Disclosure of Invention
The invention solves the problem of providing a semiconductor device and a forming method thereof, so that the performance of the formed semiconductor device is stable.
In order to solve the above problems, the present invention provides a method for forming a semiconductor device, comprising the steps of: providing a substrate, wherein a plurality of discrete arrangement fin parts are formed on the substrate; forming a pseudo gate structure crossing the fin part on the substrate; forming at least one hard mask layer which is arranged separately on the pseudo gate structure; forming a sacrificial side wall on the side wall of the hard mask layer; forming a sacrificial layer between the adjacent sacrificial side walls; removing the sacrificial side wall and the pseudo gate structure covered by the sacrificial side wall to form an opening; and filling a dielectric layer in the opening, wherein the top of the dielectric layer is flush with the top of the hard mask layer.
Optionally, the dielectric layer includes a single layer structure or a stacked layer structure.
Optionally, when the dielectric layer is in a single-layer structure, the material of the dielectric layer includes one of silicon oxide, silicon nitride, silicon oxynitride, silicon oxycarbide, silicon carbonitride, or silicon oxycarbonitride.
Optionally, when the dielectric layer is in a laminated structure, the dielectric layer includes a first dielectric layer and a second dielectric layer, and the second dielectric layer is located on the first dielectric layer.
Optionally, the material of the first dielectric layer is different from the material of the second dielectric layer.
Optionally, the material of the first dielectric layer includes one or more of silicon oxynitride or silicon oxycarbonitride.
Optionally, the material of the second dielectric layer is silicon nitride.
Optionally, the material of the hard mask layer includes one or more of silicon nitride or silicon oxide or silicon carbide or silicon oxycarbide.
Optionally, the material of the sacrificial sidewall includes one or more of silicon oxide, silicon nitride or silicon carbide.
Optionally, after filling the dielectric layer in the opening, the top of the dielectric layer is flush with the top of the hard mask layer, and then the sacrificial layer and the dummy gate structure covered by the sacrificial layer are removed.
A semiconductor device formed by the above method includes a substrate; the fin parts are separately positioned on the substrate; a dummy gate structure located on the substrate across the fin; the hard mask layers are separately positioned on the pseudo gate structure; openings located between adjacent hard mask layers and between adjacent dummy gate structures under the hard mask layers; the dielectric layer is positioned in the opening, and the top of the dielectric layer is flush with the top of the hard mask layer; and the sacrificial layer is positioned between the adjacent dielectric layers and is positioned on the dummy gate structure.
Compared with the prior art, the technical scheme of the invention has the following advantages:
the method comprises the steps of forming a plurality of hard mask layers which are arranged separately on a pseudo gate structure, forming a sacrificial side wall on the side wall of the hard mask layer, removing the sacrificial side wall and the pseudo gate structure covered by the bottom of the sacrificial side wall, forming an opening in the pseudo gate structure, filling a dielectric layer in the opening, wherein the formed dielectric layer is used as the side wall of the pseudo gate structure, and the dielectric layer is not formed on a fin part because the dielectric layer is only filled in the opening and is used as the side wall of the pseudo gate structure, so that the surface quality of the formed fin part is ensured, the performance fluctuation of a formed semiconductor device is small, the yield is improved, an epitaxial layer with good appearance quality can be formed when a source drain is formed, and the stability of the service performance of the formed semiconductor device is ensured.
Detailed Description
The method for forming the side wall on the side wall of the pseudo gate structure is generally adopted, namely, a side wall material layer is formed on the substrate, the fin part and the pseudo gate structure, the side wall material layer is etched back until the top surface of the fin part is exposed, and the side wall covering the side wall of the pseudo gate structure is formed on the fin part, but at the moment, part of side wall material is remained on the side wall of the fin part, so that the fluctuation of the performance of the formed semiconductor device is large, the yield of the semiconductor device is influenced, and meanwhile, when a source and a drain are formed, the growth morphology of an epitaxial layer is strange, and the performance of the semiconductor device is influenced.
The specific semiconductor device is formed as follows:
Referring to fig. 1, a substrate 1 is provided, and a fin 2 is formed on the substrate 1.
