DE102018101016B4 - Process for cutting metal gates and structures formed from them - Google Patents
Process for cutting metal gates and structures formed from them Download PDFInfo
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- DE102018101016B4 DE102018101016B4 DE102018101016.8A DE102018101016A DE102018101016B4 DE 102018101016 B4 DE102018101016 B4 DE 102018101016B4 DE 102018101016 A DE102018101016 A DE 102018101016A DE 102018101016 B4 DE102018101016 B4 DE 102018101016B4
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- gate stack
- gate
- dielectric
- hard mask
- forming
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- H01L29/66227—Multistep manufacturing processes of devices having semiconductor bodies comprising group 14 or group 13/15 materials the devices being controllable only by the electric current supplied or the electric potential applied, to an electrode which does not carry the current to be rectified, amplified or switched, e.g. three-terminal devices
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- H01L29/66477—Unipolar field-effect transistors with an insulated gate, i.e. MISFET
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- H01L21/77—Manufacture or treatment of devices consisting of a plurality of solid state components or integrated circuits formed in, or on, a common substrate
- H01L21/78—Manufacture or treatment of devices consisting of a plurality of solid state components or integrated circuits formed in, or on, a common substrate with subsequent division of the substrate into plural individual devices
- H01L21/82—Manufacture or treatment of devices consisting of a plurality of solid state components or integrated circuits formed in, or on, a common substrate with subsequent division of the substrate into plural individual devices to produce devices, e.g. integrated circuits, each consisting of a plurality of components
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- H01L29/00—Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor
- H01L29/40—Electrodes ; Multistep manufacturing processes therefor
- H01L29/43—Electrodes ; Multistep manufacturing processes therefor characterised by the materials of which they are formed
- H01L29/49—Metal-insulator-semiconductor electrodes, e.g. gates of MOSFET
- H01L29/51—Insulating materials associated therewith
- H01L29/517—Insulating materials associated therewith the insulating material comprising a metallic compound, e.g. metal oxide, metal silicate
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Abstract
Verfahren, umfassend:Bilden eines Dummy-Gate-Stapels (130), welcher sich über mehrere Halbleiterfinnen (124) erstreckt;Bilden von Gate-Abstandhaltern (138), so dass der Dummy-Gate-Stapel zwischen den Gate-Abstandhaltern angeordnet ist;Bilden einer Kontaktätzstoppschicht (46) und eines Zwischenschichtdielektrikums (48), so dass der Dummy-Gate-Stapel (130) und die Gate-Abstandhalter (138) in der Kontaktätzstoppschicht (148) und dem Zwischenschichtdielektrikum (48) angeordnet sind;Ersetzen des Dummy-Gate-Stapels (130) durch einen Ersatz-Gate-Stapel (168), so dass der Ersatz-Gate-Stapel einen ersten Abschnitt und einen zweiten Abschnitt und einen dritten Abschnitt umfasst, welcher den ersten Abschnitt mit dem zweiten Abschnitt verbindet;selektives Bilden einer Dielektrikums-Hartmaske (74) über dem Zwischenschichtdielektrikum (48) und mit diesem in Kontakt stehend, so dass der Ersatz-Gate-Stapel (168) direkt unter einer ersten Öffnung (70) in der Dielektrikums-Hartmaske (74) liegt;Ätzen des dritten Abschnitts des Ersatz-Gate-Stapels (168), um eine zweite Öffnung (80) zwischen den Gate-Abstandhaltern zu bilden, so dass die zweite Öffnung (80) den ersten Abschnitt des Ersatz-Gate-Stapels von dem zweiten Abschnitt des Ersatz-Gate-Stapels trennt; undFüllen eines Dielektrikumsmaterials (82) in die zweite Öffnung (80).A method comprising: forming a dummy gate stack (130) spanning a plurality of semiconductor fins (124); forming gate spacers (138) such that the dummy gate stack is disposed between the gate spacers; Forming a contact etch stop layer (46) and an interlayer dielectric (48) such that the dummy gate stack (130) and gate spacers (138) are disposed in the contact etch stop layer (148) and interlayer dielectric (48); replacing the dummy Gate stack (130) by a replacement gate stack (168) such that the replacement gate stack comprises a first section and a second section and a third section connecting the first section to the second section; selective Forming a dielectric hard mask (74) over and in contact with the interlayer dielectric (48) such that the replacement gate stack (168) is directly under a first opening (70) in the dielectric hard mask (74); Etching the third portion of the replacement gate stack (168) to form a second opening (80) between the gate spacers such that the second opening (80) separates the first portion of the replacement gate stack from the second portion of the replacement -Gate stack separates; and filling a dielectric material (82) into the second opening (80).
