Semiconductor structure and fabrication method thereof

Semiconductor structures and fabrication methods are provided. An exemplary fabrication method includes providing a to-be-etched layer; forming a first sacrificial film on the to-be-etched layer; and forming a plurality of discrete first sidewall spacers and sidewall trenches on the first sacrificial film. Each sidewall trench is located between two adjacent first sidewall spacers; the first sidewall trenches include a first sidewall trench and a second sidewall trench, and a width of the second sidewall trench is greater than that of the first sidewall trench. The method also includes forming a second sidewall spacer in the first sidewall trench to fill the first sidewall trench; and etching the first sacrificial film using the first sidewall spacers and the second sidewall spacer as an etching mask to form a plurality of discrete first sacrificial layers on the to-be-etched layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority of Chinese patent application No. 201911176061.2, filed on Nov. 26, 2019, the entirety of which is incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to the field of semiconductor manufacturing technology and, more particularly, relates to semiconductor structures and fabrication methods.

BACKGROUND

In the process of manufacturing semiconductor devices, a photolithography process is usually used to transfer patterns from a mask to a substrate. The photolithography process usually includes providing a semiconductor substrate; forming a photoresist layer on the semiconductor substrate; and exposing and developing the photoresist layer to form a patterned photoresist layer to allow the patterns on the mask to be transferred to the photoresist layer. The semiconductor substrate is etched using the patterned photoresist layer as an etching mask such that the patterns on the patterned photoresist layer are transferred to the semiconductor substrate. After transferring the patterns to the semiconductor substrate, the patterned photoresist layer may be removed.

As the size of semiconductor devices continues to shrink, the critical dimensions of the lithography process are gradually approaching or even exceeding the physical limits of photolithography, which poses more severe challenges to the lithography technology. To further reduce the size of semiconductor devices on the basis of the photolithography process, a multiple patterning process has been developed. Such a process has application prospects because of its ability to form a mask with a smaller size, and the unreachable limit of a single patterning process may be overcome.

However, after transferring patterns using the multiple patterning process, the patterns still need to be further processed. Thus, the production time and cost are increased. The disclosed methods and semiconductor structures are directed to solve one or more problems set forth above and other problems in the art.

BRIEF SUMMARY OF THE DISCLOSURE

One aspect of the present disclosure includes providing a method for forming a semiconductor structure. The method may include providing a to-be-etched layer; forming a first sacrificial film on the to-be-etched layer; and forming a plurality of discrete first sidewall spacers and a plurality of sidewall trenches on the first sacrificial film. Each of the plurality of sidewall trenches is located between two adjacent first sidewall spacers of the plurality of discrete first sidewall spacers; the plurality of first sidewall trenches include a first sidewall trench and a second sidewall trench; and a width of the second sidewall trench is greater than a width of the first sidewall trench. The method may also include forming a second sidewall spacer in the first sidewall trench to fill the first sidewall trench; and etching the first sacrificial film using the plurality of first sidewall spacers and the second sidewall spacer as an etching mask to form a plurality of discrete first sacrificial layers on the to-be-etched layer.

Optionally, the to-be-etched layer includes a multiple-layer structure, the multiple layer structure includes a substrate, a mask structure on the substrate and a first stop layer on the mask structure.

Optionally, the method for forming the plurality of first sidewall spacers may include forming a second stop layer on the first sacrificial film; and forming a plurality of discrete second sacrificial layers and a plurality of sacrificial layer trenches on the second stop layer. Each second sacrificial layer trench of the plurality of sacrificial layer trenches is located between two adjacent second sacrificial layers of the plurality of discrete second sacrificial layers; the plurality of sacrificial layer trenches include a first sacrificial layer trench and a second sacrificial layer trench; and a width of the second sacrificial layer trench is greater than a width of the first sacrificial layer trench. The method may also include forming a first sidewall spacer on a sidewall surface of a second sacrificial layer of the plurality of discrete second sacrificial layers; and removing the plurality of discrete second sacrificial layers after forming the first sidewall spacer.

