A Review Paper On Cmos, Soi and Finfet Technology
A Review Paper On Cmos, Soi and Finfet Technology
Technology
By Pavan H Vora, Ronak Lad (Einfochips Pvt. Ltd.)
In 1958, the first integrated circuit flip-flop was built using two transistors at Texas
Instruments. The chips of today contain more than 1 billion transistors. The memory
that could once support an entire company’s accounting system is now what a
teenager carries in his smartphone. This scale of growth has resulted from a
continuous scaling of transistors and other improvements in the Silicon
manufacturing process.
I. HISTORY:
A major breakthrough came in 1947, when John Baden, William Shockley and Watter
Brattain of Bell labs unveiled the first functioning point contact Germanium
transistor. In 1950, Shockley developed the first Bipolar Junction Transistor (BJT). In
comparison to a vacuum tube, transistors are more reliable, power efficient and of
lesser size. The transistor is a 3-terminal device which can be viewed as an
electrically controlled switch. One of the terminals acts as a control terminal.
Ideally, if current is applied to the control terminal, the device will act as a close
switch between the two terminals which otherwise behave as an open switch. In
1958, Jack Kilby of Texas Instruments built the first Integrated Circuit consisting of
two bipolar transistors connected on a single piece of silicon, thereby initiating the
“Silicon Age”. Early ICs used bipolar junction transistors. One of the drawbacks of
BJT is a problem due to more static power dissipation. It means that power is drawn
even when the circuit is not switching. This limits the maximum numbers of
transistors that can be integrated into a single silicon chip.
In 1963, Frank Wanlass and C.T.Sah of Fairchild unveiled the first logic gate in which
n-channel and p-channel transistors were used in a complementary symmetric circuit
configuration. This is what is known as CMOS today. It draws almost zero static
power dissipation.
Early ICs used NMOS technology, because the NMOS process was fairly simple, less
expensive and more devices could be packed into a single chip compared to CMOS
technology. The first microprocessor was announced by Intel in 1971.
Throughout the next few years, CMOS scaling and improvement in processing
technologies have led to continuous enhancement in circuit speeds, along with
further improvement in packaging densities of chips and performance-to-cost ratios
of microelectronics-based products.
Here, we discuss Bulk-Si CMOS technology, the need and importance of scaling, their
various effects and associated solutions. We also address the physical scaling limits
of transistor materials and any new materials used in advanced technology node.
Nowadays, the industry is moving from the usage of planner transistor technology
due to various limitations encountered below 32nm technology node. We discuss
new device structures: SOI and FinFET which replaced planner bulk transistor.
Here, we first discuss the basic structure, operation and important terms related to
the core unit of CMOS i.e. MOSFET or simply MOS. The first successful MOS
transistor would use metals for the gate material, SiO2 (oxide) for insulator and
semiconductor for substrate. For that reason, this device was named MOS transistor.
The name Field Effect Transistor (FET) refers to the fact that the gate is turned on
and off by the transistor with an electric field passing through the gate oxide.
A. Structure of MOS:
Based on the type of conducting channel, two kinds of MOS structures are evident: n-
channel and p-channel MOS. Here, we will only overview the NMOS transistor
because both transistors are complementary in nature.
MOS transistor is a 4-terminal device having terminal drains, source, gate and body
(substrate). Figure 1 shows the 3-dimentional structure of NMOS. The NMOS
transistor is formed on a p-type silicon substrate (also called body). On the top
center part of the device, a low resistivity electrode is formed which is separated
from the body by an insulator. Generally, poly-silicons with heavy doping of either n-
type or p-type is used as gate material. Here, silicon dioxide (SiO 2 or simply oxide) is
used as an insulator. By implanting donor impurities in two sides of the substrate,
the source and the drain are formed. In Figure 1, these regions are denoted by n +
which indicate heavy doping of donor impurities. This heavy doping results in low
resistivity for these regions.
If two n+ regions are biased at different potentials, the n + region which is at lower
potential will act as source while the other will act as drain. So, the drain and source
terminals can be interchanged as per the potential applied to them. The region
between source and drain is called the channel having width-W and length-L, which
plays an important role in deciding the characteristics of an MOS transistor.
