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Front End Manufacturing Technology C. Rinn Cleavelin Si Technology Development Texas Instruments, Inc. Dallas, Texas

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Page 1: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

Front End Manufacturing Technology

C. Rinn CleavelinSi Technology Development

Texas Instruments, Inc.Dallas, Texas

Page 2: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

2

Topics Transistor Performance Trends Transistor Scaling Challenges New Device Architectures

Advanced CMOS Non-Classical CMOS Memories

New Front End Materials & Modules Lithographic Trends Summary

Page 3: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

3

The definition of Moores Law has come to

refer to almost anything related to the

semiconductor industry that when plotted on

semi-log paper approximates a straight line.

Gordon Moore, 1995

Moores Law / Productivity

Page 4: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

4

Transistor Performance Trend

1

10

100

1,000

10,000

100,000

1980 1985 1990 1995 2000 2005 2010 2015

Freq

uenc

y (M

Hz)

2X / 4 Years

2X / 2 - 2½ Years

2X / 2½ Years

MPU Clock Frequency Historical Trend:

Transistor scaling has contributed ~ 17-19%/yearArchitectural Design innovation contributed additional ~ 13-21%/year

Innovationneeded to maintain historical trend

Sources: SEMATECH, 2001 ITRS ORTC

Historical Data 01 ITRS Projection

Year

Page 5: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

5

Topics Transistor Performance Trends Transistor Scaling Challenges New Device Architectures

Advanced CMOS Non-Classical CMOS Memories

New Front End Materials & Modules Lithographic Trends Summary

Page 6: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

6

Transistor Scaling Key Challenges

Isolation: Minimum Pitch and SOI

Gate Dielectric: Leakage vs Speed

Gate Electrode: polySi vs Metal (Mid-gap vs Dual Work Function)

Ultra-Shallow Junctions (USJ) Low resistance contacts Low resistance abrupt S/D extensions

Page 7: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

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Technology Generation 130 nm 90 nm 65 nm 45 nm 32 nm 22 nmYear Production 2001 2004 2007 2010 2013 2016MPU Gate Length (nm)MPU Gate Length (nm) 6565 3737 2525 1818 1313 99DRAM (production) 512M 1G 4G 8G 32G 64GDRAM chip (cm2) 1.27 0.93 1.83 1.81 2.39 2.38 DRAM cost (µ ¢/bit) 7.7 2.7 0.96 0.34 0.12 0.042Wafer Diameter (mm)Wafer Diameter (mm) 300300 300300 300300 300300 450450 450450Logic M gates 97 193 386 773 1546 3092 Logic M gates/cm2 69 138 276 552 1104 2209Logic chip (cm2) 1.4 1.4 1.4 1.4 1.4 1.4Frequency (GHz) 1.7 3.9 6.7 11.5 19.3 28.7µP cost (µµµµ ¢/T) 97 34 12 4.3 1.5 0.54Power/ Chip (W) 130 160 190 218 251 288Power Supply MPU (V) 1.2 1.0 0.7 0.6 0.5 0.4Levels of Metal 7 8 9 9-10 9-10 10EOT (nm)EOT (nm) 1.31.3--1.61.6 0.90.9--1.41.4 0.60.6--1.11.1 0.50.5--0.80.8 0.40.4--0.60.6 0.40.4--0.50.5XXjj at Channel (nm)at Channel (nm) 2727--4545 1515--2525 1010--1717 77--1212 55--99 44--66

2001 ITRS Scaling Projections

Page 8: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

8

Device Scaling Issues: Beyond 65nm Gate Stack

Tunneling => high Ioff Inversion Layer => EOT limit PolySi Depletion => Ion reduced Mobility degradation => Ion reduced CD control Reliability

Source/Drain Series Resistance => Ion reduced Dopant Profile Control

TED suppression USJ abrupt S/D extensions Contacts to S/D

Tunneling Drain to body & source to drain

P-WELL

STI STISOURCE DRAIN

GATE

Si-Substrate

Halo I2

Threshold Voltage: VDD VT decreases Subthreshold Slope kT/q CD Control

Page 9: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

9

Isolation Roadmap

LOCOS ! Shallow Trench Isolation STI ! STI / SOI! SOI only?

STI induced to resolve LOCOS Birds Beak

Future device scaling and alternate structures such as Double Gate Logic devices and new member elements may lead to SOI only isolation.

