Abstract: A method of fabrication of an elevated source/drain (S/D) for a MOS device. A first insulating layer having a gate opening and source/drain openings is formed over a substrate. We form a LDD resist mask having opening over the source/drain openings over the first insulating layer. Ions are implanted through the source/drain openings. A first dielectric layer is formed on the substrate in the gate opening and source/drain openings. A gate is formed in the gate opening and raised source/drain (S/D) blocks in the source/drain openings. We remove the spacer blocks to form spacer block openings. We form second LDD regions by implanting ions through the spacer block openings. We form second spacer blocks in the spacer block openings. Plug opening are formed through the raised source/drain (S/D) blocks. Contact plugs are formed in the form plug opening.

Abstract: A method of fabrication an alignment mark in a semiconductor device. The method uses one mask to that has two functions (1) a reverse active areas mask to remove the oxide from over active areas in the device areas and (2) an alignment mark open mask that removes the oxide from over the alignment mark area. The mask improves chemical-mechanical polish performance in the cell areas by removing the oxide over the active areas. Another key feature of the invention is the spacing of the alignment mark trenches that ensures that the step distance between the top of the second insulating layer in the alignment mark trench and the top surface of the substrate is greater than 2000 Å. This insures that the alignment marks are readable.

Abstract: A method of manufacturing a self aligned elevated source/drain (S/D). A first insulating layer is formed over a substrate. The first insulating layer having at least a gate opening and source/drain (S/D) openings adjacent to the gate opening. Spacer portions of the first insulating layer define the gate opening. A gate dielectric layer is formed over the substrate in the gate opening. A conductive layer is formed over the substrate. The conductive layer fills the gate opening and the source/drain (S/D) openings. The conductive layer is doped with dopants. The conductive layer is planarized to form a gate over the gate dielectric layer and filling the gate opening and filling the source/drain (S/D) opening to form elevated source/drain (S/D) regions. The conductive layer is preferably planarized so that the top surface of the conductive layer is level with the top surface of the first insulating layer. The spacer portions are removed to form spacer openings.

Abstract: The present invention provides method to fabricate a snap-back flash EEPROMS device. The method begins by forming a gate structure 22 24 28 26 on a substrate. The gate structure comprises: a tunnel oxide layer 22, a floating gate 24, integrate dielectric layer 28, and a control gate 26. A drain 14 is formed adjacent to the gate structure by an masking 51 and ion implant process. Next, a source side doped region 18 is formed adjacent to and under a portion of the gate structure 22 24 28 26 by an masking and ion implant process. Spacers 32 are now formed on the sidewalls of the gate structure. A source 20 is formed overlapping portion of the side source doped region 18 and adjacent to the spacers 32. The side source doped region has a lower dopant concentration than the source 20. This method forms a snap-back memory cell wherein the side source doped region 18 is used to apply a high voltage to operate the EEPROM cell in a snap-back erase mode.

Abstract: A method for forming an extended metal gate without poly wrap around effects. A semiconductor structure is provided having a gate structure thereon. The gate structure comprising a gate dielectric layer, a gate silicon layer, a doped silicon oxide layer, and a disposable gate layer stacked sequentially. Spacers are formed on the sidewalls of the gate structure. A dielectric gapfill layer is formed over the semiconductor structure and the gate structure and planarized, stopping on the disposable gate layer. A first silicon nitride layer is formed over the disposable gate layer, and a dielectric layer is formed over the first silicon nitride layer. The dielectric layer is patterned to form a trench over the gate structure; wherein the trench has a width greater than the width of the gate structure. The first silicon nitride layer in the bottom of the trench and the disposable gate layer are removed using one or more selective etching processes.

Abstract: The invention provides a method for forming a ROM cell surface implant region using a PLDD implant. A semiconductor structure is provided comprising a substrate having isolation structures thereon, which separate and electrically isolating a first area having a P-well formed in the substrate and a gate over the substrate, a second area having a N-well formed in the substrate and a gate over the substrate, and a third area having P-well and buried N+ regions formed in the substrate with second isolation structures overlying the buried N+ regions. A photoresist mask is formed exposing the first area, and impurity ions are implanted to form n-type lightly doped source and drain regions. The photoresist mask is removed and a new (PLDD/ROM) photoresist mask is formed exposing the second area and the third area. Impurity ions are implanted to simultaneously form p-type lightly doped source and drain regions and a ROM cell surface implant region region. The PLDD/ROM photoresist mask is then removed.

Abstract: A method for forming an L-shaped spacer using a sacrificial organic top coating. A semiconductor structure is provided having a gate structure thereon. A liner oxide layer is formed on the gate structure. A dielectric spacer layer is formed on the liner oxide layer. In the preferred embodiment, the dielectric spacer layer comprises a silicon nitride layer or a silicon oxynitride layer. A sacrificial organic layer is formed on the dielectric spacer layer. The sacrificial organic layer and the dielectric spacer layer are anisotropically etched to form spacers comprising a triangle-shaped sacrificial organic structure and an L-shaped dielectric spacer. The triangle-shaped sacrificial organic structure is removed leaving an L-shaped dielectric spacer.

