METHOD OF FORMING SHAPED SOURCE/DRAIN EPITAXIAL LAYERS OF A SEMICONDUCTOR DEVICE
First Claim
1. A semiconductor device, comprising:
- a fin field-effect-transistor (Fin FET) device including;
a fin structure protruding from a substrate layer in a first direction and extending in a second direction perpendicular to the first direction;
a source/drain (SD) epitaxial structure disposed on the fin structure;
a gate stack including a gate electrode layer and a gate dielectric layer, covering a portion of the fin structure and extending in the second direction; and
a dielectric layer over sidewalls of the fin structure in a region of the SD epitaxial structure not covered by the gate stack, wherein the dielectric layer extends an entire length of the region of the SD epitaxial structure in the second direction, and wherein the SD epitaxial structure has a diamond shape top with limited lateral growth in the second direction and including flat side surfaces parallel to the first direction, and wherein an extent of the SD epitaxial structure in the second direction is limited to about outer sidewalls of the dielectric layer in the region of the SD epitaxial structure, the outer sidewalls of the dielectric layer are further away from the SD epitaxial structure.
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Accused Products
Abstract
In a method for manufacturing a semiconductor device, an isolation insulating layer is formed over a fin structure. A first portion of the fin structure is exposed from and a second portion of the fin structure is embedded in the isolation insulating layer. A dielectric layer is formed over sidewalls of the first portion of the fin structure. The first portion of the fin structure and a part of the second portion of the fin structure in a source/drain region are removed, thereby forming a trench. A source/drain epitaxial structure is formed in the trench using one of a first process or a second process. The first process comprises an enhanced epitaxial growth process having an enhanced growth rate for a preferred crystallographic facet, and the second process comprises using a modified etch process to reduce a width of the source/drain epitaxial structure.
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Citations
20 Claims
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1. A semiconductor device, comprising:
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a fin field-effect-transistor (Fin FET) device including; a fin structure protruding from a substrate layer in a first direction and extending in a second direction perpendicular to the first direction; a source/drain (SD) epitaxial structure disposed on the fin structure; a gate stack including a gate electrode layer and a gate dielectric layer, covering a portion of the fin structure and extending in the second direction; and a dielectric layer over sidewalls of the fin structure in a region of the SD epitaxial structure not covered by the gate stack, wherein the dielectric layer extends an entire length of the region of the SD epitaxial structure in the second direction, and wherein the SD epitaxial structure has a diamond shape top with limited lateral growth in the second direction and including flat side surfaces parallel to the first direction, and wherein an extent of the SD epitaxial structure in the second direction is limited to about outer sidewalls of the dielectric layer in the region of the SD epitaxial structure, the outer sidewalls of the dielectric layer are further away from the SD epitaxial structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A semiconductor device, comprising:
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a fin structure disposed on a substrate, the fin structure protruding from the substrate in a first direction and extending in a second direction perpendicular to the first direction; an isolation insulating layer disposed over the fin structure, wherein a first portion of the fin structure is exposed from the isolation insulating layer and a second portion of the fin structure is embedded in the isolation insulating layer; a gate structure disposed over a part of the first portion of the fin structure; a source/drain (SD) epitaxial structure disposed on opposite sides of the gate structure in an S/D region; and a dielectric layer disposed over sidewalls of the first portion of the fin structure in the S/D region not covered by the gate structure, wherein the dielectric layer extends an entire length of the S/D region in the second direction, and wherein an extent of the SD epitaxial structure in the second direction is limited to about outer sidewalls of the dielectric layer in a region of the SD epitaxial structure, the outer sidewalls of the dielectric layer are further away from the SD epitaxial structure. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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17. A semiconductor device, comprising:
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a first structure including a fin made of a first material disposed on a substrate, the first structure extends in a first direction, the first structure comprises a first portion exposed and a second portion embedded; a gate structure disposed over a part of the first portion of the fin; a dielectric layer disposed over sidewalls of the first portion of the fin in a source/drain region not covered by the gate structure, wherein the dielectric layer extends an entire length of the source/drain region in the first direction; and a source/drain (SD) epitaxial structure disposed in the source/drain region, an extent of a top part of the SD epitaxial structure in a second direction perpendicular to the first direction is limited to outer sidewalls of the dielectric layer in the source/drain region, wherein the outer sidewalls of the dielectric layer are further away from the SD epitaxial structure, and wherein the top part of the SD epitaxial structure includes flat side surfaces perpendicular to the first direction. - View Dependent Claims (18, 19, 20)
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Specification