Optionally, the method for forming the first sidewall spacer on the sidewall surface of the second sacrificial layer may include forming a first sidewall film on exposed portions of a top surface of the second stop layer, and sidewall surfaces and top surfaces of the plurality of discrete second sacrificial layers; etching-back the first sidewall film on the exposed portions of the top surface of the second stop layer and the top surfaces of the plurality of discrete second sacrificial layers until the exposed portions of the top surface of the second stop layer and the top surfaces of the plurality of discrete second sacrificial layers are exposed to form the first sidewall spacer of the sidewall surface of the second sacrificial layer.

Optionally, a ratio between the width of the first sacrificial layer trench and a thickness of the first sidewall spacer is greater than 2:1; and a ratio between the width of the second sacrificial layer trench and the thickness of the first sidewall spacer is greater than 2:1.

Optionally, forming the first sidewall film includes an atomic layer deposition process.

Optionally, etching back the first sidewall film includes one of an anisotropic dry etching process or an anisotropic wet etching process.

Optionally, a material of the first sidewall film includes one of silicon nitride and silicon oxynitride.

Optionally, the method for forming the plurality of discrete second sacrificial layers may include forming a second sacrificial film on the second stop layer; forming a plurality of discrete patterned structures on the second sacrificial film; etching the second sacrificial film using the plurality of discrete patterned structures as an etching mask until the second stop layer is exposed to form the plurality of discrete second sacrificial layers; and removing the plurality of discrete patterned structures after forming the plurality of discrete second sacrificial layers.

Optionally, the method for forming the second sidewall spacer may include forming a second sidewall film on exposed portions of a top surface of the second stop layer and sidewall surfaces and top surfaces of the first sidewall spacers; and etching the second sidewall film on surfaces of the second sidewall trenches and the top surfaces of the first sidewall spacers until the top surface of the second stop layer and the top surfaces of the first sidewall spacers are exposed to form the second sidewall spacer.

Optionally, a ratio between the width of the first sidewall trench and a thickness of the second sidewall spacer is smaller than 2:1; and a ratio between the width of the second sidewall trench and the thickness of the second sidewall spacer is greater than 2:1.

Optionally, forming the second sidewall film may include an atomic layer deposition process.

Optionally, etching the second sidewall film includes one of an anisotropic dry etching process or an isotropic wet etching process.

Optionally, a material of the second sidewall film includes silicon carbonitride.

Optionally, after forming the plurality of first sacrificial layers, the method may also include removing the second sidewall spacer and the first sidewall spacers.

Optionally, the method may also include forming third sidewall spacers. The method for forming the third sidewall spacers on the sidewall surfaces of the plurality of first sacrificial layers may include forming a third sidewall film on exposed portions of a top surface of the to-be-etched layer, and sidewall surfaces and top surfaces of the plurality of first sacrificial layers; etching back the third sidewall film on the exposed portions of the top surface of the to-be-etched layer and the top surfaces of the first sacrificial layers until the exposed portions of the top surface of the to-be-etched layer and the top surfaces of the first sacrificial layers are exposed to form the third sidewall spacers; and removing the plurality of first sacrificial layers after forming the third sidewall spacers.

Optionally, forming the third sidewall film may include an atomic layer deposition process.

Optionally, a material of the third sidewall film may include one of silicon nitride and silicon oxynitride.

Optionally, after forming the third sidewall spacers, the method may further include forming a plurality of discrete fins by etching the to-be-etched layer using the third sidewall spacers as an etching mask.

Another aspect of the present disclosure includes providing a semiconductor structure. The semiconductor structure may include a to-be-etched layer; a plurality of first sacrificial layers formed on the to-be-etched layer; and a plurality of third sidewall spacers formed on sidewall surfaces of the plurality of first sacrificial layers. The plurality of third sidewall spacers are formed by forming a first sacrificial film on the to-be-etched layer; and forming a plurality of discrete first sidewall spacers and a plurality of sidewall trenches on the first sacrificial film. Each of the plurality of sidewall trenches is located between two adjacent first sidewall spacers of the plurality of discrete first sidewall spacers; the plurality of first sidewall trenches include a first sidewall trench and a second sidewall trench; and a width of the second sidewall trench is greater than a width of the first sidewall trench. The method for forming the plurality of third sidewall spacers may also include forming a second sidewall spacer in the first sidewall trench to fill the first sidewall trench; and etching the first sacrificial film using the plurality of first sidewall spacers and the second sidewall spacer as an etching mask to form the plurality of discrete first sacrificial layers on the to-be-etched layer.

