Zebra Nanosheet Multi-Stack Gate Oxide for Reliable Voltage Input

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Solution Overview

Problem

The challenge in semiconductor manufacturing lies in forming a thick extra gate (EG) oxide layer around nanosheet layers in multi-stack transistors, particularly on lower stacks, due to the limited dimensions, which is difficult and costly, impacting the reliability of input voltage reception and analog circuit performance.

Innovation Solution

A method of manufacturing a multi-stack semiconductor device that includes forming a zebra nanosheet structure with an EG oxide layer between nanosheet layers and using intervening layers as a channel structure, allowing for the easy formation of EG oxide layers and enabling both standard and EG oxide gate structures on the same substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick extra gate (EG) oxide layer is formed around nanosheet layers in multi-stack transistors, then the reliability of input voltage reception and analog circuit performance is improved, but the manufacturing complexity and cost increase due to the limited dimensions between nanosheet layers

Engineering Contradiction:
Improvereliability of input voltage receptionVSAvoidmanufacturing complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The gate oxide layer is segmented into two distinct parts: a standard gate oxide layer and an extra gate (EG) oxide layer. The EG oxide layer is formed only in specific regions where reliability is critical (around nanosheet layers in multi-stack transistors), while other regions use only the standard gate oxide layer. This segmentation allows the patent to improve reliability where needed without unnecessarily increasing manufacturing complexity across the entire substrate.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies different oxide layer configurations to different regions of the substrate based on local requirements. Regions with multi-stack transistors containing nanosheet layers receive the additional EG oxide layer for enhanced reliability, while regions with simpler transistor structures use only the standard gate oxide layer. This local quality approach ensures that the increased manufacturing complexity is applied only where it provides value.

Inventive Principle:
Principle #3Local quality

2Reliability

If a thick extra gate (EG) oxide layer is formed around nanosheet layers in multi-stack transistors, then the reliability of input voltage reception is improved, but the manufacturing cost increases

Engineering Contradiction:
Improvereliability of input voltage receptionVSAvoidmanufacturing cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The gate oxide structure is divided into a standard gate oxide layer and an optional extra gate (EG) oxide layer. The EG oxide layer is segmented to appear only in regions requiring enhanced reliability (multi-stack transistors with nanosheet layers), allowing the patent to control manufacturing costs by avoiding unnecessary EG oxide formation in simpler transistor regions.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements local quality by providing enhanced gate oxide protection only where needed. The EG oxide layer is formed selectively in regions with multi-stack transistors and nanosheet layers, while other regions use the standard, less expensive gate oxide structure. This approach improves reliability where critical without uniformly increasing manufacturing costs across the entire substrate.

Inventive Principle:
Principle #3Local quality

3Productivity

If nanosheet transistors are used to achieve higher device density and improved current control, then device density and current control performance are improved, but the manufacturing process becomes more complicated and costly compared to FinFET

Engineering Contradiction:
Improvedevice densityVSAvoidmanufacturing process complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the manufacturing approaches for nanosheet transistors and FinFETs by using a common standard gate oxide layer formation process for both. The subsequent selective formation of the EG oxide layer provides the additional protection needed for nanosheet transistors without requiring entirely separate manufacturing lines. This merging reduces overall manufacturing complexity while maintaining the high device density benefits of nanosheet structures.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The standard gate oxide layer serves a universal function for both nanosheet transistors and FinFETs, providing basic gate insulation for all device types. The optional EG oxide layer then adds enhanced protection specifically where needed. This universal base layer approach simplifies manufacturing by using a single process for the foundation structure, reducing the complexity penalty associated with nanosheet transistor production.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Ease of manufacture

If standard gate oxide layer is used in all regions, then manufacturing is simpler and less costly, but regions requiring reliable input voltage reception (analog circuits) do not have sufficient protection against hard oxide breakdown

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidprotection against hard oxide breakdown
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The gate oxide structure is segmented into a universal standard gate oxide layer and a selective extra gate (EG) oxide layer. The EG oxide layer is segmented to appear only in regions requiring enhanced protection (analog circuits and multi-stack transistors), while other regions use only the simple standard gate oxide layer. This segmentation maintains manufacturing simplicity overall while providing enhanced protection where reliability is critical.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by providing enhanced gate oxide protection only in regions where reliable input voltage reception is required (analog circuits). The EG oxide layer is formed selectively in these regions, while digital or less critical regions use only the standard gate oxide layer. This approach ensures that regions requiring high reliability have sufficient protection against hard oxide breakdown without unnecessarily complicating manufacturing in other regions.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS20250107172A1Multi-stack semiconductor device with zebra nanosheet structure
Publication Date: 2025.03.27 SAMSUNG ELECTRONICS CO LTD
  • US20250107172A1 patent drawing
  • US20250107172A1 patent drawing
  • US20250107172A1 patent drawing

AI summary

A multi-stack semiconductor device includes: a substrate; a multi-stack transistor formed on the substrate and including a nanosheet transistor and a fin field-effect transistor (FinFET) above the nanosheet transistor, wherein the nanosheet transistor includes a plurality nanosheet layers surrounded by a lower gate structure except between the nanosheet layers, the FinFET includes at least one fin structure, of which at least top and side surfaces are surrounded by an upper gate structure, and each of the lower and upper gate structures includes: a gate oxide layer formed on the nanosheet layers and the at least one fin structure; and a gate metal pattern formed on the gate oxide layer. At least one of the lower and upper gate structures includes an extra gate (EG) oxide layer formed between the gate oxide layer and the nanosheet layers and/or between the gate oxide layer and the at least one fin structure.