Globalfoundries Inc.

Akshey Sehgal

Sipeng Gu

Sunil Kumar Singh

Xiang Hu

Ravi Prakash Srivastava

Andy C Wei

Alok Vaid

Lokesh Subramany

Mark Alexander Zaleski

Teck Jung Tang

Xinyuan Dou

Seung Yeon Kim

Francis M Tambwe

Haiting Wang

Guillaume Bouche

Xusheng Kevin Wu

Roderick Alan Augur

Jason Eugene Stephens

Timothy James McArdle

Scott Beasor

Zhiguo Sun

Richard J Carter

Bharat V Krishnan

Linus Jang

Craig Child

Abner Bello

Dae Geun Yang

Dae-han Choi

Rinus Tek Po Lee

Shishir K Ray

Mariappan Hariharaputhiran

David Michael Permana

Shyam Pal

Anbu Selvam K M Mahalingam

Bamidele S Allimi

This disclosure is directed to an integrated circuit (IC) structure. The IC structure may include a semiconductor structure including two source/drain regions; a metal gate positioned on the semiconductor structure adjacent to and between the source/drain regions; a metal cap with a different metal composition than the metal gate and having a thickness in the range of approximately 0.5 nanometer (nm) to approximately 5 nm positioned on the metal gate; a first dielectric cap layer positioned above the semiconductor structure; an inter-layer dielectric (ILD) positioned above the semiconductor structure and laterally abutting both the metal cap and the metal gate, wherein an upper surface of the ILD has a greater height above the semiconductor structure than an upper surface of the metal gate; a second dielectric cap layer positioned on the ILD and above the metal cap; and a contact on and in electrical contact with the metal cap.

Integrated circuit structure to reduce soft-fail incidence and method of forming same

The present disclosure generally relates to semiconductor structures and, more particularly, to smooth sidewall structures and methods of manufacture. The method includes: forming a plurality of mandrel structures; forming a first spacer material on each of the plurality of mandrel structures; forming a second spacer material over the first spacer material; and removing the first spacer material and the plurality of mandrel structures to form a sidewall structure having a sidewall smoothness greater than the plurality of mandrel structures.

Method of forming smooth sidewall structures using spacer materials

Methods of forming an interconnect of an IC are disclosed. The methods etch a wire trench opening partially into an ILD layer using a hard mask, and form a metal liner sidewall spacer on sidewalls of the wire trench opening, prior to etching via openings that create a via-wire opening with the wire trench opening. The metal liner sidewall spacer protects against chamfering during the via etch and/or removal of an etch stop layer over conductive structures in an underlying ILD layer. In one embodiment, a barrier liner is deposited over the metal liner sidewall spacer, creating a double layered sidewall spacer on the sidewalls of the wire trench opening portion of the via-wire opening. A conductor is deposited to form a unitary via-wire conductive structure. An interconnect includes the double layered sidewall spacer on the sidewalls of a wire trench opening portion of the via-wire conductive structure.

Interconnect formation process using wire trench etch prior to via etch, and related interconnect

Semiconductor devices and methods of fabricating the semiconductor devices with chamfer-less via multi-patterning are disclosed. One method includes, for instance: obtaining an intermediate semiconductor device; performing a trench etch into a portion of the intermediate semiconductor device to form a trench pattern; depositing an etching stack; performing at least one via patterning process; and forming at least one via opening into a portion of the intermediate semiconductor device. An intermediate semiconductor device is also disclosed.

Devices with chamfer-less vias multi-patterning and methods for forming chamfer-less vias

The present disclosure generally relates to semiconductor structures and, more particularly, to finFETs with strained channels and reduced on state resistances and methods of manufacture. The structure includes: a plurality of fin structures comprising doped source and drain regions with a diffusion blocking layer between the doped source and drain regions and an underlying fin region formed within dielectric material.

FinFETs with strained channels and reduced on state resistance

Approaches for providing a substrate having a planar metrology pad adjacent a set of fins of a fin field effect transistor (FinFET) device are disclosed. Specifically, the FinFET device comprises a finned substrate, and a planar metrology pad formed on the substrate adjacent the fins in a metrology measurement area of the FinFET device. Processing steps include forming a first hardmask over the substrate, forming a photoresist over a portion of the first hardmask in the metrology measurement area of the FinFET device, removing the first hardmask in an area adjacent the metrology measurement area remaining exposed following formation of the photoresist, patterning a set of openings in the substrate to form the set of fins in the FinFET device in the area adjacent the metrology measurement area, depositing an oxide layer over the FinFET device, and planarizing the FinFET device to form the planar metrology pad in the metrology measurement area.

