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 is provided for stripping a photoresist with a carbonized crust formed during a high dose ion implant. The method may be performed in any etch tool or asher including those where a plasma is generated with a RF discharge source and bias power and tools with a microwave downstream plasma flow. An ICP plasma source is preferred for generating plasma from a flow of oxygen and one or more CxHyFz gases such as CH3F and CH2F2 where x, y and z are ≧1. A high photoresist removal rate of from 0.2 to 2 microns per minute is achieved while reducing thickness loss in exposed oxide, polysilicon, and silicon layers compared with conventional methods that employ O2 and CMFN gases. For NMOS and PMOS transistors, Idsat and contact junction leakage are improved.

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 compensating for CD variations across a semiconductor process wafer surface in a plasma etching process including providing a semiconductor wafer having a process surface including photolithographically developed features imaged from a photomask; determining a first dimensional variation of the features with respect to corresponding photomask dimensions along at least one wafer surface direction to determine a first levelness of the process surface; determining gas flow parameters in a plasma reactor for a plasma etching process required to approach a level process surface by reference to an archive of previous plasma etching process parameters carried out in the plasma reactor; carrying out the plasma etching process in the plasma rector according to the determined gas flow parameters; and, determining a second dimensional variation of the features along the at least one wafer surface direction to determine a second levelness of the process surface.

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: 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 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 new process is provided for the creation of an improved gate spacer profile. A layer of hardmask material is patterned over the surface of a layer of gate material. The layer of gate material is etch in accordance with the patterned layer of hardmask material, reducing the thickness of the patterned layer of hardmask material. A liner oxide is formed, a film of gate spacer material is deposited over the liner material. The layer of spacer material is etched, forming gate spacers and at the same time the remaining layer of hardmask material.

Abstract: A method is disclosed for smoothing the top surface of a layer of polysilicon which, as deposited, has a rough top surface due to the formation of polysilicon grains. A polymer, such as CxFyBrz, is deposited using chemical vapor deposition. The polymer layer has a thickness large enough so that the top surface of the polymer is at least a critical distance above the peaks of the grains on the top surface of the layer of polysilicon. The layer of polymer and part of the layer of polysilicon are then etched away using an etch back method which etches the polymer and polysilicon at the same etch rate. This results in a layer of polysilicon having a smooth top surface and the same thickness over the entire layer of polysilicon.

Abstract: A method is provided for improving the tungsten, W-filling of hole openings in semiconductor substrates. This is accomplished by forming an opening—which can be used either as a contact or via hole—with a faceted entrance along with tapered side-walls. This combination of faceted entrance and tapered side-walls improves substantially the tungsten W-filling of contact/via holes in substrates without the formation of key-holes, thereby resulting in metal plugs of high electrical integrity and high reliability.

Abstract: A plasma etch method for plasma etch processing a microelectronic layer formed over a substrate, comprises a two step plasma etch method. Within a first step, the microelectronic layer is etched while employing a first plasma etch method employing a first detection apparatus optimized to measure a thickness of the microelectronic layer. The first detection apparatus controls the first plasma etch method to stop prior to reaching the substrate to thus form from the microelectronic layer a partially etched microelectronic layer. Within a second step, the partially etched microelectronic layer is etched while employing a second plasma etch method employing a second detection apparatus optimized to detect the substrate. The second detection apparatus controls the second etch method to stop on the substrate when etching the partially etched microelectronic layer to form a completely etched microelectronic layer.

Abstract: A method to improve silicon oxynitride when used as an etching stop for silicon oxide plasma etching, by nitridizing with a nitrogen plasma, in the fabrication of an integrated circuit is achieved. The method is applied to forming etch stopping silicon oxynitride spacers for MOS transistors and for forming etch stopping silicon oxynitride for dual damascene interconnects. A semiconductor substrate is provided wherein devices and features have been formed in and on the semiconductor substrate. A silicon oxynitride layer is deposited overlying the semiconductor substrate. The silicon oxynitride layer is nitridized. An interlevel dielectric oxide layer is deposited overlying surface of the silicon oxynitride layer. The interlevel dielectric oxide layer is etched through to the silicon oxynitride layer where defined by photolithography and wherein the silicon oxynitride layer acts as an etching stop.

Abstract: A new method of forming a plasma-enhanced silicon-rich oxynitride layer having improved uniformity across the wafer in terms of layer thickness, refractivity, and reflectivity by using argon as the inert carrier gas is described. A semiconductor substrate is provided which may include semiconductor device structures. An Argon-based silicon-rich oxynitride etch stop layer is deposited overlying the semiconductor substrate. An oxide layer is deposited overlying the Argon-based silicon-rich oxynitride etch stop layer. An opening is etched through the oxide layer stopping at the Argon-based silicon-rich oxynitride etch stop layer. Thereafter, the Argon-based silicon-rich oxynitride etch stop layer within the opening is removed. The opening is filled with a conducting layer. This Argon-based silicon-rich oxynitride layer has improved uniformity across the wafer in terms of layer thickness, refractivity, and reflectivity as compared with a helium-based silicon-rich oxynitride layer.