Patents by Inventor Pang-Yen Tsai

Pang-Yen Tsai has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11417764
    Abstract: A method for reducing stress induced defects in heterogeneous epitaxial interfaces of a semiconductor device is disclosed. The method includes forming a fin structure with a fin base, a superlattice structure on the fin base, forming a polysilicon gate structure on the fin structure, forming a source/drain (S/D) opening within a portion of the fin structure uncovered by the polysilicon gate structure, modifying the first surfaces of the first layers to curve a profile of the first surfaces, depositing first, second, and third passivation layers on the first, second, and third surfaces, respectively, forming an epitaxial S/D region within the S/D opening, and replacing the polysilicon gate structure with a metal gate structure. The superlattice structure includes first and second layers with first and second lattice constants, respectively, and the first and second lattice constants are different from each other.
    Type: Grant
    Filed: July 28, 2020
    Date of Patent: August 16, 2022
    Inventors: Winnie Victoria Wei-Ning Chen, Pang-Yen Tsai, Yasutoshi Okuno
  • Patent number: 11410890
    Abstract: A method includes providing a p-type S/D epitaxial feature and an n-type source/drain (S/D) epitaxial feature, forming a semiconductor material layer over the n-type S/D epitaxial feature and the p-type S/D epitaxial feature, processing the semiconductor material layer with a germanium-containing gas, where the processing of the semiconductor material layer forms a germanium-containing layer over the semiconductor material layer, etching the germanium-containing layer, where the etching of the germanium-containing layer removes the germanium-containing layer formed over the n-type S/D epitaxial feature and the semiconductor material layer formed over the p-type S/D epitaxial feature, and forming a first S/D contact over the semiconductor material layer remaining over the n-type S/D epitaxial feature and a second S/D contact over the p-type S/D epitaxial feature. The semiconductor material layer may have a composition similar to that of the n-type S/D epitaxial feature.
    Type: Grant
    Filed: December 11, 2018
    Date of Patent: August 9, 2022
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Ding-Kang Shih, Pang-Yen Tsai
  • Patent number: 11393924
    Abstract: A semiconductor device structure and a method for forming a semiconductor device structure are provided. The semiconductor device structure includes multiple channel structures suspended over a semiconductor substrate. The semiconductor device structure also includes multiple epitaxial structures extending from edges of the channel structures. The semiconductor device structure further includes a gate stack wrapping around the channel structures. In addition, the semiconductor device structure includes a conductive contact wrapping around terminals of the epitaxial structures.
    Type: Grant
    Filed: May 18, 2020
    Date of Patent: July 19, 2022
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Shuen-Shin Liang, Pang-Yen Tsai, Keng-Chu Lin, Sung-Li Wang, Pinyen Lin
  • Patent number: 11257951
    Abstract: A method of manufacturing a semiconductor device includes forming a first gate stack over a substrate. The method further includes etching the substrate to define a cavity. The method further includes growing a first epitaxial (epi) material in the cavity, wherein the first epi material includes a first upper surface having a first crystal plane. The method further includes growing a second epi material on the first epi material, wherein the second epi material includes a second upper surface having the first crystal plane. The method further includes treating the second epi material, wherein treating the second epi material comprises causing the second upper surface to transform to a second crystal plane different from the first crystal plane.
    Type: Grant
    Filed: November 4, 2020
    Date of Patent: February 22, 2022
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD.
    Inventors: Lilly Su, Chii-Horng Li, Ming-Hua Yu, Pang-Yen Tsai, Tze-Liang Lee, Yen-Ru Lee
  • Patent number: 11211383
    Abstract: A semiconductor device includes first and second epitaxial structures, first and second top metal alloy layers, and first and second bottom metal alloy layers. The first and second epitaxial structures have different cross sections. The first and second top metal alloy layers are respectively in contact with the first and second epitaxial structures. The first and second bottom metal alloy layers are respectively in contact with the first and second epitaxial structures and respectively under the first and second top metal alloy layers. The first top metal alloy layer and the first bottom metal alloy layer are made of different materials.
