Abstract: A method of forming transistor devices with an air gap in the replacement gate structure is disclosed including forming a placeholder gate structure above a semiconductor material region, forming a sidewall spacer adjacent the placeholder gate structure, removing the placeholder gate structure to define a gate cavity bounded by the sidewall spacer, forming a gate insulation layer in the gate cavity, the gate insulation layer including a first portion having a first thickness and a second portion having a second thickness greater than the first thickness, forming a gate electrode in the gate cavity above the gate insulation layer, removing at least a portion of the second portion of the gate insulation layer to define an air gap cavity adjacent the gate electrode, and forming a first gate cap layer above the gate electrode, wherein the first gate cap layer seals an upper end of the air gap cavity.

Abstract: A device including RM below the top surface of an HKMG structure, and method of production thereof. Embodiments include first and second HKMG structures over a portion of the substrate and on opposite sides of the STI region, the first and second HKMG structures having a top surface; and a RM over the STI region and between the first and second HKMG structures, wherein the RM is below the top surface of the first and second HKMG structures.

Abstract: A resistor for an integrated circuit (IC), an IC and a related method are disclosed. The resistor may include a metal alloy resistor body positioned within a single diffusion break (SDB). The SDB provides an isolation region in a semiconductor fin between a pair of fin-type field effect transistors (finFETs). The resistor in the SDB allows for the resistor to be built at front-end-of-line (FEOL) layers, which saves on space and expense, and allows for precise dimensions for the resistor.

Abstract: The present disclosure relates to semiconductor structures and, more particularly, to a contact over an active gate structure and methods of manufacture. The structure includes: an active gate structure composed of conductive material located between sidewall material; an upper sidewall material above the sidewall material, the upper sidewall material being different material than the sidewall material; and a contact structure in electrical contact with the conductive material of the active gate structure. The contact structure is located between the sidewall material and between the upper sidewall material.

Abstract: A method of forming a semiconductor device such as a FinFET device includes forming a gate stack over a channel region of a semiconductor fin between spacer layers, recessing the gate stack and the spacer layers, and forming a gate conductor layer over both the recessed gate stack and the spacer layers. The gate conductor layer is adapted to inhibit etch damage to the spacer layers during a subsequent etching step used to form contact openings over source/drain regions of the fin. The resulting structure exhibits improved electrical isolation between gate and source/drain contacts.

Abstract: Gate isolation methods and structures leverage the formation of a sidewall spacer layer within a recess formed in an organic planarization layer. The spacer layer enables precise alignment of the cut region of a sacrificial gate, which may be backfilled with an isolation layer. By forming the isolation layer after a reliability anneal of the gate dielectric and after formation of a first work function metal layer, both the desired critical dimension (CD) and alignment of the isolation layer can be achieved.

Abstract: First and second fin-type field effect transistors (finFETs) are formed laterally adjacent one another extending from a top surface of an isolation layer. The first finFET has a first fin structure and the second finFET has a second fin structure. An insulator layer is on the first fin structure and the second fin structure. A gate conductor intersects the first fin structure and the second fin structure, and at least the insulator layer separates the gate conductor from the first fin structure and the second fin structure. Source and drain structures are on the first fin structure and the second fin structure laterally adjacent the gate conductor. The first fin structure has sidewalls that include a step and the second fin structure has sidewalls that do not include the step. The step is approximately parallel to the surface of the isolation layer.

Abstract: Methods form transistor devices that have source/drain regions in a layer separated by a channel region. A gate conductor is above the channel region and has sidewalls extending from the top surface of the layer. First spacers are formed to contact the sidewalls of the gate conductor. The first spacers are formed to have top portions that are relatively distal to the surface of the layer, and bottom portions that are relatively adjacent to the surface of the layer. Second spacers are formed to contact the top portions of the first spacer. Conductive contacts are formed to connect to the source/drain regions. The bottom portions of the first spacers are formed to contact and be between the conductive contacts and the gate conductor. The second spacers are formed between the top portions of the first spacers and the conductive contacts.

Abstract: First and second fin-type field effect transistors (finFETs) are formed laterally adjacent one another extending from a top surface of an isolation layer. The first finFET has a first fin structure and the second finFET has a second fin structure. An insulator layer is on the first fin structure and the second fin structure. A gate conductor intersects the first fin structure and the second fin structure, and at least the insulator layer separates the gate conductor from the first fin structure and the second fin structure. Source and drain structures are on the first fin structure and the second fin structure laterally adjacent the gate conductor. The first fin structure has sidewalls that include a step and the second fin structure has sidewalls that do not include the step. The step is approximately parallel to the surface of the isolation layer.

Abstract: A method includes forming a semiconductor device including a plurality of fins formed above a substrate, an isolation structure positioned between the plurality of fins, a plurality of sacrificial gate structures defining gate cavities, and a first dielectric material positioned between the sacrificial gate structures. A gate cut structure is formed in a first gate cavity. A trim etch process is performed to reduce a width of the gate cut structure. Replacement gate structures are formed in the gate cavities after performing the trim etch process. A first replacement gate structure in the first gate cavity is segmented by the gate cut structure.