Description
HINTERGRUNDBACKGROUND
Metalloxid-Halbleiter(Metal-Oxide-Semiconductor, MOS)-Vorrichtungen sind grundlegende Bauelemente in integrierten Schaltungen. Eine existierende MOS-Vorrichtung weist typischerweise eine Gate-Elektrode mit Polysilizium auf, welches mit Verunreinigungen des p-Typs oder des n-Typs dotiert ist, wobei Dotieroperationen wie Ionenimplantation oder Wärmediffusion angewendet werden. Die Austrittsarbeit der Gate-Elektrode wurde auf die Bandkante des Siliziums eingestellt. Für eine Metalloxid-Halbleitervorrichtung des n-Typs (NMOS) kann die Austrittsarbeit auf die Nähe des Leitungsbands des Siliziums eingestellt werden. Für eine Metalloxid-Halbleitervorrichtung des p-Typs (PMOS) kann die Austrittsarbeit auf die Nähe des Valenzbands des Siliziums eingestellt werden. Die Einstellung der Austrittsarbeit der Polysilizium-Gate-Elektrode kann durch Auswählen geeigneter Verunreinigungen erreicht werden.Metal-oxide-semiconductor (MOS) devices are fundamental components in integrated circuits. An existing MOS device typically has a gate electrode comprising polysilicon doped with p-type or n-type impurities using doping operations such as ion implantation or thermal diffusion. The work function of the gate electrode was adjusted to the band edge of the silicon. For an n-type metal oxide semiconductor device (NMOS), the work function can be set close to the conduction band of silicon. For a p-type metal oxide semiconductor device (PMOS), the work function can be set close to the valence band of silicon. Adjustment of the work function of the polysilicon gate electrode can be achieved by selecting suitable impurities.
Bei MOS-Vorrichtungen mit Polysilizium-Gate-Elektroden zeigt sich der Ladungsträger-Verarmungseffekt, welcher auch als Poly-Verarmungseffekt bezeichnet wird. Der Poly-Verarmungseffekt tritt auf, wenn die angelegten elektrischen Felder Ladungsträger aus Gate-Zonen in der Nähe von Gate-Dielektrika wegziehen, wodurch Verarmungsschichten gebildet werden. In einer n-dotierten Polysiliziumschicht umfasst die Verarmungsschicht ionisierte nichtmobile Donorstellen, während in einer p-dotierten Polysiliziumschicht die Verarmungsschicht ionisierte nichtmobile Akzeptorstellen umfasst. Der Verarmungseffekt führt zu einem Anstieg der effektiven Gate-Dielektrikums-Dicke, wodurch es schwieriger wird, eine Inversionsschicht an der Oberfläche des Halbleiters zu erzeugen.In the case of MOS devices with polysilicon gate electrodes, the charge carrier depletion effect, which is also referred to as the poly depletion effect, is exhibited. The poly depletion effect occurs when the applied electric fields pull charge carriers away from gate regions near gate dielectrics, thereby forming depletion layers. In an n-doped polysilicon layer, the depletion layer comprises ionized non-mobile donor sites, while in a p-doped polysilicon layer the depletion layer comprises ionized non-mobile acceptor sites. The depletion effect leads to an increase in the effective gate dielectric thickness, which makes it more difficult to create an inversion layer on the surface of the semiconductor.
Das Poly-Verarmungsproblem kann durch Bilden von Metall-Gate-Elektroden oder Metallsilizid-Gate-Elektroden gelöst werden, wobei die metallischen Gates, die in NMOS-Vorrichtungen und PMOS-Vorrichtungen verwendet werden, ebenfalls Bandkanten-Austrittsarbeiten aufweisen können. Da die NMOS-Vorrichtungen und PMOS-Vorrichtungen unterschiedliche Anforderungen hinsichtlich der Austrittsarbeiten aufweisen können, werden Doppel-Gate-CMOS-Vorrichtungen verwendet.The poly depletion problem can be solved by forming metal gate electrodes or metal silicide gate electrodes, and the metal gates used in NMOS devices and PMOS devices can also have band-edge work functions. Since the NMOS devices and PMOS devices may have different work function requirements, double-gate CMOS devices are used.
