Methods of cutting metal gates and structures formed thereof
First Claim
Patent Images
1. A method comprising:
- forming a dummy gate stack extending over a plurality of semiconductor fins;
forming gate spacers, with the dummy gate stack being between the gate spacers;
forming a contact etch stop layer and an inter-layer dielectric, with the dummy gate stack and the gate spacers being in the contact etch stop layer and the inter-layer dielectric;
replacing the dummy gate stack with a replacement gate stack, wherein the replacement gate stack comprises a first portion and a second portion, and a third portion joining the first portion to the second portion;
selectively depositing a dielectric hard mask over and contacting the inter-layer dielectric, wherein the replacement gate stack is directly underlying a first opening in the dielectric hard mask, wherein as a thickness of the dielectric hard mask increases during the selectively depositing of the dielectric hard mask, the first opening is simultaneously formed in the dielectric hard mask;
etching the third portion of the replacement gate stack to form a second opening between the gate spacers, wherein the second opening separates the first portion of the replacement gate stack from the second portion of the replacement gate stack; and
filling a dielectric material into the second opening.
1 Assignment
0 Petitions
Accused Products
Abstract
A method includes forming a gate stack, which includes a gate dielectric and a metal gate electrode over the gate dielectric. An inter-layer dielectric is formed on opposite sides of the gate stack. The gate stack and the inter-layer dielectric are planarized. The method further includes forming an inhibitor film on the gate stack, with at least a portion of the inter-layer dielectric exposed, selectively depositing a dielectric hard mask on the inter-layer dielectric, with the inhibitor film preventing the dielectric hard mask from being formed thereon, and etching to remove a portion of the gate stack, with the dielectric hard mask acting as a portion of a corresponding etching mask.
39 Citations
20 Claims
-
1. A method comprising:
-
forming a dummy gate stack extending over a plurality of semiconductor fins; forming gate spacers, with the dummy gate stack being between the gate spacers; forming a contact etch stop layer and an inter-layer dielectric, with the dummy gate stack and the gate spacers being in the contact etch stop layer and the inter-layer dielectric; replacing the dummy gate stack with a replacement gate stack, wherein the replacement gate stack comprises a first portion and a second portion, and a third portion joining the first portion to the second portion; selectively depositing a dielectric hard mask over and contacting the inter-layer dielectric, wherein the replacement gate stack is directly underlying a first opening in the dielectric hard mask, wherein as a thickness of the dielectric hard mask increases during the selectively depositing of the dielectric hard mask, the first opening is simultaneously formed in the dielectric hard mask; etching the third portion of the replacement gate stack to form a second opening between the gate spacers, wherein the second opening separates the first portion of the replacement gate stack from the second portion of the replacement gate stack; and filling a dielectric material into the second opening. - View Dependent Claims (2, 3, 4, 5, 6, 7)
-
-
8. A method comprising:
-
forming an inter-layer dielectric having opposing portions; forming a replacement gate stack between the opposing portions of the inter-layer dielectric, wherein the replacement gate stack comprises a gate dielectric and a metal gate electrode over the gate dielectric; planarizing the replacement gate stack and the inter-layer dielectric; forming an inhibitor film on the replacement gate stack, with at least a portion of the inter-layer dielectric exposed; selectively depositing a dielectric hard mask on the inter-layer dielectric, with the inhibitor film preventing the dielectric hard mask from being formed thereon; and etching to remove a portion of the replacement gate stack, with the dielectric hard mask acting as a portion of a corresponding etching mask. - View Dependent Claims (9, 10, 11, 12, 13, 14)
-
-
15. A method comprising:
-
forming an inter-layer dielectric having opposing portions; forming a replacement gate stack between the opposing portions of the inter-layer dielectric, wherein the replacement gate stack comprises a gate dielectric and a metal gate electrode over the gate dielectric; planarizing the replacement gate stack and the inter-layer dielectric; selectively growing an inhibitor film on the replacement gate stack and not on the inter-layer dielectric; and selectively depositing a dielectric hard mask on the inter-layer dielectric and not on the inhibitor film. - View Dependent Claims (16, 17, 18, 19, 20)
-
Specification