Methods for protecting gate stacks during fabrication of...

Semiconductor device manufacturing: process – Making field effect device having pair of active regions... – Having insulated gate

Reexamination Certificate

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C438S197000, C438S221000, C438S294000, C438S296000, C257SE21616, C257SE21628, C257SE21640, C257SE21642

Reexamination Certificate

active

07932143

ABSTRACT:
Methods for protecting gate stacks during fabrication of semiconductor devices and semiconductor devices fabricated from such methods are provided. Methods for fabricating a semiconductor device include providing a semiconductor substrate having an active region and a shallow trench isolation (STI) region. Epitaxial layer is formed on the active region to define a lateral overhang portion in a divot at the active region/STI region interface. A gate stack is formed having a first gate stack-forming layer overlying the semiconductor substrate. First gate stack-forming layer includes a non-conformal layer of metal gate-forming material which is directionally deposited to form a thinned break portion just below the lateral overhang portion. After the step of forming the gate stack, a first portion of the non-conformal layer is in the gate stack and a second portion is exposed. The thinned break portion at least partially isolates the first and second portions during subsequent etch chemistries.

REFERENCES:
patent: 7098515 (2006-08-01), Gu et al.
patent: 7105908 (2006-09-01), Lee et al.
patent: 2002/0135020 (2002-09-01), Skotnicki et al.
patent: 2004/0053457 (2004-03-01), Sohn
patent: 2007/0128789 (2007-06-01), Lim et al.
patent: 2010/0109056 (2010-05-01), Pal et al.

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