Methods of forming FinFET semiconductor devices so as to tune the threshold voltage of such devices
First Claim
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1. A method of forming a FinFET device, comprising:
- forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining at least one fin comprised of said semiconducting substrate for said device;
forming a layer of insulating material in said trenches, wherein an upper portion of said at least one fin extends above an upper surface of said layer of insulating material so as to expose all sidewall surfaces and an entirety of a top surface of said upper portion of said at least one fin;
after forming said layer of insulating material, forming a conformal mask layer on all of said exposed sidewall and top surfaces of said upper portion of said at least one fin, wherein an exposed surface of said conformal mask layer conforms to a shape of said upper portion of said at least one fin;
removing said conformal mask layer from said upper portion of said at least one fin so as to re-expose all of said sidewall and top surfaces of said upper portion;
after removing said conformal mask layer and prior to forming a gate structure above said at least one fin, performing a first epitaxial growth process to grow a first semiconductor material at least at a location on said re-exposed upper portion of said at least one fin where at least a portion of said gate structure will be formed thereabove; and
forming said gate structure above said first semiconductor material on said at least one fin.
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Abstract
Disclosed herein are various methods of forming FinFET semiconductor devices so as to tune the threshold voltage of such devices. In one example, the method includes forming a plurality of spaced-apart trenches in a semiconducting substrate to define at least one fin (or fins) for the device, prior to forming a gate structure above the fin (or fins), performing a first epitaxial growth process to grow a first semiconductor material on exposed portions of the fin (or fins) and forming the gate structure above the first semiconductor material on the fin (or fins).
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Citations
36 Claims
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1. A method of forming a FinFET device, comprising:
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forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining at least one fin comprised of said semiconducting substrate for said device; forming a layer of insulating material in said trenches, wherein an upper portion of said at least one fin extends above an upper surface of said layer of insulating material so as to expose all sidewall surfaces and an entirety of a top surface of said upper portion of said at least one fin; after forming said layer of insulating material, forming a conformal mask layer on all of said exposed sidewall and top surfaces of said upper portion of said at least one fin, wherein an exposed surface of said conformal mask layer conforms to a shape of said upper portion of said at least one fin; removing said conformal mask layer from said upper portion of said at least one fin so as to re-expose all of said sidewall and top surfaces of said upper portion; after removing said conformal mask layer and prior to forming a gate structure above said at least one fin, performing a first epitaxial growth process to grow a first semiconductor material at least at a location on said re-exposed upper portion of said at least one fin where at least a portion of said gate structure will be formed thereabove; and forming said gate structure above said first semiconductor material on said at least one fin. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 25, 26, 27)
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15. A method of forming a FinFET device, comprising:
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forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining a plurality of fins comprised of said semiconducting substrate for said device; forming a layer of insulating material in said trenches, wherein an upper portion of each of said plurality of fins extends above an upper surface of said layer of insulating material so that all surfaces of said upper portions are exposed; after forming said layer of insulating material, forming a conformal mask layer on said all exposed surfaces of said upper portion of each of said plurality of fins; removing said conformal mask layer from a respective upper portion of at least a first one of said plurality of fins so as to re-expose said all surfaces of said respective upper portion of said at least said first one of said plurality of fins; after re-exposing said all surfaces of said respective upper portion of said at least said first one of said plurality of fins and prior to forming a gate structure above said plurality of fins, performing a first epitaxial growth process to grow a first semiconductor material on at least a portion of each of said plurality of fins, wherein said first semiconductor material is formed at least at a location on each of said plurality of fins where at least a portion of said gate structure will be formed thereabove; and forming said gate structure above said first semiconductor material. - View Dependent Claims (16, 28, 29, 30)
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17. A method of forming a FinFET device, comprising:
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forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining a plurality of fins comprised of said semiconducting substrate for said device; forming a layer of insulating material in said trenches, wherein an upper portion of each of said plurality of fins extends above an upper surface of said layer of insulating material so that all surfaces of said upper portions are exposed; after forming said layer of insulating material, forming a conformal mask layer on said all exposed surfaces of said upper portion of each of said plurality of fins; selectively removing said conformal mask layer from a respective upper portion of a first one of said plurality of fins so as to re-expose said all surfaces of said respective upper portion of said first one of said plurality of fins; prior to forming a gate structure above said plurality of fins, performing a first epitaxial growth process to grow a first semiconductor material on at least a portion of said re-exposed surfaces of said first one of said plurality of fins, wherein said first semiconductor material is formed at least at a location on said first one of said plurality of fins where at least a portion of said gate structure will be formed thereabove; after performing said first epitaxial growth process, selectively removing said conformal mask layer from a respective upper portion of a second one of said plurality of fins so as to re-expose said all surfaces of said respective upper portion of said second one of said plurality of fins; performing a second epitaxial growth process to grow a second semiconductor material on at least a portion of said re-exposed surfaces of said second one of said plurality of fins and said first semiconductor material on said first one of said plurality of fins; and after performing said first and second epitaxial growth processes, forming said gate structure above said first and second semiconductor materials. - View Dependent Claims (18, 19, 31, 32)