Referring to fig. 2 to 3, a dummy gate structure 3 is formed on the substrate 1 across the fin 2.
Fig. 3 is a cross-sectional view of fig. 2 along section line A-A.
Referring to fig. 4, a sidewall material 4 is formed on the substrate 1, the fin 2, and the dummy gate structure 3.
Referring to fig. 5, the sidewall material 4 is etched back, and a sidewall 401 is formed on the sidewall of the dummy gate structure 3.
The inventor finds that after the side wall material is formed on the substrate, the fin part and the pseudo gate structure, the side wall material is etched back, a side wall is formed on the side wall of the pseudo gate structure, and part of the side wall material is also formed on the side wall of the fin part, so that the performance fluctuation of the formed semiconductor device is too large, and meanwhile, part of the side wall material is remained on the fin part, so that when source and drain are formed later, the epitaxial layer formed by epitaxial layer growth is abnormal in morphology, and the yield and performance of the formed semiconductor device are affected.
The inventor researches and discovers that a hard mask layer which is arranged separately is formed on a pseudo gate structure, a sacrificial side wall is formed on the side wall of the hard mask layer, and a sacrificial layer is formed between the adjacent sacrificial side walls; removing the sacrificial side wall and the dummy gate structure covered by the bottom of the sacrificial side wall to form an opening; filling the opening with a dielectric layer, wherein the top of the dielectric layer is flush with the top of the hard mask layer; the formed dielectric layer is used as the side wall of the pseudo gate structure, and the dielectric layer material is not deposited first, so that the dielectric layer material is not left on the fin part, the surface quality of the formed fin part is ensured, the performance of the formed semiconductor device is stable, the yield is improved, and meanwhile, when the source and the drain are formed, an epitaxial layer with good appearance can be formed, and the service performance of the formed semiconductor device is improved.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings.
First embodiment
Fig. 6 to 14 are schematic structural views of a semiconductor device forming process in the first embodiment of the present invention.
Referring first to fig. 6, a substrate 200 is provided, the substrate 200 having a plurality of discrete arrangement fins 300 formed thereon.
In this embodiment, the material of the substrate 200 is monocrystalline silicon; in other embodiments, the substrate 200 may be monocrystalline silicon, polycrystalline silicon, or amorphous silicon; the substrate 200 may also be a semiconductor material such as silicon, germanium, silicon germanium, gallium arsenide, or the like.
In this embodiment, the step of forming the fin 300 includes: forming a fin material film on the substrate 200, and forming a patterned layer on the fin material film; and etching the fin material film by taking the patterned layer as a mask to form the fin 300.
In this embodiment, the fin 300 is made of monocrystalline silicon or monocrystalline germanium silicon.
Referring to fig. 7-8, a dummy gate structure 400 is formed on the substrate 200 across the fin 300.
Fig. 8 is a cross-sectional view taken along line A-A of fig. 7.
In this embodiment, the material of the dummy gate structure 400 is polysilicon; in other embodiments, the material of the dummy gate structure 400 may also be amorphous carbon or silicon nitride.
The method of forming the dummy gate structure 400 includes: forming a gate oxide layer (not shown in the figure) on the surfaces of the substrate 200 and the fin 300, forming a gate layer on the gate oxide layer, and forming a patterned layer on the gate layer, wherein the patterned layer covers a corresponding region where the dummy gate structure 400 needs to be formed; and etching the gate layer and the gate oxide layer by taking the patterned layer as a mask until the substrate 200 is exposed, wherein the formed dummy gate structure 400 spans across the fin 300.
Referring to fig. 9, at least one hard mask layer 500 is formed on the dummy gate structure 400 in a discrete arrangement.
In this embodiment, the material of the hard mask layer 500 is silicon oxide; in other embodiments, the hard mask layer 500 may also be one or more of silicon nitride or silicon carbide or silicon oxycarbide.
