GAA Nanostructure Gate Layout for Bottom Channel Control

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Solution Overview

Problem

Existing GAA FET devices and fabrication methods are not entirely satisfactory due to challenges in controlling current through the channel region, particularly on the bottom side, which affects device performance and increases contact resistance.

Innovation Solution

A method for forming a multi-gate semiconductor structure that includes forming fin structures over a substrate, disposing a dummy gate structure, removing portions of the fin structures to form recesses, and forming nanowires and gate structures within these recesses, which enhances control over the channel region and reduces contact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a FinFET structure is used with gate electrode adjacent to three side surfaces of channel region, then device density and performance are improved, but the bottom part of channel region is far from gate electrode resulting in poor gate control and increased short-channel effects

Engineering Contradiction:
Improvegate control over channel regionVSAvoidcontrol of current through channel region
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The patent transitions from a planar FinFET structure to a three-dimensional GAA FET structure where the channel region is positioned vertically and surrounded by the gate electrode on all sides. This dimensional change allows the gate to control the channel from top, bottom, and sides, eliminating the poor control issue at the bottom surface that exists in FinFETs.

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

Solution Approach 2:

The gate electrode is positioned to surround the channel region completely, with the gate wrapping around the channel from all directions. This nested configuration allows the gate structure to enclose the channel region, providing comprehensive control over current flow through the channel from all sides including the bottom surface.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Reliability

If existing GAA FET fabrication methods are used, then device structure is formed, but contact resistance remains high and device performance is not optimized

Engineering Contradiction:
Improvedevice performanceVSAvoidfabrication process complexity
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The method performs preliminary actions by first forming the channel region and then sequentially forming the gate dielectric layer and gate electrode around it. Source and drain regions are formed at specific stages, and contact holes are created with precise depth control to ensure optimal electrical contact while minimizing resistance. This staged approach optimizes device performance while managing fabrication complexity.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent applies different materials and processing conditions to different regions of the device. The gate dielectric layer uses high-k material for improved electrical characteristics, source and drain regions are selectively doped, and contact holes are formed with specific depth control to optimize local electrical properties. This localized optimization reduces contact resistance and enhances overall device performance.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS12272726B2Semiconductor structure with nanostructure
Publication Date: 2025.04.08 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD
  • US12272726B2 patent drawing
  • US12272726B2 patent drawing
  • US12272726B2 patent drawing

AI summary

Semiconductor structures and method for forming the same are provided. The semiconductor structure includes a substrate and nanostructures formed over the substrate and spaced apart from each other in a first direction. The semiconductor structure further includes a gate structure wrapping around the nanostructures and a semiconductor layer attached to the nanostructures in a second direction different from the first direction. The semiconductor structure further includes inner spacers sandwiched between the semiconductor layer and the gate structure in the second direction and a silicide layer formed over the semiconductor layer. In addition, a first portion of the semiconductor layer is sandwiched between the inner spacers and the silicide layer in the second direction.