Abstract: A method of reducing a charge on a substrate to prevent an arcing incident in a subsequent etch process is described. A patterned substrate is fastened to a chuck in a process chamber. A discharge process is performed that includes the three steps of (a) coupling the chuck to a 0 volt connection, (b) generating a plasma, and (c) coupling the chuck to a high voltage connection. The three steps are carried out in any sequence. An inert gas or an inert gas and an etching gas are flowed into the chamber during the discharge sequence. Alternatively, a fluorocarbon CXFYHZ or a fluorocarbon and a gas such as O2, H2, N2, N2O, CO, CO2, He or Ar is flowed into the chamber during the discharge sequence. The method is compatible with batch or single wafer processes and is extendable to etching low k dielectric layers with poor thermal conductivity.

Abstract: A new method is provided for the etch of ultra-small patterns in a silicon based surface. Under the first embodiment, a hardmask layer over a substrate and a layer of ARC over the hardmask layer are successively patterned. The patterned layer of ARC is removed, the remaining patterned hardmask layer is used as a mask for etching the substrate. Under the second embodiment, a first hardmask layer over a substrate, a second hardmask layer over the first hardmask layer and a layer of ARC over the second hardmask layer are successively patterned. The patterned layer of ARC and the second hardmask layer are removed, the remaining first patterned hardmask layer is used as a mask for etching the substrate.

Abstract: A layer of Anti Reflective Coating (ARC) is first deposited over the surface of a silicon based or oxide based semiconductor surface, a dual hardmask is deposited over the surface of the layer of ARC. A layer of soft mask material is next coated over the surface of the dual hardmask layer, the layer of soft mask material is exposed, creating a soft mask material mask. The upper layer of the dual hardmask layer is next patterned in accordance with the soft mask material mask, the soft mask material mask is removed from the surface. The lower layer of the hardmask layer is then patterned after which the layer of ARC is patterned, both layers are patterned in accordance with the patterned upper layer of the dual hardmask layer. The substrate is now patterned in accordance with the patterned upper and lower layer of the dual hardmask layer and the patterned layer of ARC.

Abstract: An improved method of etching very small contact holes through dielectric layers used to separate conducting layers in multilevel integrated circuits formed on semiconductor substrates has been developed. The method uses bi-level ARC coatings in the resist structure and a unique combination of gaseous components in a plasma etching process which is used to dry develop the bi-level resist mask as well as etch through a silicon oxide dielectric layer. The gaseous components comprise a mixture of a fluorine containing gas, such as C4F8, C5F8, C4F6, CHF3 or similar species, an inert gas, such as helium or argon, an optional weak oxidant, such as CO or O2 or similar species, and a nitrogen source, such as N2, N2O, or NH3or similar species. The patterned masking layer can be used to reliably etch contact holes in silicon oxide layers on semiconductor substrates, where the holes have diameters of about 0.1 micron or less.

Abstract: A process for forming a DRAM stacked capacitor structure with increased surface area, has been developed. The process features forming lateral grooves in the sides of a polysilicon storage node structure, during a dry etching procedure used to define the storage node structure. The grooves are selectively, and laterally formed in ion implanted veins, which in turn had been placed at various depths in an intrinsic polysilicon layer via a series of ion implantation steps, each performed at a specific implant energy. An isotopic component of the storage node structure, defining dry etch procedure, selectively etches the highly doped, ion implanted veins at a greater rate than the non-ion implanted regions of polysificon, located between the ion implanted veins, resulting in a necked profile, storage node structure, featuring increased surface area as a result of the formation of the lateral grooves.

Abstract: Within a method for forming a spacer layer from a second layer formed of a second material laminated upon a first layer formed of a first material, in turn formed over a topographic feature, there is employed a three step etch method. The three step etch method employs: (1) a first etch method having a first enhanced etch selectivity for the second material with respect to the first material; (2) a second etch method having a second substantially neutral etch selectivity for the second material with respect to the first material; and (3) a third etch method having a third enhanced etch selectivity for the first material with respect to the second material. In accord with the three step etch method, the spacer layer is fabricated with enhanced dimensional control.

