TWI604569B - 半導體裝置及其形成方法 - Google Patents

半導體裝置及其形成方法 Download PDF

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TWI604569B
TWI604569B TW105137203A TW105137203A TWI604569B TW I604569 B TWI604569 B TW I604569B TW 105137203 A TW105137203 A TW 105137203A TW 105137203 A TW105137203 A TW 105137203A TW I604569 B TWI604569 B TW I604569B
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layer
oxide layer
forming
semiconductor substrate
trench
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TW201820549A (zh
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溫文瑩
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新唐科技股份有限公司
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Priority to US15/420,409 priority patent/US9905480B1/en
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Description

半導體裝置及其形成方法
本發明是關於半導體裝置,特別是有關於使用絕緣層上覆矽(silicon on insulator,SOI)基底之鰭式場效電晶體(fin field effect transistor,FinFET)及其形成方法。
在半導體裝置的產業中,鰭式場效電晶體的導入是一大進展,其三維的配置超越了平面電晶體所展現的基本效能和功效特性。鰭式場效電晶體具有豎立的鰭狀結構(fin structure),自基底垂直向上延伸,鰭狀結構內具有通道(channel),而鰭狀結構上具有閘極結構環繞著通道,使得閘極結構可自多端控制通道。鰭式場效電晶體具有降低臨界電壓、減少漏電流以及提高效能的好處。
另一方面,近年來,絕緣層上覆矽的技術被廣泛地用於積體電路的設計上,相較於傳統的塊材(bulk)半導體基底,絕緣層上覆矽基底由於具有埋植氧化層,不會產生閉鎖效應(latch-up effect),且具有較低的寄生電容、速度較快、較強的抗輻射能力,減少發生軟式錯誤(soft error)的機會,以及受短通道效應(short channel effect)的影響較小等優點。
雖然目前存在的半導體裝置及其形成方法在鰭式 場效電晶體的發展以及絕緣層上覆矽基底的應用上已足夠應付它們原先預定的用途,但它們仍未在各個方面皆徹底的符合要求,因此半導體裝置目前仍有需努力的方向。
本揭露之實施例利用第一間隙物的設置,是為製造絕緣層上覆矽(SOI)的架構,利用區域氧化隔離技術(Local Oxidation of Silicon,LOCOS)在半導體基底側壁形成氧化層,避免基底全面被氧化。再者,本揭露之實施例藉由第二間隙物的設置,蝕刻半導體基底的一部分以在第二氧化層上形成尺寸精細的鰭狀結構,使得鰭式場效電晶體在閘極施加電壓時容易達到完全空乏的狀態。此外,依據本揭露的實施例,鰭狀結構由半導體基底的一部分形成,其材料可為單晶矽,相較於以往藉由沉積和退火形成的多晶矽鰭狀結構具有開關電流比(Current on/off ratio,Ion/Ioff)較高的優勢。
