US 12,327,729 B2
Semiconductor FinFET device and method
Chih-Yu Wang, Taichung (TW)
Assigned to Taiwan Semiconductor Manufacturing Company, Ltd., Hsinchu (TW)
Filed by Taiwan Semiconductor Manufacturing Co., Ltd., Hsinchu (TW)
Filed on Jan. 17, 2023, as Appl. No. 18/155,554.
Application 18/155,554 is a division of application No. 17/012,525, filed on Sep. 4, 2020, granted, now 11,615,965.
Application 17/012,525 is a division of application No. 16/277,023, filed on Feb. 15, 2019, granted, now 10,770,302, issued on Sep. 8, 2020.
Claims priority of provisional application 62/737,780, filed on Sep. 27, 2018.
Prior Publication US 2023/0187216 A1, Jun. 15, 2023
Int. Cl. H01L 21/308 (2006.01); H01L 21/311 (2006.01); H10D 30/62 (2025.01); H10D 84/01 (2025.01); H10D 84/03 (2025.01); H10D 84/85 (2025.01)
CPC H01L 21/3086 (2013.01) [H01L 21/3081 (2013.01); H01L 21/31116 (2013.01); H10D 30/6212 (2025.01); H10D 84/0193 (2025.01); H10D 84/038 (2025.01); H10D 84/853 (2025.01)] 20 Claims
OG exemplary drawing
 
1. A method comprising:
patterning a substrate to form a semiconductor strip protruding from a top surface of the substrate, wherein sidewalls of the semiconductor strip have a first roughness, wherein the top surface of the substrate has a third roughness;
performing an etching process on the semiconductor strip and the top surface of the substrate, wherein after performing the etching process, the sidewalls of the semiconductor strip have a second roughness that is greater than the first roughness and the top surface of the substrate has a fourth roughness that is greater than the third roughness;
forming a dummy gate stack over a channel region of the semiconductor strip;
forming gate spacers on sidewalls of the dummy gate stack; and
epitaxially growing a source/drain region adjacent the channel region.
 
10. A method comprising:
depositing a mask layer over a semiconductor substrate;
patterning the mask layer to form a patterned mask;
etching the semiconductor substrate using the patterned mask to form a plurality of semiconductor fins;
performing a roughening process that roughens surfaces of the semiconductor substrate, each semiconductor fin of the plurality of semiconductor fins, and the patterned mask;
removing the patterned mask; and
forming a gate structure over the plurality of semiconductor fins, wherein the gate structure extends on the roughened surfaces of each semiconductor fin of the plurality of semiconductor fins.
 
16. A method, comprising:
forming a first fin protruding from a semiconductor substrate, wherein a top surface of the first fin has a first roughness that is less than a second roughness of a sidewall of the first fin and that is less than a third roughness of a surface of the semiconductor substrate adjacent the first fin;
forming an isolation region surrounding the first fin, wherein the isolation region extends on the sidewall of the first fin and on the surface of the semiconductor substrate;
forming a gate structure extending on the top surface of the first fin and on the sidewall of the first fin; and
forming an epitaxial source/drain region in the first fin adjacent the gate structure.