IBM 16MB DRAMIBM 4MB DRAM

LOCOSSTI

Page 10: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

10

Gate Length Scaling: ITRS ITRS Roadmap Acceleration ContinuesGate Length

10

100

1000

1995 1998 2001 2004 2007 2010 2013 2016

Year of Production

Tech

nolo

gy N

ode

-DR

AM H

alf-P

itch

(nm

)

2001 MPU Physical Gate Length

1999 ITRS MPU Gate-Length

2-year Cycle

3-year Cycle

2001 MPU Printed Gate Length

Page 11: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

11

1.E-071.E-061.E-051.E-041.E-031.E-021.E-01

1.E+001.E+011.E+02

2001 2003 2005 2007 2009 2011 2013 2015

Year

J gat

e (A

/cm

2 )

0

0.5

1

1.5

2

2.5

3T

ox (nm)

Simulated Jgate, oxynitride

Specified Jgate, ITRS

Tox

Beyond this point, oxynitride too leaky; high K needed

Simulations by C. Osburn, NCSU and ITRS

2001 ITRS Projections Versus Simulations of Direct Tunneling Gate Leakage Current Density for Low Standby Power Logic

Page 12: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

12

Topics Transistor Performance Trends Transistor Scaling Challenges New Device Architectures

Advanced CMOS Non-Classical CMOS Memories

New Front End Materials & Modules Lithographic Trends Summary

Page 13: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

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Limits of CMOS ScalingPlanarCMOS

TIME

Device EvolutionDevice Evolution

DeviceStructure

Size

Non-Planar CMOS

New SwitchStructure

0 - 7 years. 7 - 12 years 12 + Years.

Sub 50nm ?c- Sibody

source

drainPSG

gate gate PSG

HfO2

100 nmAgere 02

Page 14: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

14

New Device Architectures SOI

Partially Depleted (PD) Fully Depleted (FD): Ultra-Thin Body

Double Gate Structures FinFET Tri, Pi Gate DG-SOI

Memory Innovations FeRAM, MRAM, Ovonics, etc

Page 15: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

15

SOI Device Structures

BuriedOxide

Si-Substrate

STI STISOURCE DRAIN

GATE

CSOI CSOI

Bulk CMOS Partially Depleted CMOSPartially Depleted CMOS

P-WELL

" Short Channel Effect controlled by channel doping/halo as in Bulk" Reduced junction capacitances => faster speed, lower leakage" Device design translation straight forward between Bulk and PD SOI" Complete isolation between devices" Rad-hard

P-WELL

STI STISOURCE DRAIN

GATE

Si-Substrate

CBULK CBULK

Halo I2

Page 16: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

16

Buried oxide

Drain(VD)

Partially versus Fully Depleted

Substrate = Back gate (VE)

Source(VS)

Drain(VD)

Gate (VG)

xs xd

tSi

tBOxbody region (Vbody)Substrate =Back gate (VE)

Source(VS)

Gate (VG)

tSi

tBOx

Partially depleted device" Bulk bottom junction capacitances

replaced by thick oxide capacitance " Gate side lateral junction

capacitance comparable to Bulk case. Can be smaller for PD in case of silicon film thinning

Fully depleted device" Bulk bottom junction capacitances

replaced by thick oxide capacitance " Full depletion of silicon film suppress

lateral junction capacitance"Speed improvement compared to PD

"Smaller power consumptionCourtesy of Olivier Faynot, LETI

Page 17: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

17

Buried oxide

Drain(VD)

Partially versus Fully Depleted

Substrate = Back gate (VE)

Source(VS)

Drain(VD)

Gate (VG)

xs xd

tsi

tBOxbody region (Vbody)Substrate =Back gate (VE)

Source(VS)

Gate (VG)

tsi

tBOx

Partially depleted device" 4 or 5 nodes" Front and back gate decoupled

" internal floating body node" Floating-Body effects" VT=f (Vbody) independent of VE

Fully depleted device" 4 nodes" tsi<40nm (for deep sub-µm MOS)" No neutral floating region

" independent of 'body' voltage" subthreshold swing=60mV/decade

" Front-Back interface coupling" VT= f (VE)

Courtesy of Olivier Faynot, LETI

Page 18: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

18

SOI: Power Reduction

Page 19: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

19

Merits of Device Scaling <50nm Options

- Fabrication very difficult- Parasitic elements?

