Patents by Inventor MRUNAL A. KHADERBAD
MRUNAL A. KHADERBAD 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).
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Patent number: 11201232Abstract: Semiconductor structures and method for forming the same are provided. The semiconductor structure includes a substrate and a gate structure formed over the substrate. The semiconductor structure further includes a source/drain structure formed adjacent to the gate structure in the substrate and a contact formed over the source/drain structure. The semiconductor structure further includes a metal-containing layer formed over the contact and a dielectric layer covering the gate structure and the metal-containing layer. The semiconductor structure further includes a first conductive structure formed through dielectric layer and the metal-containing layer and landing on the contact. In addition, a bottom surface of the metal-containing layer is higher than a top surface of the gate structure.Type: GrantFiled: July 17, 2020Date of Patent: December 14, 2021Assignee: Taiwan Semiconductor Manufacturing Co., Ltd.Inventors: Mrunal A. Khaderbad, Sung-Li Wang, Yasutoshi Okuno
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Patent number: 11158539Abstract: A method includes receiving a structure having a dielectric layer over a conductive feature; etching a hole through the dielectric layer and exposing the conductive feature; depositing a first metal into the hole and in direct contact with the dielectric layer and the conductive feature; depositing a second metal over the first metal; and annealing the structure including the first and the second metals.Type: GrantFiled: October 1, 2019Date of Patent: October 26, 2021Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.Inventors: Sung-Li Wang, Hung-Yi Huang, Yu-Yun Peng, Mrunal A. Khaderbad, Chia-Hung Chu, Shuen-Shin Liang, Keng-Chu Lin
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Publication number: 20210280459Abstract: A semiconductor device that includes a semiconductor substrate, a dielectric layer over the semiconductor substrate, a conductive feature over the semiconductor substrate and buried in the dielectric layer, and a metal plug over the conductive feature and buried in the dielectric layer, where the dielectric layer has a hydrophobic sidewall facing the metal plug.Type: ApplicationFiled: May 14, 2021Publication date: September 9, 2021Inventors: Mrunal A. Khaderbad, Akira Mineji
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Publication number: 20210257302Abstract: Partial barrier-free vias and methods for forming such are disclosed herein. An exemplary interconnect structure of a multilayer interconnect feature includes a dielectric layer. A cobalt-comprising interconnect feature and a partial barrier-free via are disposed in the dielectric layer. The partial barrier-free via includes a first via plug portion disposed on and physically contacting the cobalt-comprising interconnect feature and the dielectric layer, a second via plug portion disposed over the first via plug portion, and a via barrier layer disposed between the second via plug portion and the first via plug portion. The via barrier layer is further disposed between the second via plug portion and the dielectric layer. The cobalt-comprising interconnect feature can be a device-level contact or a conductive line of the multilayer interconnect feature. The first via plug portion and the second via plug portion can include tungsten, cobalt, and/or ruthenium.Type: ApplicationFiled: May 6, 2021Publication date: August 19, 2021Inventors: Tsung-Ling Tsai, Shen-Nan Lee, Mrunal A. Khaderbad, Chung-Wei Hsu, Chen-Hao Wu, Teng-Chun Tsai
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Publication number: 20210257262Abstract: 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: ApplicationFiled: May 3, 2021Publication date: August 19, 2021Inventors: Mrunal A. Khaderbad, Pang-Yen Tsai, Yasutoshi Okuno
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Publication number: 20210184018Abstract: The structure of a semiconductor device with source/drain contact structures and via structures and a method of fabricating the semiconductor device are disclosed. A method for fabricating a semiconductor device includes forming a source/drain (S/D) region on a substrate, forming a S/D contact structure on the S/D region, and forming a via structure on the S/D contact structure. The forming of the via structure includes forming a via opening on the S/D contact structure, forming a non-metal passivation layer on sidewalls of the via opening, and depositing a via plug within the via opening in a bottom-up deposition process.Type: ApplicationFiled: December 17, 2019Publication date: June 17, 2021Applicant: Taiwan Semiconductor Manufacturing Co., Ltd.Inventors: Mrunal A. KHADERBAD, Keng-Chu LIN
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Publication number: 20210183858Abstract: An Integrated Circuit (IC) device includes a first plurality of semiconductor layers over a substrate, a first gate dielectric layer and a first gate electrode. The first gate electrode includes a first fill metal layer and a work function metal layer disposed between the first gate dielectric layer and the first fill metal layer. The IC device further includes a second plurality of semiconductor layers over the substrate, a second gate dielectric layer and a second gate electrode. The second gate electrode includes a second fill metal layer directly contacting the second gate dielectric layer. A top surface of the second fill metal layer extends above a topmost layer of the second plurality of semiconductor layers. The material of the semiconductor layers has a midgap. The work function metal layer has a work function lower than the midgap. The fill metal layer has a work function higher than the midgap.Type: ApplicationFiled: December 17, 2019Publication date: June 17, 2021Inventors: Mrunal A Khaderbad, Ziwei Fang, Keng-Chu Lin, Hsueh Wen Tsau