In this embodiment, the step of forming the hard mask layer 500 includes: including first forming the material of the mask layer 500 on top of the dummy gate structure 400, and then etching back the material of the mask layer 500 using a self-aligned double patterning process (SADP), thereby forming at least one hard mask layer 500 in a discrete arrangement on the dummy gate structure 400.
In other embodiments, at least one hard mask layer 500 may be formed separately on the dummy gate structure 400 without etching back the mask layer 500 material using a self-aligned double patterning process (SADP).
In this embodiment, the material of the hard mask layer 500 is formed on top of the dummy gate structure 400 by using an atomic layer deposition method; in other embodiments, the material of the hard mask layer 500 may be formed on top of the dummy gate structure 400 by chemical vapor deposition or physical vapor deposition.
In this embodiment, the reason for forming the hard mask layer 500 by using the atomic layer deposition method is that the atomic layer deposition method can form the hard mask layer 500 with higher density, so as to improve the protection effect of the hard mask layer 500 on the dummy gate structure 400 in the subsequent process, and ensure the performance of the formed semiconductor device.
Referring to fig. 10, sacrificial sidewall 501 is formed on the sidewall of the hard mask layer 500.
In this embodiment, by forming the sacrificial sidewall 501 on the sidewall of the hard mask layer 500, the position of forming the sidewall on the sidewall of the dummy gate structure 400 is predefined, so that it is not necessary to deposit the sidewall material first and then etch back the sidewall material.
In this embodiment, the material of the sacrificial sidewall 501 is silicon carbide; in other embodiments, the material of the sacrificial sidewall 501 may further include one or more of silicon oxide or silicon nitride.
Referring to fig. 11, a sacrificial layer 502 is formed between adjacent sacrificial side walls 501.
In this embodiment, the material of the sacrificial layer 502 is silicon nitride; in other embodiments, the material of the sacrificial layer 502 may also be silicon carbide, silicon oxide, or the like.
In this embodiment, the purpose of forming the sacrificial layer 502 protects the dummy gate structure 400 covered by the sacrificial layer 502, so as to ensure that the covered dummy gate structure 400 is not removed simultaneously in the process of removing the sacrificial sidewall 501.
Referring to fig. 12, the sacrificial sidewall 501 and the dummy gate structure 400 at the bottom of the sacrificial sidewall 501 are removed to form an opening 401.
In this embodiment, the sacrificial sidewall 501 and the dummy gate structure 400 at the bottom of the sacrificial sidewall 501 are removed by dry etching, so as to form the opening 401.
In this embodiment, the process parameters for removing the sacrificial sidewall 501 include: and removing the sacrificial side wall 501 by adopting anisotropic dry etching, wherein the technological parameters of the dry etching are as follows: fluorine-containing gas (such as CH 3F、CH2F2 or CHF 3), argon and oxygen are adopted, the etching power is 200W-400W, the pressure of an etching cavity is 30-200 mtorr, and the etching temperature is 40-60 ℃.
In other embodiments, a wet etching process or an ashing process may be used to remove the sacrificial sidewall 501.
In this embodiment, the purpose of removing the dummy gate structure 400 at the bottom of the sacrificial sidewall 501 by dry etching is to ensure the quality of the remaining dummy gate structure; meanwhile, a relatively high etching solution is required to be selected for etching, so that less damage is caused to the gate oxide layer at the bottom of the pseudo gate structure.
In this embodiment, HBr gas is used as etching gas; in other embodiments, SF6 gas may also be used as the etching gas.
Referring to fig. 13, the opening 401 is filled with a dielectric layer 600, and the top of the dielectric layer 600 is flush with the top of the hard mask layer 500.
In this embodiment, the dielectric layer 600 has a single-layer structure; in other embodiments, the dielectric layer 600 may also have a stacked structure.
In this embodiment, the material of the dielectric layer 600 is silicon nitride; in other embodiments, the material of the dielectric layer 600 may be one of silicon oxide, silicon oxynitride, silicon oxycarbide, silicon carbonitride, or silicon oxycarbonitride.
