| Patent application number | Description | Published |
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| 20140070285 | METHODS OF FORMING SEMICONDUCTOR DEVICES WITH SELF-ALIGNED CONTACTS AND THE RESULTING DEVICES - One method includes forming a sacrificial gate structure above a substrate, forming a first sidewall spacer adjacent a sacrificial gate electrode, removing a portion of the first sidewall spacer to expose a portion of the sidewalls of the sacrificial gate electrode, and forming a liner layer on the exposed sidewalls of the sacrificial gate electrode and above a residual portion of the first sidewall spacer. The method further includes forming a first layer of insulating material above the liner layer, forming a second sidewall spacer above the first layer of insulating material and adjacent the liner layer, performing an etching process to remove the second sidewall spacer and sacrificial gate cap layer to expose an upper surface of the sacrificial gate electrode, removing the sacrificial gate electrode to define a gate cavity at least partially defined laterally by the liner layer, and forming a replacement gate structure in the cavity. | 03-13-2014 |
| 20140084383 | METHODS OF FORMING 3-D SEMICONDUCTOR DEVICES USING A REPLACEMENT GATE TECHNIQUE AND A NOVEL 3-D DEVICE - One illustrative method disclosed herein includes forming a sacrificial gate structure above a fin, wherein the sacrificial gate structure is comprised of a sacrificial gate insulation layer, a layer of insulating material, a sacrificial gate electrode layer and a gate cap layer, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure, removing the sacrificial gate structure to thereby define a gate cavity that exposes a portion of the fin, and forming a replacement gate structure in the gate cavity. One illustrative device disclosed herein includes a plurality of fin structures that are separated by a trench formed in a substrate, a local isolation material positioned within the trench, a gate structure positioned around portions of the fin structures and above the local isolation material and an etch stop layer positioned between the gate structure and the local isolation material within the trench. | 03-27-2014 |
| 20140110794 | FACILITATING GATE HEIGHT UNIFORMITY AND INTER-LAYER DIELECTRIC PROTECTION - Methods of facilitating replacement gate processing and semiconductor devices formed from the methods are provided. The methods include, for instance, providing a plurality of sacrificial gate electrodes with sidewall spacers, the sacrificial gate electrodes with sidewall spacers being separated by, at least in part, a first dielectric material, wherein the first dielectric material is recessed below upper surfaces of the sacrificial gate electrodes, and the upper surfaces of the sacrificial gate electrodes are exposed and coplanar; conformally depositing a protective film over the sacrificial gate electrodes, the sidewall spacers, and the first dielectric material; providing a second dielectric material over the protective film, and planarizing the second dielectric material, stopping on and exposing the protective film over the sacrificial gate electrodes; and opening the protective film over the sacrificial gate electrodes to facilitate performing a replacement gate process. | 04-24-2014 |
| 20140124840 | PREVENTION OF FIN EROSION FOR SEMICONDUCTOR DEVICES - A dielectric metal compound liner can be deposited on a semiconductor fin prior to formation of a disposable gate structure. The dielectric metal compound liner protects the semiconductor fin during the pattering of the disposable gate structure and a gate spacer. The dielectric metal compound liner can be removed prior to formation of source and drain regions and a replacement gate structure. Alternately, a dielectric metal compound liner can be deposited on a semiconductor fin and a gate stack, and can be removed after formation of a gate spacer. Further, a dielectric metal compound liner can be deposited on a semiconductor fin and a disposable gate structure, and can be removed after formation of a gate spacer and removal of the disposable gate structure. The dielectric metal compound liner can protect the semiconductor fin during formation of the gate spacer in each embodiment. | 05-08-2014 |
| 20140124841 | METHODS OF FORMING REPLACEMENT GATE STRUCTURES ON SEMICONDUCTOR DEVICES AND THE RESULTING DEVICE - One method includes forming first sidewall spacers adjacent opposite sides of a sacrificial gate structure and a gate cap layer, removing the gate cap layer and a portion of the first sidewall spacers to define reduced-height first sidewall spacers, forming second sidewall spacers, removing the sacrificial gate structure to thereby define a gate cavity, whereby a portion of the gate cavity is laterally defined by the second sidewall spacers, and forming a replacement gate structure in the gate cavity, wherein at least a first portion of the replacement gate structure is positioned between the second sidewall spacers. A device includes a gate structure positioned above the substrate between first and second spaced-apart portions of a layer of insulating material and a plurality of first sidewall spacers, each of which are positioned between the gate structure and on one of the first and second portions of the layer of insulating material. | 05-08-2014 |
| 20140159171 | METHODS OF FORMING BULK FINFET SEMICONDUCTOR DEVICES BY PERFORMING A LINER RECESSING PROCESS TO DEFINE FIN HEIGHTS AND FINFET DEVICES WITH SUCH A RECESSED LINER - One method disclosed herein includes forming a conformal liner layer in a plurality of trenches that define a fin, forming a layer of insulating material above the liner layer, exposing portions of the liner layer, removing portions of the liner layer so as to result in a generally U-shaped liner positioned at a bottom of each of the trenches, performing at least one third etching process on the layer of insulating material, wherein at least a portion of the layer of insulating material is positioned within a cavity of the U-shaped liner layer, and forming a gate structure around the fin. A FinFET device disclosed herein includes a plurality of trenches that define a fin, a local isolation that includes a generally U-shaped liner that defines, in part, a cavity and a layer of insulating material positioned within the cavity, and a gate structure positioned around the fin. | 06-12-2014 |
| 20140191324 | METHODS OF FORMING BULK FINFET DEVICES BY PERFORMING A RECESSING PROCESS ON LINER MATERIALS TO DEFINE DIFFERENT FIN HEIGHTS AND FINFET DEVICES WITH SUCH RECESSED LINER MATERIALS - One method includes performing an etching process through a patterned mask layer to form trenches in a substrate that defines first and second fins, forming liner material adjacent the first fin to a first thickness, forming liner material adjacent the second fin to a second thickness different from the first thickness, forming insulating material in the trenches adjacent the liner materials and above the mask layer, performing a process operation to remove portions of the layer of insulating material and to expose portions of the liner materials, performing another etching process to remove portions of the liner materials and the mask layer to expose the first fin to a first height and the second fin to a second height different from the first height, performing another etching process to define a reduced-thickness layer of insulating material, and forming a gate structure around a portion of the first and second fin. | 07-10-2014 |
| 20140197468 | METHODS OF FORMING SEMICONDUCTOR DEVICE WITH SELF-ALIGNED CONTACT ELEMENTS AND THE RESULTING DEVICE - One method disclosed includes forming a final gate structure in a gate cavity that is laterally defined by sidewall spacers, removing a portion of the sidewall spacers to define recessed sidewall spacers, removing a portion of the final gate structure to define a recessed final gate structure and forming an etch stop on the recessed sidewall spacers and the recessed final gate structure. A transistor device disclosed herein includes a final gate structure that has an upper surface positioned at a first height level above a surface of a substrate, sidewall spacers positioned adjacent the final gate structure, the sidewall spacers having an upper surface that is positioned at a second, greater height level above the substrate, an etch stop layer formed on the upper surfaces of the sidewall spacers and the final gate structure, and a conductive contact that is conductively coupled to a contact region of the transistor. | 07-17-2014 |
| 20140217482 | INTEGRATED CIRCUITS HAVING REPLACEMENT GATE STRUCTURES AND METHODS FOR FABRICATING THE SAME - A method of fabricating an integrated circuit includes forming an interlayer dielectric (ILD) layer over a dummy gate stack. The dummy gate stack includes a dummy gate structure, a hardmask layer, and sidewall spacers formed over a semiconductor substrate. The method further includes removing at least an upper portion of the dummy gate stack to form a first opening within the ILD layer, extending the first opening to form a first extended opening by completely removing the dummy gate structure of the dummy gate stack, and depositing at least one workfunction material layer within the first opening and within the first extended opening. Still further, the method includes removing portions of the workfunction material within the first opening and depositing a low-resistance material over remaining portions of the workfunction material thereby forming a replacement metal gate structure that includes the remaining portion of the workfunction material and the low-resistance material. | 08-07-2014 |
| 20140217517 | INTEGRATED CIRCUITS INCLUDING FINFET DEVICES WITH LOWER CONTACT RESISTANCE AND REDUCED PARASITIC CAPACITANCE AND METHODS FOR FABRICATING THE SAME - Integrated circuits and methods for fabricating integrated circuits are provided. In one example, an integrated circuit includes a semiconductor substrate. A first fin and a second fin are adjacent to each other extending from the semiconductor substrate. The first fin has a first upper section and the second fin has a second upper section. A first epi-portion overlies the first upper section and a second epi-portion overlies the second upper section. A first silicide layer overlies the first epi-portion and a second silicide layer overlies the second epi-portion. The first and second silicide layers are spaced apart from each other to define a lateral gap. A dielectric spacer is formed of a dielectric material and spans the lateral gap. A contact-forming material overlies the dielectric spacer and portions of the first and second silicide layers that are laterally above the dielectric spacer. | 08-07-2014 |
