US 11,991,872 B2
Semiconductor device with gate recess and methods of forming the same
Jhon Jhy Liaw, Hsinchu County (TW)
Assigned to TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD., Hsinchu (TW)
Filed by Taiwan Semiconductor Manufacturing Company, Ltd., Hsinchu (TW)
Filed on Jun. 6, 2022, as Appl. No. 17/833,396.
Application 17/833,396 is a division of application No. 17/027,449, filed on Sep. 21, 2020, granted, now 11,355,502.
Prior Publication US 2022/0302135 A1, Sep. 22, 2022
Int. Cl. H10B 10/00 (2023.01); H01L 29/06 (2006.01); H01L 29/423 (2006.01); H01L 29/78 (2006.01)
CPC H10B 10/125 (2023.02) [H01L 29/0673 (2013.01); H01L 29/42392 (2013.01); H01L 29/7853 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method, comprising:
receiving a workpiece that includes:
a substrate having a p-type well and an n-type well,
a first base fin portion over the p-type well and a second base fin over the n-type well, the first base fin portion and the second base fin portion being disposed in an isolation feature disposed over the substrate, and
a first semiconductor stack disposed on the first base fin portion and a second semiconductor stack disposed on the second base fin, each of the first semiconductor stack and the second semiconductor stack comprising first semiconductor layers interleaved by second semiconductor layers;
recessing the isolation feature such that a top surface of the isolation feature is lower than a top surface of the first base fin portion by a depth;
forming a dummy gate structure over a channel region of the first semiconductor stack, a channel region of the second semiconductor stack, and the recessed isolation feature;
depositing gate spacers over sidewalls of the dummy gate structure;
after the depositing of the gate spacers, recessing source/drain regions of the first semiconductor stack and the second semiconductor stack to form source/drain trenches;
forming source/drain features in the source/drain trenches;
after the forming of the source/drain features, removing the dummy gate structure from the channel regions of the first semiconductor stack and the second semiconductor stack;
selectively removing the second semiconductor layers to release the first semiconductor layers as suspended channel layers; and
forming a gate structure to wrap around each of the suspended channel layers,
wherein the first semiconductor stack comprises a first width and the second semiconductor stack comprises a second width different from the first width.