In this embodiment, the dielectric layer 600 is filled in the opening 401, and the dielectric layer 600 is used as a sidewall of the dummy gate structure 400, so that when the sidewall of the dummy gate structure 400 is formed, the material of the sidewall is not remained on the fin portion 300, the surface quality of the fin portion 300 is ensured, the performance stability of the formed semiconductor device is enhanced, and the yield of the semiconductor device is improved; meanwhile, as the surface quality of the fin part 300 is good, an epitaxial layer with good appearance can be formed when source and drain are formed later, and the quality of a formed semiconductor device can be guaranteed.
A semiconductor device formed by the above method, comprising, a substrate 200; a plurality of fins 300, separately located on the substrate 200; a dummy gate structure 400 located on the substrate 200 across the fin 300; a plurality of hard mask layers 500 separately located on the dummy gate structure 400; openings 401 between adjacent ones of the hard mask layers 500 and between adjacent ones of the dummy gate structures 400 under the hard mask layers 500; a dielectric layer 600 located within the opening 401 with the top level with the top of the hard mask layer 500; and a sacrificial layer 502 located between adjacent dielectric layers 600 and on the dummy gate structure 400.
Referring to fig. 14, the sacrificial layer 502 and the dummy gate structure 400 covered by the sacrificial layer 502 are removed.
In this embodiment, an isotropic wet etching process is used to remove the sacrificial layer 502, where parameters of the wet etching process include: an aqueous solution of HNO 3 and HF, wherein the volume ratio of HNO3, HF and H2O is 1:3: (10 to 800) and the temperature is 40 to 90 ℃.
In this embodiment, after the sacrificial layer 502 is removed, a wet etching process is used to remove the dummy gate structure 400 covered by the sacrificial layer 502, where tetramethylammonium hydroxide (TMAH) is used as an etching solution in the wet etching process.
Second embodiment
The present embodiment differs from the first embodiment only in the structure of the dielectric layer.
In this embodiment, the dielectric layer adopts a stacked structure.
Fig. 15 to 16 are schematic structural views of a semiconductor device forming process in the second embodiment of the present invention.
Referring to fig. 15, the opening 401 is filled with a first dielectric layer 700, and the top of the first dielectric layer 700 is level with the top of the dummy gate structure 400.
In this embodiment, the top of the first dielectric layer 700 is flush with the top of the dummy gate structure 400; in other embodiments, the top of the first dielectric layer 700 may also be lower than the top of the dummy gate structure 400.
In this embodiment, the material of the first dielectric layer 700 is a material with a low dielectric constant, such as silicon oxynitride; in other embodiments, the material of the first dielectric layer 700 may be silicon oxynitride.
In this embodiment, the first dielectric layer 700 uses a material with a low dielectric constant as a part of the sidewall material, so that parasitic capacitance between the gate structure and the conductive plug can be reduced, thereby improving ac characteristics of the semiconductor device.
Referring to fig. 16, a second dielectric layer 800 is formed on the first dielectric layer 700, and the top of the second dielectric layer 800 is flush with the top of the hard mask 500.
In this embodiment, the second dielectric layer 800 uses pure silicon nitride as a part of the sidewall material, and since the pure silicon nitride has a slower etching rate, the second dielectric layer 800 is not easily etched when the conductive plug is formed later, so that the gate structure is better separated from the conductive plug, and the distance between the gate structure and the conductive plug is ensured.
A semiconductor device formed by the above method includes a substrate 200; the fin parts 300 are separately positioned on the substrate 200, and the pseudo gate structure 400 is positioned on the substrate 200 and spans across the fin parts 300; a plurality of hard mask layers 500 separately located on the dummy gate structure 400; openings 401 between adjacent ones of the hard mask layers 500 and between adjacent ones of the dummy gate structures 400 under the hard mask layers 500; a first dielectric layer 700 located within the opening 401; a second dielectric layer 800 located on the first dielectric layer 700; and a sacrificial layer 502, which is located between the adjacent second dielectric layers 800 and is located on the dummy gate structure 400.
Although the present invention is disclosed above, the present invention is not limited thereto. Various changes and modifications may be made by one skilled in the art without departing from the spirit and scope of the invention, and the scope of the invention should be assessed accordingly to that of the appended claims.