| 20140231885 | INTEGRATED CIRCUITS AND METHODS FOR FABRICATING INTEGRATED CIRCUITS HAVING METAL GATE ELECTRODES - Integrated circuits and methods for fabricating integrated circuits are provided. In an exemplary embodiment, a method for fabricating integrated circuits includes providing a sacrificial gate structure over a semiconductor substrate. The sacrificial gate structure includes two spacers and sacrificial gate material between the two spacers. The method recesses a portion of the sacrificial gate material between the two spacers. Upper regions of the two spacers are etched while using the sacrificial gate material as a mask. The method includes removing a remaining portion of the sacrificial gate material and exposing lower regions of the two spacers. A first metal is deposited between the lower regions of the two spacers. A second metal is deposited between the upper regions of the two spacers. | 08-21-2014 |
| 20140231920 | INTEGRATED CIRCUITS WITH IMPROVED GATE UNIFORMITY AND METHODS FOR FABRICATING SAME - Integrated circuits with improved gate uniformity and methods for fabricating such integrated circuits are provided. In an embodiment, an integrated circuit includes a semiconductor substrate and a replacement metal gate structure overlying the semiconductor substrate. The replacement metal gate structure includes a first metal and a second metal and has a recess surface formed by the first metal and the second metal. The first metal and the second metal include a first species of diffused foreign ions. The integrated circuit further includes a metal fill material overlying the recess surface formed by the first metal and the second metal. | 08-21-2014 |
| 20140252424 | METHODS OF FORMING SEMICONDUCTOR DEVICE WITH SELF-ALIGNED CONTACT ELEMENTS AND THE RESULTING DEVICES - One method discloses performing an etching process to form a contact opening in a layer of insulating material above at least a portion of a source/drain, region wherein, after the completion of the etching process, a portion of a gate structure of the transistor is exposed, selectively forming an oxidizable material on the exposed gate structure, converting at least a portion of the oxidizable material to an oxide material, and forming a conductive contact in the contact opening that is conductively coupled to the source/drain region. A novel transistor device disclosed herein includes an oxide material positioned between a conductive contact and a gate structure of the transistor, wherein the oxide material contacts the conductive contact and contacts a portion, but not all, of the exterior surface of the gate structure. | 09-11-2014 |
| 20140252425 | METHODS OF FORMING SEMICONDUCTOR DEVICE WITH SELF-ALIGNED CONTACT ELEMENTS AND THE RESULTING DEVICES - One method includes performing a first etching process to form a contact opening in a layer of insulating material that exposes a portion of a gate structure of the transistor, performing a second etching process on the exposed portion of the gate structure to thereby define a gate recess, selectively forming an oxidizable material in the gate recess, converting the oxidizable material to an oxide material, and forming a conductive contact in the contact opening that is conductively coupled to a source/drain region. A device includes an oxide material that is positioned at least partially in a recess formed in a gate structure, wherein the oxide material contacts a conductive contact and contacts a portion, but not all, of the exterior surface of the gate structure. | 09-11-2014 |
| 20140256106 | PREVENTION OF FIN EROSION FOR SEMICONDUCTOR DEVICES - A dielectric metal compound liner can be deposited on a semiconductor fin prior to formation of a disposable gate structure. The dielectric metal compound liner protects the semiconductor fin during the pattering of the disposable gate structure and a gate spacer. The dielectric metal compound liner can be removed prior to formation of source and drain regions and a replacement gate structure. Alternately, a dielectric metal compound liner can be deposited on a semiconductor fin and a gate stack, and can be removed after formation of a gate spacer. Further, a dielectric metal compound liner can be deposited on a semiconductor fin and a disposable gate structure, and can be removed after formation of a gate spacer and removal of the disposable gate structure. The dielectric metal compound liner can protect the semiconductor fin during formation of the gate spacer in each embodiment. | 09-11-2014 |
| 20140264479 | METHODS OF INCREASING SPACE FOR CONTACT ELEMENTS BY USING A SACRIFICIAL LINER AND THE RESULTING DEVICE - One method includes forming a sidewall spacer adjacent a gate structure, forming a first liner layer on the sidewall spacer, forming a second liner layer on the first liner layer, forming a first layer of insulating material above the substrate and adjacent the second liner layer, selectively removing at least portions of the second liner layer relative to the first liner layer, forming a second layer of insulating material above the first layer of insulating material, performing at least one second etching process to remove at least portions of the first and second layers of insulating material and at least portions of the first liner layer so as to thereby expose an outer surface of the sidewall spacer, and forming a conductive contact that contacts the exposed outer surface of the sidewall spacer and a source/drain region of the transistor. | 09-18-2014 |
| 20140315371 | METHODS OF FORMING ISOLATION REGIONS FOR BULK FINFET SEMICONDUCTOR DEVICES - One method disclosed herein includes forming a plurality of fin-formation trenches in a semiconductor substrate that define a plurality of spaced-apart fins, forming a patterned liner layer that covers a portion of the substrate positioned between the fins while exposing portions of the substrate positioned laterally outside of the patterned liner layer, and performing at least one etching process on the exposed portions of the substrate through the patterned liner layer to define an isolation trench in the substrate, wherein the isolation trench has a depth that is greater than a depth of the fin-formation trenches. | 10-23-2014 |
| 20140327088 | FINFET SEMICONDUCTOR DEVICE WITH A RECESSED LINER THAT DEFINES A FIN HEIGHT OF THE FINFET DEVICE - One method disclosed herein includes forming a conformal liner layer in a plurality of trenches that define a fin, forming a layer of insulating material above the liner layer, exposing portions of the liner layer, removing portions of the liner layer so as to result in a generally U-shaped liner positioned at a bottom of each of the trenches, performing at least one third etching process on the layer of insulating material, wherein at least a portion of the layer of insulating material is positioned within a cavity of the U-shaped liner layer, and forming a gate structure around the fin. A FinFET device disclosed herein includes a plurality of trenches that define a fin, a local isolation that includes a generally U-shaped liner that defines, in part, a cavity and a layer of insulating material positioned within the cavity, and a gate structure positioned around the fin. | 11-06-2014 |
| 20140327089 | FINFET DEVICES HAVING RECESSED LINER MATERIALS TO DEFINE DIFFERENT FIN HEIGHTS - One method includes performing an etching process through a patterned mask layer to form trenches in a substrate that defines first and second fins, forming liner material adjacent the first fin to a first thickness, forming liner material adjacent the second fin to a second thickness different from the first thickness, forming insulating material in the trenches adjacent the liner materials and above the mask layer, performing a process operation to remove portions of the layer of insulating material and to expose portions of the liner materials, performing another etching process to remove portions of the liner materials and the mask layer to expose the first fin to a first height and the second fin to a second height different from the first height, performing another etching process to define a reduced-thickness layer of insulating material, and forming a gate structure around a portion of the first and second fin. | 11-06-2014 |
| 20140327090 | FINFET DEVICE WITH AN ETCH STOP LAYER POSITIONED BETWEEN A GATE STRUCTURE AND A LOCAL ISOLATION MATERIAL - One illustrative method disclosed herein includes forming a sacrificial gate structure above a fin, wherein the sacrificial gate structure is comprised of a sacrificial gate insulation layer, a layer of insulating material, a sacrificial gate electrode layer and a gate cap layer, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure, removing the sacrificial gate structure to thereby define a gate cavity that exposes a portion of the fin, and forming a replacement gate structure in the gate cavity. One illustrative device disclosed herein includes a plurality of fin structures that are separated by a trench formed in a substrate, a local isolation material positioned within the trench, a gate structure positioned around portions of the fin structures and above the local isolation material and an etch stop layer positioned between the gate structure and the local isolation material within the trench. | 11-06-2014 |
| 20140339629 | CONTACT FORMATION FOR ULTRA-SCALED DEVICES - Embodiments of the invention provide approaches for forming gate and source/drain (S/D) contacts. Specifically, the semiconductor device includes a gate transistor formed over a substrate, a S/D contact formed over a trench-silicide (TS) layer and positioned adjacent the gate transistor, and a gate contact formed over the gate transistor, wherein at least a portion of the gate contact is aligned over the TS layer. This structure enables contact with the TS layer, thereby decreasing the distance between the gate contact and the source/drain, which is desirable for ultra-area-scaling. | 11-20-2014 |
| 20140346574 | ASYMMETRIC FINFET SEMICONDUCTOR DEVICES AND METHODS FOR FABRICATING THE SAME - Asymmetric FinFET devices and methods for fabricating such devices are provided. In one embodiment, a method includes providing a semiconductor substrate comprising a plurality of fin structures formed thereon and depositing a conformal liner over the fin structures. A first portion of the conformal liner is removed, leaving a first space between the fins structures and forming a first metal gate in the first space between the fin structures. A second portion of the conformal liner is removed, leaving a second space between the fin structures and forming a second metal gate in the second space between the fin structures. | 11-27-2014 |
