Patent ID: 9437711
Filing Date: 2016-09-06
CPC Classification: H01L

Claim Text:
1. A method of forming a replacement gate structure for a device above a silicon substrate, comprising: performing at least one first etching process to remove a sacrificial gate structure positioned between two spaced-apart sidewall spacers so as to thereby define a replacement gate cavity that exposes a surface of said substrate; performing a process operation on said exposed surface of said substrate so as to form an H-terminated silicon surface; selectively forming a sacrificial material layer at least on internal surfaces of said sidewall spacers within said replacement gate cavity but not on said H-terminated silicon surface; forming a high-k layer of insulating material within said replacement gate cavity above said H-terminated silicon surface and laterally between first spaced-apart portions of said sacrificial material layer formed on said sidewall spacers; forming at least one work-function adjusting metal layer above said high-k layer of insulating material and laterally between second spaced-apart portions of said sacrificial material layer formed on said sidewall spacers, said at least one work-function adjusting metal having a substantially planar upper surface that extends between said second spaced-apart portions of said sacrificial material layer formed on said sidewall spacers; and after forming said at least one work-function adjusting metal layer, removing said sacrificial material layer.