Patent ID: 9059042
Filing Date: 2015-06-16
Classification: H01L

Abstract:
1. A method of forming a FinFET device, comprising: forming a patterned hard mask above a layer of semiconductor material, said patterned hard mask having a pattern corresponding to a fin structure to be formed in said layer of semiconductor material; forming a sacrificial gate structure above said patterned hard mask and said layer of semiconductor material; after forming said sacrificial gate structure, forming a first sidewall spacer adjacent said sacrificial gate structure; forming a layer of insulating material adjacent said first sidewall spacer; performing at least one first etching process to remove said first sidewall spacer and thereby define a spacer cavity between said layer of insulating material and said sacrificial gate structure; substantially filling at least said spacer cavity with an insulating material so as to define at least second sidewall spacers in said spacer cavity; performing at least one second etching process to remove said sacrificial gate structure and thereby define a replacement gate cavity positioned between said second sidewall spacers; performing at least one etching process through said replacement gate cavity to define said fin structure in said layer of semiconductor material using said patterned hard mask exposed within said replacement gate cavity as an etch mask; and forming a replacement gate structure in said replacement gate cavity around at least a portion of said fin structure.