Abstract: A method for forming a patterned target layer from a blanket target layer employs a pair of blanket hard mask layers laminated upon the blanket target layer. A patterned third mask layer is formed thereover. The method also employs four separate etch steps. One etch step is an anisotropic etch step for forming a patterned upper lying hard mask layer from the blanket upper lying hard mask layer. The patterned upper lying hard mask layer is then isotropically etched in a second etch step to form an isotropically etched patterned upper lying hard mask layer. The method is particularly useful for forming gate electrodes of diminished linewidths and enhanced dimensional control within semiconductor products.

Abstract: A method for monitoring plasma parameters during a plasma process such as a plasma etching process, comparing the measured plasma parameters to predetermined parameter specifications, and either terminating the plasma process or modifying the plasma process in progress to re-establish the plasma parameters within the parameter specifications. The plasma parameters may be measured by the self-excited electron resonance spectroscopy (SEEKS) technique or by microwave interferometry.

Abstract: A method of forming a composite gate structure for a planar MOSFET device, as well as for vertical, double gate, FINFET device, has been developed. The method features a composite gate structure comprised of an overlying silicon gate structure shape, and an underlying titanium nitride gate structure shape. The titanium nitride component allows a lower work function, and thus lower device operating voltages to be realized when compared to counterpart gate structures formed with only polysilicon. A novel, two step gate structure definition procedure, featuring an anisotropic first etch procedure for definition of the polysilicon gate structure shape, followed by a wet or dry isotropic second etch procedure for definition of the titanium nitride gate structure shape, is employed.

Abstract: A process is described for transferring a photoresist pattern into a substrate. In one embodiment a stack comprised of a top photoresist layer, a middle ARC layer, and a bottom hardmask is formed over a gate electrode layer. A line in the photoresist pattern is anisotropically transferred through the ARC and hardmask. Then an isotropic etch to trim the linewidth by 0 to 50 nm per edge is performed simultaneously on the photoresist, ARC and hardmask. This method minimizes the amount of line end shortening to less than three times the dimension trimmed from one line edge. Since a majority of the photoresist layer is retained, the starting photoresist thickness can be reduced by 1000 Angstroms or more to increase process window. The pattern is then etched through the underlying layer to form a gate electrode. The method can also be used to form STI features in a substrate.

Abstract: A cleaning tool for cleaning substrates, comprising a circulation conduit through which is circulated a cleaning liquid or gas. The circulation conduit is disposed in fluid communication with an upstream flow chamber and a downstream cleaning chamber, the cross-sectional area of which cleaning chamber is less than the cross-sectional area of the flow chamber. In use, the cleaning chamber receives a wafer substrate for cleaning of particles or removal of polymer films from the substrate. The smaller cross-sectional area of the cleaning chamber accelerates the flow of a cleaning fluid flowing through the cleaning chamber from the flow chamber. The rapidly-flowing cleaning fluid removes the particles and/or films from the substrate while preventing dropping of the removed particles or re-deposition of the film back onto the substrate. A particle filter may be provided in the circulation conduit downstream of the cleaning chamber for removing the particles.

Abstract: A method for semiconductor device feature development using a bi-layer photoresist including providing a non-silicon containing photoresist layer over a substrate; providing a silicon containing photoresist layer over the non-silicon containing photoresist layer; exposing an exposure surface of the silicon containing photoresist layer to an activating light source said exposure surface defined by an overlying pattern according to a photolithographic process; developing the silicon containing photoresist layer according to a photolithographic process to reveal a portion the non-silicon containing photoresist layer; and, dry developing said non-silicon containing photoresist layer in a plasma reactor by igniting a plasma from an ambient mixture including at least hydrogen and carbon monoxide.

