplifies the process steps. 
     Referring to  FIG. 16 , the resultant semiconductor structure is subjected to an anneal treatment, for example spike anneal. The anneal treatment is used to activate the dopants injected at the previous implantation steps and to eliminate implant damages. 
     After the anneal treatment, the doping profile in the fin  23 ′ of semiconductive material is also shown in  FIG. 16 , which includes a source region  12  and a drain region  13  provided at the bottom of the trenches  38 , a source extension  12 ′ adjacent to the source region  12 , a drain extension  13 ′ adjacent to the drain region  13 , a source halo  12 ″ adjacent to the source extension  12 ′ and extending towards to the central portion of the fin  23 ′, and a drain halo  13 ″ adjacent to the drain extension  13 ′ and extending towards to the central portion of the fin  23 ′. 
     Then, by a conventional deposition process, such as PVD, CVD, atomic layer deposition, sputtering and the like, stressors  39  and epitaxial silicon layer  40  are epitaxially grown in sequence in the trenches  38 . Due to the epitaxial growth, the to stressors  39  form only on the thin layer of semiconductive material at the bottom of the trenches  38 . For a p-type MOSFET, the stressors  39  may be made of SiGe which has a Ge content of about 20-50% and is doped with B in-situ, so as to apply a compressive stress to the channel region from the source/drain regions after the epitaxial growth to improve an electrical property of the p-type MOSFET. For an n-type MOSFET, the stressors  39  may be made of Si:C which has a C content of about 0.5-2% and is doped with As or P in-situ, so as to apply a tensile stress to the channel region from the source/drain regions after the epitaxial growth to improve an electrical property of the n-type MOSFET. 
     Then, the resultant semiconductor structure is subjected to oxidation so that a top of the epitaxial silicon layer  40  is oxidized and provides a thin oxide layer  36 ′ which has a thickness of about 3-10 nm. The epitaxial silicon layer  40  at the top of the stressors  39  is used to provide a high-quality SiO 2  layer. 
     Referring to  FIG. 17 , with the oxide layer  33  formed in the step shown in  FIG. 8  as a hard mask and the buried oxide layer  22  of the SOI wafer as a stop layer, portions of the metal layer  31 , the thin oxide layer  26 ′, the Si layer  25 , the SiGe layer  24  and the fin  23 ′ are removed in sequence by dry etching such as ion beam milling, plasma etching, reactive ion etching, laser ablation and the like, so as to provide a trench  41  in a self-aligned manner. Consequently, a thickness of the fin  23 ′ is reduced to be approximately equal to a sum of the thickness of the oxide layer  28  and that of the nitride spacer  29 . As mentioned above, the channel region is formed in the fin. Due to the removed materials in the trench, the stress induced in the channel region is enhanced so as to further improve an electrical property of the device. 
     At the right portion of the sidewall (i.e. a portion of the inner wall) of the trench  41 , a portion of the stack of the thin oxide layer  26 ′, the metal layer  31 , the polysilicon layer  32  and the oxide layer  33  remains. In the manufacture of an integrated circuit including a plurality of MOSFETs having the same structure, the portion of the stack of the thin oxide layer  26 ′, the metal layer  31 , the polysilicon layer  32  and the oxide layer  33  at the right portion of the sidewall of the trench  41  may be used to provide a gate, region for a next MOSFET (not shown in  FIG. 17 ), and the insulating filler in the trench  41  may provide a shallow trench isolation. 
     Moreover, as shown in  FIG. 17 , the nitride spacers  37  formed in the step shown in  FIG. 12  remain at the sidewall of the multilayer gate conductor. 
     Referring to  FIG. 18 , by dry etching such as ion beam milling, plasma etching, reactive ion etching, laser ablation and the like, the portions of the thin oxide layer  26 ′ and the metal layer  31  that remain at the sidewall (i.e. the right portion of the sidewall shown in  FIG. 18 ) of the trench  41  are selectively removed relative to the oxide layer  33 . 
     Preferably, ions are implanted into the fin  23 ′ of semiconductive material by an angular ion implantation, followed by an anneal treatment (for example, laser anneal) for activating the dopants, so as to provide a super steep retrograde well (SSRW)  42  in the fin  23 ′ at the side near the trench  41 . The trench  41  provides a window for ion implantation. The process for forming SSRW can be found in the following documents:
     1) G. G. Shahidi, D. A. Antoniadis and H. I. Smith, IEEE TED Vol. 36, p. 2605, 1989   2) C. Fiegna, H. Iwai, T. Wada, M. Saito, E. Sangiorgi and B. Riccò, IEEE TED Vol. 41, p. 941, 1994.   3) J. B. Jacobs and D. A. Antoniadis, IEEE TED Vol. 42, p. 870, 1995.   4) S. E. Thompson, P. A. Packan and M. T. Bohr, VLSI Tech Symp., p. 154, 1996.   

     Referring to  FIGS. 19 and 20 , the spacer  37  at the left side can be removed in three steps. At the first step, with the oxide layer  33  as a mask, an angular ion implantation of Ge is performed so as to cause damages in the spacer at the left side, as shown in  FIG. 19 . At the second step, the photoresist pattern is removed by ashing or dissolution with a solvent. At the third step, by wet etching or dry etching, the spacer at the left side is selectively removed relative to the spacer at the right side, as shown in  FIG. 20 . 
     Referring to  FIG. 21 , for example by CVD, a conformal thin oxide layer  33 ′ which has a thickness of about 2-5 nm is formed on the whole surface of the semiconductor structure. For example by CVD, a nitride is then deposited to a thickness sufficient for filling the trench  41 . The nitride layer is selectively etched back relative to the oxide layer  33 ′ so that the portion of the nitride layer around the trench  41  is completely removed and the nitride filler  43  remains in the trench  41 . 
     Referring to  FIGS. 22A and 22B , by dry etching such as ion beam milling, plasma etching, reactive ion etching, laser ablation and the like, the oxide is selectively removed relative to the nitride filler  43 . 
     The etching step removes completely the portion of the oxide layer  33 ′ that exposes at the main surface of the semiconductor structure, and the portion of the oxide layer  33 ′ that is located at the sidewall and the bottom of the trench is protected by the nitride filler  41  and remains. Consequently, a top surface and a left side of the polysilicon layer  32  of the multilayer gate conductor, and a top surface of the epitaxial silicon layer  40  at the source/drain regions are exposed. 
     The etching step also removes a portion of the buried oxide layer  22  of the SOI substrate. 
     Referring to  FIGS. 23A and 238 , by a conventional silicidation process, a portion of the top surface and the left side of the polysilicon layer  32  of the multilayer gate conductor, and at least a portion of the epitaxial silicon layer  40  at the source/drain regions are converted to a silicide layer, so as to minimize a contact resistance between the gates, the source/drain and the corresponding metal contacts. 
     For example, a Ni layer which has a thickness of about 5-12 nm is firstly deposited, and then subjected to a heat treatment at a temperature in a range of about 300-500° C. for about 1-10 seconds, so that at least a portion of the polysilicon layer  32  and the epitaxial silicon layer  40  is converted to NiSi. Finally, the unreacted Ni is removed by wet etching. 
     After the steps shown in  FIGS. 2-23  are finished, an interlayer insulator may be formed on the resultant semiconductor structure, and vias may be provided therein, wirings and electrical contacts may be provided on an upper surface of the interlayer insulator in conventional processes well known in the art, so that other parts of the semiconductor device are formed. 
     While the invention has been described with reference to specific embodiments, the description is illustrative of the invention and is not to be considered as limiting the invention. Various modifications and applications may occur for those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.

Technology Category: 5