| 20140346599 | FINFET SEMICONDUCTOR DEVICES WITH LOCAL ISOLATION FEATURES AND METHODS FOR FABRICATING THE SAME - FinFET semiconductor devices with local isolation features and methods for fabricating such devices are provided. In one embodiment, a method for fabricating a semiconductor device includes providing a semiconductor substrate comprising a plurality of fin structures formed thereon, wherein each of the plurality of fin structures has sidewalls, forming spacers about the sidewalls of the plurality of fin structures, and forming a silicon-containing layer over the semiconductor substrate and in between the plurality of fin structures. The method further includes removing at least a first portion of the silicon-containing layer to form a plurality of void regions while leaving at least a second portion thereof in place and depositing an isolation material in the plurality of void regions. | 11-27-2014 |
| 20140367788 | METHODS OF FORMING GATE STRUCTURES FOR CMOS BASED INTEGRATED CIRCUIT PRODUCTS AND THE RESULTING DEVICES - One illustrative method disclosed herein includes forming gate insulation layers and a first metal layer for NMOS and PMOS devices from the same material, selectively forming a first metal layer only for the PMOS device, and forming different shaped metal silicide regions within the NMOS and PMOS gate cavities. A novel integrated circuit product disclosed herein includes an NMOS transistor with an NMOS gate insulation layer, an NMOS metal silicide having a generally rectangular cross-sectional configuration and an NMOS metal layer positioned on the NMOS metal silicide region. The product also includes a PMOS transistor with the same gate insulation material, a first PMOS metal and a PMOS metal silicide region, wherein the NMOS and PMOS metal silicide regions are comprised of the same metal silicide. | 12-18-2014 |
| 20140367790 | METHODS OF FORMING GATE STRUCTURES FOR CMOS BASED INTEGRATED CIRCUIT PRODUCTS AND THE RESULTING DEVICES - One illustrative method disclosed herein includes forming replacement gate structures for an NMOS transistor and a PMOS transistor by forming gate insulation layers and a first metal layer for the devices from the same materials and selectively forming a metal-silicide material layer only on the first metal layer for the NMOS device but not on the PMOS device. One example of a novel integrated circuit product disclosed herein includes an NMOS device and a PMOS device wherein the gate insulation layers and the first metal layer of the gate structures of the devices are made of the same material, the gate structure of the NMOS device includes a metal silicide material positioned on the first metal layer of the NMOS device, and a second metal layer that is positioned on the metal silicide material for the NMOS device and on the first metal layer for the PMOS device. | 12-18-2014 |
| 20140367795 | METHODS OF FORMING DIFFERENT FINFET DEVICES HAVING DIFFERENT FIN HEIGHTS AND AN INTEGRATED CIRCUIT PRODUCT CONTAINING SUCH DEVICES - One illustrative method disclosed herein includes forming a plurality of trenches in a plurality of active regions of a substrate that defines at least a first plurality of fins and a second plurality of fins for first and second FinFET devices, respectively, forming liner materials adjacent to the first and second plurality of fins, wherein the liner materials adjacent the first fins and the second fins have a different thickness. The method also includes removing insulating material to expose portions of the liner materials, performing an etching process to remove portions of the liner materials so as to expose at least one fin in the first plurality of fins to a first height and at least one of the second plurality of fins to a second height that is different from the first height. | 12-18-2014 |
| 20150021683 | METHODS OF FORMING SEMICONDUCTOR DEVICE WITH SELF-ALIGNED CONTACT ELEMENTS AND THE RESULTING DEVICES - One method disclosed herein includes forming a sacrificial etch stop material in a recess above a replacement gate structure, with the sacrificial etch stop material in position, forming a self-aligned contact that is conductively coupled to the source/drain region, after forming the self-aligned contact, performing at least one process operation to expose and remove the sacrificial etch stop material in the recess so as to thereby re-expose the recess, and forming a third layer of insulating material in at least the re-exposed recess. | 01-22-2015 |
| 20150035086 | METHODS OF FORMING CAP LAYERS FOR SEMICONDUCTOR DEVICES WITH SELF-ALIGNED CONTACT ELEMENTS AND THE RESULTING DEVICES - One method disclosed herein includes forming an etch stop layer above recessed sidewall spacers and a recessed replacement gate structure and, with the etch stop layer in position, forming a self-aligned contact that is conductively coupled to the source/drain region after forming the self-aligned contact. A device disclosed herein includes an etch stop layer that is positioned above a recessed replacement gate structure and recessed sidewall spacers, wherein the etch stop layer defines an etch stop recess that contains a layer of insulating material positioned therein. The device further includes a self-aligned contact. | 02-05-2015 |
| 20150041905 | METHODS OF FORMING REPLACEMENT GATE STRUCTURES FOR TRANSISTORS AND THE RESULTING DEVICES - Disclosed herein are illustrative methods and devices that involve forming spacers with internally trimmed internal surfaces to increase the width of the upper portions of a gate cavity. In some embodiments, the internal surface of the spacer has a stepped cross-sectional configuration or a tapered cross-sectional configuration. In one example, a device is disclosed wherein the P-type work function metal for a PMOS device is positioned only within the lateral space defined by the untrimmed internal surfaces of the spacers, while the work function adjusting metal for the NMOS device is positioned laterally between the lateral spaces defined by both the trimmed and untrimmed internal surfaces of the sidewall spacers. | 02-12-2015 |
| 20150054078 | METHODS OF FORMING GATE STRUCTURES FOR FINFET DEVICES AND THE RESULTING SMEICONDUCTOR PRODUCTS - One method disclosed herein includes forming a stack of material layers to form gate structures, performing a first etching process to define an opening through the stack of materials that defines an end surface of the gate structures, forming a gate separation structure in the opening and performing a second etching process to define side surfaces of the gate structures. A device disclosed herein includes first and second active regions that include at least one fin, first and second gate structures, wherein each of the gate structures have end surfaces, and a gate separation structure positioned between the gate structures, wherein opposing surfaces of the gate separation structure abut the end surfaces of the gate structures, and wherein an upper surface of the gate separation structure is positioned above an upper surface of the at least one fin. | 02-26-2015 |
| 20150060960 | METHODS OF FORMING CONTACT STRUCTURES ON FINFET SEMICONDUCTOR DEVICES AND THE RESULTING DEVICES - A method includes forming a raised isolation structure with a recess above a substrate, forming a gate structure above the fin, forming a plurality of spaced-apart buried fin contact structures within the recess that have an outer perimeter surface that contacts at least a portion of an interior perimeter surface of the recess and forming at least one source/drain contact structure for each of the buried fin contact structures. One device includes a plurality of spaced-apart buried fin contact structures positioned within a recess in a raised isolation structure on opposite sides of a gate structure. The upper surface of each of the buried fin contact structures is positioned below an upper surface of the raised isolation structure and an outer perimeter surface of each of the buried fin contact structures contacts at least a portion of an interior perimeter surface of the recess. | 03-05-2015 |
| 20150069532 | METHODS OF FORMING FINFET SEMICONDUCTOR DEVICES WITH SELF-ALIGNED CONTACT ELEMENTS USING A REPLACEMENT GATE PROCESS AND THE RESULTING DEVICES - One method disclosed herein includes removing a sacrificial gate structure and forming a replacement gate structure in its place, after forming the replacement gate structure, forming a metal silicide layer on an entire upper surface area of each of a plurality of source/drain regions and, with the replacement gate structure in position, forming at least one source/drain contact structure for each of the plurality of source/drain regions, wherein the at least one source/drain contact structure is conductively coupled to a portion of the metal silicide layer and a dimension of the at least one source/drain contact structure in a gate width direction of the transistor is less than a dimension of the source/drain region in the gate width direction. | 03-12-2015 |
| 20150076609 | METHODS OF FORMING STRESSED LAYERS ON FINFET SEMICONDUCTOR DEVICES AND THE RESULTING DEVICES - One method includes forming a raised isolation structure with a recess above a substrate, forming a gate structure above the fin, forming a plurality of spaced-apart buried fin contact structures within the recess and forming a stress-inducing material layer above the buried fin contact structures. One device includes a plurality of spaced-apart buried fin contact structures positioned within a recess in a raised isolation structure on opposite sides of a gate structure, a stress-inducing material layer formed above the buried fin contact structures and a source/drain contact that extends through the stress-inducing material layer. | 03-19-2015 |
| 20150091100 | METHODS OF FORMING FINFET SEMICONDUCTOR DEVICES USING A REPLACEMENT GATE TECHNIQUE AND THE RESULTING DEVICES - One method disclosed includes, among other things, forming a raised isolation post structure between first and second fins, wherein the raised isolation post structure partially defines first and second spaces between the first and second fins, respectively, and forming a gate structure around the first and second fins and the raised isolation post structure, wherein at least portions of the gate structure are positioned in the first and second spaces. One illustrative device includes, among other things, first and second fins, a raised isolation post structure positioned between the first and second fins, first and second spaces defined by the fins and the raised isolation post structure, and a gate structure positioned around a portion of the fins and the isolation post structure. | 04-02-2015 |