Bei der Bildung der Metall-Gate-Elektroden wird zunächst ein langes Dummy-Gate gebildet, welches dann derart geätzt wird, dass die Abschnitte des langen Dummy-Gate voneinander getrennt werden. Anschließend wird ein Dielektrikumsmaterial in die Öffnung gefüllt, die durch den geätzten Abschnitt des langen Dummy-Gates zurückgelassen wird. Das Dielektrikumsmaterial wird dann poliert, wobei ein Abschnitt des Dielektrikumsmaterials zwischen den zurückbleibenden Abschnitten des Dummy-Gate verbleibt. Die getrennten Abschnitte des Dummy-Gate werden dann durch Metall-Gates ersetzt. Dieses Verfahren kann als Poly-Schnittverfahren bezeichnet werden, da das Dummy-Gate aus Polysilizium gebildet werden kann.When forming the metal gate electrodes, a long dummy gate is first formed, which is then etched in such a way that the sections of the long dummy gate are separated from one another. A dielectric material is then filled into the opening left by the etched portion of the long dummy gate. The dielectric material is then polished, leaving a portion of the dielectric material between the remaining portions of the dummy gate. The separated sections of the dummy gate are then replaced with metal gates. This process can be referred to as a poly-cut process because the dummy gate can be formed from polysilicon.
Die
Die
Die
Die
Die
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Die
Die
FigurenlisteFigure list
Erscheinungsformen der vorliegenden Offenbarung sind am besten zu verstehen aus der folgenden detaillierten Beschreibung in Verbindung mit den begleitenden Figuren. Es sei angemerkt, dass gemäß der üblichen Praxis in der Technik verschiedene Elemente nicht maßstabsgetreu dargestellt sind. Tatsächlich können die Abmessungen der verschiedenen Elemente zur Verdeutlichung der Beschreibung beliebig vergrößert oder verkleinert sein.
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1 bis18A und18B veranschaulichen die Querschnittsansichten und perspektivischen Ansichten von Zwischenstufen bei der Bildung von Finnen-Feldeffekttransistoren (FinFETs) gemäß einigen Ausführungsformen. -
19 bis27A und27B veranschaulichen die Querschnittsansichten und perspektivischen Ansichten von Zwischenstufen bei der Bildung von FinFETs gemäß einigen Ausführungsformen. -
28 bis35 veranschaulichen die Querschnittsansichten und perspektivischen Ansichten von Zwischenstufen bei der Bildung von FinFETs gemäß einigen Ausführungsformen. -
35 bis43A und43B veranschaulichen die Querschnittsansichten und perspektivischen Ansichten von Zwischenstufen bei der Bildung von FinFETs gemäß einigen Ausführungsformen. -
44 zeigt eine Draufsicht auf FinFETs mit Isolationszonen, die durch Metall-Gate-Schnittverfahren gemäß einigen Ausführungsformen gebildet werden. -
45 veranschaulicht einen Ablaufplan von Verfahren zum Bilden von FinFETs gemäß einigen Ausführungsformen.
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1 until18A and18B -
19th until27A and27B -
28 until35 10 illustrate the cross-sectional and perspective views of intermediate stages in the formation of FinFETs in accordance with some embodiments. -
35 until43A and43B -
44 FIG. 10 shows a top view of FinFETs with isolation regions formed by metal gate cutting processes in accordance with some embodiments. -
