Globalfoundries Inc.

Globalfoundries U.S. Inc.

Yuping Ren

Guoxiang Ning

Paul Willard Ackmann

Haigou Huang

Rui Chen

Xiang Hu

Chin Teong Lim

Huang Liu

Xusheng Kevin Wu

Sipeng Gu

Minghao Tang

Ming Hao Tang

Duohui Bei

Ruilong Xie

Hui Zang

Haiting Wang

Sunil Kumar Singh

Scott Beasor

Ravi Prakash Srivastava

Sean Xuan Lin

Zhiguo Sun

Shao Beng Law

Wei Zhao

Qiang Fang

Bradley Morgenfeld

Genevieve Beique

Zheng G Chen

Guo Xiang Ning

David N Power

Cheng Xu

Xun Xiang

Lalit Shokeen

The present disclosure relates to semiconductor structures and, more particularly, to gap fill void and connection structures and methods of manufacture. The structure includes: a gate structure comprising source and drain regions; a gate contact in direct contact and overlapping the gate structure; and source and drain contacts directly connecting to the source and drain regions, respectively.

Gap fill void and connection structures

Methods of fabricating an interconnect structure. A hardmask is deposited over a dielectric layer, and a block mask is formed that is arranged over an area on the hardmask. After forming the block mask, a first mandrel and a second mandrel are formed on the hardmask. The first mandrel is laterally spaced from the second mandrel, and the area on the hardmask is arranged between the first mandrel and the second mandrel. The block mask may be used to provide a non-mandrel cut separating the tips of interconnects subsequently formed in the dielectric layer.

Interconnects with non-mandrel cuts formed by early block patterning

A method of fabricating interconnects in a semiconductor device is provided, which includes forming an interconnect layer having a conductive line and depositing a first aluminum-containing layer over the interconnect layer. A dielectric layer is deposited over the first aluminum-containing layer, followed by a second aluminum-containing layer deposited over the dielectric layer. A via opening is formed in the second aluminum-containing layer through to the conductive line, wherein the via opening has chamferless sidewalls.

Chamferless interconnect vias of semiconductor devices

A method of forming isolation pillars for a gate structure, the method including: providing a preliminary structure including a substrate having a plurality of fins thereon, an STI formed between adjacent fins, an upper surface of the STIs extending higher than an upper surface of the fins, and a hardmask over the upper surface of the fins and between adjacent STIs; forming a first trench in a first selected STI and between adjacent fins in a gate region, and forming a second trench in a second selected STI and between adjacent fins in a TS region; and filling the first and second trenches with an isolation fill thereby forming a first isolation pillar in the gate region and a second isolation pillar in the TS region, the first and second isolation pillars extending below the upper surface of the STIs.

Isolation pillar first gate structures and methods of forming same

This disclosure relates to a structure for aligning layers of an integrated circuit (IC) structure that may include a first dielectric layer positioned above a semiconductor substrate having one or more active devices, a trench stop layer positioned above the first dielectric layer, a second dielectric layer positioned above the trench stop layer, and a plurality of metal-filled marking trenches extending vertically through the second dielectric layer and the trench stop layer and at least partially into the first dielectric layer. The metal-filled trenches are electrically isolated from any active devices contained in the IC.

Mark structure for aligning layers of integrated circuit structure and methods of forming same

Methods of self-aligned multiple patterning. A mandrel line is formed over a hardmask layer, and forming a block mask is formed over a first portion of the mandrel line that is linearly arranged between respective second portions of the mandrel line. After forming the first block mask, the second portions of the mandrel line are removed with an etching process to cut the mandrel line and expose respective portions of the hardmask layer. A second portion of the mandrel line is covered by the block mask during the etching process to define a mandrel cut in the mandrel line.

Multiple patterning with mandrel cuts formed using a block mask

Methods of fabricating an interconnect structure. A first sacrificial layer is deposited over a dielectric layer, and a block mask is formed that covers an area on the first sacrificial layer. A second sacrificial layer is deposited over the block mask and the first sacrificial layer. After the block mask is formed, the second sacrificial layer is patterned to form a mandrel that is arranged in part on a portion of the block mask.

Interconnects with cuts formed by block patterning

Methods for identification and partial re-routing of selected areas (e.g., including critical areas) in a layout of an IC design and the resulting device are disclosed. Embodiments include comparing design data of an IC device against criteria of manufacturing processes to manufacture the IC device; identifying in the design data a layout area based, at least in part, on proximity of metal segments, interconnecting segments, or a combination thereof in the layout area; performing partial re-routing in the layout area to substantially meet the criteria, wherein at least one interconnecting element is shifted or extended; and integrating the partial re-routing into the design data for use in the manufacturing processes.

Method for selective re-routing of selected areas in a target layer and in adjacent interconnecting layers of an IC device

A method and apparatus for generating a final dielectric etch compensation table and a final hard mask etch compensation table for either OPC or MPC process flows are provided. Embodiments include performing an overlap pattern classification on a wafer; calibrating a dielectric etch bias or a hard mask etch bias based on the pattern classification; comparing either a CD overlap of a via layer with a metal layer and a CD overlap of the via layer with a lower connecting metal layer or a CD overlap of the metal layer with an upper connecting via layer and a CD overlap of the metal layer with the via layer against a criteria; outputting final dielectric etch compensation and hard mask etch compensation tables to either OPC or MPC process flows; and repeating the steps of calibrating, comparing, and outputting for either the via layer or metal layer remaining.

Hard mask etch and dielectric etch aware overlap for via and metal layers

Methods are provided for dimension-controlled via formation over a circuit structure, including over multiple adjacent conductive structures. The method(s) includes, for instance, providing a patterned multi-layer stack structure above the circuit structure, the stack structure including at least one layer, and a pattern transfer layer above the at least one layer, the pattern transfer layer being patterned with at least one via opening; providing a sidewall spacer layer within the at least one via opening to form at least one dimension-controlled via opening; and etching through the at least one layer of the stack structure using the at least one dimension-controlled via opening to facilitate providing the via(s) over the circuit structure. In one implementation, the stack structure includes a trench-opening within a patterned hard mask layer disposed between a dielectric layer and a planarization layer, and the via(s) is partially self-aligned to the trench.

Dimension-controlled via formation processing

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Clifton Park, NY, United States of America

Yuping Ren