Comparing with the existing technologies, the technical solutions of the present disclosure may have at least the following beneficial effects.

In the disclosed fabrication method, in a multiple patterning process, a second sidewall spacer may be used to fill the first sidewall trench to merge the first sidewall spacers at two sides of the first sidewall trench. In the following pattern transfer process, and the portions of the to-be-etched layer corresponding to the merged first sidewall spacers and the second sidewall spacer may not form a fin. Thus, the process for subsequently removing a portion of the fins by a photolithography process may be omitted. Accordingly, the production time and the production cost may be reduced.

DETAILED DESCRIPTION

FIGS.1-3illustrate structures corresponding to certain stages during a fabrication process of a semiconductor structure.

As shown inFIG.1, the fabrication process includes providing an initial substrate100; forming a mask layer101on the initial substrate100; and forming a plurality of discrete sacrificial layers102on the mask layer101. The plurality of sacrificial layers102may be formed by a multiple patterning processes.

Further, as shown inFIG.2, the mask layer101and the initial substrate100may be etched using the sacrificial layers102as a mask to form a substrate103and a plurality of discrete fins104on the substrate103. After forming the substrate103and the plurality of fins104, the sacrificial layer102and the mask layer101are removed.

Further, as shown inFIG.3, a photolithography patterning process is used to remove a portion (a certain number) of the plurality of fins104.

In such a fabrication process, after the fins104are formed, according to different design requirements, it is often necessary to remove the portion of the fins104to increase the distance between adjacent fins104. In particular, after forming the fins104, the portion of the fins104are removed by a photolithography patterning process. The method not only increases the production time, but also requires an additional mask during the process. Thus, it will also increase the production cost.

The present disclosure provides a semiconductor structure and a method for forming a semiconductor structure. In a multiple patterning process, a second sidewall spacer may be used to fill the first sidewall trench. In the subsequent pattern transfer process, the to-be-etched layer corresponding to such a position may not form a fin. Thus, the need to use a photolithography patterning process to remove a portion of the fins may be not required, and the manufacturing time and manufacturing cost may be reduced.

To make the above-mentioned objects, features and advantages of the present disclosure more obvious and understandable, specific embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings.

FIG.15illustrates an exemplary fabrication process of a semiconductor structure consistent with various disclosed embodiments of the present disclosure.FIGS.4-14illustrate structures corresponding to certain stages during the exemplary fabrication process of the semiconductor structure.

As shown inFIG.15, at the beginning of the fabrication process, a to-be-etched layer with certain structures is provided (S101).FIG.4illustrates a corresponding structure.

As shown inFIG.4, a to-be-etched layer200is provided. A first sacrificial film201may be formed on the to-be-etched layer200.

In one embodiment, the to-be-etched layer200may include a multiple-layer structure. The to-be-etched layer200may include a substrate202, a mask structure on the substrate202, and a first stop layer203on the mask structure.

In one embodiment, the substrate202may be made of silicon. In some embodiments, the material of the substrate may also be germanium, silicon germanium, silicon carbide, gallium arsenide, or indium gallium, etc.

In one embodiment, as shown inFIG.4, the mask structure may include a first mask layer204, and a second mask layer205formed on the first mask layer204.

The material of the first mask layer204may be nitrogen-doped silicon oxycarbide. The first mask layer204made of nitrogen-doped silicon oxycarbide may have a desired bonding ability with the substrate202. When the substrate202is subsequently etched using the etched first mask layer204as an etching mask, the first mask layer204may not be prone to peeling or warping. Thus, the first mask layer204may have a desired ability to maintain the etched patterns. Accordingly, it may be beneficial to make the morphology of the openings formed in the substrate202to be as desired, and the accuracy of the patterns after the etching process may be effectively improved.

The material of the second mask layer205may be titanium nitride. The bonding ability between the second mask layer205and the first mask layer204may be as desired. The second mask layer205may be able to protect the surface of the first mask layer204during subsequently etching the substrate202such that the first mask layer204may not be thinned. Further, the physical strength of the second mask layer205may be relatively large. Accordingly, in the subsequent process for etching the to-be-etched layer200, the patterns of the second mask layer205and the first mask layer204may be kept stable; and the formation of the openings with desired morphologies may be facilitated.

