Patent ID: 9412839
Filing Date: 2016-08-09
CPC Classification: H01L

Claim Text:
1. A method of forming a replacement gate structure for a FinFET device, comprising: forming a plurality of trenches in a semiconductor substrate so as to define a fin having an upper surface and a plurality of side surfaces; forming at least one layer of insulating material above said substrate, said at least one layer of insulating material having a substantially planar upper surface and comprising a first layer of insulating material that is positioned in said plurality of trenches and a second layer of insulating material that is positioned on an upper surface of said first layer of insulating material, wherein said upper surface of said first layer of insulating material is substantially planar with said upper surface of said fin and an upper surface of said second layer of insulating material is positioned at a level that is above a level of said upper surface of said fin; forming a layer of sacrificial gate material on said substantially planar upper surface of said at least one layer of insulating material, said layer of sacrificial gate material having an as-deposited upper surface and a substantially uniform thickness; forming a layer of gate cap material on said as-deposited upper surface of said layer of sacrificial gate material; performing at least one etching process to define a patterned sacrificial gate structure comprised of at least said gate cap material and said sacrificial gate material; forming sidewall spacers adjacent said patterned sacrificial gate structure; removing said patterned sacrificial gate structure and portions of said at least one layer of insulating material positioned between said spacers so as to thereby define a replacement gate cavity and thereby expose said upper surface and said side surfaces of said fin within said replacement gate cavity; and forming a replacement gate structure in said replacement gate cavity around said exposed upper surface and side surfaces of said fin.