International Business Machines Corporation

Adeia Semiconductor Bonding Technologies Inc.

Globalfoundries Inc.

Stuart A Sieg

Fee Li Lie

Sivananda K Kanakasabapathy

Gauri V Karve

Indira P Seshadri

Brent A Anderson

Junli Wang

John Ryan Sporre

Eric R Miller

Nelson M Felix

Bruce Bennett Doris

Hong He

Chi-Chun Liu

Ekmini Anuja De Silva

Yann A M Mignot

Yann Mignot

Christopher Joseph Waskiewicz

Ruilong Xie

Kevin Shawn Petrarca

Sean David Burns

Byeong Yeol Kim

Allen H Gabor

Praveen Joseph

David J Conklin

Juntao Li

Soon-Cheon Seo

John Christopher Arnold

Derrick Liu

Daniel James Dechene

Anuja E DeSilva

Theodorus E Standaert

Hemanth Jagannathan

Wenyu Xu

Matthew Earl Colburn

Su Chen Fan

Yunpeng Yin

Sean Teehan

Jeffrey C Shearer

Somnath Ghosh

Eric Peter Solecky

Eric Miller

Romain Lallement

Kourosh Nafisi

Kangguo Cheng

Alexander Reznicek

Chanro Park

Shogo Mochizuki

Dechao Guo

Mukta G Farooq

Lars W Liebmann

Balasubramanian Pranatharthiharan

Terence B Hook

Hsueh-Chung Chen

Andrew Mark Greene

Subramanian Srikanteswara Iyer

Shreesh Narasimha

Koichi Motoyama

Kisik Choi

Guillaume Bouche

Huiming Bu

Rajasekhar Venigalla

Rishikesh Krishnan

Huimei Zhou

Robert Hannon

Albert M Young

Gen Tsutsui

Scott Marshall Mansfield

Geng Han

Mahender Kumar

Xintuo Dai

Ardasheir Rahman

Lei L Zhuang

Ahmed Hassan

Bassem M Hamieh

A semiconductor device includes a first buried power rail (BPR) disposed through etch stop layers and a second BPR disposed in direct contact with the first BPR, where the first BPR has a larger critical dimension (CD) than the second BPR. A bottom surface of the first BPR directly contacts a via-to buried power rail (VBPR) contact. Source/drain contacts (CA) are disposed adjacent the VBPR contact and source/drain regions collectively defining middle-of-line (MOL) components. Back-end-of-line (BEOL) components are then constructed adjacent to the MOL components, and the MOL and BEOL components bond to a carrier wafer. The second BPR is then constructed on the carrier wafer.

Buried power rail at tight cell-to-cell space

A semiconductor structure is provided in which a via to buried power rail (VBPR) contact structure is present that has a via portion contacting a buried power rail and a non-via portion contacting a source/drain region of a first functional gate structure present in a first device region. A dielectric spacer structure including a base dielectric spacer and a replacement dielectric spacer is located between the VPBR contact structure and the first functional gate structure. The replacement dielectric spacer is composed of a gate cut trench dielectric material that is also present in a gate cut trench that is located between the first functional gate structure present in the first device region, and a second functional gate structure that is present in a second device region. The replacement dielectric spacer replaces a damaged region of a dielectric spacer that is originally present during VBPR formation.

Structure containing a via-to-buried power rail contact structure or a via-to-backside power rail contact structure

A method is presented for constructing a semiconductor device. The method includes forming a plurality of fins over a nanosheet stack and a substrate, forming spacers between the nanosheet stack and one or more of the plurality of fins, each spacer defining a different shape, forming gate spacers adjacent the plurality of fins, the gate spacers directly contacting the one or more of the plurality of fins having a spacer, forming a barrier spacer between a set of fins of the plurality of fins, the barrier spacer directly contacting a top surface of a shallow trench isolation (STI) region, forming n-type epitaxial regions between the plurality of fins, forming p-type epitaxy regions over the n-type epitaxial regions, and forming a first contact extending vertically through the semiconductor device adjacent the barrier spacer and extending laterally away from the barrier spacer to directly contact a sidewall of an n-type epitaxial region.

Bottom contact for stacked GAA FET

A high aspect ratio contact structure formed within a dielectric material includes a top portion and a bottom portion. The top portion of the contact structure includes a tapering profile towards the bottom portion. A first metal stack surrounded by an inner spacer is located within the top portion of the contact structure and a second metal stack is located within the bottom portion of the contact structure. A width of the bottom portion of the contact structure is greater than a minimum width of the top portion of the contact structure.

