Globalfoundries Inc.

Bastian Haussdoerfer

Joachim Patzer

Ardechir Pakfar

Peter Baars

Peter Javorka

Markus Lenski

Juergen Faul

Berthold Reimer

Dominic Thurmer

Remi Riviere

Robert Melzer

Chih-Chun Wang

Martin Weisheit

An issue arises when manufacturing semiconductor circuits including PFETs with an SiGe alloy embedded in their source/drain regions and NFETs without any embedded SiGe alloy. In this case, the thickness of the NFET spacers is considerably greater than that of the PFET spacers. In order to alleviate this asymmetry in spacer thickness, a manufacturing flow is proposed wherein a spacer-reducing etching process is introduced before the salicidation. The etching process is performed directly after the ion implantation performed in order to form deep regions of source/drain regions of the NFETs. Thus, the spacer-reducing etching process may be performed in the presence of the same mask used during the NFET deep implantations. The spacer-reducing etching process results in thinning of the NFET spacer structures, thus alleviating the spacer thickness imbalance between NFETs and PFETs.

Balancing asymmetric spacers

A method for the manufacture of a semiconductor device is provided, including the steps of providing a semiconductor substrate including a first area separated from a second area by a first isolation region, wherein the second area includes an intermediate transistor comprising a gate electrode, forming an oxide layer over the first and second areas, forming an optical planarization layer (OPL) over the oxide layer, forming a mask layer over the OPL in the first area without covering the OPL in the second area, and etching the OPL with the mask layer being present to expose the oxide layer over the gate electrode of the transistor.

Method of forming a semiconductor device employing an optical planarization layer

A method of forming a spacer is disclosed that involves forming a layer of spacer material above an etch stop layer, performing a first main etching process on the layer of spacer material to remove some of material, stopping the etching process prior to exposing the etch stop layer and performing a second over-etch process on the layer of spacer material, using the following parameters: an inert gas flow rate of about 50-200 sscm, a reactive gas flow rate of about 3-20 sscm, a passivating gas flow rate of about 3-20 sscm, a processing pressure about 5-15 mT, a power level of about 200-500 W for ion generation and a bias voltage of about 300-500 V. A device includes a gate structure positioned above a semiconducting substrate, a substantially triangular-shaped sidewall spacer positioned proximate the gate structure and an etch stop layer positioned between the spacer and the gate structure.

Methods of forming a sidewall spacer having a generally triangular shape and a semiconductor device having such a spacer

One method disclosed includes forming a sidewall spacer proximate a gate structure, forming a sacrificial layer of material above a protective cap layer, the sidewall spacer and a substrate, forming a sacrificial protection layer above the sacrificial layer, reducing a thickness of the sacrificial protection layer such that its upper surface is positioned at a level that is below the upper surface of the protective cap layer, performing a first etching process to remove a portion of the sacrificial layer and thereby expose the protective cap layer for further processing, performing a wet acid etching process that includes diluted HF acid in the etch chemistry to remove the protective cap layer and performing at least one process operation to remove at least one of the reduced-thickness sacrificial protection layer or the sacrificial layer from above the surface of the substrate.

Methods of forming a semiconductor device by performing a wet acid etching process while preventing or reducing loss of active area and/or isolation regions

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Dresden, Germany

Bastian Haussdoerfer