- Best case for SCE control- Relaxed constraint on Tsi

Double Gate

- Parasitic capacitances increase- Reduced SCE

- Relaxed constraint on Tsi

Partial Ground Plane

- Parasitic capacitances increase

- Subthreshold swing increase

- Reduced SCE- Relaxed constraint on Tsi

Ground Plane

- Scalability: Ultra-thin film- Small parasitic capacitances

- Simpler FD architecture

Standard FD device

WeaknessesStrengths

Page 20: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

20

SOI is ~1.5 3x over bulk wafer pricing Etch Pit Density, typically ~600-1000/cm2

PD and to lesser extent FD have floating body effects which must be comprehended

FD requires Silicon body thickness control less than ~0.2 - 0.4x of Lg or for example 18nm Lg, tsi~36 - 72A for 45nm node

SOI Fabrication/Process Issues

Page 21: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

21

New Device Architectures SOI

Partially Depleted (PD) Fully Depleted (FD): Ultra-Thin Body

Double Gate Structures FinFET Tri, Pi Gate DG-SOI

Memory Innovations FeRAM, MRAM, Ovonics, etc

Page 22: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

22

Double Gate Structures: FinFET

Page 23: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

23

Double Gate Structures: FinFET Gate

Page 24: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

24

Double Gate Structures: Tri-Gate

Page 25: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

25

Double Gate Structures: Tri-Gate

Page 26: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

26

DG Fabrication/Process Issues Moat etch

Defines vertical gates Etch and gate dielectric interaction on vertical gate

structures Gate dielectric (including high-K integration)

Integrity, mobility, manufacturability Gate materials and etch

Depletion issues, hence Metal gate Junction and Contact

Ion Implant, PLAD, SEG Ground plane design

Implant through thin BOx

Page 27: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

27

Options Below 50nm

High +++10-20nmHigh1015-1016GP, PGP & Metal gate

Very High +++

++15-30nmHigh1015-1016DG & Metal gate

Very High +++

++5-15nmHigh1015-1016FD & Metal gate

High ++++10-20nmMedium1017-1018DG & N+ /P+ Poly

High ++10-20nmLow1018-1019GP, PGP, DG & N+ Poly

Very High ++++5-15nmLow1018-1019FD & N+ Poly

High ++50-150nmLow1018-1019PD

Ref. o-/Low1018-1019BULK

PerfParasitic cap

Silicon filmMobilityDoping

Page 28: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

28

New Device Architectures SOI

Partially Depleted (PD) Fully Depleted (FD): Ultra-Thin Body

Double Gate Structures FinFET Tri, Pi Gate DG-SOI

Memory Innovations FeRAM, MRAM, Ovonics, etc

Page 29: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

29Many choices in development

4b/cVt1111 0000

#cel

ls

Bit-Sense Line

M1 Word Lines

M4 Word Lines

Magnetic Storage Bits

M2 MetalM3 Metal

Top View

Side ViewSide ViewInterlayerDielectrics

M1 Word Lines

M4 Word Lines

1 1 1 10 0

Sense CurrentDirections

Data Storage Region

ResistiveElectrode

AmorphousChalcogenide

MaterialHeater

CrystallineAmorphousChalcogenide

Material

Crystalline

PolymerNROMETOX®-

4bpc

MRAM OUMFERAM

Word line

Charge Storage Sites in Nitride:

2 LocationsONO Stack

P-Sub

Bit Line

Oxide

Buried Diffusion Bit lines

* Other brands and names are the property of their respective owners

Word linePolymer Layer

Bit line Bit line Bit linePolymer Layer

Word line

Word line

S. Lai - Intel

Memory Technologies

Phase Change

Page 30: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

30

Memory Technologies Comparison

Log Number of Erase/Write Cycles

Log

Writ

e Ti

me

(fast

er >

)

ROM Space

ROMEPROM

Not in-systemChangeableUnlimited Read

Cycles

VolatileMemorySpace

SRAMDRAM

New NV RAM Space

FeRAM OUM MRAMLimited Unlimited Read Read Cycles Cycles

Flash Space

ETOX NAND

Unlimited Read Cycles

S. Lai - Intel

Page 31: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

31

FeRAMWhat Is FeRAM?

