Multi-Vt Gate-All-Around Transistors via Dipole Diffusion

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Solution Overview

Problem

Current semiconductor technologies face challenges in scaling down device size while achieving different gate threshold voltages without degrading performance, particularly for gate-all-around transistors, due to limitations in device-device spacing and the need for thicker gate dielectrics for higher voltage operations.

Innovation Solution

The method involves forming nanosheet stacks with varying work function metal layer thicknesses and diffusing a dipole material into an interfacial layer to create different gate threshold voltages without patterning, using a single dipole layer thickness and adjusting sacrificial material thicknesses to achieve multiple threshold voltage pairs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If device dimensions are reduced to enable scaling, then device density increases, but device-device spacing becomes insufficient for higher voltage operation

Engineering Contradiction:
Improvedevice densityVSAvoiddevice-device spacing
Core Design Contradiction:
ProductivityVSLength of moving object

Solution Approach 1:

The patent implements different gate dielectric thicknesses in different regions of the semiconductor device. Specifically, first gate dielectric layers are formed with a first thickness in first regions, while second gate dielectric layers are formed with a second thickness in second regions. This local differentiation allows high voltage devices to have thicker dielectrics for adequate spacing while low voltage logic devices can have thinner dielectrics for higher density, thereby resolving the contradiction between device density and device-device spacing for higher voltage operation.

Inventive Principle:
Principle #3Local quality

2Reliability

If thicker gate dielectrics are used for higher voltage operation, then voltage operation capability improves, but device scaling is limited

Engineering Contradiction:
Improvevoltage operation capabilityVSAvoiddevice scaling
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent applies different gate dielectric thicknesses to different functional regions. High voltage devices (such as input/output circuits) receive thicker gate dielectric layers that provide the necessary breakdown voltage and reliability, while logic devices receive thinner gate dielectric layers that enable continued scaling and higher device density. This localized approach allows the system to achieve both high voltage operation capability and continued device scaling.

Inventive Principle:
Principle #3Local quality

3Adaptability or versatility

If different gate threshold voltages are achieved through patterning, then multi-Vt capability is obtained, but manufacturing complexity increases

Engineering Contradiction:
Improvemulti-Vt capabilityVSAvoidmanufacturing complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent achieves multi-threshold voltage capability by changing the physical parameters of the gate structure. Specifically, it varies the thickness of gate dielectric layers and work function metal layers across different regions. By controlling these dimensional parameters during deposition, the patent creates devices with different threshold voltages without requiring additional patterning steps or complex manufacturing processes, thus obtaining multi-Vt capability while minimizing manufacturing complexity.

Inventive Principle:
Principle #35Parameter changes

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 enables multi-Vt schemes for gate-all-around transistors without sacrificing device performance, allowing for viable scaling beyond the 7 nm node and compatibility with aggressively scaled nanosheet devices by modulating threshold voltages effectively.

Implementation Method 1

diffusing the dipole material, by anneal, into the IL to provide different gate threshold voltages

Methodology Applied
Scientific EffectDiffusion: Diffusion

Implementation Method 2

diffusing the dipole material, by anneal, into the IL

Methodology Applied
Scientific EffectAnnealing: Annealing

Data Source

PatentUS11152264B2Multi-Vt scheme with same dipole thickness for gate-all-around transistors
Publication Date: 2021.10.19 INTERNATIONAL BUSINESS MACHINE CORPORATION
  • US11152264B2 patent drawing
  • US11152264B2 patent drawing
  • US11152264B2 patent drawing

AI summary

A method is presented for attaining different gate threshold voltages across a plurality of field effect transistor (FET) devices. The method includes forming first, second, and third nanosheet stacks, removing sacrificial layers of the first, second, and third nanosheet stacks, and depositing an interfacial layer and a high-k layer within the first, second, and third nanosheet stacks. The method further includes depositing a first work function metal (WFM) layer within the first nanosheet stack having a first thickness, depositing a second WFM layer within the second nanosheet stack having a second thickness, wherein the second thickness is greater than the first thickness, depositing a third WFM layer within the third nanosheet stack having a third thickness, wherein the third thickness is greater than the second thickness, depositing a dipole material, and diffusing the dipole material into the IL to provide different gate threshold voltages for the plurality of FET devices.