US 12,310,078 B2
Method of forming metal gate fin electrode structure by etching back metal fill
Shih-Hang Chiu, Taichung (TW); Wei-Cheng Wang, Hsinchu (TW); Chung-Chiang Wu, Taichung (TW); and Chi On Chui, Hsinchu (TW)
Assigned to Taiwan Semiconductor Manufacturing Co., Ltd., Hsinchu (TW)
Filed by Taiwan Semiconductor Manufacturing Co., Ltd., Hsinchu (TW)
Filed on Mar. 22, 2022, as Appl. No. 17/700,998.
Claims priority of provisional application 63/278,532, filed on Nov. 12, 2021.
Prior Publication US 2023/0155002 A1, May 18, 2023
Int. Cl. H10D 64/01 (2025.01); H01L 21/02 (2006.01); H01L 21/28 (2006.01); H10D 30/01 (2025.01); H10D 30/67 (2025.01); H10D 62/10 (2025.01)
CPC H10D 64/017 (2025.01) [H01L 21/0259 (2013.01); H01L 21/28088 (2013.01); H10D 30/031 (2025.01); H10D 30/6735 (2025.01); H10D 30/6739 (2025.01); H10D 30/6757 (2025.01); H10D 62/118 (2025.01); H10D 64/018 (2025.01)] 19 Claims
OG exemplary drawing
 
1. A method comprising:
forming a fin over a substrate;
forming a dummy gate structure over the fin;
forming a source/drain region on either side of the dummy gate structure;
depositing a first interlayer dielectric (ILD) over the source/drain region;
recessing the first ILD and forming a self-align mask over the first ILD;
performing a gate replacement cycle to replace the dummy gate structure with a replacement metal gate, the gate replacement cycle comprising:
removing the dummy gate structure to form a first recess;
depositing a gate dielectric in the first recess,
forming a metal gate over the gate dielectric,
depositing a metal fill over the metal gate, and
etching back the gate dielectric, the metal gate, and the metal fill, to form an electrode fin from the metal fill; and
forming a gate contact contacting a sidewall of the electrode fin.