Operation Selected crystalline materials

have spontaneous polarization Data is stored by applying a

voltage to align the internal dipoles Up or Down

Attributes Non-Volatile Fast Random Read Access Fast Write with very low power

consumption Destructive read, limited read and

write cycles

E

P

Ec

Pr

Esat

Source: Physics Today 7/98

Page 32: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

32

Operation Cell is 1 MJT + 1 Transistor Electric current switches the

magnetic polarity Change in magnetic polarity

sensed as resistance change Attributes

Non-Volatile, High Density Non Destructive Read Low Voltage & Low Power Write = Read Speed, < 50 nsec Unlimited R/W Endurance Material compatibility with

CMOS a key challenge

Bit-Sense Line

M1 Word Lines

M4 Word Lines

Magnetic Storage Bits

M2 MetalM3 Metal

Top View

Side ViewSide ViewInterlayerDielectrics

M1 Word Lines

M4 Word Lines

1 1 1 10 0

Sense CurrentDirections

MRAM

S. Lai - Intel

Page 33: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

33

Topics Transistor Performance Trends Transistor Scaling Challenges New Device Architectures

Advanced CMOS Non-Classical CMOS Memories

New Front End Materials & Modules Lithographic Trends Summary

Page 34: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

34

New Front End Materials & Modules

Substrates: Strained Si SOI; Ultra Thin Body (UTB) Si 450mm

Gate Dielectrics: Oxide to High-k Gate Electrodes: doped polySi to metal gate Ultra-Shallow Junctions:

Raised S/D Non-equilibrium annealing

Gate Etch / CD Control and Clean

Page 35: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

35

SubstratesProgression of CMOS substrate technologies:Bulk SiliconBulk Silicon with Backside GetteringEpitaxial Silicon (P/P+)Partially Depleted (PD-SOI)Strained Silicon (SiGe Relaxed Hetero-structure)Partially Depleted Strained SiliconFully Depleted (FD-SOI)Fully Depleted Strained Silicon

Page 36: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

36

Strained-Si MOSFET Structures

Graded Layer0.05

=x

Drain

p+

n- Si1-yGeyy=

y

n+ Si Substrate

n+poly

n Strained Si

SourceSiO

p- Si1-yGey Graded Layery=0.05

y=x

p+ Si Substrate

n+poly

p Strained Si

Source DrainSiO2

Gate

n+ n+

high mobility (µ)channels

p- Relaxed Si1-xGex

2

Gate

n- Relaxed Si1-xGex

Strained Si1-xGex

Courtesy of J. Hoyt - MIT

p+

Graded Layer0.05

=x

Drain

p+

n- Si1-yGeyy=

y

n+ Si Substrate

n+poly

n Strained Si

SourceSiO

p- Si1-yGey Graded Layery=0.05

y=x

p+ Si Substrate

n+poly

p Strained Si

Source DrainSiO2

Gate

n+ n+

high mochannels

p- Relaxed Si1-xGex

2

Gate

n- Relaxed Si1-xGex

Strained Si1-xGexp+

+ Increased effective mobility, increased Ion

- Difficult integration issues: manufacturability- Compatibility with ultra-thin body SOI- Cost (~50% cost adder @300mm)

Page 37: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

37

Strained Silicon CMOS

Page 38: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

38

Gate Ox. 60 Å

Gate Poly-silicon

Strained Si n-MOSFETon Relaxed Si0.8Ge0.2Lpoly = 0.13 µm

LTOGate Spacer

High mobilityStrained Si Channel130 Å

Relaxed Si0.8Ge0.2

X200000

100 Å

Photo courtesy ofAPRDL, Motorola Inc.

Cross-Section TEM of Strained Si Channel

Rim, Hoyt,and Gibbons,IEDM 1998

Page 39: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

39

Cross-Section TEM of Strained Si Transistor

Courtesy UMC/Amberwave

Page 40: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

40

Strained Silicon Mobility Enhancement

Vertical Effective Field (MV/cm)0.1 0.2 0.3 0.4 0.5 0.6 0.7

Effe

ctiv

e M

obilit

y (c

m2 / V

-sec

)

0

200

400

600

800

0.290.200.10

VDS = 10 mV Substrate Ge Content, x :

CZ Si Control0

Vertical Effective Field (MV/cm)0.1 0.2 0.3 0.4 0.5 0.6 0.7

Effe

ctiv

e M

obilit

y (c

m2 / V

-sec

)0

50

100

150

200

0.290.220.10

VDS = -10 mV 295 K

Substrate Ge Content, x :

low-field electron and hole mobilities increase with tensile strain in Si peak mobility enhancement ratios: ~ 1.8 for 30% Ge substrate

NMOS PMOS

Courtesy Judy L. Hoyt

Page 41: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

41

SOI: Ultra Thin Body (UTB) Si

Yee-Chia Yeo, et. al. UTBFET for NanoCMOS

UTB SI with Strained Si combines advantages of SiGe/Si heterostructure with UTB low leakage

Page 42: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

42

Wafer Area Generation Model

0

1

10

100

1,000

10,000

100,00019

60

1965

1970

1975

1980

1985

1990

1995

2000

2005

2010

2015

2020

2025

Year

Area

Dem

and

Per Y

ear (

10^6

Sq.