| 20150102422 | INTEGRATED CIRCUITS INCLUDING FINFET DEVICES WITH LOWER CONTACT RESISTANCE AND REDUCED PARASITIC CAPACITANCE AND METHODS FOR FABRICATING THE SAME - Integrated circuits and methods for fabricating integrated circuits are provided. In one example, an integrated circuit includes a semiconductor substrate. A first fin and a second fin are adjacent to each other extending from the semiconductor substrate. The first fin has a first upper section and the second fin has a second upper section. A first epi-portion overlies the first upper section and a second epi-portion overlies the second upper section. A first silicide layer overlies the first epi-portion and a second silicide layer overlies the second epi-portion. The first and second silicide layers are spaced apart from each other to define a lateral gap. A dielectric spacer is formed of a dielectric material and spans the lateral gap. A contact-forming material overlies the dielectric spacer and portions of the first and second silicide layers that are laterally above the dielectric spacer. | 04-16-2015 |
| 20150111373 | REDUCING GATE HEIGHT VARIATION IN RMG PROCESS - A method of forming transistors is provided. The method includes forming a plurality of transistor structures to have a plurality of dummy gates on a substrate. Each dummy gate is surrounded by sidewall spacers of a height, which is less than the dummy gate and is different for different transistor structures resulting in divots of different depths above the sidewall spacers. The method then deposits a conformal dielectric layer on top of the dummy gates and inside the divots of the plurality of transistor structures with the conformal dielectric layer having a thickness of at least half of a width of the divots, removes only a portion of the conformal dielectric layer that is on top of the dummy gates to expose the dummy gates; and replaces the dummy gates with a plurality of high-k metal gates. | 04-23-2015 |
| 20150123166 | METHODS OF FORMING FINFET DEVICES WITH ALTERNATIVE CHANNEL MATERIALS - are methods and devices that involve formation of alternating layers of different semiconductor materials in the channel region of FinFET devices. The methods and devices disclosed herein involve forming a doped silicon substrate fin and thereafter forming a layer of silicon/germanium around the substrate fin. The methods and devices also include forming a gate structure around the layer of silicon/germanium using gate first or gate last techniques. | 05-07-2015 |
| 20150129934 | METHODS OF FORMING SUBSTANTIALLY SELF-ALIGNED ISOLATION REGIONS ON FINFET SEMICONDUCTOR DEVICES AND THE RESULTING DEVICES - One method disclosed includes performing a selective etching process through a gate cavity to selectively remove a portion of a first semiconductor material relative to a second layer of a second semiconductor material and a substrate so as to thereby define a space between the second semiconducting material and the substrate, filling substantially all of the space with an insulating material so as to thereby define a substantially self-aligned channel isolation region positioned under at least what will become the channel region of the FinFET device. | 05-14-2015 |
| 20150129962 | METHODS OF FORMING REPLACEMENT GATE STRUCTURES AND FINS ON FINFET DEVICES AND THE RESULTING DEVICES - One method disclosed includes, among other things, removing a sacrificial gate structure to thereby define a replacement gate cavity, performing an etching process through the replacement gate cavity to define a fin structure in a layer of semiconductor material using a patterned hard mask exposed within the replacement gate cavity as an etch mask and forming a replacement gate structure in the replacement gate cavity around at least a portion of the fin structure. | 05-14-2015 |
| 20150129970 | METHODS AND STRUCTURES FOR ELIMINATING OR REDUCING LINE END EPI MATERIAL GROWTH ON GATE STRUCTURES - One method disclosed herein includes, among other things, forming a line-end protection layer in an opening on an entirety of each opposing, spaced-apart first and second end face surfaces of first and second spaced-apart gate electrode structures, respectively, and forming a sidewall spacer adjacent opposing sidewall surfaces of each of the gate electrode structures but not adjacent the opposing first and second end face surfaces having the line-end protection layer positioned thereon. | 05-14-2015 |
| 20150200353 | MAGNETIC TUNNEL JUNCTION BETWEEN METAL LAYERS OF A SEMICONDUCTOR DEVICE - Embodiments herein provide a magnetic tunnel junction (MTJ) formed between metal layers of a semiconductor device. Specifically, provided is an approach for forming the semiconductor device using only one or two masks, the approach comprising: forming a first metal layer in a dielectric layer of the semiconductor device, forming a bottom electrode layer over the first metal layer, forming a MTJ over the bottom electrode layer, forming a top electrode layer over the MTJ, patterning the top electrode layer and the MTJ with a first mask, and forming a second metal layer over the top electrode layer. Optionally, the bottom electrode layer may be patterned using a second mask. Furthermore, in another embodiment, an insulator layer (e.g., manganese) is formed atop the dielectric layer, wherein a top surface of the first metal layer remains exposed following formation of the insulator layer such that the bottom electrode layer contacts the top surface of the first metal layer. By forming the MJT between the metal layers using only one or two masks, the overall number of processing steps is reduced. | 07-16-2015 |
| 20150214219 | GATE STRUCTURE CUT AFTER FORMATION OF EPITAXIAL ACTIVE REGIONS - A gate structure straddling a plurality of semiconductor material portions is formed. Source regions and drain regions are formed in the plurality of semiconductor material portions, and a gate spacer laterally surrounding the gate structure is formed. Epitaxial active regions are formed from the source and drain regions by a selective epitaxy process. The assembly of the gate structure and the gate spacer is cut into multiple portions employing a cut mask and an etch to form multiple gate assemblies. Each gate assembly includes a gate structure portion and two disjoined gate spacer portions laterally spaced by the gate structure portion. Portions of the epitaxial active regions can be removed from around sidewalls of the gate spacers to prevent electrical shorts among the epitaxial active regions. A dielectric spacer or a dielectric liner may be employed to limit areas in which metal semiconductor alloys are formed. | 07-30-2015 |
| 20150214365 | MULTIWIDTH FINFET WITH CHANNEL CLADDING - An improved structure and methods of fabrication for finFET devices utilizing a cladding channel are disclosed. A staircase fin is formed where the fin comprises an upper portion of a first width and a lower portion of a second width, wherein the lower portion is wider than the upper portion. The narrower upper portion allows the cladding channel to be deposited and still have sufficient space for proper gate deposition, while the lower portion is wide to provide improved mechanical stability, which protects the fins during the subsequent processing steps. | 07-30-2015 |
| 20150221749 | METHODS OF FORMING GATE STRUCTURES FOR SEMICONDUCTOR DEVICES USING A REPLACEMENT GATE TECHNIQUE AND THE RESULTING DEVICES - One method and device disclosed includes, among other things, forming a recessed sacrificial gate electrode having a recessed upper surface, performing at least one second etching process to define recessed sidewall spacers positioned adjacent the recessed sacrificial gate electrode, forming a plurality of sidewall spacers within a gate opening above the recessed sidewall spacers, wherein one of the spacers comprises a low-k insulating material that is positioned laterally between two other spacers and a gate cap layer, removing the recessed sacrificial gate electrode and forming a replacement gate structure in its place. | 08-06-2015 |
| 20150228776 | METHODS OF FORMING CONTACTS TO SEMICONDUCTOR DEVICES USING A BOTTOM ETCH STOP LAYER AND THE RESULTING DEVICES - One method disclosed includes, among other things, forming a patterned high-k etch stop layer above source/drain regions, performing at least etching process to form at least one contact opening in a layer of insulating material, wherein the patterned high-k etch stop layer acts as an etch stop during the etching process, performing a second etching process to remove portions of the patterned high-k etch stop layer exposed by the contact opening and forming a conductive contact in the contact opening that is conductively coupled to the source/drain regions. The device includes a patterned high-k etch stop layer positioned between the conductive contact and an outermost sidewall spacer, wherein an outer side surface of the patterned high-k etch stop layer contacts the conductive contact. | 08-13-2015 |
| 20150228792 | METHODS OF FORMING A NON-PLANAR ULTRA-THIN BODY SEMICONDUCTOR DEVICE AND THE RESULTING DEVICES - One device disclosed includes a gate structure positioned around a perimeter surface of the fin, a layer of channel semiconductor material having an axial length in the channel length direction of the device that corresponds approximately to the overall width of the gate structure being positioned between the gate structure and around the outer perimeter surface of the fin, wherein an inner surface of the layer of channel semiconductor material is spaced apart from and does not contact the outer perimeter surface of the fin. One method disclosed involves, among other things, forming first and second layers of semiconductor material around the fin, forming a gate structure around the second semiconductor material, removing the portions of the first and second layers of semiconductor material positioned laterally outside of sidewall spacers and removing the first layer of semiconductor material positioned below the second layer of semiconductor material. | 08-13-2015 |
| 20150243604 | CAP LAYERS FOR SEMICONDUCTOR DEVICES WITH SELF-ALIGNED CONTACT ELEMENTS - One method disclosed herein includes forming an etch stop layer above recessed sidewall spacers and a recessed replacement gate structure and, with the etch stop layer in position, forming a self-aligned contact that is conductively coupled to the source/drain region after forming the self-aligned contact. A device disclosed herein includes an etch stop layer that is positioned above a recessed replacement gate structure and recessed sidewall spacers, wherein the etch stop layer defines an etch stop recess that contains a layer of insulating material positioned therein. The device further includes a self-aligned contact. | 08-27-2015 |