High aspect ratio contact structure with multiple metal stacks

A method of semiconductor manufacture comprising forming a plurality of first mandrels as the top layer of the multi-layered hard mask and forming a first spacer around each of the plurality of first mandrels. Removing the plurality of first mandrels and cutting the first spacer to form a plurality of second mandrels. Forming a second spacer around each of the plurality of second mandrels and forming a first self-aligned pattern that includes a plurality of third mandrels. Removing the plurality of second mandrels and the second spacer and etching the multi-layered hard mask to transfer the first-self aligned pattern to a lower layer of the multi-layered hard mask. Forming a second self-aligned pattern, wherein the second self-aligned pattern is intermixed with the first self-aligned pattern and etching the first self-aligned pattern and the second self-aligned pattern into the conductive metal layer.

Structure and method to pattern pitch lines

A method of forming a semiconductor structure includes forming a nanosheet stack including alternating layers of a sacrificial material and a channel material over a substrate, the layers of channel material providing nanosheet channels for one or more nanosheet field-effect transistors. The method also includes forming a hard mask stack over the nanosheet stack, and forming a patterning layer over the hard mask stack. The method further includes patterning a lithographic mask over the patterning layer, the lithographic mask defining (i) one or more first regions for direct printing of one or more fins of a first width in the nanosheet stack and the substrate and (ii) one or more second regions for setting the spacing between two or more fins of a second width in the nanosheet stack and the substrate using self-aligned double patterning. The second width is less than the first width.

Using a same mask for direct print and self-aligned double patterning of nanosheets

Integrated chips and methods of forming the same include forming a stack of layers, including a device stack above a first sacrificial layer, above a substrate. The first sacrificial layer is replaced with a first etch stop layer. The substrate is removed, exposing a substrate-side of the stack of layers. The substrate-side of the stack of layers is etched to form a trench, stopping on the first etch stop layer. A conductive line is formed in the trench.

Buried power rails located in a base layer including first, second, and third etch stop layers

A method for forming fins includes forming a three-color hardmask fin pattern on a fin base layer. The three-color hardmask fin pattern includes hardmask fins of three mutually selectively etchable compositions. Some of the fins of the first color are etched away with a selective etch that does not remove fins of a second color or a third color and that leaves at least one fin of the first color behind. The fins of the second color are etched away. Fins are etched into the fin base layer by anisotropically etching around remaining fins of the first color and fins of the third color.

Alternating hardmasks for tight-pitch line formation

Embodiments of the present invention are directed to a method for increasing the available width of a shallow trench isolation region. In a non-limiting embodiment of the invention, a semiconductor fin is formed over a substrate. A source or drain is formed on a surface of the substrate between the semiconductor fin and the substrate. A liner is formed over a surface of the semiconductor fin and a surface of the substrate is recessed to expose a sidewall of the source or drain. A mask is formed over the semiconductor fin and the liner. The mask is patterned to expose a top surface and a sidewall of the liner. A sidewall of the source or drain is recessed and a shallow trench isolation region is formed on the recessed top surface of the substrate. The shallow trench isolation region is adjacent to the recessed sidewall of the source or drain.

Selective source/drain recess for improved performance, isolation, and scaling

A method of forming adjacent fin field effect transistor devices is provided. The method includes forming at least two vertical fins in a column on a substrate, depositing a gate dielectric layer on the vertical fins, and depositing a work function material layer on the gate dielectric layer. The method further includes depositing a protective liner on the work function material layer, and forming a fill layer on the protective liner. The method further includes removing a portion of the fill layer to form an opening between an adjacent pair of two vertical fins, where the opening exposes a portion of the protective liner. The method further includes depositing an etch-stop layer on the exposed surfaces of the fill layer and protective liner, forming a gauge layer in the opening to a predetermined height, and removing the exposed portion of the etch-stop layer to form an etch-stop segment.

Fin field effect transistor devices with self-aligned gates

Methods of forming fins include masking a region on a three-color hardmask fin pattern, leaving a fin of a first color exposed. The exposed fin of the first color is etched away with a selective etch that does not remove fins of a second color or a third color. The mask and all fins of a second color are etched away. Fins are etched into a fin base layer using the fins of the first color and the fins of the third color.

A tunable amorphous silicon layer for use with multilayer patterning stacks can be used to maximize transparency and minimize reflections so as to improve overlay metrology contrast. By increasing the hydrogen content in the amorphous silicon layer, the extinction coefficient (k) value and the refractive index (n) value can be decreased to desired values. Methods for improving overlay metrology contrast with the tunable amorphous silicon layer are disclosed.

Tunable hardmask for overlayer metrology contrast

Methods for forming semiconductor fins include forming a protective layer around a base of a hardmask fin on an underlying semiconductor layer. A portion of the hardmask fin is etched away with an etch that is selective to the protective layer. A semiconductor fin is etched from the semiconductor layer using the etched hardmask fin as a mask.

Fin cut profile using fin base liner

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Hopewell Junction, NY, United States of America

Stuart A Sieg