FinFET Channel Isolation Structure to Suppress Fermi-Level Pinning

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Solution Overview

Problem

Current semiconductor manufacturing processes face challenges in achieving high integration density and efficient electrostatic control due to direct contact between source/drain regions and channel layers, leading to fermi-level pinning and reduced mobility.

Innovation Solution

The process involves forming insulating layers between the source/drain regions and the channel layer, which separates them, using techniques like oxidation and deposition of high-k dielectric materials, and patterning to create a finFET structure with specific layer configurations to enhance channel width and reduce contact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If source/drain regions are formed in direct contact with channel layer, then manufacturing process is simple, but fermi-level pinning occurs and mobility decreases

Engineering Contradiction:
Improvemanufacturing process simplicityVSAvoiddevice performance
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

An insulating layer is introduced as an intermediary between the source/drain regions and the channel layer. This insulating layer prevents direct contact while maintaining electrical functionality, thereby suppressing fermi-level pinning and improving carrier mobility without significantly complicating the manufacturing process.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If insulating layer is introduced between source/drain regions and channel layer, then fermi-level pinning is suppressed and mobility increases, but device structure becomes more complex

Engineering Contradiction:
Improvedevice performanceVSAvoidstructure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The device structure is segmented into distinct functional regions with the insulating layer creating a clear separation between the source/drain regions and the channel layer. This segmentation allows each region to be optimized independently while maintaining overall device performance and controlling complexity through modular design.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The insulating layer is applied locally only where needed at the interface between source/drain regions and channel layer, rather than throughout the entire device. This localized approach improves mobility where required while minimizing the overall structural complexity and material usage.

Inventive Principle:
Principle #3Local quality

3Reliability

If finFET structure with increased channel width is created, then electrostatic control is improved, but manufacturing precision requirements increase

Engineering Contradiction:
Improveelectrostatic controlVSAvoidlayer configuration precision
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The channel is extended into the vertical dimension by forming fins that protrude from the substrate. This three-dimensional finFET structure increases the effective channel width and improves electrostatic control without requiring proportional increases in lateral dimensions, thereby managing manufacturing precision requirements more effectively.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The finFET structure employs nested layering where the insulating layer is positioned within the vertical stack between the source/drain regions and the channel layer. This nested configuration allows multiple functional layers to be integrated in a compact vertical arrangement, improving electrostatic control while managing the complexity of layer alignment.

Inventive Principle:
Principle #7Nested doll (Nesting)

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

This approach effectively suppresses fermi-level pinning, improves electrostatic control, and increases intrinsic mobility, resulting in enhanced semiconductor device performance and reliability.

Implementation Method 1

forming insulating layers between the source/drain regions and the channel layer

Methodology Applied
Scientific EffectOxidation: Oxidation

Implementation Method 2

deposition of high-k dielectric materials

Methodology Applied
Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS20240113172A1Semiconductor device and manufacturing method thereof
Publication Date: 2024.04.04 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD
  • US20240113172A1 patent drawing
  • US20240113172A1 patent drawing
  • US20240113172A1 patent drawing

AI summary

A semiconductor device includes a substrate, a channel layer, a gate structure, source/drain regions, and an insulating layer. The channel layer is disposed over the substrate. The gate structure is disposed over the channel layer. The source/drain regions are disposed over the substrate and disposed at two opposite sides of the channel layer. The insulating layer is disposed between the channel layer and the source/drain regions.