Abstract:
An improved method for fabricating a semiconductor device is provided. The method includes: depositing a dielectric layer on a substrate; depositing a first cap layer on the dielectric layer; depositing an etch stop layer on the dielectric layer; and depositing a dummy cap layer on the etch stop layer to form a partial gate structure. Also provided is a partially formed semiconductor device. The partially formed semiconductor device includes: a substrate; a dielectric layer on the substrate; a first cap layer on the dielectric layer; an etch stop layer on the dielectric layer; and a dummy cap layer on the etch stop layer forming a partial gate structure.
Abstract:
Methods for controlling the length of a replacement metal gate to a designed target gate length and the resulting device are disclosed. Embodiments may include removing a dummy gate from above a substrate forming a cavity, wherein side surfaces of the cavity are lined with an oxidized spacer layer and a bottom surface of the cavity is lined with a gate oxide layer, conformally forming a sacrificial oxide layer over the substrate and the cavity, and removing the sacrificial oxide layer from the bottom surface of the cavity and the substrate leaving sacrificial oxide spacers lining the side surfaces of the cavity.
Abstract:
A method of manufacturing a semiconductor device includes the formation of an oxide spacer layer to modify the critical dimension of a gate cut opening in connection with a replacement metal gate process. The oxide spacer layer is deposited after etching a gate cut opening in an overlying hard mask such that the oxide spacer layer is deposited onto sidewall surfaces of the hard mask within the opening and directly over the top surface of a sacrificial gate. The oxide spacer may also be deposited into recessed regions within an interlayer dielectric located adjacent to the sacrificial gate. By filling the recessed regions with an oxide, the opening of trenches through the oxide spacer layer and the interlayer dielectric to expose source/drain junctions can be simplified.
Abstract:
A method of manufacturing a FinFET structure involves forming gate cuts within a sacrificial gate layer prior to patterning and etching the sacrificial gate layer to form longitudinal sacrificial gate structures. By forming transverse cuts in the sacrificial gate layer before defining the sacrificial gate structures longitudinally, dimensional precision of the gate cuts at lower critical dimensions can be improved.
Abstract:
A method for eliminating line voids during RMG processing and the resulting device are provided. Embodiments include forming dummy gates over PFET and NFET regions of a substrate, each dummy gate having spacers at opposite sides, and an ILD filling spaces between spacers; removing dummy gate material from the gates, forming a cavity between each pair of spacers; forming a high-k dielectric layer over the ILD and spacers and in the cavities; forming a metal capping layer over the high-k dielectric layer; forming a first work function metal layer over the metal capping layer; removing the first work function metal layer from the PFET region; forming a second work function metal layer over the metal capping layer in the PFET region and over the first work function metal layer in the NFET region; and forming a metal layer over the second work function metal layer, filling the cavities.
Abstract:
A method of forming RMG multi-WF layers for an nFET and pFET, and the resulting device are provided. Embodiments include forming a Si fin; forming a nFET RMG trench and a pFET RMG trench; forming a first Ti layer in the nFET and pFET RMG trenches; implanting N2 in the first Ti layer vertically at a 0° implant angle in the pFET RMG trench; annealing the N2 implanted first Ti layer to form a TiN layer in the pFET RMG trench; stripping un-reacted Ti of the first Ti layer; forming a second Ti layer in the nFET and pFET RMG trenches; implanting Al or C in the second Ti layer vertically at 0°; annealing the Al or C implanted second Ti layer to form TiAl or TiC at a bottom of the nFET and pFET RMG trenches, respectively; and filling the nFET and pFET RMG trenches with Al or W.