Abstract: Transistors formed according to the present invention include an oxide layer/nitride layer gate insulator and a silicide gate conductor. An oxide layer is formed to a thickness of between 15 and 25 Angstroms across a substrate and partially removed so that a thickness of approximately 4 Angstroms remains. A nitride layer is formed upon oxide layer to a thickness of 10 to 20 Angstroms. Polysilicon gate conductors are then formed above the active regions of the substrate using a deposition and patterning technique. Spacers are then formed about the polysilicon gate conductor, lightly doped drain regions are formed and then source/drain regions are formed. In forming the lightly doped drain regions and the source/drain regions, the polysilicon gate conductor is doped. Then, a silicidation metal layer is deposited upon the polysilicon gate conductors and exposed portions of the nitride layer.

Abstract: A method of fabricating an integrated circuit includes forming a gate stack upon an active region of a substrate which includes a gate dielectric, a polysilicon gate conductor and a polysilicon consumption metal layer portion. The polysilicon consumption metal layer portion is then reacted with the polysilicon gate conductor to form a high conductivity gate conductor (silicide). In one embodiment, the polysilicon gate conductor is fully consumed. In another embodiment, the polysilicon gate conductor is substantially consumed but a portion of the polysilicon gate conductor adjacent the gate dielectric remains. In forming such a gate structure, a gate dielectric layer is first formed and a polysilicon gate layer is formed upon the gate dielectric layer. A polysilicon consumption metal layer is then formed upon the polysilicon gate layer. The surface is then patterned mask so that the location of the gate structures is protected. The substrate is then anisotropically etched to form the gate structures.

Abstract: A method is provided for forming high quality nitride sidewall spacers laterally adjacent to the opposed sidewall surfaces of a gate conductor dielectrically spaced above a semiconductor substrate. In an embodiment, a polysilicon gate conductor is provided which is arranged between a pair of opposed sidewall surfaces upon a gate dielectric. The gate dielectric is arranged upon a semiconductor substrate. Nitride is deposited from a high density plasma source across exposed surfaces of the substrate and the gate conductor. The high density plasma source may be generated within an ECR or ICP reactor containing a gas bearing N2 and SiH4. The energy and flux of electrons, ions, and radicals within the plasma are strictly controlled by the magnetic field such that a substantially stoichiometric and contaminant-free nitride is deposited upon the semiconductor topography. Thereafter, the nitride is anisotropically etched so as to form nitride spacers laterally adjacent the sidewall surfaces of the gate conductor.

Abstract: A method is provided for forming a multi-level interconnect in which capacitive coupling between laterally adjacent conductors employed by an integrated circuit is reduced. According to an embodiment, a conductor is dielectrically spaced above a semiconductor substrate, and a masking structure is arranged upon an upper surface of the conductor. Select portions of the conductor are removed such that opposed ends of the masking structure extend beyond opposed sidewall surfaces of the conductor. An interlevel dielectric is deposited to a level above the masking structure such that air gaps are formed laterally adjacent the opposed sidewall surfaces of the conductor, and the interlevel dielectric is planarized to a level spaced above an upper surface of the masking structure.

Abstract: A semiconductor process includes forming a spacer support structure on an upper surface of a semiconductor substrate. The semiconductor substrate includes a channel region that is laterally displaced between first and second source/drain regions. A. The spacer support structure includes a substantially vertical sidewall that is laterally aligned over a boundary between the first source/drain region and the channel region of the semiconductor substrate. A gate dielectric is then grown and a transistor gate fabricated by forming a first spacer structure on the sidewall of the spacer support structure. The first spacer structure includes a substantially vertical first sidewall in contact with the spacer support structure sidewall and further includes a second sidewall that is laterally aligned over a boundary between the channel region and the second source/drain region of the semiconductor substrate.

Abstract: An improved planarization process for a trench dielectric is presented. A shallow trench isolation structure is formed into the semiconductor substrate. A thin oxide layer is grown upon the trench floor and upon the trench sidewalls, and then a trench dielectric, preferably TEOS deposited using a chemical-vapor deposition CVD process, is deposited into the trench dielectric and upon the semiconductor substrate. The upper surface of the trench dielectric conforms to the underlying contour defined by the shallow trench and the semiconductor substrate. Subsequent device formation requires a substantially planar semiconductor. Conventionally, a combination of masking and etching are used, prior to chemical-mechanical polishing ("CMP"), to aid the planarization process. The extra steps add cost and unnecessary complexity to the process. An alternative planarization process is proposed which uses hydrogen silsequioxane-based flowable oxide ("HSQ").

Abstract: A method for protecting the trench dielectric fill for a shallow trench isolation structure by forming a protective layer upon the upper surface of the trench dielectric is presented. In a preferred embodiment, the protective layer comprises a layer of nitride formed upon a layer of oxide. Various etch and cleaning processes during the semiconductor device formation may cause damage to the trench dielectric. A shallow trench is typically formed early in the process sequence. A trench dielectric is deposited into the shallow trench and then planarized so that the upper surface of the trench dielectric is at the same level as the upper surface of the trench dielectric.

Abstract: An in situ process is provided for isolating semiconductor devices according to a LOCOS process. The invention contemplates performing field oxide growth, nitride layer removal, sacrificial oxide growth and removal, and gate oxide growth all within a single chamber without removing the wafers from the chamber during processing. The invention is believed to result in increased yields and process throughput by reducing the exposure of the wafers to outer-chamber contaminants, thermal stress, and transportation damage, as well as reducing inter-chamber transportation time. The invention also contemplates an in situ processing chamber adapted for performing field oxide growth, nitride layer removal, sacrificial oxide growth and removal, and gate oxide growth as part of a LOCOS isolation process. The in situ processing chamber is adapted for thermal oxidation and etching processes to implement the LOCOS isolation structure.