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Patent number: 11018053Abstract: The present disclosure provides a method of fabricating an integrated circuit (IC) structure. The method includes patterning a dielectric layer on a semiconductor substrate to form a trench, exposing a conductive feature within the trench; performing an ion implantation process to introduce a doping species into sidewalls of the dielectric layer within the trench, thereby forming a barrier layer on the sidewalls, the barrier layer having a densified structure to effectively prevent inter-diffusion and a modified surface characteristic to boost a bottom-up deposition; and performing the bottom-up deposition to fill the trench with a metal material, thereby forming a metal plug landing on the conductive feature.Type: GrantFiled: April 10, 2019Date of Patent: May 25, 2021Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.Inventors: Mrunal A. Khaderbad, Akira Mineji
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Patent number: 11004794Abstract: Partial barrier-free vias and methods for forming such are disclosed herein. An exemplary interconnect structure of a multilayer interconnect feature includes a dielectric layer. A cobalt-comprising interconnect feature and a partial barrier-free via are disposed in the dielectric layer. The partial barrier-free via includes a first via plug portion disposed on and physically contacting the cobalt-comprising interconnect feature and the dielectric layer, a second via plug portion disposed over the first via plug portion, and a via barrier layer disposed between the second via plug portion and the first via plug portion. The via barrier layer is further disposed between the second via plug portion and the dielectric layer. The cobalt-comprising interconnect feature can be a device-level contact or a conductive line of the multilayer interconnect feature. The first via plug portion and the second via plug portion can include tungsten, cobalt, and/or ruthenium.Type: GrantFiled: April 30, 2019Date of Patent: May 11, 2021Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.Inventors: Tsung-Ling Tsai, Shen-Nan Lee, Mrunal A. Khaderbad, Chung-Wei Hsu, Chen-Hao Wu, Teng-Chun Tsai
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Patent number: 10998241Abstract: 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: GrantFiled: June 27, 2019Date of Patent: May 4, 2021Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.Inventors: Mrunal A. Khaderbad, Pang-Yen Tsai, Yasutoshi Okuno
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Publication number: 20210104431Abstract: 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: ApplicationFiled: November 23, 2020Publication date: April 8, 2021Inventors: Mrunal A. Khaderbad, Yasutoshi Okuno, Sung-Li Wang, Pang-Yen Tsai, Shen-Nan Lee, Teng-Chun Tsai
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Publication number: 20210098295Abstract: A method includes receiving a structure having a dielectric layer over a conductive feature; etching a hole through the dielectric layer and exposing the conductive feature; depositing a first metal into the hole and in direct contact with the dielectric layer and the conductive feature; depositing a second metal over the first metal; and annealing the structure including the first and the second metals.Type: ApplicationFiled: October 1, 2019Publication date: April 1, 2021Inventors: Sung-Li Wang, Hung-Yi Huang, Yu-Yun Peng, Mrunal A. Khaderbad, Chia-Hung Chu, Shuen-Shin Liang, Keng-Chu Lin
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Publication number: 20210091182Abstract: A semiconductor device includes a first semiconductor fin, a first epitaxial layer, a first alloy layer and a contact plug. The first semiconductor fin is on a substrate. The first epitaxial layer is on the first semiconductor fin. The first alloy layer is on the first epitaxial layer. The first alloy layer is made of one or more Group IV elements and one or more metal elements, and the first alloy layer comprises a first sidewall and a second sidewall extending downwardly from a bottom of the first sidewall along a direction non-parallel to the first sidewall. The contact plug is in contact with the first and second sidewalls of the first alloy layer.Type: ApplicationFiled: November 30, 2020Publication date: March 25, 2021Applicant: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.Inventors: Sung-Li WANG, Mrunal A. KHADERBAD, Yasutoshi OKUNO
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Publication number: 20210083119Abstract: A structure includes a transistor including a first source/drain region, a source/drain contact plug over and electrically coupling to the first source/drain region, and a via over and contacting the source/drain contact plug. The via has a bottom portion having a first length, and an upper portion having a second length. The first length is greater than the second length. Both of the first length and the second length are measured in a same direction parallel to a top surface of the source/drain contact plug.Type: ApplicationFiled: September 17, 2019Publication date: March 18, 2021Inventors: Mrunal A. Khaderbad, Keng-Chu Lin, Sung-Li Wang