The early MOS fabrication process started with the definition and doping of source
and drain regions. Then, the gate mask was used which defines the gate oxide
region which would later form the aluminum metal gate.
One of the major drawbacks of such a fabrication process is that if the gate mask is
misaligned, it creates a parasitic overlap input capacitance C gd and Cgs, as shown in
figure-2(a). The capacitance Cgd is more harmful because it is a feedback
capacitance. As a result of miller capacitance, there is a reduction in the transistor’s
switching speed.
One of the solutions to the misalignment of the gate mask is what is known as a
“Self-aligned Gate Process”. This process starts with the creation of the gate region
followed by the creation of the drain and source regions using ion-implantation. The
thin gate oxide under the gate acts as a mask for doping process preventing further
doping under gate region (channel). So, this process makes the gate self-aligned with
respect to the source and drain. As a result of all this, the source and drain do not
extend under the gate. Thereby reducing Cgd and Cgs as shown in figure 2(b).
Figure 2. (a) Cgd – Cgs Parasitic Cpacitances, (b) Reduced Cgd and Cgs as a result of
Self aligned process
The doping process of the drain and source require very high temperature annealing
methods (>8000*C). If aluminum is used as a gate material, it would melt under such
high temperature. This is because the melting point of Al is approximately 660
degree C. But, if polysilicon is used as a gate material, it would not melt. Thus, the
self-alignment process is possible with polysilicon gate. While in the case of Al-gate,
it is not possible, which results in high Cgd and Cgs. Undoped polysilicon has very high
resistivity, approximately 108 ohm/Cm. So, polysilicon is doped in such a way that its
resistance is reduced.
The other reason for selecting poly is that the threshold voltage of MOS transistor is
correlated with the work function difference between the gate and the channel.
Earlier, metal gates were used when operating voltages were in the range of 3-5
volts. But, as the transistors were scaled down, which ensured that the operating
voltages of the device were also brought down. A transistor with such high threshold
voltage becomes non-operational under such conditions. Using metal as gate
material resulted in high threshold voltage compared to polysilicon, since polysilicon
would be of the same or similar composition as the bulk-Si channel. Also, as
polysilicon is a semiconductor, its work function can be modulated by adjusting the
level of doping.
For MOS transistor, the gate voltage determines whether a current flow between the
drain and source will happen or not. Let’s see further. When a sufficiently positive V gs
voltage is applied to the gates of NMOS, the positive charges are placed over the
gate as shown in figure-3. These positive charges will repel the minority carriers of
p-type substrate i.e. holes from the substrate, leaving behind negative charge
acceptor ions which create depletion region. If we increase Vgs further, at some
potential level it will even make the surface attractive to electrons. So, plenty of
electrons are attracted to the surface. This situation is called inversion because the
surface of p-type body normally has a large number of holes but the newer surfaces
have a large numbers of electrons.
Drain-to-body and source-to-body are kept in reverse bias. Here in figure-3, source-to-
body is kept at zero bias. As drain-to-body potential is more positive than source-to-
body potential, the reverse bias across drain-to-body is larger resulting in deeper
depletion under drain region compared to source side.
When positive potential across drain-to-source is applied, electrons flow from the
source through the conducting channel and are drained by the drain. So, a positive
current Id flows from drain-to-source.
Figure 3. NMOS Transistor in inversion region
The demand for battery-operated portable gadgets have increased day by day with
tons of applications including hearing aids, cellular phone, laptops etc. The “basic
requirements” of such an application are less area, lower power consumption and
cheaper development. For such portable devices, power dissipation is important
because the power provided by the battery is rather limited. Unfortunately, battery
technologies cannot be expected to improve the battery storage capacity by more
than 30% every five years. This is not sufficient to handle the increasing power
needed in portable devices.
For long channel devices, “edge effects” along the four sides of the channel are
really negligible. For long channel devices, the electric field lines are everywhere
perpendicular to the surface of the channel. These electric fields are controlled by
gate voltage and back gate voltage. But, for short channel devices, the drain and
source structure are closer to the channel, especially when the longitudinal electric
field in the channel comes into picture. The longitudinal electric field is controlled by
drain-source voltage. The longitudinal electric field is parallel to the current flow
direction. The device is called short channel device if channel length is not much
larger than the sum of source and drain depletion widths.
