Patent ID: 9059134
Filing Date: 2015-06-16
Classification: H01L

Abstract:
1. A method of forming a semiconductor structure comprising: providing a structure including a plurality of sacrificial gate stacks located on a surface of a semiconductor substrate, wherein each sacrificial gate stack includes a spacer located on a vertical sidewall thereof, and wherein a metal semiconductor alloy layer is at least located on an exposed surface of the semiconductor substrate between neighboring sacrificial gate stacks; forming a self-aligned dielectric liner on exposed surfaces of each sacrificial gate stack, said spacer and said metal semiconductor alloy layer; forming a planarized dielectric material having a contact opening that is partially filled with a recessed contact metal, wherein portions of the self-aligned dielectric liner are removed from horizontal surfaces within the contact opening; replacing each sacrificial gate stack of said plurality of sacrificial gate stacks with a permanent gate stack thereby providing a plurality of permanent gate stacks on said surface of said semiconductor substrate, wherein each permanent gate stack includes a high k gate dielectric layer, a work function metal layer and a conductive metal, wherein an uppermost surface of each of said high k gate dielectric layer, said work function metal layer and said conductive metal is coplanar with each other, and wherein said uppermost surface of each of said high k gate dielectric layer, said work function metal layer and said conductive metal is located beneath an uppermost surface of both of said planarized dielectric material and said spacer; and forming another contact metal having a first portion that is located on and in direct contact with an upper surface of the recessed contact metal and a second portion that is located on and in direct contact with said uppermost surface of each of said high k gate dielectric layer, said work function metal layer and said conductive metal of one of the permanent gate stacks, wherein said forming another contact metal comprises: