Abstract: A method of monitoring a critical dimension of a structural element in an integrated circuit is provided comprising the following steps: collecting an optical interference endpoint signal produced during etching one or more layers to form the structural element; and determining based upon the optical interference endpoint signal the critical dimension of the structural element.

Abstract: A method for forming a patterned silicon-containing layer is disclosed. The method includes providing a substrate, providing a polysilicon layer on the substrate, providing a hard mask layer on the polysilicon layer, patterning and etching the hard mask layer and etching the polysilicon layer according to the pattern of the hard mask layer using a fluorine-containing etchant gas. The resulting sidewall profile of the etched polysilicon layer is substantially straight, uniform and devoid of a necking or notched configuration.

Abstract: A method is described for selectively etching a high k dielectric layer that is preferably a hafnium or zirconium oxide, silicate, nitride, or oxynitride with a selectivity of greater than 2:1 relative to silicon oxide, polysilicon, or silicon. The plasma etch chemistry is comprised of one or more halogen containing gases such as CF4, CHF3, CH2F2, CH3F, C4F8, C4F6, C5F6, BCl3, Br2, HF, HCl, HBr, HI, and NF3 and leaves no etch residues. An inert gas or an inert gas and oxidant gas may be added to the halogen containing gas. In one embodiment, a high k gate dielectric layer is removed on portions of an active area in a MOS transistor. Alternatively, the high k dielectric layer is used in a capacitor between two conducting layers and is selectively removed from portions of an ILD layer.

Abstract: A method for dry etching a dielectric layer including providing a substrate; forming at least one overlying dielectric layer over the substrate; subjecting the at least one overlying layer to a plasma oxidizing process; and, subjecting the at least one overlying layer to a plasma etching process.

Abstract: A field effect transistor gate structure and a method of fabricating the gate structure with a high-k gate dielectric material and high-k spacer are described. A gate pattern or trench is first etched in a dummy organic or inorganic film deposited over a silicon substrate with source/drain regions. A high-k dielectric material liner is then deposited on all exposed surfaces. Excess poly-silicon gate conductor film is then deposited within and over the trench to provide adequate overburden. Poly-silicon is then planarized with chemical mechanical polishing or etch-back methods such that the high-k material film on top of the dummy film surface is removed during this step. In the final step, the dummy film is disposed off, leaving the final transistor gate structure with high-k gate dielectric and high-k spacer surrounding the gate conductor poly-silicon, with the entire gate structure fabricated to form an FET device on a silicon substrate.

Abstract: A method of defining a patterned, conductive gate structure for a MOSFET device on a semiconductor substrate includes forming a conductive layer over the semiconductor substrate and forming a capping insulator layer over the conductive layer. An anti-reflective coating (ARC) layer is formed over the capping insulator layer and a patterned photoresist shape is formed on the ARC layer. A first etch procedure using the photoresist shape as an etch mask defines a stack comprised of an ARC shape and a capping insulator shape. A second etch procedure using the stack as an etch mask defines the patterned, conductive gate structure in the conductive layer.

Abstract: A method for forming an offset spacer adjacent a CMOS gate structure with improved critical dimension control including providing a substrate that has a gate structure; forming at least one oxide layer over the substrate; forming at least one nitride layer over the at least one oxide layer; dry etching the at least one nitride layer in a first dry etching process to expose a first portion of the at least one oxide layer; carrying out a wet etching process to remove the first portion of the at least one oxide layer; and, dry etching the at least one nitride layer in a second dry etching process to remove the at least one nitride layer leaving a second portion of the at least one oxide layer to form an oxide offset spacer along sidewalls of the gate structure.

Abstract: An integrated process flow including a plasma step for removing oxide residues following oxygen ashing of a photoresist layer is disclosed. The oxide removal step is effective in preventing micro mask defects and is preferably performed in the same process chamber used for the oxygen ashing step and for a subsequent plasma etch used for pattern transfer. The oxide removal step takes less than 60 seconds and involves a halogen containing plasma that is generated from one or more of NF3, Cl2, CF4, CH2F2, and SF6. Optionally, HBr or a fluorocarbon CXFYHZ where x and y are integers and z is an integer or is equal to 0 may be used alone or with one of the aforementioned halogen containing gases. The oxide removal step may be incorporated in a variety of applications including a damascene scheme, shallow trench (STI) fabrication, or formation of a gate electrode in a transistor.

Abstract: The present invention provides aqueous compositions for cleaning integrated circuit substrates. Specifically, in the cleaning of an integrated circuit substrate, disclosed is a method for removing the by-products of the high-k dielectric dry etch process from the integrated circuit substrate, the method including: contacting the integrated circuit substrate with an aqueous composition including an amount, effective for the purpose of a (a) hydrogen fluoride, followed by (b) a mixture of hydrogen peroxide with a compound selected from the group consisting of ammonium hydroxide, hydrochloric acid and sulfuric acid.

Abstract: A method of manufacturing a semiconductor device is provided. A semiconductor element is formed on a substrate. The semiconductor element has at least one nickel silicide contact region, an etch stop layer formed over said element, and an insulating layer formed over said etch stop layer. A portion of the etch stop layer immediately over a selected contact region is removed using a process that does not substantially react with the contact region, to form a contact opening. The contact opening is then filled with a conductive material to form a contact.