45 FIG. 11 illustrates a flow diagram of methods of forming FinFETs in accordance with some embodiments.
DETAILLIERTE BESCHREIBUNGDETAILED DESCRIPTION
Die Erfindung ist durch die unabhängigen Ansprüche definiert. Die abhängigen Ansprüche betreffen entsprechende Weiterbildungen. In der folgenden Offenbarung werden viele verschiedene Ausführungsformen oder Beispiele für die Realisierung verschiedener Merkmale der Erfindung vorgestellt. Nachstehend werden spezielle Beispiele für Komponenten und Anordnungen beschrieben, um die vorliegende Offenbarung zu vereinfachen. Zum Beispiel kann die Bildung eines ersten Merkmals über oder auf einem zweiten Merkmal in der folgenden Beschreibung Ausführungsformen umfassen, bei welchen das erste und zweite Merkmal in direktem Kontakt gebildet werden, und kann auch Ausführungsformen umfassen, bei welchen zwischen dem ersten und zweiten Merkmal zusätzliche Merkmale gebildet werden können, so dass das erste und zweite Merkmal nicht in direktem Kontakt stehen. Außerdem können in der vorliegenden Offenbarung in den verschiedenen Beispielen Bezugszahlen und/oder -buchstaben wiederholt werden. Diese Wiederholung dient der Vereinfachung und Klarheit und bestimmt als solche keine Beziehung zwischen den verschiedenen beschriebenen Ausführungsformen und/oder Konfigurationen.The invention is defined by the independent claims. The dependent claims relate to corresponding developments. Many different embodiments or examples for implementing various features of the invention are presented in the following disclosure. Specific examples of components and arrangements are described below to simplify the present disclosure. For example, the formation of a first feature over or on a second feature in the following description may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features between the first and second features can be formed so that the first and second features are not in direct contact. In addition, reference numbers and / or letters may be repeated in the various examples in the present disclosure. This repetition is for the sake of simplicity and clarity and as such does not determine any relationship between the various embodiments and / or configurations described.
Ferner können hierin zur Vereinfachung der Beschreibung Begriffe der räumlichen Beziehung wie „unterhalb“, „unter“, „untere“, „über“, „obere“ und dergleichen verwendet werden, um die Beziehung eines Elements oder Merkmals zu (einem) anderen Element(en) oder Merkmal(en) zu beschreiben, wie in den Figuren veranschaulicht. Die Begriffe der räumlichen Beziehung sollen zusätzlich zu der Orientierung, die in den Figuren abgebildet ist, andere Orientierungen der in Gebrauch oder in Betrieb befindlichen Vorrichtung umfassen. Die Vorrichtung kann anders orientiert sein (um 90 Grad gedreht sein oder andere Orientierungen aufweisen) und die hierin verwendeten Deskriptoren der räumlichen Beziehung können gleichermaßen entsprechend interpretiert werden.Furthermore, to simplify the description, terms of the spatial relationship such as “below”, “below”, “lower”, “above”, “upper” and the like may be used to describe the relationship of an element or feature to (a) other element ( Describe s) or feature (s) as illustrated in the figures. The terms of spatial relationship are intended to encompass other orientations of the device in use or in operation in addition to the orientation depicted in the figures. The device may be oriented differently (rotated 90 degrees or have different orientations) and the spatial relationship descriptors used herein may equally be interpreted accordingly.
Gemäß verschiedenen beispielhaften Ausführungsformen werden ein Transistor und die Verfahren zum Bilden desselben bereitgestellt. Gemäß einigen Ausführungsformen werden die Zwischenstufen beim Bilden der Transistoren veranschaulicht. Es werden einige Variationen einiger Ausführungsformen beschrieben. Überall in den verschiedenen Ansichten und beispielhaften Ausführungsformen werden gleiche Bezugszahlen verwendet, um gleiche Elemente zu kennzeichnen. In den dargestellten beispielhaften Ausführungsformen wird die Bildung von Finnen-Feldeffekttransistoren (FinFETs) als ein Beispiel verwendet, um das Konzept der vorliegenden Offenbarung zu erläutern. Planare Transistoren können bei Anwendung der Ausführungsformen der vorliegenden Offenbarung ebenso gebildet werden.According to various example embodiments, a transistor and the methods of forming the same are provided. In accordance with some embodiments, the intermediate stages in forming the transistors are illustrated. Some variations of some embodiments are described. Like reference numbers are used throughout the various views and exemplary embodiments to identify like elements. In the illustrated exemplary embodiments, the formation of fin field effect transistors (FinFETs) is used as an example to explain the concept of the present disclosure. Planar transistors can also be formed using the embodiments of the present disclosure.