根據一些實施例,提供半導體裝置的形成方法。此半導體裝置的形成方法包含形成第一氮化層於半導體基底上,形成第一氧化層於第一氮化層上,形成第一溝槽穿過第一氧化層、第一氮化層和一部份的半導體基底。此半導體裝置的形成方法還包含形成第一間隙物於第一溝槽的側壁上,以第一間隙物為遮罩,在半導體基底內形成第二溝槽,移除第一氧化層以形成第三溝槽。此半導體裝置的形成方法更包含形成第二氧化層於第二溝槽內,第二氧化層側向延伸至半導體基底內且位於第一間隙物之下方,形成第二間隙物於第三溝槽的側壁上,以及以第二間隙物為遮罩,蝕刻移除部分的第一氮化層和 部分的半導體基底,形成鰭狀結構於第二氧化層上。
根據一些實施例,提供半導體裝置。此半導體裝置包含設置於半導體基底內且鄰近半導體基底的表面的第二氧化層,設置於第二氧化層上的鰭狀結構。此半導體裝置更包含設置於鰭狀結構、半導體基底和第二氧化層上的閘極介電層,以及設置於閘極介電層上的閘極電極層。
100a‧‧‧半導體裝置
101‧‧‧半導體基底
102‧‧‧第一溝槽
103‧‧‧第一氮化層
104‧‧‧第二溝槽
105‧‧‧第一氧化層
106‧‧‧第三溝槽
107‧‧‧圖案化光阻層
109‧‧‧第二氮化層
109a‧‧‧第一間隙物
111a、111b、111c、111d‧‧‧第二氧化層
113‧‧‧第三氧化層
113a、113b‧‧‧第二間隙物
117‧‧‧閘極介電層
119‧‧‧閘極電極層
C‧‧‧連接部
D‧‧‧汲極區
F‧‧‧鰭狀結構
h‧‧‧半導體基底圖案之高度
H‧‧‧鰭狀結構之高度
P‧‧‧半導體基底圖案
S‧‧‧源極區
W‧‧‧鰭狀結構之寬度
藉由以下的詳述配合所附圖式,我們能更加理解本揭露的觀點。值得注意的是,根據工業上的標準慣例,一些特徵部件(feature)可能沒有按照比例繪製。事實上,為了能清楚地討論,不同特徵部件的尺寸可能被增加或減少。
第1A-1L圖是根據本揭露的一些實施例,顯示形成半導體裝置之方法的不同階段的剖面示意圖;第2圖是根據本揭露的一些實施例,顯示半導體裝置的部份上視圖,其中第1L圖是顯示沿第2圖線A-A’的剖面示意圖。
以下揭示提供了很多不同的實施例或範例,用於實施所提供的半導體裝置之不同元件。各元件和其配置的具體範例描述如下,以簡化本揭露之說明。當然,這些僅僅是範例,並非用以限定本揭露。舉例而言,敘述中若提及第一元件形成在第二元件之上,可能包含第一和第二元件直接接觸的實施例,也可能包含額外的元件形成在第一和第二元件之間,使得它們不直接接觸的實施例。此外,本揭露可能在不同的範例中 重複參考數字及/或字母。如此重複是為了簡明和清楚,而非用以表示所討論的不同實施例及/或形態之間的關係。
以下描述實施例的一些變化。在不同圖式和說明的實施例中,相似的參考數字被用來標明相似的元件。可以理解的是,在方法的前、中、後可以提供額外的操作,且一些敘述的操作可為了該方法的其他實施例被取代或刪除。
本揭露之實施例係利用第一間隙物的設置,在半導體基底內形成第二氧化層,並藉由第二間隙物的設置,蝕刻半導體基底的一部分以在第二氧化層上形成深度和寬度皆在約20nm至約250nm之間的鰭狀結構,此鰭狀結構由半導體基底形成,其材料可為單晶矽。本揭露之實施例的半導體裝置之形成方法具備了絕緣層上覆矽基底的優勢,且能產生微細尺寸的鰭狀結構,進而產生容易達到完全空乏狀態之鰭式場效電晶體。此外,藉由本揭露之實施例,能製成單晶矽的鰭狀結構,進而提高半導體裝置的開關電流比。
第1A-1L圖是根據本揭露的一些實施例,顯示形成第1L圖之半導體裝置100a之方法的不同階段的剖面示意圖。
根據一些實施例,如第1A圖所示,提供半導體基底101。一些實施例中,半導體基底101可由單晶矽、多晶矽或其他半導體材料製成,或者,半導體基底101可包含其他元素半導體材料,例如鍺(Ge)。一些實施例中,半導體基底101由化合物半導體製成,例如碳化矽、氮化鎵、砷化鎵、砷化銦或磷化銦。一些實施例中,半導體基底101由合金半導體製成, 例如矽鍺、碳化矽鍺、磷化砷鎵或磷化銦鎵。一些實施例中,半導體基底101包含磊晶層。舉例而言,半導體基底101有覆蓋在塊材半導體之上的磊晶層。一些實施例中,半導體基底101可為輕摻雜之P型或N型基底。一些實施例中,可在半導體基底101上形成墊氧化層(pad oxide layer),並於適當的區域離子植入N型或P型的摻質。