    Type: Grant
    Filed: July 13, 2020
    Date of Patent: December 28, 2021
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Sung-Li Wang, Pang-Yen Tsai, Yasutoshi Okuno
  • Publication number: 20210399099
    Abstract: A semiconductor device structure according to the present disclosure includes a source feature and a drain feature, at least one channel structure extending between the source feature and the drain feature, a gate structure wrapped around each of the at least on channel structure, a semiconductor layer over the gate structure, a dielectric layer over the semiconductor layer, a doped semiconductor feature extending through the semiconductor layer and the dielectric layer to be in contact with the source feature, a metal contact plug over the doped semiconductor feature, and a buried power rail disposed over the metal contact plug.
    Type: Application
    Filed: January 4, 2021
    Publication date: December 23, 2021
    Inventors: Chia-Hung Chu, Sung-Li Wang, Shuen-Shin Liang, Hsu-Kai Chang, Ding-Kang Shih, Tsungyu Hung, Pang-Yen Tsai, Keng-Chu Lin
  • Publication number: 20210359125
    Abstract: A semiconductor device structure and a method for forming a semiconductor device structure are provided. The semiconductor device structure includes multiple channel structures suspended over a semiconductor substrate. The semiconductor device structure also includes multiple epitaxial structures extending from edges of the channel structures. The semiconductor device structure further includes a gate stack wrapping around the channel structures. In addition, the semiconductor device structure includes a conductive contact wrapping around terminals of the epitaxial structures.
    Type: Application
    Filed: May 18, 2020
    Publication date: November 18, 2021
    Applicant: Taiwan Semiconductor Manufacturing Co., Ltd.
    Inventors: Shuen-Shin LIANG, Pang-Yen TSAI, Keng-Chu LIN, Sung-Li WANG, Pinyen LIN
  • Publication number: 20210313236
    Abstract: A method for forming an epitaxial source/drain structure in a semiconductor device includes providing a substrate having a plurality of fins extending from the substrate. In some embodiments, a liner layer is formed over the plurality of fins. The liner layer is patterned to expose a first group of fins of the plurality of fins in a first region. In some embodiments, a first epitaxial layer is formed over the exposed first group of fins and a barrier layer is formed over the first epitaxial layer. Thereafter, the patterned liner layer may be removed. In various examples, a second epitaxial layer is selectively formed over a second group of fins of the plurality of fins in a second region.
    Type: Application
    Filed: June 14, 2021
    Publication date: October 7, 2021
    Inventors: Cheng-Long CHEN, Yasutoshi OKUNO, Pang-Yen TSAI
  • Patent number: 11133223
    Abstract: A semiconductor device and a method of making the same are provided. A method according to the present disclosure includes providing a workpiece comprising a first source/drain region in a first device region and a second source/drain region in a second device region, depositing a dielectric layer over the first source/drain region and the second source drain region, forming a first via opening in the dielectric layer to expose the first source/drain region and a second via opening in the dielectric layer to expose the second source/drain region, annealing the workpiece to form a first semiconductor oxide feature over the exposed first source/drain region and a second semiconductor oxide feature over the exposed second source/drain region, removing the first semiconductor oxide feature to expose the first source/drain region in the first via opening in dielectric layer, and selectively forming a first epitaxial feature over the exposed first source/drain region.
    Type: Grant
    Filed: July 16, 2019
    Date of Patent: September 28, 2021
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Ding-Kang Shih, Cheng-Long Chen, Pang-Yen Tsai
  • Publication number: 20210272956
    Abstract: A semiconductor device includes a semiconductive substrate, a semiconductive fin, an isolation structure, a source/drain epitaxial structure, a first cap layer, and a second cap layer. The semiconductive fin protrudes from the semiconductive substrate. The isolation structure is over the semiconductive substrate and laterally surrounds the semiconductive fin. The source/drain epitaxial structure is over the semiconductive fin. The source/drain epitaxial structure has a rounded corner extending laterally and a top above the rounded corner. The first cap layer extends from the rounded corner of the source/drain epitaxial structure to the top of the source/drain epitaxial structure. The second cap layer covers the rounded corner and a bottom of the source/drain epitaxial structure. The first and second cap layers are made of different materials.
