Process for fabricating a floating gate of a flash memory in a self-aligned manner

Abstract

The present invention provides a process for fabricating a floating gate of a flash memory. First, an isolation region is formed in a semiconductor substrate and the isolation region has a height higher than the substrate. A gate oxide layer and a first polysilicon layer are then formed. The first polysilicon layer is formed according to the contour of the isolation region to form a recess in the first polysilicon layer. A sacrificial insulator is filled into the recess. The first polysilicon layer is then selectively removed in a self-aligned manner using the sacrificial insulator as a hard mask to expose the isolation region. A polysilicon spacer is formed on the sidewalls of the first polysilicon layer. A first mask layer is formed on the isolation region, the sacrificial insulator in the recess is removed, and a floating gate region is defined. Then, the surfaces of the first polysilicon layer and polysilicon spacer in the floating gate region are oxidized to form a polysilicon oxide layer. Finally, the polysilicon oxide layer is used as a mask to pattern the underlying first polysilicon layer and polysilicon spacer in a self-aligned manner to form a floating gate. During the oxidation process, the polysilicon spacer of the present invention serves as a buffer layer, which is oxidized and protects the floating gate from being oxidized. Thus, the floating gate and STI overlay, and current leakage caused by insufficient overlay is prevented.