United Integrated Circuits Corp.

Russell Chen

Kwang-Ming Lin

A method for forming a SAC opening is provided. As a self-aligned contact (SAC) opening is formed in a dielectric layer on a semiconductor substrate to expose one of source/drain regions in the substrate, a misalignment of the SAC opening may occur to expose a portion of the gate structure. The gate structure has a gate, which is covered by a cap layer on the top, a thin oxide layer on each sidewall of the gate and the cap layer, and a spacer on the thin oxide layer. The SAC opening causes a clearance between the spacer and the gate since a portion of the thin oxide layer is removed. The method contains forming an insulating layer over the substrate to fill the clearance. An etching back process is performed to remove the insulating layer so that a remaining portion of the insulating layer fills the clearance to fully isolate the gate.

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Hsinchu, Taiwan

Russell Chen