| 20150249036 | METHODS OF FORMING DIFFERENT SPACER STRUCTURES ON INTEGRATED CIRCUIT PRODUCTS HAVING DIFFERING GATE PITCH DIMENSIONS AND THE RESULTING PRODUCTS - One example disclosed herein involves forming source/drain conductive contacts to first and second source/drain regions, the first source/drain region being positioned between a first pair of transistor devices having a first gate pitch dimension, the second source/drain region being positioned between a second pair of transistor devices having a second gate pitch dimension that is greater than the first gate pitch dimension, wherein the first and second pairs of transistor devices have a gate structure and sidewall spacers positioned adjacent the gate structure. | 09-03-2015 |
| 20150249127 | METHODS OF FORMING FINS FOR FINFET SEMICONDUCTOR DEVICES AND SELECTIVELY REMOVING SOME OF THE FINS BY PERFORMING A CYCLICAL FIN CUTTING PROCESS - One illustrative method disclosed herein includes forming a plurality of initial fins in a substrate, wherein at least one of the initial fins is a to-be-removed fin, forming a material adjacent the initial fins, forming a fin removal masking layer above the plurality of initial fins, removing a desired portion of the at least one to-be-removed fin by: (a) performing a recess etching process on the material to remove a portion, but not all, of the material positioned adjacent the sidewalls of the at least one to-be-removed fin, (b) after performing the recess etching process, performing a fin recess etching process to remove a portion, but not all, of the at least one to be removed fin and (c) repeating steps (a) and (b) until the desired amount of the at least one to-be-removed fin is removed. | 09-03-2015 |
| 20150249152 | METHODS OF FORMING REPLACEMENT GATE STRUCTURES AND FINS ON FINFET DEVICES AND THE RESULTING DEVICES - One method disclosed includes, among other things, removing a sacrificial gate structure to thereby define a replacement gate cavity, performing an etching process through the replacement gate cavity to define a fin structure in a layer of semiconductor material using a patterned hard mask exposed within the replacement gate cavity as an etch mask and forming a replacement gate structure in the replacement gate cavity around at least a portion of the fin structure. | 09-03-2015 |
| 20150255542 | METHODS OF FORMING STRESSED CHANNEL REGIONS FOR A FINFET SEMICONDUCTOR DEVICE AND THE RESULTING DEVICE - One method disclosed includes, among other things, covering the top surface and a portion of the sidewalls of an initial fin structure with etch stop material, forming a sacrificial gate structure around the initial fin structure, forming a sidewall spacer adjacent the sacrificial gate structure, removing the sacrificial gate structure, with the etch stop material in position, to thereby define a replacement gate cavity, performing at least one etching process through the replacement gate cavity to remove a portion of the semiconductor substrate material of the fin structure positioned under the replacement gate cavity that is not covered by the etch stop material so as to thereby define a final fin structure and a channel cavity positioned below the final fin structure and substantially filling the channel cavity with a stressed material. | 09-10-2015 |
| 20150255555 | METHODS OF FORMING A NON-PLANAR ULTRA-THIN BODY DEVICE - One illustrative method disclosed herein involves, among other things, forming a first epi semiconductor material on the exposed opposite sidewalls of a fin to thereby define a semiconductor body, performing at least one etching process to remove at least a portion of the substrate portion of the fin positioned between the first epi semiconductor materials positioned on the opposite sidewalls of the fin and to thereby define a back-gate cavity, forming a back-gate insulating material within the back-gate cavity and on the first epi semiconductor materials, forming a back-gate electrode on the back-gate insulation material within the back-gate cavity and forming a gate structure comprised of a gate insulation layer and a gate electrode around the semiconductor bodies. | 09-10-2015 |
| 20150255561 | SEMICONDUCTOR DEVICE WITH LOW-K SPACERS - One method disclosed herein includes forming at least one sacrificial sidewall spacer adjacent a sacrificial gate structure that is formed above a semiconducting substrate, removing at least a portion of the sacrificial gate structure to thereby define a gate cavity that is laterally defined by the sacrificial spacer, forming a replacement gate structure in the gate cavity, removing the sacrificial spacer to thereby define a spacer cavity adjacent the replacement gate structure, and forming a low-k spacer in the spacer cavity. A novel device disclosed herein includes a gate structure positioned above a semiconducting substrate, wherein the gate insulation layer has two upstanding portions that are substantially vertically oriented relative to an upper surface of the substrate. The device further includes a low-k sidewall spacer positioned adjacent each of the vertically oriented upstanding portions of the gate insulation layer. | 09-10-2015 |
| 20150255608 | METHODS OF FORMING STRESSED CHANNEL REGIONS FOR A FINFET SEMICONDUCTOR DEVICE AND THE RESULTING DEVICE - One method disclosed includes, among other things, forming an initial fin structure comprised of portions of a substrate, a first epi semiconductor material and a second epi semiconductor material, forming a layer of insulating material so as to over-fill the trenches that define the fin, recessing a layer of insulating material such that a portion, but not all, of the second epi semiconductor portion of the final fin structure is exposed, forming a gate structure around the final fin structure, further recessing the layer of insulating material such that the first epi semiconductor material is exposed, removing the first epi semiconductor material to thereby define an under-fin cavity and substantially filling the under-fin cavity with a stressed material. | 09-10-2015 |
| 20150263120 | REPLACEMENT GATE STRUCTURE WITH LOW-K SIDEWALL SPACER FOR SEMICONDUCTOR DEVICES - One method and device disclosed includes, among other things, forming a recessed sacrificial gate electrode having a recessed upper surface, performing at least one second etching process to define recessed sidewall spacers positioned adjacent the recessed sacrificial gate electrode, forming a plurality of sidewall spacers within a gate opening above the recessed sidewall spacers, wherein one of the spacers comprises a low-k insulating material that is positioned laterally between two other spacers and a gate cap layer, removing the recessed sacrificial gate electrode and forming a replacement gate structure in its place. | 09-17-2015 |
| 20150263160 | SEMICONDUCTOR DEVICE WITH SELF-ALIGNED CONTACT ELEMENTS - One method disclosed herein includes forming a sacrificial etch stop material in a recess above a replacement gate structure, with the sacrificial etch stop material in position, forming a self-aligned contact that is conductively coupled to the source/drain region, after forming the self-aligned contact, performing at least one process operation to expose and remove the sacrificial etch stop material in the recess so as to thereby re-expose the recess, and forming a third layer of insulating material in at least the re-exposed recess. | 09-17-2015 |
| 20150270176 | METHODS OF FORMING REDUCED RESISTANCE LOCAL INTERCONNECT STRUCTURES AND THE RESULTING DEVICES - A method includes forming a layer of insulating material above first and second transistors, within the layer of insulating material, forming a set of initial device-level contacts for each of the first and second transistors, wherein each set of initial device-level contacts comprises a plurality of source/drain contacts and a gate contact, forming an initial local interconnect structure that is conductively coupled to one of the initial device-level contacts in each of the first and second transistors, and removing the initial local interconnect structure and portions, but not all, of the initial device-level contacts for each the first and second transistors. The method also includes forming a copper local interconnect structure and copper caps above the recessed device-level contacts. | 09-24-2015 |
| 20150270262 | GATE STRUCTURES WITH PROTECTED END SURFACES TO ELIMINATE OR REDUCE UNWANTED EPI MATERIAL GROWTH - One method disclosed herein includes, among other things, forming a line-end protection layer in an opening on an entirety of each opposing, spaced-apart first and second end face surfaces of first and second spaced-apart gate electrode structures, respectively, and forming a sidewall spacer adjacent opposing sidewall surfaces of each of the gate electrode structures but not adjacent the opposing first and second end face surfaces having the line-end protection layer positioned thereon. | 09-24-2015 |
| 20150279742 | METHODS OF FORMING REPLACEMENT GATE STRUCTURES USING A GATE HEIGHT REGISTER PROCESS TO IMPROVE GATE HEIGHT UNIFORMITY AND THE RESULTING INTEGRATED CIRCUIT PRODUCTS - One method disclosed includes, among other things, forming a gate registration structure above an isolation region, wherein the gate registration structure comprises a plurality of layers of material, the uppermost layer of which is a polish-stop layer, forming first and second sacrificial gate structures above first and second active regions, respectively, wherein the first and second sacrificial gate structures abut and engage opposite sides of the gate registration structure, and performing at least one first chemical mechanical polishing (CMP) process to remove the gate cap layer so as to thereby expose a sacrificial gate electrode in each of the first and second sacrificial gate structures, wherein the uppermost layer of the gate registration structure serves as a polish-stop layer during the at least one first CMP process. | 10-01-2015 |
| 20150279935 | SEMICONDUCTOR DEVICES WITH CONTACT STRUCTURES AND A GATE STRUCTURE POSITIONED IN TRENCHES FORMED IN A LAYER OF MATERIAL - One illustrative device disclosed herein includes, among other things, an active region defined in a semiconductor substrate, a layer of material positioned above the substrate, a plurality of laterally spaced-apart source/drain trenches formed in the layer of material above the active region, a conductive source/drain contact structure formed within each of the source/drain trenches, a gate trench formed at least partially in the layer of material between the spaced-apart source/drain trenches in the layer of material, wherein portions of the layer of material remain positioned between the source/drain trenches and the gate trench, a gate structure positioned within the gate trench, and a gate cap layer positioned above the gate structure. | 10-01-2015 |