In some embodiments, the mask structure may also be a single-layer structure.

In one embodiment, the material of the first sacrificial film201may be amorphous silicon. In some embodiments, the material of the first sacrificial film may also be silicon nitride, silicon carbide, silicon carbonitride, silicon carbon oxynitride, silicon oxide, silicon oxynitride, boron nitride, or boron carbonitride, etc.

A plurality of discrete first sidewall spacers and a plurality of sidewall trenches may be formed on the first sacrificial film201, and each of the sidewall trenches may be located between adjacent first sidewall spacers. The plurality of sidewall trenches may include a first sidewall trench and a second sidewall trench, and the width of the second sidewall trench may be greater than the width of the first sidewall trench.FIGS.5-8illustrate structures corresponding certain stages during a fabrication process of the first sidewall spacers and the sidewall trenches.

Returning toFIG.15, after providing the to-be-etched layer, a second stop layer, a second sacrificial film and a plurality of discrete patterned structures may be formed (S102).FIG.5illustrates a corresponding structure.

As shown inFIG.5, a second stop layer206may be formed on the first sacrificial film201; a second sacrificial film207may be formed on the second stop layer206; and a plurality of discrete patterned structures208may be formed on the second sacrificial film207.

In one embodiment, the second stop layer206may be used to stop the etching process when the second sacrificial film207is subsequently etched to prevent the etching process from continuing to etch the first sacrificial film201.

In one embodiment, the material of the second stop layer206may be different from the material of the second sacrificial film207. The purpose for using different materials for the second stop layer206and the second sacrificial film207may be to stop the etching process on the surface of the second stop layer206when etching the second sacrificial film207in the subsequent etching process. The material of the second stop layer206may be silicon oxide, etc.

In one embodiment, the material of the second sacrificial film207may be amorphous silicon. In some embodiments, the material of the second sacrificial film may also be silicon nitride, silicon carbide, silicon carbonitride, silicon carbon oxynitride, silicon oxynitride, boron nitride, or boron carbonitride, etc.

In one embodiment, the material of the plurality of patterned structures208may be photoresist.

Returning toFIG.15, after forming the plurality of patterned structures, a plurality of second sacrificial layers and a plurality of second sacrificial layer trenches may be formed (S103).FIG.6illustrates a corresponding structure.

As shown inFIG.6, after forming the plurality of patterned structures208, the second sacrificial film207may be etched using the plurality of patterned structures208as an etching mask until the second stop layer206is exposed to form a plurality of discrete second sacrificial layers209and a plurality of sacrificial layer trenches. Each of the plurality of sacrificial layer trenches may be located between two adjacent second sacrificial layers209. The plurality of sacrificial layer trenches may include a first sacrificial layer trench210and a second sacrificial layer trench211. The width of the second sacrificial layer trench211may be greater than the width of the first sacrificial layer trench210. After forming the second sacrificial layers209, the plurality of patterned structures208may be removed.

In one embodiment, the width direction of the first sacrificial layer trench210and the second sacrificial layer trench211may be a direction parallel to the top surface of the second stop layer206.

The process for forming the patterned structures208may include a photolithography patterning process. The process for removing the patterned structures208may include a wet stripping process or an ashing process, etc. In one embodiment, the process for removing the patterned structures208is an ashing process, and the gas of the ashing process may be an oxygen-containing gas, such as oxygen, or ozone, etc.

Returning toFIG.15, after forming the plurality of sacrificial layer trenches, a first sidewall spacer film may be formed (S104).FIG.7illustrates a corresponding structure.

As shown inFIG.7, after removing the patterned structures208, a first sidewall film212may formed on the exposed portions of the top surface of the second stop layer206, and the sidewall surfaces and the top surfaces of the second sacrificial layers209.

The first sidewall film212may be formed by any appropriate process. In one embodiment, the process for forming the first sidewall film212may include an atomic layer deposition (ALD) process. The first sidewall film212formed by the ALD process may have a better step coverage. Further, the thickness of the first sidewall film212may be more uniform, and may be easy to control.

The material of the first sidewall film212may include silicon nitride, or silicon oxynitride, etc. In one embodiment, the material of the first sidewall film212is silicon nitride.