接著,參見第1A圖,在半導體基底101上形成第一氮化層103,在第一氮化層103上形成第一氧化層105,並在第一氧化層105上形成圖案化光阻層107。一些實施例中,第一氮化層103的材料為氮化矽,第一氧化層105的材料為二氧化矽。一些實施例中,第一氮化層103和第一氧化層105是藉由化學氣相沉積(chemical vapor deposition,CVD)、原子層沉積(atomic layer deposition,ALD)、旋轉塗佈(spin coating)或前述之組合所形成。
根據一些實施例,如第1B圖所示,利用圖案化光阻層107為遮罩,將第一氧化層105、第一氮化層103和一部分的半導體基底101圖案化,以形成第一溝槽102和半導體基底圖案P。一些實施例中,第一溝槽102係穿過第一氧化層105、第一氮化層103和一部分的半導體基底101。一些實施例中,半導體基底圖案P之高度h在約20nm至約250nm的範圍內。一些實施例中,半導體基底圖案P之高度h在約100nm至約200nm的範圍內。半導體基底圖案P之高度h即為後續製程中形成的鰭狀結構F(如第1J圖所示)的高度。
根據一些實施例,如第1C圖所示,在第一溝槽102 的側壁和底面上,以及第一氧化層105上毯覆性地形成第二氮化層109。換言之,第二氮化層109係形成於半導體基底101的表面上、半導體基底圖案P的側壁上、第一氮化層103的側壁上以及第一氧化層105的側壁和頂面上。一些實施例中,第二氮化層109的材料為氮化矽。一些實施例中,第二氮化層109是藉由化學氣相沉積(CVD)、低壓化學氣相沉積(low-pressure CVD,LPCVD)、電漿增強化學氣相沉積(plasma enhanced CVD,PECVD)、原子層沉積(ALD)、旋轉塗佈、濺鍍(sputter)或前述之組合所形成。
根據一些實施例,如第1D圖所示,藉由異向性蝕刻(例如乾式蝕刻)移除位於第一溝槽102之底部和第一氧化層105上的第二氮化層109,以形成第一間隙物109a。換言之,藉由異向性蝕刻移除位於半導體基底101的表面上和第一氧化層105之頂面上的第二氮化層109,以在第一溝槽102的側壁上形成第一間隙物109a。如第1D圖所示,第一間隙物109a係位於半導體基底圖案P的側壁上、第一氮化層103的側壁上和第一氧化層105的側壁上,且接觸部分的半導體基底101。值得注意的是,設置第一間隙物109a的目的係在後續製程中定義出第二氧化層111a、111b、111c和111d(如第1G圖所示)的位置,此第二氧化層111a、111b、111c和111d相當於絕緣層上覆矽(SOI)基底中的埋置氧化層(buried oxide layer)。
根據一些實施例,如第1E圖所示,以第一間隙物109a為遮罩,實施蝕刻製程,在半導體基底101內形成第二溝槽104。第二溝槽104係形成於第一溝槽102的下方,且第二 溝槽104的寬度和深度均較第一溝槽102小。一些實施例中,第二溝槽104係由異向性蝕刻(例如乾性蝕刻)形成。如第1E圖所示,在形成第二溝槽104之後,由於第二溝槽104的寬度小於第一溝槽102的寬度,半導體基底101具有階梯狀的剖面。
接續前述,如第1F圖所示,移除第一氧化層105以形成第三溝槽106。一些實施例中,藉由圖案化光阻層(未繪示)遮蔽鰭狀結構以外的區域,實施蝕刻製程以移除位於鰭狀結構區域未被圖案化光阻層遮蔽的第一氧化層105。由於第1F圖為沿著鰭狀結構區域的剖面示意圖,圖中所顯示的第一氧化層105皆被移除,並形成第三溝槽106。換言之,第三溝槽106的位置即為原本第一氧化層105的位置,因此,第三溝槽106的底面為第一氮化層103的頂面,且第三溝槽106的兩側為第一間隙物109a。