    Type: Application
    Filed: May 20, 2021
    Publication date: September 2, 2021
    Applicant: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Sung-Li WANG, Pang-Yen TSAI, Yasutoshi OKUNO
  • Publication number: 20210265220
    Abstract: A method of fabricating a semiconductor device with superlattice structures on a substrate with an embedded isolation structure is disclosed. The method includes forming an etch stop layer on a substrate, forming a superlattice structure on the etch stop layer, depositing an isolation layer on the superlattice structure, depositing a semiconductor layer on the isolation layer, forming a bi-layer isolation structure on the semiconductor layer, removing the substrate and the etch stop layer, etching the superlattice structure, the isolation layer, the semiconductor layer, and the bi-layer isolation structure to form a fin structure, and forming a gate-all-around structure on the fin structure.
    Type: Application
    Filed: August 28, 2020
    Publication date: August 26, 2021
    Applicant: Taiwan Semiconductor Manufacturing Co., Ltd.
    Inventors: Pei-Wei LEE, Pang-Yen TSAI, Tsungyu HUNG, Huang-Lin CHAO
  • Publication number: 20210257262
    Abstract: A first dielectric layer is selectively formed such that the first dielectric layer is formed over a source/drain region of a first type of transistor but not over a source/drain region of a second type of transistor. The first type of transistor and the second type of transistor have different types of conductivity. A first silicide layer is selectively formed such that the first silicide layer is formed over the source/drain region of the second type of transistor but not over the source/drain region of the first type of transistor. The first dielectric layer is removed. A second silicide layer is formed over the source/drain region of the first type of transistor.
    Type: Application
    Filed: May 3, 2021
    Publication date: August 19, 2021
    Inventors: Mrunal A. Khaderbad, Pang-Yen Tsai, Yasutoshi Okuno
  • Publication number: 20210234044
    Abstract: A method for reducing stress induced defects in heterogeneous epitaxial interfaces of a semiconductor device is disclosed. The method includes forming a fin structure with a fin base, a superlattice structure on the fin base, forming a polysilicon gate structure on the fin structure, forming a source/drain (S/D) opening within a portion of the fin structure uncovered by the polysilicon gate structure, modifying the first surfaces of the first layers to curve a profile of the first surfaces, depositing first, second, and third passivation layers on the first, second, and third surfaces, respectively, forming an epitaxial S/D region within the S/D opening, and replacing the polysilicon gate structure with a metal gate structure. The superlattice structure includes first and second layers with first and second lattice constants, respectively, and the first and second lattice constants are different from each other.
    Type: Application
    Filed: July 28, 2020
    Publication date: July 29, 2021
    Applicant: Taiwan Semiconductor Manufacturing Co., Ltd.
    Inventors: Winnie Victoria Wei Ning CHEN, Pang-Yen TSAI, Yasutoshi OKUNO
  • Publication number: 20210234002
    Abstract: A semiconductor device according to the present disclosure includes a substrate including a plurality of atomic steps that propagate along a first direction, and a transistor disposed on the substrate. The transistor includes a channel member extending a second direction perpendicular to the first direction, and a gate structure wrapping around the channel member.
    Type: Application
    Filed: July 30, 2020
    Publication date: July 29, 2021
    Inventors: Pei-Wei Lee, Yasutoshi Okuno, Pang-Yen Tsai
  • Publication number: 20210210608
    Abstract: Examples of an integrated circuit with an interface between a source/drain feature and a contact and examples of a method for forming the integrated circuit are provided herein. In some examples, a substrate is received having a source/drain feature disposed on the substrate. The source/drain feature includes a first semiconductor element and a second semiconductor element. The first semiconductor element of the source/drain feature is oxidized to produce an oxide of the first semiconductor element on the source/drain feature and a region of the source/drain feature with a greater concentration of the second semiconductor element than a remainder of the source/drain feature. The oxide of the first semiconductor element is removed, and a contact is formed that is electrically coupled to the source/drain feature. In some such embodiments, the first semiconductor element includes silicon and the second semiconductor element includes germanium.