Returning toFIG.15, after forming the first sidewall film, first sidewall spacers and sidewall trenches may be formed (S105).FIG.8illustrates a corresponding structure.

As shown inFIG.8, after forming the sidewall film212, the sidewall film212on the top surface of the second stop layer206and the first sidewall film212on the top surfaces of the second sacrificial layers209may be etched back until the top surface of the second stop layer206and the top surfaces of the second sacrificial layers209are exposed to form a plurality of first sidewall spacers213. Further, the second sacrificial layers209may be removed to form a plurality of sidewall trenches. Each sidewall trench may be located between two adjacent first sidewall spacers213. The plurality of sidewall trenches may include a first sidewall trench214and a second sidewall trench215. The width of the second sidewall trench215may be greater than the width of the first sidewall trench214.

In one embodiment, the width direction of the first sidewall trench214and the second sidewall trench215may be a direction parallel to the top surface of the second stop layer206.

In one embodiment, in particular, the plurality of discrete first sidewall spacers213and the plurality of the sidewall trenches may be formed on the second stop layer206.

The process used for etching back the first sidewall film212may include an anisotropic dry etching process or an anisotropic wet etching process, etc. In one embodiment, the process used to etch back the first sidewall film212is an anisotropic dry etching process. The etching gas may include one or more of fluorine-containing gases, such as CF4, CHF3, or C2F6, etc.

In one embodiment, the ratio between the width of the first sacrificial layer trench210and the thickness of the first sidewall spacer213may be greater than 2:1. The ratio between the width of the second sacrificial layer trench211and the thickness of the first sidewall spacer213may be greater than 2:1. The thickness direction of the first sidewall spacer213may be a direction parallel to the top surface of the second stop layer206.

By setting the widths of the first sacrificial layer trench210and the second sacrificial layer trench211to be greater than twice the thickness of the first sidewall spacer213, the overall width of the first sidewall spacer213and the second sidewall spacer subsequently formed in the first sacrificial layer210may be effectively enlarged. The need for an additional trimming in the subsequent process when the widths of the first sacrificial layer trench210and the second sacrificial layer trench211are relatively small may be avoided; and the production efficiency may be improved.

In one embodiment, after forming the first sidewall spacers213, a second sidewall spacer may be subsequently formed in the first sidewall trench214. The second sidewall spacer may fill the first sidewall trench214.FIGS.9-10illustrate structures corresponding to certain stages during a process for forming the second sidewall spacer.

Returning toFIG.15, after forming the first sidewall spacers, a second sidewall film may be formed (S106).FIG.9illustrates a corresponding structure.

As shown inFIG.9, a second sidewall film216may be formed on the exposed portions of the top surface of the second stop layer206and the sidewall surfaces and the top surfaces of the first sidewall spacers213.

In one embodiment, the second stop layer206may also be used to subsequently stop etching the second sidewall film216to prevent the etching process from continuing to damage the first sacrificial film201.

In one embodiment, the process for forming the second sidewall film216may include an atomic layer deposition (ALD) process, etc.

In one embodiment, the material of the second sidewall film216may be different from the material of the first sidewall film212. Such an arrangement may prevent the subsequent etching process of the second sidewall film216from damaging the first sidewall spacers213. The material of the second sidewall film216may be silicon carbonitride, etc.

Returning toFIG.15, after forming the second sidewall film, a second sidewall spacer may be formed (S107).FIG.10illustrates a corresponding structure.

As shown inFIG.10, the second sidewall film216on the surface of the second sidewall trench215and the top surfaces of the first sidewall spacers213may be etched until the top surface of the second stop layer206and the top surfaces of the first sidewall spacers213are exposed to form the second sidewall spacer217.

In one embodiment, the ratio between the width of the first sidewall trench214and the thickness of the second sidewall spacer217may be less than 2:1, and the ratio between the width of the second sidewall trench215and the thickness of the second sidewall spacer217may be greater than 2:1. The thickness direction of the second sidewall spacer217may be a direction parallel to the second stop layer206.