根據一些實施例,如第1G圖所示,形成多個第二氧化層111a、111b、111c和111d,各自位於每一個第二溝槽104內,並且這些第二氧化層111a、111b、111c和111d還側向延伸至半導體基底101內,位於第一間隙物109a的下方和部分半導體基底圖案P的下方。如第1G圖所示,這些第二氧化層111a、111b、111c和111d係設置在半導體基底101內,且鄰近半導體基底101的表面。一些實施例中,第二氧化層111a、111b、111c和111d是藉由熱氧化法(thermal oxidation)所形成。一些實施例中,第二氧化層111a、111b和111c彼此不相連,而第二氧化層111c和111d則藉由連接部C相連。
值得注意的是,藉由熱氧化法形成的第二氧化層 111a、111b、111c和111d的表面可能會不平整,且每一個單一第二氧化層111a、111b、111c和111d的形成速率和狀態可能會不同,其中,連接部C為第二氧化層111c和111d在製程過程中過度地側向成長而連接在一起的部分。一些實施例中,可調控第二氧化層111a、111b、111c和111d的成長速率,使得第二氧化層111a、111b、111c和111d側向成長超過第三溝槽104的距離約大於250nm。一些實施例中,第二氧化層111a、111b、111c和111d側向成長超過第三溝槽104的距離約大於500nm,確保後續製程中所產生的鰭狀結構F(如第1J圖所示)能完全位於第二氧化層111a、111b、111c和111d的上方。
本揭露之實施例的第二氧化層111a、111b、111c和111d的設置目的與絕緣層上覆矽(SOI)基底中的埋置絕緣層相同,差別在於第二氧化層111a、111b、111c和111d係藉由熱氧化法形成,而以往埋置絕緣層係藉由氧離子植入形成,本揭露之一些實施例可避免氧離子植入在絕緣層上覆矽基底之表面產生缺陷的問題。一些實施例中,藉由熱氧化法形成的第二氧化層111a、111b、111c和111d的表面不共平面。
根據一些實施例,如第1H圖所示,在第三溝槽106的底部和側壁上、第一間隙物109a的頂部和側壁上,以及第二氧化層111a、111b、111c和111d上毯覆性地形成第三氧化層113。換言之,第三氧化層113係形成於第一氮化層103上、第一間隙物109a的頂部和側壁上,以及第一溝槽102的部分底面上。一些實施例中,第三氧化層113的材料為氧化矽。
之後,根據一些實施例,如第1I圖所示,藉由異 向性蝕刻(例如乾式蝕刻)移除位於第三溝槽106之底部、第一間隙物109a之頂部和第二氧化層111a、111b、111c和111d上的第三氧化層113,形成第二間隙物113a和113b。換言之,藉由異向性蝕刻移除位於第一氮化層103上、第一間隙物109a之頂部和第一溝槽102之底面上的第三氧化層113,以在第三溝槽106的側壁上形成第二間隙物113a,並且也在第一溝槽102內的第一間隙物109a的側壁上形成第二間隙物113b。換言之,第二間隙物113a和113b係分別位於第一間隙物109a的兩側,且分別位於第三溝槽106的側壁上和第一溝槽102內的第一間隙物109a的側壁上。一些實施例中,由於第二間隙物113a位在突出於半導體基底101表面之第一氮化層103和半導體基底圖案P之上方,第二間隙物113a的高度小於第二間隙物113b的高度。
接續前述,如第1J圖所示,以第二間隙物113a為遮罩,蝕刻移除部分的第一氮化層103和部分的半導體基底圖案P,以在第二氧化層111a、111b、111c和111d上形成多個鰭狀結構F,其中每個第二氧化層111a、111b、111c和111d上有至少兩個鰭狀結構F。值得注意的是,這些鰭狀結構F係由異向性蝕刻(例如乾式蝕刻)移除部分的半導體基底圖案P直至暴露出第二氧化層111a、111b、111c和111d,以確保鰭狀結構F彼此之間不相連。
