Abstract: An apparatus and a method of fabricating a semiconductor device including the steps of forming a gate dielectric layer on a semiconductor substrate; forming a gate electrode over the gate dielectric layer wherein the gate electrode defines a channel interposed between source/drain regions formed within an active region of the semiconductor substrate; and forming contact etch resistant spacers on sidewalls of the gate electrode and sidewalls of the gate dielectric layer, the contact etch resistant spacers are of a non-silicon oxide and a non-nitride material.

Abstract: To reduce the width of a MOSFET gate, the gate is formed with a hardmask formed thereupon. An isotropic etch is then performed to trim the gate in order to reduce the width of the gate. The resulting gate may be formed with a width that is narrower than a minimum width achievable solely through conventional projection lithography techniques.

Abstract: In the present method of trimming photoresist to form a mask for a layer of a semiconductor device, which layer may include polysilicon and/or nitride, the method is practiced substantially in accordance with: wmin=(h0−Rvtmax)/ARmax where w1=minimum width of trimmed photoresist; h0=height of photoresist prior to trim; Rv=resist vertical etch rate; tmax=maximum etch time to reach resist vertical etch limit; ARmax=maximum allowable aspect ratio of trimmed photoresist.

Abstract: There is provided a method for forming a photoresist layer for photolithographic applications that reduces or eliminates pattern collapse due to capillary forces on photoresist structures during spin developing and/or spin rinsing. The photoresist layer is developed in a near vertical orientation with developer solution showered onto the photoresist layer. Rinse solution is showered onto the photoresist layer and the photoresist layer is dried by flowing air or nitrogen over the surface. Also provided are a semiconductor fabrication method and a semiconductor processing apparatus configured to accomplish the disclosed methods.

Abstract: A method is provided for fabricating a T-gate structure. A structure is provided that has a silicon layer having a gate oxide layer, a polysilicon layer over the gate oxide layer, and an ARC layer over the polysilicon layer. A gate structure is formed by removing the ARC layer and a portion of the polysilicon layer around a gate region. Spacers are then formed around the gate structure. Undercut regions are formed in the gate structure by performing an isotropic etch to provide the gate structure with a base region and a contact region. The base region has a width smaller than the contact region.

Abstract: A method for fabricating a T-gate structure is provided. The method comprises the steps of providing a silicon layer having a gate oxide layer, a protection layer over the gate oxide layer, a first sacrificial layer over the protection layer and a second sacrificial layer over the first sacrificial layer. A photoresist layer is formed over the second sacrificial layer. An opening is formed in the photoresist layer. An opening is then formed in the second sacrificial layer beneath the opening in the photoresist layer. The opening is then expanded in the photoresist layer to expose portions of the top surface of the second sacrificial layer around the opening in the second sacrificial layer. The opening is extended in the second sacrificial layer through the first sacrificial layer and the opening is expanded in the second sacrificial layer to form a T-shaped opening in the first and second sacrificial layers. The photoresist layer is removed and the T-shaped opening is filled with a conductive material.

Abstract: A method for fabricating a T-gate structure is provided. A structure is provided that has a silicon layer having a gate oxide layer, a protection layer over the gate oxide layer and a sacrificial layer over the protection layer. An opening is then formed in the sacrificial layer. A contact material is deposited over the sacrificial layer filling the opening with the contact material and forming a contact layer. Portions of the contact material outside a gate region are then removed. Finally, the sacrificial layer and portions of the protection layer and the gate oxide layer not forming a part of the T-gate structure are removed.

Abstract: A method for fabricating a Y-gate structure is provided. The method comprises the steps of providing a silicon layer having a gate oxide layer, a protection layer over the gate oxide layer, a first sacrificial layer over the protection layer and a second sacrificial layer over the first sacrificial layer. An inwardly sloping opening is formed in the second sacrificial layer and the opening is extended vertically in the first sacrificial layer. A contact material is deposited over the second sacrificial layer filling the opening with the contact material and forming a contact layer and portions of the contact material outside a gate region are removed. The first sacrificial layer and the second sacrificial layer are then removed.

Abstract: The present invention addresses a problem associated with exposing a photoresist layer of non-uniform thickness. Oftentimes, trench patterns etched into a layer of a semiconductor structure will have trenches of varying sizes. Larger trenches in the structure become filled with photoresist material, while smaller trenches do not leading to non-uniformity of photoresist layer thickness with respect to the large and small trenches. The present invention addresses this non-uniformity in photoresist layer thickness by employing at least two exposure steps when exposing the photoresist layer. A first exposure step exposes portions of the photoresist layer corresponding to the large trenches using a first reticle and first energy level. Next, a second exposure step exposes portions of the photoresist layer corresponding to the small trenches using a second reticle and second energy level.

Abstract: A method for fabricating a T-gate structure is provided. A structure is provided that has a silicon layer having a gate oxide layer, a polysilicon layer over the gate oxide layer and an insulating layer over the gate oxide layer. A photoresist layer is formed over the insulating layer. An opening is the formed extending through the photoresist layer and partially into the insulating layer. The opening in the insulating layer extends from a top surface of the insulating layer to a first depth. The photoresist layer is swelled to reduce the size of the opening in the photoresist layer. The opening is then extended in the insulating layer from the first depth to a second depth. The opening is wider from the top surface of the insulating layer to the first depth than the opening is from the first depth to the second depth. The opening is then filled with a conductive material to form a T-gate structure.

Abstract: A method for fabricating a T-gate structure is provided. A structure is provided that has a silicon layer having a gate oxide layer, a polysilicon layer over the gate oxide layer and an insulating layer over the gate oxide layer. An opening is formed extending partially into the insulating layer. The opening in the insulating layer extends from a top surface of the insulating layer to a first depth. Spacers are then formed on the sides of the opening. The opening is then extended in the insulating layer from the first depth to a second depth. The opening is wider from the top surface of the insulating layer to the first depth than the opening is from the first depth to the second depth. The spacers are then removed from the opening. The opening is then filled with a conductive material to form a T-gate structure.

Abstract: A method of forming an alignment mark protection structure is disclosed and includes forming an alignment mark protection layer over a substrate which has an alignment mark associated therewith. The method also includes forming a negative photoresist layer over the alignment mark protection layer and removing a portion of the negative photoresist layer which does not overlie the alignment mark. The removal exposes a portion of the alignment mark protection layer which does not overlie the alignment mark and the exposed portion of the alignment mark protection layer is then removed. Preferably, the removal of a portion of the negative photoresist includes selectively exposing a peripheral portion thereof using an edge-bead removal tool, thereby allowing for the formation of an alignment mark protection structure without an extra masking step.