| 20150279963 | METHODS OF FORMING A FINFET SEMICONDUCTOR DEVICE SO AS TO REDUCE PUNCH-THROUGH LEAKAGE CURRENTS AND THE RESULTING DEVICE - One method disclosed includes, among other things, covering a top surface and a portion of the sidewalls of a fin with etch stop material, forming a sacrificial gate structure above and around the fin, forming a sidewall spacer adjacent the sacrificial gate structure, performing at least one process operation to remove the sacrificial gate structure and thereby define a replacement gate cavity, forming a counter-doped region in the fin below an upper surface of the fin and below the channel region of the device, wherein the counter-doped region is doped with a second type of dopant material that is of an opposite type relative to the first type of dopant material, and forming a replacement gate structure in the replacement gate cavity. | 10-01-2015 |
| 20150279971 | METHODS OF FORMING FINS FOR FINFET SEMICONDUCTOR DEVICES AND THE SELECTIVE REMOVAL OF SUCH FINS - One method includes forming a plurality of first trenches in a semiconductor substrate to thereby define a plurality of initial fins in the substrate, removing at least one, but less than all, of the plurality of initial fins, forming a fin protection layer on at least the sidewalls of the remaining initial fins, with the fin protection layer in position, performing an etching process to extend a depth of the first trenches to thereby define a plurality of final trenches with a final trench depth, wherein the final trenches define a plurality of final fin structures that each comprise an initial fin, removing the fin protection layer, and forming a recessed layer of insulating material in the final trenches, wherein the recessed layer of insulating material has a recessed surface that exposes a portion of the final fin structures. | 10-01-2015 |
| 20150279972 | METHODS OF FORMING SEMICONDUCTOR DEVICES USING A LAYER OF MATERIAL HAVING A PLURALITY OF TRENCHES FORMED THEREIN - One method disclosed includes, among other things, forming a plurality of laterally spaced-apart source/drain trenches and a gate trench in a layer of material above an active region, performing at least one process operation through the spaced-apart source/drain trenches to form doped source/drain regions, forming a gate structure within the gate trench, and forming a gate cap layer above the gate structure positioned within the gate trench. | 10-01-2015 |
| 20150279999 | FINFET DEVICES WITH DIFFERENT FIN HEIGHTS IN THE CHANNEL AND SOURCE/DRAIN REGIONS - One method disclosed includes, forming a sacrificial gate structure trench in a stack of sacrificial material layers, forming a sacrificial gate structure within the trench, performing at least one process operation to remove at least portions of the stack of sacrificial material layers and thereby expose sidewalls of the sacrificial gate structure, forming a sidewall spacer adjacent the exposed sidewalls of the sacrificial gate structure, removing the sacrificial gate structure so as to define a replacement gate cavity between the spacers, forming a replacement gate structure in the replacement gate cavity, and forming a gate cap above the replacement gate structure within the replacement gate cavity. | 10-01-2015 |
| 20150287648 | FINFET INCLUDING TUNABLE FIN HEIGHT AND TUNABLE FIN WIDTH RATIO - A semiconductor substrate includes a bulk substrate layer that extends along a first axis to define a width and a second axis perpendicular to the first axis to define a height. A plurality of hetero semiconductor fins includes an epitaxial material formed on a first region of the bulk substrate layer. A plurality of non-hetero semiconductor fins is formed on a second region of the bulk substrate layer different from the first region. The non-hetero semiconductor fins are integrally formed from the bulk substrate layer such that the material of the non-hetero semiconductor fins is different from the epitaxial material. | 10-08-2015 |
| 20150294912 | METHODS OF FORMING SUBSTANTIALLY SELF-ALIGNED ISOLATION REGIONS ON FINFET SEMICONDUCTOR DEVICES AND THE RESULTING DEVICES - One method disclosed includes performing a selective etching process through a gate cavity to selectively remove a portion of a first semiconductor material relative to a second layer of a second semiconductor material and a substrate so as to thereby define a space between the second semiconducting material and the substrate, filling substantially all of the space with an insulating material so as to thereby define a substantially self-aligned channel isolation region positioned under at least what will become the channel region of the FinFET device. | 10-15-2015 |
| 20150311081 | METHODS OF FORMING GATE STRUCTURES FOR SEMICONDUCTOR DEVICES USING A REPLACEMENT GATE TECHNIQUE AND THE RESULTING DEVICES - One method disclosed herein includes forming a sacrificial gate structure comprised of upper and lower sacrificial gate electrodes, performing at least one etching process to define a patterned upper sacrificial gate electrode comprised of a plurality of trenches that expose a portion of a surface of the lower sacrificial gate electrode and performing another etching process through the patterned upper sacrificial gate electrode to remove the lower sacrificial gate electrode and a sacrificial gate insulation layer and thereby define a first portion of a replacement gate cavity that is at least partially positioned under the patterned upper sacrificial gate electrode. | 10-29-2015 |
| 20150318178 | METHODS OF FORMING A SEMICONDUCTOR DEVICE WITH A SPACER ETCH BLOCK CAP AND THE RESULTING DEVICE - One illustrative method disclosed herein includes, among other things, forming a sacrificial gate structure above a semiconductor substrate, forming a sidewall spacer adjacent opposite sides of the sacrificial gate structure, removing the sacrificial gate structure and forming a replacement gate structure in its place, at some point after forming the replacement gate structure, performing an etching process to reduce the height of the spacers so as to thereby define recessed spacers having an upper surface that partially defines a spacer recess, and forming a spacer etch block cap on the upper surface of each recessed spacer structure and within the spacer recess. | 11-05-2015 |
| 20150318215 | METHODS FOR REMOVING SELECTED FINS THAT ARE FORMED FOR FINFET SEMICONDUCTOR DEVICES - One illustrative method disclosed herein includes, among other things, forming a plurality of trenches in a semiconductor substrate to thereby define a plurality of fins in the substrate, forming a layer of insulating material in the trenches, performing an etching process sequence to remove at least a portion of one of the plurality of fins and thereby define a fin cavity, wherein the etching process sequence includes performing a first anisotropic etching process and, after performing the first anisotropic etching process, performing a second isotropic etching process. In this embodiment, the method concludes with the step of forming additional insulating material in the fin cavity. | 11-05-2015 |
| 20150318398 | METHODS OF FORMING EPI SEMICONDUCTOR MATERIAL IN A TRENCH FORMED ABOVE A SEMICONDUCTOR DEVICE AND THE RESULTING DEVICES - One method disclosed includes, among other things, forming a gate structure above an active region of a semiconductor substrate, wherein a first portion of the gate structure is positioned above the active region and second portions of the gate structure are positioned above an isolation region formed in the substrate, forming a sidewall spacer adjacent opposite sides of the first portion of the gate structure so as to define first and second continuous epi formation trenches comprised of the spacer that extend for less than the axial length of the gate structure, and forming an epi semiconductor material on the active region within each of the first and second continuous epi formation trenches. | 11-05-2015 |
| Patent application number | Description | Published |
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| 20130040450 | Methods of Forming a Dielectric Cap Layer on a Metal Gate Structure - Disclosed herein are various methods of forming metal-containing insulating material regions on a metal layer of a gate structure of a semiconductor device. In one example, the method includes forming a gate structure of a transistor, the gate structure comprising at least a first metal layer, and forming a first metal-containing insulating material region in the first metal layer by performing a gas cluster ion beam process using to implant gas molecules into the first metal layer. | 02-14-2013 |
| 20130078791 | SEMICONDUCTOR DEVICE FABRICATION METHODS WITH ENHANCED CONTROL IN RECESSING PROCESSES - Semiconductor device fabrication methods having enhanced control in recessing processes are provided. In a method for fabricating a semiconductor device or plurality of them, a structure is formed. The method includes preparing a limited amount of the structure having a depth of less than ten atomic layers for removal. Further, the method includes performing a removal process to remove the limited amount of the structure. The method repeats preparation of successive limited amounts of the structure for removal, and performance of the removal process to form a recess at an upper portion of the structure. | 03-28-2013 |
| 20130161729 | Methods of Forming Isolation Structures on FinFET Semiconductor Devices - One illustrative method disclosed herein includes performing at least one etching process on a semiconducting substrate to form a plurality of trenches and a plurality of fins for the FinFET device in the substrate, forming a first layer of insulating material in the trenches, wherein an upper surface of the first layer of insulating material is below an upper surface of the substrate, forming an isolation layer within the trenches above the first layer of insulating material, wherein the isolation layer has an upper surface that is below the upper surface of the substrate, forming a second layer of insulating material above the isolation layer, wherein the second layer of insulating material has an upper surface that is below the upper surface of the substrate, and forming a gate electrode structure above the second layer of insulating material. | 06-27-2013 |