根據一些實施例,如第1K圖所示,移除第一間隙物109a、第二間隙物113a和113b,以及第一氮化層103,以完整地露出鰭狀結構F。如前所述,鰭狀結構F的高度相當於 第1B圖中半導體基底圖案P的高度h。一些實施例中,鰭狀結構F之高度H和寬度W皆在約20nm至約250nm的範圍內。一些實施例中,鰭狀結構F之高度H和寬度W皆在約100nm至約200nm的範圍內。
一些實施例中,鰭狀結構F係由蝕刻半導體基底101之半導體基底圖案P而形成,故鰭狀結構F和半導體基底101為相同材料,且鰭狀結構F之材料可為單晶矽,相較於以往藉由沉積和退火形成的多晶矽鰭狀結構,本揭露之實施例所形成的單晶矽鰭狀結構具有開關電流比較高的優勢。另一方面,藉由第二間隙物113a和113b的設置,蝕刻移除一部分的半導體基底圖案P,以在第二氧化層111a、111b、111c和111d上形成尺寸精細的鰭狀結構,可免除昂貴之製程設備的使用,降低製程成本。
根據一些實施例,如第1L圖所示,在鰭狀結構F、半導體基底101和第二氧化層111a、111b、111c和111d上形成閘極介電層117,以及在閘極介電層117上形成閘極電極層119。一些實施例中,閘極介電層117係使用熱氧化製程、化學氣相沉積(CVD)製程、流動式化學氣相沉積(flowable CVD,FCVD)製程、原子層沉積(ALD)製程、低壓化學氣相沉積(low-pressure CVD,LPCVD)製程、電漿增強化學氣相沉積(PECVD)製程、其他合適的製程或前述之組合形成,閘極電極層119係使用化學氣相沉積(CVD)製程、原子層沉積(ALD)製程、低壓化學氣相沉積(LPCVD)製程、電漿增強化學氣相沉積(PECVD)製程、其他合適的製程或前述之組合形成。
一些實施例中,閘極介電層117可由氧化矽或高介電常數之介電材料製成,其中高介電常數之介電材料可由氧化鉿、氧化鋯、氧化鋁、二氧化鉿-氧化鋁合金(hafnium dioxide-alumina alloy)、鉿矽氧化物、鉿矽氮氧化物、鉿鉭氧化物、鉿鈦氧化物、鉿鋯氧化物、其他合適的高介電常數材料或前述之組合製成。一些實施例中,閘極電極層119包含金屬或其他合適的導電材料,例如:鎢、銅、鎳、鋁、矽化鎢、多晶矽或前述之組合。一些實施例中,在閘極介電層117和閘極電極層119形成之後,在鰭狀結構F之適當的區域形成N型或P型的摻雜區作為源/汲極(S/D)區,並形成源/汲極(S/D)區的金屬接觸(未繪示),以完成半導體裝置100a之鰭式場效電晶體。
第2圖是根據本揭露的一些實施例,顯示半導體裝置100a的部份上視圖,其中第1L圖是顯示沿第2圖線A-A’的剖面示意圖。
根據一些實施例,如第2圖所示,鰭狀結構F上具有閘極結構(包含閘極介電層117和閘極電極層119)環繞著鰭狀結構F內的通道區,使得閘極結構可自多端控制通道區。此外,鰭狀結構F在閘極結構的兩端分別為源極區S和汲極區D。
上述實施例提供了半導體裝置100a及其形成方法,半導體裝置100a為使用絕緣層上覆矽基底的鰭式場效電晶體,為了使鰭式場效電晶體在閘極施加電壓時能達到完全空乏(fully depletion)的狀態,通道的寬度或深度必須在約20nm至約250nm的範圍內,但製造寬度或深度在250nm以下之鰭 狀結構的鰭式場效電晶體需要昂貴的製程成本(例如使用價格較高的精密曝光設備)。另一方面,絕緣層上覆矽的基底雖然相較於塊材基底具有許多優點,但由於絕緣層上覆矽的基底表面在形成埋置氧化層的氧離子植入製程中,經過氧離子撞擊容易產生缺陷,以及生成電荷累積的中性區,產生浮動基底效應(floating body effect),使得鰭式場效電晶體的臨界電壓(threshold voltage)容易變動,造成電路設計的困難。