In this section, we will discuss various undesirable effects arising as a result of two-
dimensional potential distribution and high electric fields in the short channel.
The electron drift velocity in the channel is proportional to the electric field for lower
electric field values. These drift velocities tend to saturate at high electric fields.
This is called velocity saturation. For short channel devices, the longitudinal electric
field typically also increases. At such high electric fields, a velocity saturation
occurs which affects I-V characteristics of the MOSFET. It has been observed that,
for the same gate voltage, the saturation mode of MOSFET is achieved at smaller
values of drain-source voltage and saturation current reductions.
Due to higher vertical electric fields, the carriers of the channel scatter off of the
oxide interface. This results in the degradation of carrier mobility and the reduction
in drain current.
Another short channel effect is called DIBL which refers to the reduction of threshold
voltage at higher drain voltage. If the gate voltage is not sufficient to invert the
surface (i.e. gate voltage < threshold voltage), the carriers in the channel will face a
potential barrier that could block the flow. By increasing gate potential, we eliminate
this potential barrier. But, for short channel devices, such a potential barrier is
controlled by both Vgs and Vds. If this drain voltage is increased, the depletion region
of the drain-body increases in size and extends under the gate. So, the potential
barrier in the channel decreases leading to carriers (electrons) flowing between
source and drain, even at Vgs lower than Vt. The concept of drain lowering the
channel barrier and reducing the threshold voltage is called DIBL. This reduction in
threshold voltage with channel length is called Vt roll-off. The current that flows
under such conditions is called sub-threshold current (off-state current). DIBL causes
drain current to increase with a rise in drain bias even in saturation mode.
C. Punch-through:
Punch-through is a severe case of barrier lowering. When the drain bias is increased,
the depletion region surrounding the drain can extend further towards the source
with two depletion regions merging. This condition is called punch-through. Under
such conditions, the gate voltage loses its control over the drain current with rising
drain current sharply. The punch-through effect increases with decreasing channel
length. Due to punch-through, we cannot turn off the device, so the device becomes
useless as shown in the figure 4.
For smaller geometric devices, the electric field increases especially near the drain.
As a result, the electrons (carriers) get a significant amount of energy which are
called hot carriers.
Some of them get nearly enough energy which lead to impact ionization near drain,
whereby new electron-hole pairs are generated. As an effect, it gives rise to drain-to-
body current (Idb). A small numbers of hot electrons may tunnel through oxide and
collect themselves by gate. While some hot carriers can even damage the oxide
resulting in device degradation.
We observed in the previous section that if channel length is small compared to the
depletion regions, short channel effects become intolerable. This limits the further
reduction achievable in gate length. To limit these effects, the depletion region
width should be reduced with corresponding reduction in channel length. This can be
achieved by either increasing channel doping concentration or increasing gate
capacitance, or both. Gate capacitance determines the gate’s control over the
channel. Equation 1 indicates that gate capacitance can be increased by scaling
(reducing) gate oxide thickness. It has been observed that a device with thinner gate
oxide has reduced depletion width, and hence, improved SCE characteristics.
Where,
For Intel’s process nodes in the last 25 years, it has been observed that the oxide
has been scaled roughly in proportion to the channel length in order to limit SCE. The
relationship between channel length and oxide thickness for Intel’s technology
nodes is given in Equation-2.
L = 45 X TOX (Equation - 2)
Where,
L: Channel Length,
TOX : Oxide Thickness
For making compressive strain in the silicon channel, the source and drain regions
are filled with Si-Ge film by an epitaxial growth. Si-Ge typically comprises of 20%
germanium and 80% silicon mixture. The number of Si and Ge atoms are equal to
original Si atoms. Germanium atoms are larger than silicon atoms. So when a force is
created, it pushes the channel and raises the hole mobility. Increasing the mobility
of the semiconductor improves drive current and transistor speed.
The strained silicon techniques for MOS transistor were first used by Intel in their
90nm process technology in 2003. In this technology node, the Si-Ge source drain
structure used for PMOS transistor induces compressive strain in the channel,
improving current by 25%. While NMOS strain is introduced by adding high stress
Si3N4 capping layer around transistor, improving current by 10%.