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Patent number: 10854716Abstract: A semiconductor device includes a first semiconductor fin, a first epitaxial layer, a first alloy layer and a contact plug. The first semiconductor fin is on a substrate. The first epitaxial layer is on the first semiconductor fin. The first alloy layer is on the first epitaxial layer. The first alloy layer is made of one or more Group IV elements and one or more metal elements, and the first alloy layer comprises a first sidewall and a second sidewall extending downwardly from a bottom of the first sidewall along a direction non-parallel to the first sidewall. The contact plug is in contact with the first and second sidewalls of the first alloy layer.Type: GrantFiled: January 18, 2019Date of Patent: December 1, 2020Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.Inventors: Sung-Li Wang, Mrunal A. Khaderbad, Yasutoshi Okuno
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Patent number: 10847413Abstract: 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: GrantFiled: August 24, 2018Date of Patent: November 24, 2020Assignee: Taiwan Semiconductor Manufacturing Company, Ltd.Inventors: Mrunal A Khaderbad, Yasutoshi Okuno, Sung-Li Wang, Pang-Yen Tsai, Shen-Nan Lee, Teng-Chun Tsai
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Publication number: 20200350421Abstract: Semiconductor structures and method for forming the same are provided. The semiconductor structure includes a substrate and a gate structure formed over the substrate. The semiconductor structure further includes a source/drain structure formed adjacent to the gate structure in the substrate and a contact formed over the source/drain structure. The semiconductor structure further includes a metal-containing layer formed over the contact and a dielectric layer covering the gate structure and the metal-containing layer. The semiconductor structure further includes a first conductive structure formed through dielectric layer and the metal-containing layer and landing on the contact. In addition, a bottom surface of the metal-containing layer is higher than a top surface of the gate structure.Type: ApplicationFiled: July 17, 2020Publication date: November 5, 2020Applicant: Taiwan Semiconductor Manufacturing Co., Ltd.Inventors: Mrunal A. KHADERBAD, Sung-Li WANG, Yasutoshi OKUNO
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Patent number: 10797161Abstract: Methods for forming semiconductor structures are provided. The method includes forming a gate structure over a substrate and forming a source/drain structure adjacent to the gate structure. The method further includes forming a mask structure over the gate structure and forming a contact over the source/drain structure. The method further includes selectively forming a metal-containing layer over a top surface of the contact and forming a dielectric layer over the substrate and covering the gate structure and the contact. The method further includes forming a trench through the dielectric layer and the metal-containing layer to expose the top surface of the contact and forming a conductive structure in the trench.Type: GrantFiled: October 4, 2018Date of Patent: October 6, 2020Assignee: Taiwan Semiconductor Manufacturing Co., Ltd.Inventors: Mrunal A. Khaderbad, Sung-Li Wang, Yasutoshi Okuno
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Publication number: 20200273794Abstract: A semiconductor device and a method of forming the same are provided. The semiconductor device includes a substrate, a gate stack and a first dielectric layer over the substrate, a source/drain (S/D) region, a contact, and a via. The first dielectric layer is laterally aside and over the gate stack. The S/D region is located in the substrate on sides of the gate stack. The contact penetrates through the first dielectric layer to electrically connect to the S/D region. The via penetrates through a second dielectric layer to connect to the contact. The via includes a conductive layer and an adhesion promoter layer on sidewalls of the conductive layer. The conductive layer is in contact with the contact.Type: ApplicationFiled: February 25, 2019Publication date: August 27, 2020Applicant: Taiwan Semiconductor Manufacturing Co., Ltd.Inventors: Mrunal A. Khaderbad, Keng-Chu Lin, Sung-Li Wang, Shuen-Shin Liang, Yasutoshi Okuno, Yu-Yun Peng, Chia-Hung Chu
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Publication number: 20200273695Abstract: A method for forming a semiconductor structure is provided. The method includes forming a dielectric structure on a semiconductor substrate, introducing a first gas on the dielectric structure to form first conductive structures on the dielectric structure, and introducing a second gas on the first conductive structures and the dielectric structure. The second gas is different from the first gas. The method also includes introducing a third gas on the first conductive structures and the dielectric structure to form second conductive structures on the dielectric structure. The first gas and the third gas include the same metal.Type: ApplicationFiled: February 22, 2019Publication date: August 27, 2020Applicant: Taiwan Semiconductor Manufacturing Co., Ltd.Inventors: Mrunal A. KHADERBAD, Keng-Chu LIN, Shuen-Shin LIANG, Sung-Li WANG, Yasutoshi OKUNO, Yu-Yun PENG