Abstract: A method for reducing RC delay by forming an air gap between conductive lines. A sacrificial layer is formed over a semiconductor structure, filling the gaps between conductive lines on the semiconductor structure. An air bridge layer is formed over the sacrificial layer. The semiconductor structure is exposed to an oxygen plasma, which penetrates through pores in the air bridge layer to react with the sacrificial layer, whereby the sacrificial layer is removed through the air bridge layer. The sacrificial layer and/or the air bridge layer comprise buckminsterfullerene. The air bridge layer can comprise buckminsterfullerene incorporated in an inorganic spin-on material. The buckminsterfullerene reacts with the oxygen plasma and is removed to form a porous air bridge layer. Then the oxygen species from the plasma penetrate the porous air bridge layer to react with and remove the sacrificial layer.

Abstract: A method to form a passivation layer using an electrochemical process over a MR Sensor so that the passivation layer defines the MR track width. The passivation layer is formed by anodizing the MR sensor. The passivation layer is an electrical insulator (preventing Sensor current (I) from shunting through the overspray) and a heat conductor to allow MR heat to dissipate away from the MR sensor through the overspray. The method comprises: forming a passivation layer on the MR sensor; the passivation layer formed using an electrochemical process. Then we spinning-on and printing a lift-off photoresist structure over the passivation layer. The passivation layer is etched to remove the passivation layer not covered by the lift-off structure thereby defining a track width of the MR sensor. Then we deposit a lead layer over the passivation layer and MR sensor. The lift-off structure is removed where by the passivation layer defines a track width.

Abstract: The invention provides a method for fabricating a shallow trench isolation which is not susceptable to buried contact trench formation. The invention also provides immunity from the STI “kink effect,” as well as benefits associated with nitridation. The process begins by forming a pad oxide layer on a semiconductor substrate. A nitride layer is formed on the pad oxide layer. The nitride layer, the pad oxide layer, and the semiconductor substrate are patterned to form trenches. Next, a fill oxide layer is formed over the nitride layer, the pad oxide layer, and the semiconductor substrate. The fill oxide layer is chemical-mechanical polished, stopping on the nitride layer to form fill oxide regions. N2 ions are implanted into the fill oxide regions. An anneal is performed to form a buried oxynitride layer. The buried oxynitride layer is partially above the level of the top surface of the semiconductor substrate and partially below the level of the top surface of the semiconductor substrate.

Abstract: A method for a T-gate and salicide process that allows narrow bottom gate widths below 0.25 &mgr;m and wide top gate widths to allow silicide gate contacts on the top of the T-gate. A dummy gate composed of an insulating material is formed over the substrate. Then we form LDD regions adjacent to the dummy gate preferably by ion implanting f (I/I) impurity ions into the substrate using the dummy gate as a mask. A pad oxide layer and dielectric layer are formed over the substrate surface. The dielectric layer over the dummy gate is removed preferably by a CMP process. We then remove the dummy gate to form a gate opening exposing the substrate surface. A gate dielectric layer is formed over the substrate surface in the gate opening. We form a polysilicon layer over the dielectric layer and the substrate surface in the gate opening. The polysilicon layer is patterned to form a T-gate. The dielectric layer is removed. We forming source/drain (S/D) regions adjacent to the T-gate by an Ion implant process.

Abstract: This invention provides a method for forming a self-aligned silicide with low sheet resistance in the N+ source and drain regions and the N+ polysilicon regions in a semiconductor device using a titanium nitride barrier layer to prevent nitridation of an underlying titanium layer during rapid thermal anneal. The process begins by providing a substrate structure having a gate thereon. A titanium layer is deposited over the substrate structure and the gate. Mixing ions are implanted through the titanium layer into source and drain regions adjacent to the gate. A titanium nitride barrier layer is deposited on the titanium layer. The substrate structure is rapid thermal annealed causing the titanium layer to react with the underlying silicon to form silicide. The substrate structure is selectively etched to remove the titanium nitride barrier layer and unreacted titanium. A second rapid thermal anneal is performed.

Abstract: A method for preventing and controlling Arcing Across Thin Dielectric Film in sputtering and other process that generate electric fields and cause arcing across conductive structures. In a first embodiment, when the wafer is subjected to RF electric fields from a RF generating tool, the leads are oriented in a first direction which is perpendicular to the RF fields (in a second direction) generated by a RF generating tool (e.g., sputter tool). In a second embodiment, leads are shaped so that the leads extend on both sides of the ABS line so that the MR window 40 is close to the geometric center of the leads. In a third embodiment, an extraneous window or two extraneous windows are formed in a second dielectric layer under at least of a portion of a lead to that a “hot spot” area is created where arcing is more likely to occur.

Abstract: The present invention provides a boat and method for holding one or more substrates during a ball grid array packaging assembly. The boat comprises a base and one or more spring locks. The base has one or more openings which provide access to both faces of said substrates. The base has bottom supports protruding into the openings to retain the substrates from below and top supports protruding into the openings to retain the substrates from above. The spring locks apply lateral pressure to the substrates forcing the substrates over the bottom supports and under the top supports, whereby the boat can be flipped with the substrates retained between the top supports and the bottom supports. In one embodiment, substrates are installed in the boat, and the entire boat is flipped when the opposite face needs to be accessed, rather than manually flipping each substrate.