The thickness of SiO2 (oxide) dielectric should be scaled in proportion to its channel
length. The 65nm node, require Effective Oxide Thickness (EOT) of approximately
2.3nm (actual 1.6nm). But, if oxide thickness is reduced further below this point, the
direct tunneling of carrier phenomena will be dominant. As a result of all this, the
gate leakage increases to an unacceptable limit. So, the thickness limit for the oxide
is approximately 1.6nm which is set by gate-to-channel tunneling leakage (also
called quantum mechanical tunneling).
EOT is given by equation 3. The equation 3 implies that 6nm thick HfO2 provides EOT
of approximately 1nm.
Where,
A depletion region forms at the interface of poly-silicon and gate oxide. As the device
continues to scale down, this poly-silicon depletion becomes larger and a larger
fraction of the equivalent oxide thickness will limit gate oxide capacitance. The
negative effects of poly-depletion is due to reduction in inversion layer charge
density and a degradation of device performance. So, apart from gate oxide
thickness, poly depletion layer thickness also needs to be minimized.
Moreover, poly gates can also be incompatible with high-K dielectric because of
effects such as threshold voltage pinning and photon scattering which make it
difficult to obtain low threshold voltage and reduce the channel’s mobility.
One solution to eliminate poly-depletion effect is the use of metal gate instead of
poly gate. A metal gate not only eliminates poly-depletion effect, but also enables
the use of high-K dielectric.
Intel had first introduced 45nm node using high-K dielectric and metal gate
technology. Different metals are used for NMOS and PMOS as different work-
functions are required for NMOS and PMOS.
A transistor process flow starts with the deposition of high-K dielectric and dummy
poly-silicon. After the high temperature annealing process, the inter layer dielectric
is deposited and polished to expose poly-silicon. Then, a dummy poly-silicon is
removed. At last, PMOS and then NMOS work function metals are deposited in the
gate trenches.
For conventional MOS structure, as the channel length shrinks, the gate does not
have full control over the channel which is not desirable. One of its effects is to
cause more sub-threshold leakage from drain to source, which is not good from
power consumption point of view. In conventional MOS, the gate cannot control
leakage path which is far removed from the it. This can be improved using various
MOS structures which allow the scaling of a transistor beyond conventional MOS
scaling limit. In this section, we will discuss two new MOS structures, SOI and
FinFET. The main objective of both the structures is to maximize gate-to-channel
capacitance and minimize drain-to-channel capacitance.
A. Silicon-On-Insulator (SOI):
The main difference between conventional MOS structure and SOI MOS structure is
that SOI device has a buried oxide layer, which isolates the body from the substrate.
As shown in the Figure 7, SOI transistor is a planner device.
The fabrication process of SOI MOS is similar to bulk MOS (conventional MOS)
process except for the starting silicon wafer. SOI wafers have three layers; 1. Thin
surface layer of silicon (where the transistors are formed). 2. An underlying layer of
insulating material. 3. A support or "handle" silicon wafer.
The basic idea behind buried oxide layer is, that it will reduce the parasitic junction
capacitance. And the smaller the parasitic capacitance, the faster will the transistor
work. Giving higher performance. Due to BOX layer, there is no unwanted leakage
paths which are far from the gate. This leads to lower power consumption.
Depending on the condition of the thin body during operation, SOI devices are
categorized as Partially Depleted (PD) SOI and Fully Depleted (FD) SOI. Compared to
PD SOI, FD SOI have very thin body structures, hence the body is fully depleted
during operation. This FD SOI also called Ultra-Thin-Body SOI. For PD SOI, body is 50
nm to 90 nm thick. While for FD SOI, the body is about 5 nm to 20 nm thick.
One of the drawbacks of PD SOI device is that they suffer from history effect.
In PD SOI, as the body becomes thicker, a floating body is evident. So, the
body voltage is dependent on the previous state of the device. This floating
body voltage can change the threshold voltage of the device. It could cause
significant mismatch between two identical transistors.
The other problem with an SOI device is self-heating. In SOI device, the active
thin body is on silicon oxide which is good thermal insulator. During an
operation, the power consumed by the active region cannot be dissipated
easily. As a result, the temperature of the thin body rises which decreases the
mobility and current of the device.