Abstract: In conjunction with a replacement metal gate (RMG) process for forming a fin field effect transistor (FinFET), gate isolation methods and associated structures leverage the formation of distinct narrow and wide gate cut regions in a sacrificial gate. The formation of a narrow gate cut between closely-spaced fins can decrease the extent of etch damage to interlayer dielectric layers located adjacent to the narrow gate cut by delaying the deposition of such dielectric layers until after formation of the narrow gate cut opening. The methods and resulting structures also decrease the propensity for short circuits between later-formed, adjacent gates.

Abstract: A device is formed including fins formed above a substrate, an isolation structure between the fins, a plurality of structures defining gate cavities, and a first dielectric material positioned between the structures. A patterning layer above the first dielectric material and in the gate cavities has a first opening positioned above a first gate cavity exposing a portion of the isolation structure and defining a first recess, a second opening above a second gate cavity exposing a first portion of the fins, and a third opening above a first portion of a source/drain region in the fins to expose the first dielectric material. Using the patterning layer, a second recess is formed in the substrate and a third recess is defined in the first dielectric material. A second dielectric material is formed in the recesses to define a gate cut structure, a diffusion break structure, and a contact cut structure.

Abstract: At least one method, apparatus and system disclosed herein involves adjusting for a misalignment of a gate cut region with respect to semiconductor processing. A plurality of fins are formed on a semiconductor substrate. A gate region is formed over a portion of the fins. The gate region comprises a first dummy gate and a second dummy gate. A gate cut region is formed over the first dummy gate. A conformal fill material is deposited into the gate cut region. At least one subsequent processing step is performed.

Abstract: Structures and methods of fabricating structures that include contacts coupled with a source/drain region of a field-effect transistor. Source/drain regions are formed adjacent to a temporary gate structure. A sacrificial layer may be disposed over the source/drain regions and a dielectric pillar is formed in the sacrificial layer between the source/drain regions, followed by deposition of a fill material, replacement of the temporary gate structure with a functional gate structure, and removal of the fill material. Alternatively, the fill material is formed first and the temporary gate structure is replaced by a functional gate structure; following removal of the fill material, a sacrificial layer is disposed over the source/drain regions and a dielectric pillar is formed in the sacrificial layer between the source/drain regions. A conductive layer having separate portions contacting the separate source/drain regions is formed, with the dielectric pillar separating the portions of the conductive layer.

Abstract: Methods of forming a CT pillar with reduced width and increased distance from neighboring fins and the resulting devices are provided. Embodiments include providing a first pair of fins and a second pair of fins in an oxide layer, wherein the first and second pair of fins include Si; and forming a CT pillar including SiN between the first and second pair of fins and over a portion of the oxide layer, wherein width of the CT pillar and distance between the CT pillar and the first and second pair of fins are inversely proportional.

Abstract: One illustrative integrated circuit product disclosed herein includes a transistor device comprising a T-shaped gate structure positioned above an active region defined in a semiconducting substrate, the T-shaped portion of the gate structure comprising a relatively wider upper portion and a relatively narrower lower portion, and first and second conductive source/drain structures positioned adjacent opposite sidewalls of the T-shaped gate structure. In this example, the product also includes first and second air gaps positioned adjacent opposite sidewall of the T-shaped gate structure, wherein each of the air gaps is positioned between at least the lower portion of one of the sidewalls of the T-shaped gate structure and the adjacent conductive source/drain structure.

Abstract: The disclosure provides integrated circuit (IC) structures with single diffusion break (SDB) abutting end isolation regions, and methods of forming the same. An IC structure may include: a plurality of fins positioned on a substrate; a plurality of gate structures each positioned on the plurality of fins and extending transversely across the plurality of fins; an insulator region positioned on the plurality of fins and laterally between the plurality of gate structures; at least one single diffusion break (SDB) positioned within the insulator region and one of the plurality of fins, the at least one SDB region extending from an upper surface of the substrate to an upper surface of the insulator region; and an end isolation region abutting a lateral end of the at least one SDB along a length of the plurality of gate structures, the end isolation region extending substantially in parallel with the plurality of fins.

Abstract: Gate isolation methods and structures leverage the formation of a sidewall spacer layer within a recess formed in an organic planarization layer. The spacer layer enables precise alignment of the cut region of a sacrificial gate, which may be backfilled with an isolation layer. By forming the isolation layer after a reliability anneal of the gate dielectric and after formation of a first work function metal layer, both the desired critical dimension (CD) and alignment of the isolation layer can be achieved.

Abstract: One illustrative method disclosed herein includes forming a plurality of transistors on a semiconductor substrate, wherein each of the transistors comprise source/drain epitaxial semiconductor material in the source/drain regions, a contact etch stop layer (CESL) positioned above the source/drain epitaxial semiconductor material and an insulating material positioned above the contact etch stop layer, and forming a plurality of contact isolation cavities by performing at least one etching process sequence, wherein the etching process sequence is adapted to sequentially remove the insulating material, the CESL and the source/drain epitaxial semiconductor material, and forming a contact isolation structure in each of the contact isolation cavities.

Abstract: Gate isolation methods and structures for a FinFET device leverage the definition and formation of a gate cut opening within a sacrificial gate layer prior to patterning the sacrificial gate layer to form a sacrificial gate. The gate cut opening formed in the sacrificial gate layer is filled with a sacrificial isolation layer. After forming source/drain junctions over source/drain regions of a fin, the sacrificial isolation layer is replaced with an isolation layer, and the sacrificial gate is replaced with a functional gate.