US 12,302,595 B2
Dummy hybrid film for self-alignment contact formation
Bor Chiuan Hsieh, Taoyuan (TW); Tsai-Jung Ho, Xihu Township (TW); Po-Cheng Shih, Hsinchu (TW); and Tze-Liang Lee, Hsinchu (TW)
Assigned to Taiwan Semiconductor Manufacturing Co., Ltd., Hsinchu (TW)
Filed by Taiwan Semiconductor Manufacturing Co., Ltd., Hsinchu (TW)
Filed on Jan. 14, 2022, as Appl. No. 17/648,037.
Claims priority of provisional application 63/264,396, filed on Nov. 22, 2021.
Prior Publication US 2023/0163194 A1, May 25, 2023
Int. Cl. H10D 30/01 (2025.01); H10D 30/62 (2025.01); H10D 64/01 (2025.01)
CPC H10D 30/0215 (2025.01) [H10D 30/024 (2025.01); H10D 30/6211 (2025.01); H10D 30/6219 (2025.01); H10D 64/01 (2025.01); H10D 64/017 (2025.01)] 20 Claims
OG exemplary drawing
 
1. A method comprising:
forming a dummy gate stack over a semiconductor region;
forming gate spacers on opposing sides of the dummy gate stack;
forming a source/drain region on a side of the dummy gate stack;
forming a first inter-layer dielectric over the source/drain region;
replacing the dummy gate stack with a replacement gate stack;
recessing the replacement gate stack to form a recess between the gate spacers;
depositing a liner extending into the recess;
depositing a masking layer over the liner and extending into the recess;
forming an etching mask covering a portion of the masking layer;
etching the first inter-layer dielectric to form a source/drain contact opening, wherein the source/drain region is underlying and exposed to the source/drain contact opening;
forming a source/drain contact plug in the source/drain contact opening; and
forming a gate contact plug extending between the gate spacers and electrically connecting to the replacement gate stack.