One of the challenges with FD SOI is the difficulty in manufacturing thin body
SOI wafers.
B. FinFET:
Former TSMC CTO and Berkeley professor Chenming Hu and his team presented the
concept of FinFET in 1999 and UTB-SOI (FD SOI) in 2000. The main principle behind
both the structures is a thin body, so the gate capacitance is closer to whole
channel. The body is very thin, around 10nm or less. So, there is no leakage path
which is far from the gate. The gate can effectively control the leakage.
The basic structure of FinFET which they proposed would be a channel controlled by
more than one side of channel. One of the Double-Gate Structures is shown in Figure
8.
Figure 8. Double Gate Structure
Modern FinFETs are 3D structures as shown in the Figure 9 also called tri-gate
transistor. FinFETs can be implemented either on bulk silicon or SOI wafer. This
FinFET structure consists of thin (vertical) fin of silicon body on a substrate. The
gate is wrapped around the channel providing excellent control from three sides of
the channel. This structure is called the FinFET because its Si body resembles the
back fin of a fish.
The drive current of the FinFET can be increased by increasing the width of the
channel i.e. by increasing the height of the Fin. We can also increase the device
drive current by constructing parallel multiple fins connected together as shown in
the Figure 10. It implies that for a FinFET, the arbitrary channel width is not possible,
since it is always a multiple of fin height. So, effective width of the device becomes
quantized. While in planner devices, there is the freedom to choose the device’s
drive strength by varying channel width.
In conventional MOS, a doping is inserted into the channel, reducing the various
SCEs and ensuring high Vth. While in FinFET, the gate structure is wrapped around
the channel and the body is thin, providing better SCEs, so channel doping becomes
optional. It implies that FinFET suffers less from dopant-induced variations. Low
channel doping also ensures better mobility of the carriers inside the channel.
Hence, higher performance. One thing noticed over here is that both FinFET and SOI
technologies have introduced Body Thickness as a new scaling parameter.
FinFET technology provides numerous advantages over bulk CMOS, such as higher
drive current for a given transistor footprint, hence higher speed, lower leakage,
hence lower power consumption, no random dopant fluctuation, hence better
mobility and scaling of the transistor beyond 28nm.
VIII. SOI VS FINFET:
As SOI technology is very close to planner bulk technology, it does not require much
investment in Fab. So, existing bulk technology libraries can easily be converted to
SOI libraries. Another advantage of SOI over FinFET is, that it has good back gate
bias option. By creating back gate region below BOX, we can also control V t. This
make it suitable for low power applications.
The primary limitation of SOI technology is the cost of an SOI wafer which is higher
than a bulk Silicon wafer because it is very difficult to control the tin silicon film
throughout the wafers. Another stumbling block for SOI adoption is a limited number
of SOI wafer suppliers. According to Intel, SOI wafer adds approximately 10% to the
total process cost.
In comparison to SOI, FinFET has higher drive current. Moreover in FinFET, the strain
technology can be used to increase carrier mobility.
STMicroelectronics released its first FD-SOI chips for mobile processor at 28nm in
2012. Foundries that are offering FD-SOI technology are IBM, Global Foundry, and
Samsung. Some of the products using SOI technology are AMD's processor, PowerPC
microprocessor and Sony's PlayStation.
X. WHAT NEXT?:
Both FinFET and SOI structure have better gate control and lower threshold voltage
with less leakage. But, when we move to lower technology node say below 10nm
node, the issue of leakage starts again. This leads to many other issues like
threshold flattening, increase in power density, and thermal dissipation. FinFET
structure is less efficient in terms of heat dissipations, as heat can easily be
accumulated on the fins. These concerns can lead to a new class of design rule -
Design for Thermal, unlike other design rule like Design for Manufacturability. As
these devices are approaching their limitations, eInfochips is working with Academia
to come with potential solutions which include modification in device structure,
replacing existing silicon material with new materials. Among them, Carbon
Nanotube (CNT) FET, Gate-All-Around Nanowire FET or FinFETs with compound
semiconductors may prove as promising solutions in future technology nodes.