Inch

es)

2002

Total Wafer Area Trend Model 1976-2025: 10% CAGRCAGRCAGRCAGR

100%

10%

33%

Ironman

Pilot LineLineLineLine

75/100mm125/150mm

200mm300mm

450mm

38/51mm

Sources: VLSI Research, SEMATECH, I300I

450mm out450mm out

2001 Projection for 450mm, 2013

Page 43: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

43

New Front End Materials & Modules

Substrates: Strained Si SOI; Ultra Thin Body (UTB) Si 450mm

Gate Dielectrics: Oxide to High-k Gate Electrodes: doped polySi to metal gate Ultra-Shallow Junctions:

Raised S/D Non-equilibrium annealing

Gate Etch / CD Control and Clean

Page 44: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

44

PolyPoly--Si /Si /

cc--SiSi

HfSiONHfSiON

Gate Dielectric: SiO2 to High-k

Si/SiO2Interface Control

Gate Oxide Thickness

Poly Si/SiOPoly Si/SiO22/Si TEM Cross/Si TEM Cross--sectionsection

Poly Si/SiOxNy/Si Poly Si/Poly Si/SiOSiOxxNNyy/Si /Si

N profile

Node: >/~250nm 180nm ~65nm ≤65nm?

Si Oxide+ Long History+ Reliable- Leaky < 25A

Si Oxide+ Long History+ Reliable- Leaky < 25A

Si Oxynitride+ Low B penetration+ Reliable- Not scalable <1nm

Si Oxynitride+ Low B penetration+ Reliable- Not scalable <1nm

HfSiON+ Mid High-k+ Scalable <1nm+ Low B penetration- Mobility degraded ~15%

Page 45: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

45

MOCVD HfO2 High-κ κ κ κ Dielectric

0

20

40

60

80

100

120

140

-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6

Voltage [V]

Cap

acita

nce

[pF]

Corrected Freq DataCVC Model

CVC ModelEOT = 0.95

nmVfb = -0.239 V

Nsurf = 2.11E15

Area = 5.0E-5 cm2Frequency = 100 and 250 kHzGate Electrode : PVD TiN

Gate Leakage4.3 A/cm2 @ 1V10 A/cm2 @ Vfb+1

HfO2 @ 485CInterface: N2O at 750C

PVD TiN 450 Å

HfO2 21 Å Interfacial layer 12 Å

Silicon substrate

TEM (left) for MOCVD HfO2 with EOT = 0.95 nm and CV curve (right) [80]Courtesy International SEMATECH

Effective Dielectric Constant ~ 13.5

Page 46: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

46

High-k Leakage Current versus EOT (trends)

1.E-08

1.E-06

1.E-04

1.E-02

1.E+00

1.E+02

1.E+04

1.E+06

0 5 10 15 20 25Equivalent Oxide Thickness [A]

Jg @

+/-

|Vfb

+1| [

A/cm

2 ]

SiO2 modelGoal LineALCVD HfO2

ALCVD Hf-AluminateALCVD Stacks

GoalJg 1A/cm2 @ EOT 1 nm

Page 47: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

47

High-k Manufacturability Issues Interface dielectric preparation and control High-k dielectric amorphous phase thermal

limitations Material etch characteristics / selectivity Boron penetration resistance High-k dielectric interactions with gate electrode Deposition complexities for multi-component

dielectric materials Conformal depositions for non-planar gate

structures Metrology of heterogeneous multilayer dielectric

films

Page 48: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

48

Gate Dielectric Scaling

Lattice fringes for gate dielectric

14 Å 17 Å 20 Å 29 ÅC-V

HRTEM 14.2 ± 1.7 Å 17.1 ± 2.0 Å 18.6 ± 1.7 Å 26.2 ± 2.2 ÅVert

ical

Sca

ling

Interface Control is critical to achieve <10A effective Gate Dielectric - To achieve 7A effective thickness:

