Globalfoundries Inc.

International Business Machines Corporation

Eric C T Harley

Judson Robert Holt

Alexander Reznicek

Yue Ke

Shogo Mochizuki

Thomas N Adam

Timothy James McArdle

Dominic Joseph Schepis

Abhishek Dube

Ashima B Chakravarti

Keith Howard Tabakman

Kangguo Cheng

Devendra K Sadana

Veeraraghavan S Basker

Stephen W Bedell

Michael Patrick Chudzik

Brian Joseph Greene

Renee Tong Mo

Gauri V Karve

Henry K Utomo

Rishikesh Krishnan

Derrick Liu

Linda R Black

Shwu-Jen Jeng

Michael D Steigerwalt

Matthew W Stoker

Melissa Alyson Smith

Hasan Munir Nayfeh

Rick J Carter

Yinxiao Yang

Jeremy John Kempisty

A semiconductor structure includes a fin upon a semiconductor substrate. A clean epitaxial growth surface is provided by forming a buffer layer upon fin sidewalls and an upper surface of the fin. The buffer layer may be epitaxially grown. Diamond shaped epitaxy is grown from the buffer layer sidewalls. In some implementations, the diamond shaped epitaxy may be subsequently merged with surrounding dielectric. A dopant concentration of the surrounding dielectric may be higher than a dopant concentration of the diamond shaped epitaxy.

Diamond shaped source drain epitaxy with underlying buffer layer

A method for producing a semiconductor structure, as well as a semiconductor structure, that uses a partial removal of an insulating layer around a semiconductor fin, and subsequently epitaxially growing an additional semiconductor material in the exposed regions, while maintaining the shape of the fin with the insulating layer.

Epitaxial growth of material on source/drain regions of FinFET structure

The present invention relates generally to semiconductor devices and more particularly, to a structure and method of forming an abrupt junction in the channel regions of high density technologies, such as tight pitch FinFET devices, using recessed source-drain (S-D) regions and annealing techniques. In an embodiment, a faceted buffer layer, deposited before the S-D region is formed, may be used to control the profile and dopant concentration of the junction under the channel. In another embodiment, the profile and dopant concentration of the junction may be controlled via a dopant concentration gradient in the S-D region.

Uniform junction formation in FinFETs

Embodiments of the present invention provide a method for epitaxially growing a FinFET. One method may include providing a semiconductor substrate including an insulator and an underlayer; forming a channel layer on the semiconductor substrate using epitaxial growth; etching a recess into the channel layer and epitaxially regrowing a portion on the channel layer; etching the channel layer and the underlayer to form fins; forming a gate structure and a set of spacers; etching a source drain region into the channel layer; and forming a source drain material in the source drain region.

Epitaxially grown silicon germanium channel FinFET with silicon underlayer

An embedded, strained epitaxial semiconductor material, i.e., an embedded stressor element, is formed at the footprint of at least one pre-fabricated field effect transistor that includes at least a patterned gate stack, a source region and a drain region. As a result, the metastability of the embedded, strained epitaxial semiconductor material is preserved and implant and anneal based relaxation mechanisms are avoided since the implants and anneals are performed prior to forming the embedded, strained epitaxial semiconductor material.

Stressed transistor with improved metastability

Methods of integrating reverse embedded silicon germanium (SiGe) on an NFET and SiGe channel on a PFET, and a related structure are disclosed. One method may include providing a substrate including an NFET area and a PFET area; performing a single epitaxial growth of a silicon germanium (SiGe) layer over the substrate; forming an NFET in the NFET area, the NFET including a SiGe plug in a channel thereof formed from the SiGe layer; and forming a PFET in the PFET area, the PFET including a SiGe channel formed from the SiGe layer. As an option, the SiGe layer over the PFET area may be thinned.

Methods of integrating reverse eSiGe on NFET and SiGe channel on PFET, and related structure

A semiconductor fabrication method involving the use of eSiGe is disclosed. The eSiGe approach is useful for applying the desired stresses to the channel region of a field effect transistor, but also can introduce complications into the semiconductor fabrication process. Embodiments of the present invention disclose a two-step fabrication process in which a first layer of eSiGe is applied using a low hydrogen flow rate, and a second eSiGe layer is applied using a higher hydrogen flow rate. This method provides a way to balance the tradeoff of morphology, and fill consistency when using eSiGe. Embodiments of the present invention promote a pinned morphology, which reduces device sensitivity to epitaxial thickness, while also providing a more consistent fill volume, amongst various device widths, thereby providing a more consistent eSiGe semiconductor fabrication process.

Method of forming source and drain of a field-effect-transistor and structure thereof

Solutions for fabricating a semiconductor structure. One embodiment includes a method for fabricating a semiconductor structure, the method including: forming a first dielectric structure on a substrate, the first dielectric structure including silicon nitride (SiN); forming a second dielectric structure in proximity to the first dielectric structure; and growing a non-epitaxial thin film from a surface of the first dielectric structure; wherein the growing includes using a combination of precursor, carrier and etchant with a ratio among the precursor, carrier, and etchant being adjusted for selective growth of the thin film on the surface, and wherein the thin film includes one selected from a group consisting of: a monocrystalline material, an amorphous material, a polycrystalline material and a combination thereof.

Fabricating semiconductor structures

Methods of fabricating a semiconductor structure with a non-epitaxial thin film disposed on a surface of a substrate of the semiconductor structure; and semiconductor structures formed thereof are disclosed. The methods provide selective non-epitaxial growth (SNEG) or deposition of amorphous and/or polycrystalline materials to form a thin film on the surface thereof. The surface may be a non-crystalline dielectric material or a crystalline material. The SNEG on non-crystalline dielectric further provides selective growth of amorphous/polycrystalline materials on nitride over oxide through careful selection of precursors-carrier-etchant ratio. The non-epitaxial thin film forms resultant and/or intermediate semiconductor structures that may be incorporated into any front-end-of-the-line (FEOL) fabrication process. Such resultant/intermediate structures may be used, for example, but are not limited to: source-drain fabrication; hardmask strengthening; spacer widening; high-aspect-ratio (HAR) vias filling; micro-electro-mechanical-systems (MEMS) fabrication; FEOL resistor fabrication; lining of shallow trench isolations (STI) and deep trenches; critical dimension (CD) tailoring and claddings.

Method for fabricating a semiconductor structures and structures thereof

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Lagrangeville, NY, United States of America

Eric C T Harley