    Type: Application
    Filed: March 1, 2021
    Publication date: July 8, 2021
    Inventors: Ding-Kang Shih, Sung-Li Wang, Pang-Yen Tsai
  • Patent number: 11037837
    Abstract: A method for forming an epitaxial source/drain structure in a semiconductor device includes providing a substrate having a plurality of fins extending from the substrate. In some embodiments, a liner layer is formed over the plurality of fins. The liner layer is patterned to expose a first group of fins of the plurality of fins in a first region. In some embodiments, a first epitaxial layer is formed over the exposed first group of fins and a barrier layer is formed over the first epitaxial layer. Thereafter, the patterned liner layer may be removed. In various examples, a second epitaxial layer is selectively formed over a second group of fins of the plurality of fins in a second region.
    Type: Grant
    Filed: August 8, 2019
    Date of Patent: June 15, 2021
    Assignee: Taiwan Semiconductor Manufacturing Co., Ltd.
    Inventors: Cheng-Long Chen, Yasutoshi Okuno, Pang-Yen Tsai
  • Publication number: 20210175345
    Abstract: Semiconductor device and the manufacturing method thereof are disclosed herein. An exemplary method of forming a semiconductor device comprises forming a fin over a substrate, wherein the fin comprises a first semiconductor layer and a second semiconductor layer comprising different semiconductor materials, and the fin includes a channel region and a source/drain region; forming a dummy gate structure over the substrate and the fin; etching a portion of the fin in the source/drain region; selectively removing an edge portion of the second semiconductor layer in the channel region of the fin such that the second semiconductor layer is recessed, and an edge portion of the first semiconductor layer is suspended; performing a reflow process to the first semiconductor layer to form an inner spacer, wherein the inner spacer forms sidewall surfaces of the source/drain region of the fin; and epitaxially growing a sour/drain feature in the source/drain region.
    Type: Application
    Filed: February 23, 2021
    Publication date: June 10, 2021
    Inventors: Tsungyu Hung, Pang-Yen Tsai, Pei-Wei Lee
  • Publication number: 20210151434
    Abstract: A semiconductor device is provided. The semiconductor device includes a substrate and a semiconductor layer formed over a substrate. The semiconductor device further includes an isolation region covering the semiconductor layer and nanostructures formed over the semiconductor layer. The semiconductor layer further includes a gate stack wrapping around the nanostructures. In addition, the isolation region is interposed between the semiconductor layer and the gate stack.
    Type: Application
    Filed: January 4, 2021
    Publication date: May 20, 2021
    Applicant: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD.
    Inventors: Winnie Victoria Wei-Ning CHEN, Meng-Hsuan HSIAO, Tung-Ying LEE, Pang-Yen TSAI, Yasutoshi OKUNO
  • Patent number: 10998241
    Abstract: A first dielectric layer is selectively formed such that the first dielectric layer is formed over a source/drain region of a first type of transistor but not over a source/drain region of a second type of transistor. The first type of transistor and the second type of transistor have different types of conductivity. A first silicide layer is selectively formed such that the first silicide layer is formed over the source/drain region of the second type of transistor but not over the source/drain region of the first type of transistor. The first dielectric layer is removed. A second silicide layer is formed over the source/drain region of the first type of transistor.
    Type: Grant
    Filed: June 27, 2019
    Date of Patent: May 4, 2021
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Mrunal A. Khaderbad, Pang-Yen Tsai, Yasutoshi Okuno
  • Publication number: 20210104431
    Abstract: A semiconductor device and a method of forming the same are provided. A method includes forming a gate over a semiconductor structure. An epitaxial source/drain region is formed adjacent the gate. A dielectric layer is formed over the epitaxial source/drain region. An opening extending through the dielectric layer and exposing the epitaxial source/drain region is formed. A conductive material is non-conformally deposited in the opening. The conductive material fills the opening in a bottom-up manner.
    Type: Application
    Filed: November 23, 2020
    Publication date: April 8, 2021
    Inventors: Mrunal A. Khaderbad, Yasutoshi Okuno, Sung-Li Wang, Pang-Yen Tsai, Shen-Nan Lee, Teng-Chun Tsai