Epitaxial Source/Drain Isolation Layer for Leakage Control

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Solution Overview

Problem

As minimum feature size reduces in semiconductor devices, issues such as leakage and parasitic devices arise, necessitating improved isolation between source/drain regions to mitigate these side effects.

Innovation Solution

A selective gap fill process is employed to form a high-quality bottom isolation layer using a dielectric material, followed by an epitaxial process to create source/drain regions, enhancing isolation and adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If minimum feature size is reduced to increase integration density, then more components can be integrated into a given chip area, but leakage and parasitic devices occur

Engineering Contradiction:
Improveintegration densityVSAvoidleakage and parasitic devices
Core Design Contradiction:
ProductivityVSObject-generated harmful factors

Solution Approach 1:

The source/drain structure is segmented into multiple discrete regions separated by dielectric material layers. The bottom dielectric layer divides the source/drain into distinct segments, preventing parasitic device formation and leakage between adjacent regions while maintaining high integration density.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

A bottom dielectric layer is introduced as an intermediary material between the source and drain regions. This dielectric layer acts as a mediator that electrically isolates the source/drain regions, eliminating leakage paths and parasitic devices while allowing the miniaturized structure to function properly.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of manufacture

If conventional isolation methods are used without bottom dielectric layer, then fabrication is simpler, but leakage occurs between source/drain regions across gate structure

Engineering Contradiction:
Improvefabrication simplicityVSAvoidleakage between source/drain regions
Core Design Contradiction:
Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The bottom dielectric layer is formed preliminarily before the source/drain regions are created. This preliminary isolation layer is deposited and patterned in advance, establishing electrical isolation boundaries before the conductive source/drain regions are formed, thereby preventing leakage from the outset.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The dielectric material is selectively placed only where isolation is needed - specifically at the bottom of source/drain regions and in mesa regions beneath the gate structure. This localized application of dielectric material provides targeted leakage prevention without complicating the overall fabrication process.

Inventive Principle:
Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides effective isolation between source/drain regions, reducing leakage and parasitic device formation, thereby improving device performance and reliability.

Implementation Method 1

depositing a first material layer

Methodology Applied
Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Implementation Method 2

treating the first material layer to convert the first material layer into a dielectric-containing material layer

Methodology Applied
Scientific EffectPhase Change: Phase Change

Implementation Method 3

growing an epitaxial source/drain region over the bottom isolation layer

Methodology Applied
Scientific EffectEpitaxy: Epitaxy

Data Source

PatentUS20250393270A1Semiconductor devices with epitaxial source/drain region with a bottom dielectric layer and methods of fabrication thereof
Publication Date: 2025.12.25 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD
  • US20250393270A1 patent drawing
  • US20250393270A1 patent drawing
  • US20250393270A1 patent drawing

AI summary

Embodiments with present disclosure provides a gate-all-around FET device including a bottom isolation layer. The bottom isolation layer prevents leaks around the source/drain regions and improve device performance.