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20. A method of forming a FinFET device, comprising:
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forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining a plurality of fins comprised of said semiconducting substrate for said device; forming a layer of insulating material in said trenches, wherein an upper portion of each of said plurality of fins extends above an upper surface of said layer of insulating material so that all surfaces of said upper portions are exposed; after forming said layer of insulating material, forming a conformal hard mask layer that covers said all surfaces of a respective upper portion of at least a first one of said plurality of fins but leaves said all surfaces of a respective upper portion of at least a second one of said plurality of fins exposed for further processing, wherein said conformal hard mask layer is formed on and in direct contact with said all surfaces of said respective upper portion of said at least said first one of said plurality of fins and an exposed surface of said conformal hard mask layer conforms to a shape of said respective upper portion of said at least said first one of said plurality of fins; and performing a first epitaxial growth process in the presence of said conformal hard mask layer to grow a first semiconductor material on said all surfaces of said at least said second one of said plurality of fins exposed for further processing, said first semiconductor material extending along an entire axial length of said at least said second one of said plurality of fins. - View Dependent Claims (21, 22, 23, 24)
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33. A method of forming a FinFET device, comprising:
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forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining at least one fin comprised of said semiconducting substrate for said device; forming a layer of insulating material in said trenches, wherein an upper portion of said at least one fin extends above an upper surface of said layer of insulating material so as to expose all sidewall surfaces and an entirety of a top surface of said upper portion of said at least one fin; after forming said layer of insulating material, forming a conformal mask layer on all of said exposed sidewall and top surfaces of said upper portion of said at least one fin; removing said conformal mask layer from said upper portion of said at least one fin so as to re-expose all of said sidewall and top surfaces of said upper portion; after removing said conformal mask layer and prior to forming a gate structure above said at least one fin, performing a first epitaxial growth process to grow a first semiconductor material at least at a location on said re-exposed upper portion of said at least one fin where at least a portion of said gate structure will be formed thereabove; and forming said gate structure above said first semiconductor material on said at least one fin.
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34. A method of forming a FinFET device, comprising:
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forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining a plurality of fins comprised of said semiconducting substrate for said device; forming a layer of insulating material in said trenches, wherein an upper portion of each of said plurality of fins extends above an upper surface of said layer of insulating material so that all surfaces of said upper portions are exposed; after forming said layer of insulating material, forming a conformal hard mask layer that covers said all surfaces of a respective upper portion of at least a first one of said plurality of fins but leaves said all surfaces of a respective upper portion of at least a second one of said plurality of fins exposed for further processing; and performing a first epitaxial growth process in the presence of said conformal hard mask layer to grow a first semiconductor material on said all surfaces of said at least said second one of said plurality of fins exposed for further processing, said first semiconductor material extending along an entire axial length of said at least said second one of said plurality of fins. - View Dependent Claims (35)
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36. A method of forming a FinFET device, comprising:
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forming a plurality of spaced-apart trenches in a semiconducting substrate, said trenches defining a plurality of fins comprised of said semiconducting substrate for said device; forming a layer of insulating material in said trenches, wherein an upper portion of each of said plurality of fins extends above an upper surface of said layer of insulating material so that all surfaces of said upper portions are exposed; after forming said layer of insulating material, forming a conformal hard mask layer that covers said all surfaces of a respective upper portion of at least a first one of said plurality of fins but leaves said all surfaces of a respective upper portion of at least a second one of said plurality of fins exposed for further processing; performing a first epitaxial growth process in the presence of said conformal hard mask layer to grow a first semiconductor material on said all surfaces of said at least said second one of said plurality of fins exposed for further processing; and performing a second epitaxial growth process through said conformal hard mask layer to form a second semiconductor material on said first semiconductor material, said second semiconductor material extending along an entire axial length of said at least said second one of said plurality of fins.
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Specification