Die STI-Zonen
Bezug nehmend auf
In den oben dargestellten beispielhaften Ausführungsformen kann die Definition der Strukturen der Finnen durch ein beliebiges geeignetes Verfahren erreicht werden. Beispielsweise können die Finnen durch ein oder mehrere Photolithographieverfahren strukturiert werden, umfassend Doppelstrukturierungs- oder Mehrfachstrukturierungsverfahren. Im Allgemeinen werden bei Doppelstrukturierungs- oder Mehrfachstrukturierungsverfahren Photolithographie- und Selbstausrichtungsverfahren kombiniert, wodurch ermöglicht wird, dass Strukturen erzeugt werden, welche beispielsweise Mittenabstände aufweisen, die kleiner sind als die, die ansonsten über ein einzelnes direktes Photolithographieverfahren zu erhalten sind. Zum Beispiel wird in einer Ausführungsform eine Opferschicht über einem Substrat gebildet und durch ein Photolithographieverfahren strukturiert. Entlang der strukturierten Opferschicht werden durch ein Selbstausrichtungsverfahren Abstandhalter gebildet. Anschließend wird die Opferschicht entfernt und die zurückbleibenden Abstandhalter oder Dorne können dann verwendet werden, um die Finnen zu strukturieren.In the exemplary embodiments presented above, the definition of the structures of the fins can be achieved by any suitable method. For example, the fins can be structured by one or more photolithography processes, including double structuring or multiple structuring processes. In general, in double structuring or multiple structuring processes, photolithography and self-alignment processes are combined, whereby it is possible to produce structures which, for example, have center-to-center distances that are smaller than those which can otherwise be obtained via a single direct photolithography process. For example, in one embodiment, a sacrificial layer is formed over a substrate and patterned by a photolithography process. Spacers are formed along the structured sacrificial layer by a self-alignment process. The sacrificial layer is then removed and the remaining spacers or mandrels can then be used to structure the fins.
Die Materialien der vorstehenden Finnen
Bezug nehmend auf
Als Nächstes werden, wie ebenfalls in
Nach dem Epitaxieschritt kann in die Epitaxiezonen
Gemäß einigen Ausführungsformen der vorliegenden Offenbarung wird statt des Bildens der umhüllenden Source/Drain-Zonen ein Ätzschritt (hierin im Folgenden als Source/Drain-Aussparung bezeichnet) durchgeführt, um die Abschnitte der vorstehenden Finnen
Anschließend werden die Kontaktätzstoppschicht (Contact Etch Stop Layer, CESL) 46 und das Zwischenschichtdielektrikum (ILD)
Als Nächstes werden die Dummy-Gate-Stapel
Als Nächstes wird das High-k-Dielektrikum
Es werden die gestapelten Schichten
Jede der gestapelten Schichten
In der beispielhaften Ausführungsform, wie in
Als Nächstes wird, wie ebenfalls in
In einem anschließenden Schritt, wie in
Gemäß einigen Ausführungsformen der vorliegenden Offenbarung werden die Inhibitor-Filme
In anschließenden Schritten wird ein Metall-Gate-Schnittverfahren durchgeführt, so dass lange Metall-Gates
Wie in
Als Nächstes werden die Abschnitte der Gate-Stapel
In einem anschließenden Schritt werden der Photoresist
Bezug nehmend auf
Bezug nehmend auf
Wieder Bezug nehmend auf
Da die Dielektrikums-Hartmaske
Die Anfangsschritte dieser Ausführungsformen sind im Wesentlichen dieselben, wie in
Bezug nehmend auf
Als Nächstes werden die frei liegenden Abschnitte der Gate-Stapel
Die Inhibitor-Filme
Als Nächstes werden die frei liegenden Abschnitte der Gate-Stapel
Gemäß alternativen Ausführungsformen stoppt das Planarisierungsverfahren auf den Gate-Stapeln
Die Anfangsschritte dieser Ausführungsformen sind im Wesentlichen dieselben wie in
Als Nächstes werden die frei liegenden Abschnitte der Gate-Stapel
Die Ausführungsformen der vorliegenden Offenbarung weisen einige vorteilhafte Merkmale auf. Durch Bilden von Dielektrikums-Hartmasken zum Schützen des ILD werden die Abschnitte des ILD geschützt, die ansonsten für das Metall-Gate-Schnittverfahren frei liegen würden, und es wird in dem ILD keine unerwünschte Öffnung gebildet. Die Dielektrikums-Hartmasken werden durch Bilden von Metallfilmen und/oder Inhibitor-Filmen selektiv gebildet, um zu verhindern, dass die Dielektrikums-Hartmasken die Metall-Gates bedecken. So werden die Herstellungskosten gesenkt.The embodiments of the present disclosure have several advantageous features. By forming dielectric hard masks to protect the ILD, the portions of the ILD that would otherwise be exposed to the metal gate cutting process are protected and no undesirable opening is formed in the ILD. The dielectric hard masks are selectively formed by forming metal films and / or inhibitor films to prevent the dielectric hard masks from covering the metal gates. Thus, the manufacturing costs are reduced.