為了解決上述問題,本揭露之實施例利用第一間隙物的設置,在半導體基底內形成第二氧化層,以形成用於半導體裝置之絕緣層上覆矽的基底,可避免因氧離子撞擊而對半導體基底的表面造成損壞。再者,本揭露之實施例藉由第二間隙物的設置,蝕刻半導體基底的一部分以在第二氧化層上形成尺寸精細的鰭狀結構,使得鰭式場效電晶體在閘極施加電壓時容易達到完全空乏的狀態。此外,由於鰭狀結構之材料與半導體基底相同可為單晶矽,相較於以往藉由沉積和退火形成的多晶矽鰭狀結構,本揭露之單晶矽鰭狀結構具有開關電流比較高的優勢。
以上概述數個實施例為特徵,以便在本發明所屬技術領域中具有通常知識者可以更理解本揭露的觀點。在發明所屬技術領域中具有通常知識者應該理解他們能以本揭露為基礎,設計或修改其他製程和結構以達到與在此介紹的實施例相同之目的及/或優勢。在發明所屬技術領域中具有通常知識者也應該理解到,此類等效的結構並無悖離本揭露的精神與範圍,且他們能在不違背本揭露之精神和範圍之下,做各式各樣 的改變、取代和替換。
100a‧‧‧半導體裝置
101‧‧‧半導體基底
111a、111b、111c、111d‧‧‧第二氧化層
117‧‧‧閘極介電層
119‧‧‧閘極電極層
F‧‧‧鰭狀結構

Claims (11)

  1. 一種半導體裝置的形成方法,包括:形成一第一氮化層於一半導體基底上;形成一第一氧化層於該第一氮化層上;形成一第一溝槽穿過該第一氧化層、該第一氮化層和一部份的該半導體基底;形成一第一間隙物於該第一溝槽的側壁上;以該第一間隙物為遮罩,在該半導體基底內形成一第二溝槽;移除該第一氧化層以形成一第三溝槽;形成一第二氧化層於該第二溝槽內,該第二氧化層側向延伸至該半導體基底內且位於該第一間隙物之下方;形成一第二間隙物於該第三溝槽的側壁上;以及以該第二間隙物為遮罩,蝕刻移除部分的該第一氮化層和部分的該半導體基底,形成一鰭狀結構於該第二氧化層上。
  2. 如申請專利範圍第1項所述之半導體裝置的形成方法,更包括:於蝕刻移除部分的該第一氮化層和部分的該半導體基底之後,移除該第一間隙物、該第二間隙物和該第一氮化層,以暴露該鰭狀結構;形成一閘極介電層於該鰭狀結構、該半導體基底和該第二氧化層上;以及形成一閘極電極層於該閘極介電層上。
  3. 如申請專利範圍第1項所述之半導體裝置的形成方法,其中 形成該第一間隙物之步驟包括:形成一第二氮化層於該第一溝槽之底部和側壁上,以及該第一氧化層上;以及藉由異向性蝕刻移除位於該第一溝槽之底部和該第一氧化層上的該第二氮化層。
  4. 如申請專利範圍第1項所述之半導體裝置的形成方法,其中形成該第二間隙物之步驟包括:形成一第三氧化層於該第三溝槽的底部和側壁上、該第一間隙物的頂部和側壁上,以及該第二氧化層上;以及藉由異向性蝕刻移除位於該第三溝槽的底部、該第一間隙物的頂部和該第二氧化層上的該第三氧化層。
  5. 如申請專利範圍第4項所述之半導體裝置的形成方法,其中該第二間隙物更形成在該第一溝槽內之該第一間隙物的側壁上。
  6. 如申請專利範圍第1項所述之半導體裝置的形成方法,其中該第二氧化層係由熱氧化法形成,且該第二氧化層與相鄰的另一第二氧化層相連。
  7. 如申請專利範圍第1項所述之半導體裝置的形成方法,其中蝕刻移除部分的該半導體基底至暴露出該第一氮化層下的該第二氧化層。
  8. 如申請專利範圍第1項所述之半導體裝置的形成方法,其中該鰭狀結構係由蝕刻該半導體基底形成,且該鰭狀結構之材料包括單晶矽。
  9. 一種半導體裝置,包括:一第二氧化層,設置於一半導體基底內且鄰近該半導體基底的表面;一鰭狀結構,設置於該第二氧化層上,其中該鰭狀結構與該半導體基底之材料相同且包括單晶矽;一閘極介電層,設置於該鰭狀結構、該半導體基底和該第二氧化層上;以及一閘極電極層,設置於該閘極介電層上。
  10. 如申請專利範圍第9項所述之半導體裝置,其中該第二氧化層與相鄰的另一第二氧化層相連。
  11. 如申請專利範圍第9項所述之半導體裝置,其中該第二氧化層與相鄰的另一第二氧化層不相連。
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