Abstract: A wet etchant solution composition and method for etching oxides of hafnium and zirconium including at least one solvent present at greater than about 50 weight percent with respect to an arbitrary volume of the wet etchant solution; at least one chelating agent present at about 0.1 weight percent to about 10 weight percent with respect to an arbitrary volume of the wet etchant solution; and, at least one halogen containing acid present from about 0.0001 weight percent to about 10 weight percent with respect to an arbitrary volume of the wet etchant solution.

Abstract: A plasma etch method for etching a dielectric layer and an etch stop layer to reach a metal silicide layer formed thereunder employs for etching the etch stop layer an etchant gas composition comprising a fluorine containing gas and a nitrogen containing gas, preferably with a carrier gas such as argon or helium, but without an oxygen containing gas or a carbon and oxygen containing gas. The plasma etch method is selective for the etch stop layer with respect to the metal silicide layer, thus maintaining the physical and electrical integrity of the metal silicide layer.

Abstract: A process for forming a DRAM stacked capacitor structure with increased surface area, has been developed. The process features forming lateral grooves in the sides of a polysilicon storage node structure, during a dry etching procedure used to define the storage node structure. The grooves are selectively, and laterally formed in ion implanted veins, which in turn had been placed at various depths in an intrinsic polysilicon layer via a series of ion implantation steps, each performed at a specific implant energy. An isotopic component of the storage node structure, defining dry etch procedure, selectively etches the highly doped, ion implanted veins at a greater rate than the non-ion implanted regions of polysilicon, located between the ion implanted veins, resulting in a necked profile, storage node structure, featuring increase surface area as a result of the formation of the lateral grooves.

Abstract: Partial photoresist etching is disclosed. A film on a semiconductor wafer includes a hard mask, doped polysilicon below the hard mask, undoped polysilicon below the doped polysilicon, and a stop layer below the undoped polysilicon. Photoresist etching is performed through the hard mask and the doped polysilicon by using a photoresist mask. After the photoresist mask is removed, photoresist-free etching is performed through the undoped polysilicon through to the stop layer by using the hard mask. A semiconductor device is disclosed that may be fabricated using this partial photoresist etching process.

Abstract: Within a method for fabricating a split gate field effect transistor (FET) device there is employed a two step etch method for forming a floating gate electrode. Within the two step etch method there is employed a patterned first masking layer and a blanket second masking layer to assist in providing the floating gate electrode with a sharply pointed tip within at least either an upper edge of the floating gate electrode or sidewall of the floating gate electrode. The sharply pointed tip provides the split gate field effect transistor (FET) device with enhanced data erasure performance.

Abstract: Within a method for forming a spacer layer from a second layer formed of a second material laminated upon a first layer formed of a first material, in turn formed over a topographic feature, there is employed a three step etch method. The three step etch method employs: (1) a first etch method having a first enhanced etch selectivity for the second material with respect to the first material; (2) a second etch method having a second substantially neutral etch selectivity for the second material with respect to the first material; and (3) a third etch method having a third enhanced etch selectivity for the first material with respect to the second material. In accord with the three step etch method, the spacer layer is fabricated with enhanced dimensional control.

Abstract: An apparatus and method for controllably etching a semiconductor wafer fabricated by a semiconductor processing system. Generally, an etcher is associated with the semiconductor processing system, such that etcher includes one or more electrodes thereof. An electrode position monitor can then be utilized for monitoring a position of the electrode, thereby permitting an adjustable size control of the etch head, which is controllable according to an associated etching recipe. The etch head is generally moveable according to a step mode. Such an arrangement thus increases wafer uniformity and precision process control during wafer fabrication and etching.

Abstract: Borderless contacts are used in integrated circuits in order to conserve chip real estate. As part of the process for manufacturing borderless contacts, an etch-stopping layer of silicon nitride is first laid over the area that is to be contacted Investigation has now shown that this can lead to damage to the silicon at the edges of the via. The present invention eliminates this damage by introducing a buffer layer between the silicon surface and said silicon nitride layer. Suitable materials for the buffer layer that have been found to be effective include silicon oxide and silicon oxynitride with the latter offering some additional advantages over the former. Experimental data confirming the effectiveness of the buffer layer are provided, together with a process for its manufacture.