Gemäß einigen Ausführungsformen der vorliegenden Offenbarung umfasst ein Verfahren Bilden eines Dummy-Gate-Stapels, welcher sich über mehrere Halbleiterfinnen erstreckt; Bilden von Gate-Abstandhaltern, wobei der Dummy-Gate-Stapel zwischen den Gate-Abstandhaltern angeordnet ist; Bilden einer Kontaktätzstoppschicht und eines Zwischenschichtdielektrikums, wobei der Dummy-Gate-Stapel und die Gate-Abstandhalter in der Kontaktätzstoppschicht und dem Zwischenschichtdielektrikum angeordnet sind; Ersetzen des Dummy-Gate-Stapels durch einen Ersatz-Gate-Stapel, wobei der Ersatz-Gate-Stapel einen ersten Abschnitt und einen zweiten Abschnitt und einen dritten Abschnitt umfasst, welcher den ersten Abschnitt mit dem zweiten Abschnitt verbindet; selektives Bilden einer Dielektrikums-Hartmaske über dem Zwischenschichtdielektrikum und mit diesem in Kontakt stehend, wobei der Ersatz-Gate-Stapel direkt unter einer ersten Öffnung in der Dielektrikums-Hartmaske liegt; Ätzen des dritten Abschnitts des Ersatz-Gate-Stapels, um eine zweite Öffnung zwischen den Gate-Abstandhaltern zu bilden, wobei die zweite Öffnung den ersten Abschnitt des Ersatz-Gate-Stapels von dem zweiten Abschnitt des Ersatz-Gate-Stapels trennt; und Füllen eines Dielektrikumsmaterials in die Öffnung. In einer Ausführungsform umfasst das Verfahren Bilden eines Inhibitor-Films auf dem Ersatz-Gate-Stapel, wobei verhindert wird, dass die Dielektrikums-Hartmaske auf dem Inhibitor-Film gebildet wird. In einer Ausführungsform erfolgt die Bildung des Inhibitor-Films selektiv, so dass der Inhibitor-Film so gebildet wird, dass er den Ersatz-Gate-Stapel überlappt, und nicht ausgehend von dem Zwischenschichtdielektrikum gebildet wird. In einer Ausführungsform umfasst das Bilden des Inhibitor-Films Bilden von plasmapolymerisiertem Fluorkohlenstoff. Gemäß einigen Ausführungsformen umfasst das Verfahren Aussparen des dritten Abschnitts des Ersatz-Gate-Stapels vor dem Bilden der Dielektrikums-Hartmaske. Gemäß einigen Ausführungsformen umfasst das Verfahren Bilden einer Metallschicht über dem Ersatz-Gate-Stapel und mit diesem in Kontakt stehend durch ein selektives Abscheidungsverfahren, so dass die Metallschicht auf dem Ersatz-Gate-Stapel abgeschieden wird und nicht von dem Zwischenschichtdielektrikum ausgehend abgeschieden wird. Gemäß einigen Ausführungsformen umfasst das Verfahren Bilden eines strukturierten Photoresists, wobei der dritte Abschnitt des Ersatz-Gate-Stapels direkt unter einer Öffnung in dem strukturierten Photoresist liegt, und das Ätzen des dritten Abschnitts des Ersatz-Gate-Stapels erfolgt durch die Öffnung in dem strukturierten Photoresist hindurch.According to some embodiments of the present disclosure, a method includes forming a dummy gate stack that spans multiple semiconductor fins; Forming gate spacers with the dummy gate stack sandwiched between the gate spacers; Forming a contact etch stop layer and an interlayer dielectric, wherein the dummy gate stack and gate spacers are disposed in the contact etch stop layer and the interlayer dielectric; Replacing the dummy gate stack with a replacement gate stack, the replacement gate stack comprising a first portion and a second portion and a third portion connecting the first portion to the second portion; selectively forming a dielectric hard mask over and in contact with the interlayer dielectric with the replacement gate stack directly under a first opening in the dielectric hard mask; Etching the third portion of the replacement gate stack to form a second opening between the gate spacers, the second opening separating the first portion of the replacement gate stack from the second portion of the replacement gate stack; and filling a dielectric material into the opening. In one embodiment, the method includes forming an inhibitor film on the replacement gate stack, preventing the dielectric hard mask from being formed on the inhibitor film. In one embodiment, the formation of the inhibitor film is selective such that the inhibitor film is formed to overlap the replacement gate stack and is not formed from the interlayer dielectric. In one embodiment, forming the inhibitor film comprises forming plasma polymerized fluorocarbon. In accordance with some embodiments, the method includes recessing the third portion of the replacement gate stack prior to forming the dielectric hard mask. According to some embodiments, the method includes forming a metal layer over and in contact with the replacement gate stack by a selective deposition process such that the metal layer is deposited on the replacement gate stack and is not deposited from the interlayer dielectric. According to some embodiments, the method includes forming a patterned photoresist, wherein the third portion of the replacement gate stack is directly below an opening in the patterned photoresist, and the etching of the third portion of the replacement gate stack is through the opening in the patterned one Photoresist through.