Planar metrology pad adjacent a set of fins of a fin field effect transistor device

Integrated circuits and methods for fabricating integrated circuits are provided. In one example, a method for fabricating an integrated circuit includes depositing an organic dielectric material overlying a semiconductor substrate for forming an organic interlayer dielectric (OILD) layer. An opening is formed in the OILD layer and a conductive metal fill is deposited in the opening for forming a metal line and/or a via.

Integrated circuits including organic interlayer dielectric layers and methods for fabricating the same

Embodiments of the present invention provide a semiconductor structure for BEOL (back end of line) integration. A directed self assembly (DSA) material is deposited and annealed to form two distinct phase regions. One of the phase regions is selectively removed, and the remaining phase region serves as a mask for forming cavities in an underlying layer of metal and/or dielectric. The process is then repeated to form complex structures with patterns of metal separated by dielectric regions.

Methods and structures for back end of line integration

Measurement of thickness of layers of a circuit structure is obtained, where the thickness of the layers is measured using an optical critical dimension (OCD) measurement technique, and the layers includes a high-k layer and an interfacial layer. Measurement of thickness of the high-k layer is separately obtained, where the thickness of the high-k layer is measured using a separate measurement technique from the OCD measurement technique. The separate measurement technique provides greater decoupling, as compared to the OCD measurement technique, of a signal for thickness of the high-k layer from a signal for thickness of the interfacial layer of the layers. Characteristics of the circuit structure, such as a thickness of the interfacial layer, are ascertained using, in part, the separately obtained thickness measurement of the high-k layer.

Decoupling measurement of layer thicknesses of a plurality of layers of a circuit structure

Approaches for providing a planar metrology pad adjacent a set of fins of a fin field effect transistor (FinFET) device are disclosed. A previously deposited amorphous carbon layer can be removed from over a mandrel that has been previously formed on a subset of a substrate, such as using a photoresist. A pad hardmask can be formed over the mandrel on the subset of the substrate. This formation results in the subset of the substrate having the pad hardmask covering the mandrel thereon and the remainder of the substrate having the amorphous carbon layer covering the mandrel thereon. This amorphous carbon layer can be removed from over the mandrel on the remainder of the substrate, allowing a set of fins to be formed therein while the amorphous carbon layer keeps the set of fins from being formed in the portion of the substrate that it covers.

Devices and methods for forming semiconductor devices with fins at tight fin pitches are provided. One method includes, for instance: obtaining an intermediate semiconductor device; growing an epi layer over the substrate; forming a doped layer below the epi layer; depositing a first oxide layer on the epi layer; applying a dielectric material on the first oxide layer; and depositing a lithography stack on the dielectric material. One intermediate semiconductor device includes, for instance: a substrate with at least one n-well region and at least one p-well region; a doped layer over the substrate; an epi layer over the doped layer; a first oxide layer over the epi layer; a dielectric layer over the first oxide layer; and a lithography stack over the dielectric layer.

Devices and methods of forming fins at tight fin pitches

A FinFET device includes a plurality of fin structures positioned in and above a semiconducting substrate, wherein each of the fin structures includes a first portion of the semiconducting substrate, an undoped layer of semiconducting material positioned above the first portion of the semiconducting substrate, and a dopant-containing layer of semiconducting material positioned between the first portion of the semiconducting substrate and the undoped semiconducting material, wherein the dopant material is adapted to retard diffusion of one of boron and phosphorous. A gate electrode is positioned around at least the undoped layer of semiconducting material of each of the plurality of fin structures, wherein a height level of a bottom surface of the gate electrode is positioned approximately level with or lower than a height level of a bottom of the undoped layer of semiconducting material of each of the plurality of fin structures.

Methods of forming a FinFET semiconductor device with undoped fins

One method disclosed herein includes, prior to forming an isolation region in a semiconducting substrate for the device, forming a doped well region and a doped punch-stop region in the substrate, introducing a dopant material that is adapted to retard diffusion of boron or phosphorous into the substrate to form a dopant-containing layer proximate an upper surface of the substrate, performing an epitaxial deposition process to form an undoped semiconducting material above the dopant-containing layer, forming a plurality of spaced-apart trenches that extend at least partially into the substrate, wherein the trenches define a fin for the device comprised of at least the undoped semiconducting material, forming at least a local isolation insulating material in the trenches, and forming a gate structure around at least the undoped semiconducting material, wherein a bottom of a gate electrode is positioned approximately level with or below a bottom of the undoped semiconducting material.

Growing community of inventors

Malta, NY, United States of America

Akshey Sehgal