| 20130181263 | Methods of Forming a Dielectric Cap Layer on a Metal Gate Structure - Disclosed herein are various methods of forming isolation structures on FinFETs and other semiconductor devices, and the resulting devices that have such isolation structures. In one example, the method includes forming a plurality of spaced-apart trenches in a semiconducting substrate, wherein the trenches define a fin for a FinFET device, forming a layer of insulating material in the trenches, wherein the layer of insulating material covers a lower portion of the fin but not an upper portion of the fin, forming a protective material on the upper portion of the fin, and performing a heating process in an oxidizing ambient to form a thermal oxide region on the covered lower portion of the fin. | 07-18-2013 |
| 20130187203 | FORMATION OF THE DIELECTRIC CAP LAYER FOR A REPLACEMENT GATE STRUCTURE - Gate to contact shorts are reduced by forming dielectric caps in replaced gate structures. Embodiments include forming a replaced gate structure on a substrate, the replaced gate structure including an ILD having a cavity, a first metal on a top surface of the ILD and lining the cavity, and a second metal on the first metal and filling the cavity, planarizing the first and second metals, forming an oxide on the second metal, removing the oxide, recessing the first and second metals in the cavity, forming a recess, and filling the recess with a dielectric material. Embodiments further include dielectric caps having vertical sidewalls, a trapezoidal shape, a T-shape, or a Y-shape. | 07-25-2013 |
| 20130187228 | FinFET Semiconductor Devices with Improved Source/Drain Resistance and Methods of Making Same - Disclosed herein are various FinFET semiconductor devices with improved source/drain resistance and various methods of making such devices. One illustrative device disclosed herein includes a plurality of spaced-apart trenches in a semiconducting substrate, wherein the trenches at least partially define a fin for the device, an etch stop layer positioned above a bottom surface of each of the trenches, and a metal silicide region formed on all exposed surfaces of the fin that are positioned above an upper surface of the etch stop layer. | 07-25-2013 |
| 20130187236 | Methods of Forming Replacement Gate Structures for Semiconductor Devices - Disclosed herein are methods of forming replacement gate structures. In one example, the method includes forming a sacrificial gate structure above a semiconducting substrate, removing the sacrificial gate structure to thereby define a gate cavity, forming a layer of insulating material in the gate cavity and forming a layer of metal within the gate cavity above the layer of insulating material. The method further includes forming a sacrificial material in the gate cavity so as to cover a portion of the layer of metal and thereby define an exposed portion of the layer of metal, performing an etching process on the exposed portion of the layer of metal to thereby remove the exposed portion of the layer of metal from within the gate cavity, and, after performing the etching process, removing the sacrificial material and forming a conductive material above the remaining portion of the layer of metal. | 07-25-2013 |
| 20130292805 | METHODS OF FORMING SPACERS ON FINFETS AND OTHER SEMICONDUCTOR DEVICES - Disclosed herein are various methods of forming spacers on FinFETs and other semiconductor devices. In one example, the method includes forming a plurality of spaced-apart trenches in a semiconducting substrate that defines a fin, forming a first layer of insulating material in the trenches that covers a lower portion of the fin but exposes an upper portion of the fin, and forming a second layer of insulating material on the exposed upper portion of the fin. The method further comprises selectively forming a dielectric material above an upper surface of the fin and in a bottom of the trench, depositing a layer of spacer material above a gate structure of the device and above the dielectric material above the fin and in the trench, and performing an etching process on the layer of spacer material to define sidewall spacers positioned adjacent the gate structure. | 11-07-2013 |
| 20130307032 | METHODS OF FORMING CONDUCTIVE CONTACTS FOR A SEMICONDUCTOR DEVICE - One illustrative method disclosed herein involves forming a contact opening in a layer of insulating material, forming a layer of conductive material above the layer of insulating material that overfills the contact opening, performing at least one chemical mechanical polishing process to remove portions of the conductive material positioned outside of the contact opening and thereby define a conductive contact positioned in the contact opening and, after performing the chemical mechanical polishing process, performing a selective metal deposition process to selectively form additional metal material on an upper surface of the conductive contact. | 11-21-2013 |
| 20130307087 | METHOD FOR FORMING A SELF-ALIGNED CONTACT OPENING BY A LATERAL ETCH - A self-aligned source/drain contact formation process without spacer or cap loss is described. Embodiments include providing two gate stacks, each having spacers on opposite sides, and an interlayer dielectric (ILD) over the two gate stacks and in a space therebetween, forming a vertical contact opening within the ILD between the two gate stacks, and laterally removing ILD between the two gate stacks from the vertical contact opening toward the spacers, to form a contact hole. | 11-21-2013 |
| 20130309868 | METHODS FOR FORMING AN INTEGRATED CIRCUIT WITH STRAIGHTENED RECESS PROFILE - Methods are provided for forming an integrated circuit. In an embodiment, the method includes forming a sacrificial mandrel overlying a base substrate. Sidewall spacers are formed adjacent sidewalls of the sacrificial mandrel. The sidewall spacers have a lower portion that is proximal to the base substrate, and the lower portion has a substantially perpendicular outer surface relative to the base substrate. The sidewall spacers also have an upper portion that is spaced from the base substrate. The upper portion has a sloped outer surface. A first dielectric layer is formed overlying the base substrate and is conformal to at least a portion of the upper portion of the sidewall spacers. The upper portion of the sidewall spacers is removed after forming the first dielectric layer to form a recess having a re-entrant profile in the first dielectric layer. The re-entrant profile of the recess is straightened. | 11-21-2013 |
| 20130328111 | RECESSING AND CAPPING OF GATE STRUCTURES WITH VARYING METAL COMPOSITIONS - A method for recessing and capping metal gate structures is disclosed. Embodiments include: forming a dummy gate electrode on a substrate; forming a hard mask over the dummy gate electrode; forming spacers on opposite sides of the dummy gate electrode and the hard mask; forming an interlayer dielectric (ILD) over the substrate adjacent the spacers; forming a first trench in the ILD down to the dummy gate electrode; removing the dummy gate electrode to form a second trench below the first trench; forming a metal gate structure in the first and second trenches; and forming a gate cap over the metal gate structure. | 12-12-2013 |
| 20130328112 | SEMICONDUCTOR DEVICES HAVING IMPROVED GATE HEIGHT UNIFORMITY AND METHODS FOR FABRICATING SAME - Semiconductor devices and methods for fabricating semiconductor devices are provided. In an embodiment, a method for fabricating a semiconductor device includes forming on a semiconductor surface a temporary gate structure including a polysilicon gate and a cap. A spacer is formed around the temporary gate structure. The cap and a portion of the spacer are removed. A uniform liner is deposited overlying the polysilicon gate. The method removes a portion of the uniform liner overlying the polysilicon gate and the polysilicon gate to form a gate trench. Then, a replacement metal gate is formed in the gate trench. | 12-12-2013 |
| 20140035010 | INTEGRATED CIRCUIT HAVING A REPLACEMENT GATE STRUCTURE AND METHOD FOR FABRICATING THE SAME - A method for fabricating an integrated circuit includes forming a temporary gate structure on a semiconductor substrate. The temporary gate structure includes a temporary gate material disposed between two spacer structures. The method further includes forming a first directional silicon nitride liner overlying the temporary gate structure and the semiconductor substrate, etching the first directional silicon nitride liner overlying the temporary gate structure and the temporary gate material to form a trench between the spacer structures, while leaving the directional silicon nitride liner overlying the semiconductor substrate in place, and forming a replacement metal gate structure in the trench. An integrated circuit includes a replacement metal gate structure overlying a semiconductor substrate, a silicide region overlying the semiconductor substrate and positioned adjacent the replacement gate structure; a directional silicon nitride liner overlying a portion of the replacement gate structure; and a contact plug in electrical communication with the silicide region. | 02-06-2014 |
| 20140042502 | SEMICONDUCTOR DEVICES WITH SELF-ALIGNED CONTACTS AND LOW-K SPACERS - One illustrative method disclosed herein includes removing a portion of a sacrificial sidewall spacer to thereby expose at least a portion of the sidewalls of a sacrificial gate electrode and forming a liner layer on the exposed sidewalls of the sacrificial gate electrode. In this example, the method also includes forming a sacrificial gap fill material above the liner layer, exposing and removing the sacrificial gate electrode to thereby define a gate cavity that is laterally defined by the liner layer, forming a replacement gate structure, removing the sacrificial gap fill material and forming a low-k sidewall spacer adjacent the liner layer. A device is also disclosed that includes a gate cap layer, a layer of silicon nitride or silicon oxynitride positioned on each of two upstanding portions of a gate insulation layer and a low-k sidewall spacer positioned on the layer of silicon nitride or silicon oxynitride. | 02-13-2014 |
| 20140054723 | ISOLATION STRUCTURES FOR FINFET SEMICONDUCTOR DEVICES - One illustrative device disclosed herein includes a plurality of fins separated by a trench formed in a semiconducting substrate, a first layer of insulating material positioned in the trench, the first layer of insulating material having an upper surface that is below an upper surface of the substrate, an isolation layer positioned within the trench above the first layer of insulating material, the isolation layer having an upper surface that is below the upper surface of the substrate, a second layer of insulating material positioned within the trench above the isolation layer, the second layer of insulating material having an upper surface that is below the upper surface of the substrate, and a gate structure positioned above the second layer of insulating material. | 02-27-2014 |