Gemäß einigen Ausführungsformen der vorliegenden Offenbarung umfasst ein Verfahren Bilden eines Gate-Stapels, welcher ein Gate-Dielektrikum und eine Metall-Gate-Elektrode über dem Gate-Dielektrikum umfasst; Bilden eines Zwischenschichtdielektrikums auf gegenüberliegenden Seiten des Gate-Stapels; Planarisieren des Gate-Stapels und des Zwischenschichtdielektrikums; Bilden eines Inhibitor-Films auf dem Gate-Stapel, wobei wenigstens ein Abschnitt des Zwischenschichtdielektrikums frei bleibt; selektives Abscheiden einer Dielektrikums-Hartmaske auf dem Zwischenschichtdielektrikum, wobei der Inhibitor-Film verhindert, dass die Dielektrikums-Hartmaske darauf gebildet wird; und Ätzen zum Entfernen eines Abschnitts des Gate-Stapels, wobei die Dielektrikums-Hartmaske als ein Abschnitt einer entsprechenden Ätzmaske fungiert. In einer Ausführungsform umfasst das Verfahren Entfernen des Inhibitor-Films, bevor der Abschnitt des Gate-Stapels entfernt wird und nachdem die Dielektrikums-Hartmaske selektiv abgeschieden ist. In einer Ausführungsform umfasst das Verfahren Füllen einer Isolationsschicht in eine Öffnung, die durch den entfernten Abschnitt des Gate-Stapels zurückgelassen wird, wobei die Isolationsschicht einen Abschnitt umfasst, welcher den Inhibitor-Film überlappt und mit diesem in Kontakt steht. In einer Ausführungsform umfasst das Bilden des Inhibitor-Films Bilden von plasmapolymerisiertem Fluorkohlenstoff. In einer Ausführungsform umfasst das Bilden des plasmapolymerisierten Fluorkohlenstoffs sowohl Fluor als auch Kohlenstoff und ist im Wesentlichen frei von anderen Elementen als Fluor und Kohlenstoff. In einer Ausführungsform weist der plasmapolymerisierte Fluorkohlenstoff einen Kohlenstoff-Prozentsatz von etwa 30 Prozent bis etwa 80 Prozent auf. In einer Ausführungsform umfasst das selektive Abscheiden der Dielektrikums-Hartmaske Abscheiden eines Materials, ausgewählt aus der Gruppe, die im Wesentlichen aus ZrO2, HfO2, Y2O3, HfZrOx, HfSiOx, Zirkoniumsilikat (ZrSiOx), Yttriumsilikaten (YSiOx), HfZrSiOx, Al2O3, HfAlOx, ZrAlOx, La2O3, Lanthansilikat (LaSiOx), ZnO, TiO2 und Kombinationen davon besteht.According to some embodiments of the present disclosure, a method includes forming a gate stack including a gate dielectric and a metal gate electrode over the gate dielectric; Forming an interlayer dielectric on opposite sides of the gate stack; Planarizing the gate stack and the interlayer dielectric; Forming an inhibitor film on the gate stack leaving at least a portion of the interlayer dielectric exposed; selectively depositing a dielectric hard mask on the interlayer dielectric, the inhibitor film preventing the dielectric hard mask from being formed thereon; and etching to remove a portion of the gate stack, wherein the dielectric hard mask acts as a portion of a corresponding etch mask. In one embodiment, the method includes removing the inhibitor film before removing the portion of the gate stack and after the dielectric hard mask is selectively deposited. In one embodiment, the method includes filling an insulating layer into an opening left by the removed portion of the gate stack, the insulating layer including a portion that overlaps and is in contact with the inhibitor film. In one embodiment, forming the inhibitor film comprises forming plasma polymerized fluorocarbon. In one embodiment, forming the plasma polymerized fluorocarbon comprises both fluorine and carbon and is substantially free of elements other than fluorine and carbon. In one embodiment, the plasma polymerized fluorocarbon has a carbon percentage of from about 30 percent to about 80 percent. In one embodiment, the selective deposition of the dielectric hard mask comprises deposition of a material selected from the group consisting essentially of ZrO 2 , HfO 2 , Y 2 O 3 , HfZrO x , HfSiO x , zirconium silicate (ZrSiOx), yttrium silicates (YSiO x ), HfZrSiO x , Al 2 O 3 , HfAlO x , ZrAlO x , La 2 O 3 , lanthanum silicate (LaSiO x ), ZnO, TiO 2 and combinations thereof.