Interface Dielectric <1AHigh-k dielectric <1APoly Depletion <1A => Metal GateChannel Quantum Effect ~4A

Page 49: Front End Manufacturing Technology · Memory Technologies Comparison Log Number of Erase/Write Cycles Log Write Time (faster >) ROM Space ROM EPROM Not in-system Changeable Unlimited

49

New Front End Materials & Modules

Substrates: Strained Si SOI; Ultra Thin Body (UTB) Si 450mm

Gate Dielectrics: Oxide to High-k Gate Electrodes: doped polySi to metal gate Ultra-Shallow Junctions:

Raised S/D Non-equilibrium annealing

Gate Etch / CD Control and Clean

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Gate Electrode: Why metal gate? polySi depletion

EOT reduces => Eox lower => inversion charge lower

For EOT scaling => polySidoping must increase

PMOSFETs: B penetration with thin gate dielectrics Nitrided gates used to reduce B

penetration Compatibility of polySi with

high-k dielectrics Gate resistance of very thin

gates even with silicide

Polysilicon Gate

Gate Oxide

Substrate

Depletion Layer

Tox

Inversion Layer

Wd,Poly

XC,QM

XC,Poly

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Gate Electrode Options

- Identification of Dual Metal system

- Integration difficult, esp. Dual Metal

- No poly depletion- VT can be lower than

0.4V- Intrinsic devices:(high µ expected)

Metal gate

- VT can not be lower than 0.4V

- No poly depletion - Intrinsic devices:(high µ expected)

Mid-gap gate

- Required doping level higher than PD/Bulk- Simpler Process

N+ Poly gate

Con'sPro's

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New Front End Materials & Modules

Substrates: Strained Si SOI; Ultra Thin Body (UTB) Si 450mm

Gate Dielectrics: Oxide to High-k Gate Electrodes: doped polySi to metal gate Ultra-Shallow Junctions:

Raised S/D Non-equilibrium annealing

Gate Etch / CD Control and Clean

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Ultra-Shallow Junctions - USJ

10

100

1000

10000

0 10 20 30 40 50 60 70 80Junction Depth (nm)

Rs

(ohm

/sq.

)

180-nm130-nm100-nm70-nm50-nm35-nmCrystalline DataPreamorphized DataLTA DataUHV-RTCVD DataVortek BF2 Data

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USJ Advanced Spike RTA

1.E+17

1.E+18

1.E+19

1.E+20

1.E+21

1.E+22

0 100 200 300 400 500 600Depth (A)

Bor

on C

once

ntra

tion

(atm

/cc)

PAI / 1.2E15 BF2 @ 5keV / 950°°°°C Spike

As Implanted

1050°°°°C SpikeRsh = 412

1050°°°°C Refined SpikeImproved T-tRsh = 481

1075°°°°C Refined SpikeRsh = 382

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1E+18

1E+19

1E+20

1E+21

0 50 100 150 200 250depth (Å)

conc

entra

tion

(/cc)

as implanted

1189°C flash - 414 Ω/

1370°C flash - 433 Ω/

Flash assisted Impulse Anneal, 800°C Flash assisted Impulse Anneal, 800°C Intermediate TemperatureIntermediate Temperature

T

Time

IntermediateTemperature

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Raised Source/Drain

Raised Source/DrainRaised Source/Drain

Advantages Improves drive current Improves SCE Essential for FD-SOI with

ultra-thin-body Needs

Low Temp Selective EPI process <650 C

Facet control at sidewall edge

High doping (Ge, B, P) Low defects Good uniformity Low CoO

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New Front End Materials & Modules

Substrates: Strained Si SOI; Ultra Thin Body (UTB) Si 450mm

Gate Dielectrics: Oxide to High-k Gate Electrodes: doped polySi to metal gate Ultra-Shallow Junctions:

Raised S/D Non-equilibrium annealing

Gate Etch / CD Control and Clean

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Parameters involved in Line-edge roughness add in quadrature:σσσσ LER

2 = σσσσSHOTNOISE2 + σσσσDIFFUSION

2 + σσσσ AERIAL IMAGE2 + σσσσ DEVELOPMENT

2 + σσσσ ETCH 2 + σσσσ MASK

2

Gate Stack Etch

Issues:LER of resist • resist molecular scales (~ 5 nm)• image contrast and flare• mask roughness• development effects