| 20140077274 | INTEGRATED CIRCUITS WITH IMPROVED GATE UNIFORMITY AND METHODS FOR FABRICATING SAME - Integrated circuits with improved gate uniformity and methods for fabricating such integrated circuits are provided. In an embodiment, a method for fabricating an integrated circuit includes providing a structure including a first region and a second region and a structure surface formed by the first region and the second region. The first region is formed by a first material and the second region is formed by a second material. In the method, the structure surface is exposed to a gas cluster ion beam (GCIB) and an irradiated layer is formed in the structure in both the first region and the second region. The irradiated layer is etched to form a recess. | 03-20-2014 |
| 20140110798 | METHODS OF FORMING A SEMICONDUCTOR DEVICE WITH LOW-K SPACERS AND THE RESULTING DEVICE - One method disclosed herein includes forming at least one sacrificial sidewall spacer adjacent a sacrificial gate structure that is formed above a semiconducting substrate, removing at least a portion of the sacrificial gate structure to thereby define a gate cavity that is laterally defined by the sacrificial spacer, forming a replacement gate structure in the gate cavity, removing the sacrificial spacer to thereby define a spacer cavity adjacent the replacement gate structure, and forming a low-k spacer in the spacer cavity. A novel device disclosed herein includes a gate structure positioned above a semiconducting substrate, wherein the gate insulation layer has two upstanding portions that are substantially vertically oriented relative to an upper surface of the substrate. The device further includes a low-k sidewall spacer positioned adjacent each of the vertically oriented upstanding portions of the gate insulation layer. | 04-24-2014 |
| 20140138779 | INTEGRATED CIRCUITS AND METHODS FOR FABRICATING INTEGRATED CIRCUITS WITH REDUCED PARASITIC CAPACITANCE - Integrated circuits and methods for fabricating integrated circuits are provided. In an embodiment, a method for fabricating an integrated circuit includes forming a sacrificial gate structure over a semiconductor substrate. A spacer is formed around the sacrificial gate structure and a dielectric material is deposited over the spacer and semiconductor substrate. The method includes selectively etching the spacer to form a trench between the sacrificial gate structure and the dielectric material. The trench is bounded by a trench surface upon which a replacement spacer material is deposited. The method merges an upper region of the replacement spacer material to enclose a void within the replacement spacer material. | 05-22-2014 |
| 20140145257 | SEMICONDUCTOR DEVICE HAVING A METAL RECESS - Provided is a semiconductor device (e.g., transistor such as a FinFET or planar device) having a a liner layer and a metal layer (e.g., Tungsten (W)) in a trench (e.g., via CVD and/or ALD). A single chamber (e.g., an extreme fill chamber) will be utilized to separately etch back the liner layer and the metal layer. In general, the liner layer may be etched back further than the metal layer to provide for larger contact and lower resistance. After etching is complete, a bottom-up fill/growth of metal (e.g., W) will be performed (e.g., via CVD in a W chamber or the like) to increase the presence of gate metal in the trench. | 05-29-2014 |
| 20140159169 | RECESSING AND CAPPING OF GATE STRUCTURES WITH VARYING METAL COMPOSITIONS - A approach for recessing and capping metal gate structures is disclosed. Embodiments include: forming a dummy gate electrode on a substrate; forming a hard mask over the dummy gate electrode; forming spacers on opposite sides of the dummy gate electrode and the hard mask; forming an interlayer dielectric (ILD) over the substrate adjacent the spacers; forming a first trench in the ILD down to the dummy gate electrode; removing the dummy gate electrode to form a second trench below the first trench; forming a metal gate structure in the first and second trenches; and forming a gate cap over the metal gate structure. | 06-12-2014 |
| 20140203376 | FINFET INTEGRATED CIRCUITS WITH UNIFORM FIN HEIGHT AND METHODS FOR FABRICATING THE SAME - Methods for fabricating FinFET integrated circuits with uniform fin height and ICs fabricated from such methods are provided. A method includes etching a substrate using an etch mask to form fins. A first oxide is formed between the fins. A first etch stop is deposited on the first oxide. A second oxide is formed on the first etch stop. A second etch stop is deposited on the second oxide. A third oxide is deposited overlying the second etch stop. An STI extends from at least a surface of the substrate to at least a surface of the second etch stop overlying the fins to form a first active region and a second active region. The first etch stop overlying the fins is removed. The third oxide is removed to expose the second etch stop. A gate stack is formed overlying a portion of each of the fins. | 07-24-2014 |
| 20140299924 | FORMATION OF THE DIELECTRIC CAP LAYER FOR A REPLACEMENT GATE STRUCTURE - Gate to contact shorts are reduced by forming dielectric caps in replaced gate structures. Embodiments include forming a replaced gate structure on a substrate, the replaced gate structure including an ILD having a cavity, a first metal on a top surface of the ILD and lining the cavity, and a second metal on the first metal and filling the cavity, planarizing the first and second metals, forming an oxide on the second metal, removing the oxide, recessing the first and second metals in the cavity, forming a recess, and filling the recess with a dielectric material. Embodiments further include dielectric caps having vertical sidewalls, a trapezoidal shape, a T-shape, or a Y-shape. | 10-09-2014 |
| 20150044855 | METHODS OF FORMING SPACERS ON FINFETS AND OTHER SEMICONDUCTOR DEVICES - Disclosed herein are various methods of forming spacers on FinFETs and other semiconductor devices. In one example, the method includes forming a plurality of spaced-apart trenches in a semiconducting substrate that defines a fin, forming a first layer of insulating material in the trenches that covers a lower portion of the fin but exposes an upper portion of the fin, and forming a second layer of insulating material on the exposed upper portion of the fin. The method further comprises selectively forming a dielectric material above an upper surface of the fin and in a bottom of the trench, depositing a layer of spacer material above a gate structure of the device and above the dielectric material above the fin and in the trench, and performing an etching process on the layer of spacer material to define sidewall spacers positioned adjacent the gate structure. | 02-12-2015 |
| 20150056796 | METHOD FOR FORMING A SEMICONDUCTOR DEVICE HAVING A METAL GATE RECESS - Provided are approaches of forming a semiconductor device (e.g., transistor such as a FinFET or planar device) having a gate metal recess. In one approach, a liner layer and a metal layer (e.g., W) are applied in a trench (e.g., via CVD and/or ALD). Then, a single chamber (e.g., an extreme fill chamber) will be utilized to separately etch back the liner layer and the metal layer. In general, the liner layer may be etched back further than the metal layer to provide for larger contact and lower resistance. After etching is complete, a bottom-up fill/growth of metal (e.g., W) will be performed (e.g., via CVD in a W chamber or the like) to increase the presence of gate metal in the trench. | 02-26-2015 |
| 20150097246 | INTEGRATED CIRCUIT AND METHOD FOR FABRICATING THE SAME HAVING A REPLACEMENT GATE STRUCTURE - An integrated circuit includes a first FET structure and a second FET structure, both of which being formed over a silicon substrate. The first FET structure includes a high-k material layer, a layer of a first workfunction material formed over the high-k material layer, a layer of a barrier material formed over the first workfunction material layer; and a layer of a gate fill material formed over the barrier material layer. The entirety of the barrier material layer and the gate fill material layer are formed above the first workfunction material layer. The second FET structure includes a layer of the high-k material, a layer of a second workfunction material formed over the high-k material layer, a low-resistance material layer formed over the second workfunction material layer and a layer of the barrier material formed over the low-resistance material layer. | 04-09-2015 |
| 20150145071 | METHODS OF FORMING SPACERS ON FINFETS AND OTHER SEMICONDUCTOR DEVICES - Disclosed herein are various methods of forming spacers on FinFETs and other semiconductor devices. In one example, the method includes forming a plurality of spaced-apart trenches in a semiconducting substrate that defines a fin, forming a first layer of insulating material in the trenches that covers a lower portion of the fin but exposes an upper portion of the fin, and forming a second layer of insulating material on the exposed upper portion of the fin. The method further comprises selectively forming a dielectric material above an upper surface of the fin and in a bottom of the trench, depositing a layer of spacer material above a gate structure of the device and above the dielectric material above the fin and in the trench, and performing an etching process on the layer of spacer material to define sidewall spacers positioned adjacent the gate structure. | 05-28-2015 |
| 20150311337 | FINFET DEVICE COMPRISING A THERMAL OXIDE REGION POSITIONED BETWEEN A PORTION OF THE FIN AND A LAYER OF INSULATING MATERIAL - Disclosed herein are various methods of forming isolation structures on FinFETs and other semiconductor devices, and the resulting devices that have such isolation structures. In one example, the method includes forming a plurality of spaced-apart trenches in a semiconducting substrate, wherein the trenches define a fin for a FinFET device, forming a layer of insulating material in the trenches, wherein the layer of insulating material covers a lower portion of the fin but not an upper portion of the fin, forming a protective material on the upper portion of the fin, and performing a heating process in an oxidizing ambient to form a thermal oxide region on the covered lower portion of the fin. | 10-29-2015 |