Abstract: A method for forming a low resistance metal/polysilicon gate for use in CMOS devices comprising: (1) a novel anneal step prior to formation of a diffusion barrier layer and (2) a novel diffusion barrier layer composed of titanium nitride deposited over titanium silicide or titanium nitride deposited directly on the polysilicon. A first insulating layer is formed over a silicon substrate, and a polysilicon layer is formed over the first insulating layer. In a key step, the polysilicon layer is annealed to prevent peeling of the subsequently formed diffusion barrier layer. A diffusion barrier layer comprising titanium nitride deposited over titanium silicide or titanium nitride deposited directly on the polysilicon is formed over the polysilicon layer. A tungsten layer is formed over the diffusion barrier layer, and a capping layer comprising a silicon nitride layer over an oxide layer can be formed over the tungsten layer.

Abstract: A method of etching silicon nitride spacers beside a gate structure comprising: providing a gate electrode over a gate oxide layer on a substrate. A liner oxide layer is provided over the substrate and the gate electrode. A silicon nitride layer is provided over the liner oxide layer. The invention's nitride etch recipe is performed in a plasma etcher to anisotropically etch the silicon nitride layer to create spacers. The nitride etch recipe comprises a main etch step and an over etch step. The main etch step comprises the following conditions: a Cl2 flow between 35 and 55 molar %, a He flow between 35 and 55 molar %, a backside He pressure between 4 and 10 torr; and a HBr flow between 7.5 and 12.5 molar %; a pressure between 400 to 900 mTorr; at a power between 300 and 600 Watts. The etch recipe provides a spacer width to nitride layer thickness ratio of about 1:1 and does not pit the Si substrate surface.

Abstract: A method of fabricating a gate stack having an endpoint detect layer and a multi-step etch process to prevent damage to a gate dielectric layer. The special endpoint detect layer emits an endpoint signal that allows the etch chemistry to be changed to a more selective polysilicon to oxide ratio to prevent damage to the gate oxide layer. The invention begins by forming a gate dielectric layer over a substrate. We then form an endpoint detect layer over the gate dielectric layer. A gate stack is formed over the bottom silicon layer. Then a mask is formed over the gate stack. The mask defines a gate electrode. We etch the gate stack and the endpoint detect layer using a multi-step etch comprising at least 3 steps. In a main etch step, the gate stack and the endpoint detect layer are etched using a first etch chemistry. Upon an endpoint detection signal generated by etching the gate stack, the first etch step is stopped.

Abstract: A method of forming a high transmittance attenuated phase-shifting mask blank, comprising the following steps. An attenuated phase-shifting mask is provided that includes a shifter layer overlying a transparent substrate. The attenuated phase-shifting mask having a first transmittance and an initial phase angle. The attenuated phase-shifting mask and more specifically the shifter layer is treated with an aqueous solution of NH4OH:H2O2 for a first predetermined time increasing the first transmittance to a second transmittance and decreasing the initial phase angle to a second phase angle. The attenuated phase-shifting mask is then treated with a selected acid or base for a second predetermined time increasing the second transmittance to a third, predetermined transmittance and increasing the phase angle to a third, predetermined phase angle. The third phase angle is preferably substantially identical to the initial phase angle.

Abstract: A method to form a passivation layer over a MR Sensor so that the passivation layer defines the track width. The passivation layer is formed simultaneously with the development of the lift off structure in a novel developing/oxidizing solution that oxidizes the MR sensor and develops the photoresist. The passivation layer is an electrical insulator that prevents sensor current from shunting through the overspray of the leads and a heat conductor to allow MR heat to dissipate through the overspray. The method comprises: spinning-on and printing a lift-off photoresist structure over the MR sensor. Next, the lift-off photoresist structure is developed. The MR sensor is anodized in a developing/oxidizing solution to: (1) remove portions of the lower photoresist and (2) to form a (e.g., thin NiFeO) passivation layer on the MR layer at least partially under the upper photoresist layer. The passivation layer is etched to remove the passivation layer not covered by the lift-off structure.

Abstract: The invention has two embodiments for forming a contact plug having large nail shaped landing pad. The large pad areas increase the overlay tolerances. The first embodiment comprises forming first 20 and second 24 insulating layers over a semiconductor structure. A first photoresist layer 28 with a first opening is formed over the second insulating layer 24. The second insulating layer 24 is isotropically etched using an etchant with a high selectivity thereby forming a disk shaped opening 26A. The disk shaped opening is used to define the large nail shaped landing pad. The first insulating layer 20 is etched using a dry etch thereby forming a nail shaped contact opening 26. The opening is filled with polysilicon to form the nail shaped conductive plug 36. The second embodiment begins by forming a first insulating layer 40 over a semiconductor structure. A first photoresist layer 44 with a first opening is formed over the first insulating layer 24.