Etched gate edge roughness• transfer of LER from resist • does not scale with etch bias• granularity of film stack adds

Line and sidewall edge roughness

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Atomistic Lateral Scaling of Gate Length

Gate Edge CD Control and Transistor Performance critical to etching and cleaning chemistries

Gate Stack CD Control

293 lattice planes = 91.9nm wide

Dr. T.J. Headley, Sandia IMRL

Late

ral S

calin

g

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FEOL Clean Challenges New Materials and Processes

Cleaning and drying High Aspect Ratio (HAR) structures Interface control for deposited high-k dielectrics Post high-k gate stack etch cleans compatible with exposed

materials and CD control Interface control for epitaxial Si and Si-Ge

Scaling and Defect Levels Removal of small particles without affecting materials and

structures Control of contaminates (carbon, etc) for non-oxide gate

dielectrics ESH

Chemical, DI water, energy reduction, and hazardous chemical elimination and avoidance

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Topics Transistor Performance Trends Transistor Scaling Challenges New Device Architectures

Advanced CMOS Non-Classical CMOS Memories

New Front End Materials & Modules Lithographic Trends Summary

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32

1.51

0.4 0.350.25

0.180.13

0.10.07

0.05

0.50.6

0.01

0.1

1

10

1980 1990 2000 2010Year

Mic

rons

The Sub-Wavelength Gap

Stretching out wavelength

Abovewavelength

Nearwavelength

Belowwavelength

g-lineλλλλ=436nm

i-lineλλλλ=365nm

DUVλλλλ=248nm

193λλλλ=193nm 157 (VUV)

λλλλ=157nm

Pulling in feature size

Source: Numerical Technologies

0.035

λλλλ =EUV 13.5 nm

Res

olut

ion

Lithographic Front End Trends

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Lithographic Front End Trends

Start mass production

2001 2003 2005 2007

Technology generation

130 nm 90 nm 65 nm 45 nm

Minimum half-pitch

160 nm 115 nm 80 nm 55 nm

k1-factor

λ=248 nm, NA=0.7

0.45 λ=193 nm, NA=0.63

0.52

λ=193 nm, NA=0.63

0.38 λ=193 nm, NA=0.75

0.45

λ=193 nm, NA=0.85

0.35 λ=157 nm, NA=0.85

0.43

λ=157 nm, NA=0.95?

0.33 λ=157 nm, NA=1.25?

0.44 Respective

DOF in micron

0.48

0.47

0.47

0.32

0.25

0.22

0.16

0.09

Layer-layer overlay

45 nm 32 nm 22 nm 15 nm

Liquid immersion lithography, assuming index = 1.4 and NA = 0.9 in liquid

In Keeping Pace with Moores Law

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Summary Front End Manufacturing Technology will undergo

significant changes both in the near-term and long-term as new processes, materials, and structures are introduced to meet Roadmap scaling requirements.

Material and process solutions potentially include high-k dielectrics, metal gate electrodes (mid-gap/dual), SOI (PD/FD), Strained Si, Spike and/or non-equilibrium annealing, Raised S/D, and others yet to be identified.

Longer-term new non-classical CMOS structures such as Dual Gate, FinFET, PI/Tri-gate, may be required in combination with new materials to provide the ultimate End-of-Roadmap devices.

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Acknowledgements

Allen Bowling, Texas Instruments Olivier Faynot, LETI Judy Hoyt, MIT Majid Mansoori, Texas Instruments Shane Palmer, Texas Instruments Walt Trybula, International SEMATECH Rick Wise, Texas Instruments Peter Zeitzoff, International SEMATECH

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Backup Charts

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∆ Es ~ 670.x(meV)

Effects of Biaxial Tensile Strain on Si Energy Bands and Mobility

Conduction BandSplitting between ∆2 and ∆4

- reduced intervalleyscattering

- smaller in-plane effectivetransport mass

k

Bulk Si Strained Si

HH

LH

Spin-Orbit

E EValence Band

HH/LH degeneracy lifted at Γ

- reduced interbandscattering

- smaller in-plane transport mass due to band deformation

Γin-plane out-of-

planek

∆2

∆4

[001]

[010]

[100]

∆4

∆2

∆6Ec

Bulk Si Strained Si

ml

mtmt

mt < mlµ = q τ

m*c

Strained Si grown on Relaxed Si1-xGexbiaxial tension

Courtesy of J. Hoyt - MIT