Gemäß einigen Ausführungsformen der vorliegenden Offenbarung umfasst eine Vorrichtung ein Zwischenschichtdielektrikum; einen ersten Gate-Stapel und einen zweiten Gate-Stapel; eine Isolationszone, welche den ersten Gate-Stapel mit dem zweiten Gate-Stapel verbindet, wobei der erste Gate-Stapel, der zweite Gate-Stapel und die Isolationszone in Kombination eine kombinierte Zone bilden; einen Gate-Abstandhalter, welcher Abschnitte auf gegenüberliegenden Seiten der kombinierten Zone umfasst und mit Rändern derselben Kontakt steht; eine Dielektrikums-Hartmaske, die Abschnitte umfasst, welche das Zwischenschichtdielektrikum überlappt, wobei sich die Dielektrikums-Hartmaske außerhalb der Zone direkt über dem ersten Gate-Stapel und dem zweiten Gate-Stapel befindet; und eine Dielektrikumsschicht, welche eine untere Fläche aufweist, die mit einer oberen Fläche der Dielektrikums-Hartmaske, einer oberen Fläche des ersten Gate-Stapels und einer oberen Fläche des zweiten Gate-Stapels in Kontakt steht. In einer Ausführungsform umfasst die Dielektrikums-Hartmaske ferner einen Abschnitt, welcher den Gate-Abstandhalter überlappt. In einer Ausführungsform erstreckt sich die Dielektrikums-Hartmaske nicht direkt über dem Gate-Abstandhalter. In einer Ausführungsform umfasst die Vorrichtung ferner eine Gate-Hartmaske zwischen den Abschnitten des Gate-Abstandhalters, welche den ersten Gate-Stapel überlappt, wobei die Gate-Hartmaske und die Isolationszone aus einem gleichen Dielektrikumsmaterial ausgebildet sind. In einer Ausführungsform umfasst die Vorrichtung ferner einen Inhibitor-Film, welcher den ersten Gate-Stapel überlappt und unter der Gate-Hartmaske liegt, wobei der Inhibitor-Film Fluorkohlenstoff umfasst. In einer Ausführungsform liegt ein Kohlenstoff-Prozentsatz in dem Inhibitorfilm in einem Bereich von etwa 30 Prozent bis etwa 80 Prozent.In accordance with some embodiments of the present disclosure, a device includes an interlayer dielectric; a first gate stack and a second gate stack; an isolation region connecting the first gate stack to the second gate stack, the first gate stack, the second gate stack, and the isolation region in combination forming a combined region; a gate spacer comprising portions on opposite sides of the combined zone and in contact with edges thereof; a dielectric hard mask including portions that overlap the interlayer dielectric, the dielectric hard mask being outside of the region directly over the first gate stack and the second gate stack; and a dielectric layer having a bottom surface that is in contact with a top surface of the dielectric hard mask, a top surface of the first gate stack, and a top surface of the second gate stack. In one embodiment, the dielectric hard mask further includes a portion that overlaps the gate spacer. In one embodiment, the dielectric hard mask does not extend directly over the gate spacer. In one embodiment, the device further comprises a gate hard mask between the sections of the gate spacer which overlaps the first gate stack, the gate hard mask and the isolation zone being formed from the same dielectric material. In one embodiment, the device further comprises an inhibitor film overlapping the first gate stack and underlying the gate hard mask, the inhibitor film comprising fluorocarbon. In one embodiment, a percentage of carbon in the inhibitor film ranges from about 30 percent to about 80 percent.
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