Method and structure for forming dielectric isolated finFET with improved source/drain epitaxy
View Patent ↗Described herein is a FinFET device in which epitaxial layers of semiconductor material are formed in the source/drain regions on dielectrically isolated fin portions. The fin portions are located within a dielectric layer that is deposited on a semiconductor substrate. Surfaces of the fin portions are oriented in the {100} lattice plane of the crystalline material of the fin portions, providing for good epitaxial growth. Further described are methods for forming the FinFET device.
1. A method for forming a field effect transistor (FinFET) device, comprising:
depositing a dielectric layer on a semiconductor substrate material to surround crystalline fins;
applying an oxidation protection material to top portions of the fins and oxidizing lower portions of the fins to convert same to an oxide material;
removing a dielectric layer portion to leave fin portions within the dielectric layer;
removing the oxidation protection material from the upper portions of the fins;
annealing to remove the fins above the fin portions within the dielectric layer, the fin portions within the dielectric layer being dielectrically isolated from each other by the dielectric layer; and
forming, in source/drain regions, epitaxial layers of semiconductor material on seed surfaces of the fin portions that are within the dielectric layer.
2. The method of claim 1 , further comprising forming a gate structure between the source/drain regions.
3. The method of claim 2 , wherein the forming of the gate structure comprises forming a sacrificial gate structure on the device prior to annealing; and
replacing the sacrificial gate structure with a metal gate structure after forming the epitaxial layers of semiconductor material.
4. The method of claim 3 , further comprising forming an insulating layer comprising a high dielectric constant material around the metal gate structure.
5. The method of claim 1 , wherein the fins are formed out of the semiconductor substrate material by selectively removing material from the semiconductor substrate layer in a fin-forming pattern.
6. The method of claim 1 , wherein the annealing is conducted in an atmosphere comprising a hydrogen gas selected from hydrogen, deuterium and a combination of hydrogen and deuterium.
7. The method of claim 1 , wherein the seed surfaces of the fin portions are oriented in the {100} lattice plane.
8. A method for forming a field effect transistor (FinFET) device, comprising:
applying an oxidation protection material to top portions of crystalline fins;
depositing a dielectric layer on a crystalline semiconductor substrate material to enclose the fins;
oxidizing lower portions of the fins, converting same into fin tails;
removing a top portion of the dielectric layer, exposing upper fin parts extending from the fin tails and leaving fin tails within the dielectric layer;
removing the oxidation protection material from the upper fin parts;
forming a sacrificial gate structure between the source/drain regions;
annealing to remove the upper fin parts, the fin tails being left within the dielectric layer, the fin tails being dielectrically isolated from each other by the dielectric layer; and
forming, in source/drain regions, epitaxial layers of semiconductor material on seed surfaces of the fin tails.
9. The method of claim 8 , further comprising replacing the sacrificial gate structure with a metal gate structure.
10. The method of claim 9 , further comprising forming an insulating layer comprising a high dielectric constant material around the metal gate structure.
11. The method of claim 8 , wherein the annealing is conducted in an atmosphere comprising a hydrogen gas selected from hydrogen, deuterium and a combination of hydrogen and deuterium.
12. The method of claim 8 , wherein the seed surfaces of the fin tails are oriented in the {100} lattice plane.