Abstract: A fully dry etch method is described for removing a high k dielectric layer from a substrate without damaging the substrate and has a high selectivity with respect to a gate layer. The etch is comprised of BCl3, a fluorocarbon, and an inert gas. A low RF bias power is preferred. The method can also be used to remove an interfacial layer between the substrate and the high k dielectric layer. A HfO2 etch rate of 55 Angstroms per minute is achieved without causing a recess in a silicon substrate and with an etch selectivity to polysilicon of greater than 10:1. Better STI oxide divot control is also provided by this method. The etch through the high k dielectric layer may be performed in the same etch chamber as the etch process to form a gate electrode.

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 isotopic second etch procedure for definition of the titanium nitride gate structure shape, is employed.

Abstract: A field effect transistor gate structure and a method of fabricating the gate structure with a high-k gate dielectric material and high-k spacer are described. A gate pattern or trench is first etched in a dummy organic or inorganic film deposited over a silicon substrate with source/drain regions. A high-k dielectric material liner is then deposited on all exposed surfaces. Excess poly-silicon gate conductor film is then deposited within and over the trench to provide adequate overburden. Poly-silicon is then planarized with chemical mechanical polishing or etch-back methods such that the high-k material film on top of the dummy film surface is removed during this step. In the final step, the dummy film is disposed off, leaving the final transistor gate structure with high-k gate dielectric and high-k spacer surrounding the gate conductor poly-silicon, with the entire gate structure fabricated to form an FET device on a silicon substrate.

Abstract: A method of forming a gate electrode comprising the following steps. A substrate having a high-k gate dielectric layer formed thereover is provided. A gate layer is formed over the high-k gate dielectric layer. A gate ARC layer is formed over the gate layer. The gate ARC layer and the gate layer are patterned to form a patterned gate ARC layer and a patterned gate layer. The high-k gate dielectric layer not under the patterned gate layer is partially etched and a smooth exposed upper surface of the patterned gate layer is formed. The partially etched high-k gate dielectric layer portions not under the patterned gate layer are removed to form the gate electrode comprised of the patterned gate layer and the etched high-k gate dielectric layer.

Abstract: A method for improving a polysilicon gate electrode profile to avoid preferential RIE etching in a polysilicon gate electrode etching process including carrying out a multi-step etching process wherein at least one of a lower RF source power and RF bias power are reduced to complete a polysilicon etching process and an in-situ plasma treatment with an inert gas plasma is carried out prior to neutralize an electrical charge imbalance prior to carrying out an overetch step.

Abstract: A method of defining a gate structure for a MOSFET device featuring the employment of dual anti-reflective coating (ARC) layers to enhance gate structure resolution, and featuring a dry procedure for removal of all ARC layers avoiding the use of hot phosphoric acid, has been developed. After formation of a polysilicon layer on an underlying silicon dioxide gate insulator layer, a capping silicon oxide, a dielectric ARC layer, and an overlying organic ARC layer are deposited. A photoresist shape is formed and used as an etch mask to allow a first anisotropic RIE procedure to define the desired gate structure shape in the dual ARC layers and in the capping silicon oxide layer. After removal of the photoresist shape and the overlying organic ARC layer a second anisotropic RIE procedure is used to define a desired polysilicon gate structure, with the second anisotropic RIE procedure also resulting in the removal of the dielectric ARC shape.

Abstract: Low-k organosilicate dielectric material can be exposed to a series of reagents, including a halogenation reagent, an alkylation reagent, and a termination reagent, in order to reverse degradation of dielectric properties caused by previous processing steps.

Abstract: A plasma etch method for forming a patterned target layer within a microelectrcnic product forms an etch residue layer adjoining a patterned mask layer formed upon a blanket target layer. After removing the patterned mask layer, the etch residue layer is laterally increased to form a laterally increased etch residue layer. The laterally increased etch residue layer is employed as an etch mask for forming the patterned target layer from the blanket target layer. The method is particularly useful for forming gate electrodes within semiconductor products.

Abstract: A method of forming gate electrode layer portions having differing widths comprising the following steps. A structure having a gate electrode layer and a hard mask layer thereover and including two or more active areas is provided. The hard mask layer is patterned to form two or more respective hard mask layer portions within the two or more active areas. One or more of the two or more respective hard mask layer portions is/are selectively trimmed to reduce its/their width to a second width leaving at least one the respective hard mask layer portions untrimmed. The gate electrode layer is then patterned.

Abstract: A method for forming a gate electrode comprising the following steps. A substrate having a high-k gate dielectric layer formed thereover is provided. A gate layer is formed over the high-k gate dielectric layer. A gate ARC layer is formed over the gate layer. The gate ARC layer and the gate layer are patterned to form a pattern gate ARC layer and a patterned gate layer. The high-k gate dielectric layer not under the patterned gate layer is partially etched and a smooth exposed upper surface of the patterned gate layer is formed. The partially etched high-k gate dielectric layer portions not under the patterned gate layer are removed to form the gate electrode comprised of the patterned gate layer and the etched high-k gate dielectric layer.