By setting the width of the first sidewall trench214to be less than twice the thickness of the second sidewall spacer217, while the width of the second sidewall trench215may be set to be greater than twice the thickness of the second sidewall spacer217, it may ensure that, after etching the second sidewall film216, the formed second sidewall spacer217may fill the first sidewall trench214and may not be formed in the second sidewall trenches215. Accordingly, the second sidewall spacer217may be merged with the first sidewall spacers213on both sides of the first sidewall trench214. In the subsequent pattern transfer process, the portion of the to-be-etched layer200corresponding to the merged first sidewall spacers213and the second sidewall spacer217may not form a fin. Thus, there may be no need to use a photolithography patterning process to remove a portion of the fins; and the production time and the production cost may be reduced.

The process used to etch the second sidewall film216may include an isotropic dry etching process, or an isotropic wet etching process, etc. In one embodiment, the process used for etching the second sidewall film216may include an isotropic dry etching process. The parameters of the isotropic dry etching process may include a following combination. The etching gas may include CF4, CHF3, O2, and N2, etc. The flow rate of CF4may be in a range of approximately 50 sccm-500 sccm; the flow rate of CHF3may be in a range of approximately 0 sccm-200 sccm; the flow rate O2may be in a range of approximately 0 sccm-100 sccm; and the flow rate of N2may be in a range of approximately 0 sccm-200 sccm.

Returning toFIG.15, after forming the second sidewall spacer, a plurality of first sacrificial layers may be formed (S108).FIG.11illustrates a corresponding structure.

As shown inFIG.11, the first sacrificial film201may be etched using the first sidewall spacers213and the second sidewall spacer217as an etching mask to form a plurality of first sacrificial layers218on the to-be-etched layer200.

In one embodiment, after forming the plurality of first sacrificial layers218, the method may further include removing the first sidewall spacers213, the second sidewall spacer217, and the second stop layer206.

After removing the first sidewall spacers213, the second sidewall spacer217, and the second stop layer206, third sidewall spacers may be subsequently formed on the sidewall surfaces of the first sacrificial layers218to form third sidewall spacers.FIGS.12-13illustrate structures corresponding to certain stages during the process for forming third sidewall spacers.

Returning toFIG.15, after forming the plurality of first sacrificial layers, a third sidewall film may be formed (S109).FIG.12illustrates a corresponding structure.

As shown inFIG.12, a third sidewall film219may be formed on the exposed portions of the top surface of the to-be-etched layer200and the sidewall surfaces and the top surfaces of the first sacrificial layers218.

In one embodiment, the process for forming the third sidewall film219may include an atomic layer deposition (ALD) process.

The material of the third sidewall film219may include silicon nitride, or silicon oxynitride, etc. In one embodiment, the material of the third sidewall film219is silicon nitride.

Returning toFIG.15, after forming the third sidewall film, a plurality of third sidewall spacers may be formed (S110).FIG.13illustrates a corresponding structure.

As shown inFIG.13, the third sidewall film219on the exposed portions of the top surface of the to-be-etched layer200and the top surfaces of the first sacrificial layers218may be etched back until the top surface of the to-be-etched layer200and the top surfaces of the first sacrificial layers218are exposed to form a plurality of third sidewall spacers220.

In one embodiment, the etching-back process of the third sidewall film219may specifically be stopped at the first stop layer203. Thus, the material of the first stop layer203may different from the material of the third sidewall film219. The material of the first stop layer203may be silicon oxide.

The process used to etch the third sidewall film219may include an anisotropic dry etching process or an anisotropic wet etching process. In one embodiment, the process used to etch the third sidewall film219is an anisotropic dry etching process.

Returning toFIG.15, after forming the third sidewall spacers, a plurality of fins may be formed (S111).FIG.14illustrates a corresponding structure.

As shown inFIG.14, after forming the third sidewall spacers220, the first sacrificial layers218may be removed. Then, the to-be-etched layer200may be etched using the third sidewall spacers220as an etching mask to form a plurality of discrete fins221.

In this embodiment, the plurality of fins221may be formed in the substrate202. the plurality of fins221may be used to subsequently form semiconductor devices.

The plurality of fins221formed by using the third sidewall spacers220as the etching mask may have different spacings to meet the subsequent fabrication requirements of semiconductor devices.

In one embodiment, referring toFIG.14, after forming the plurality of fins221, the third sidewall spacers220, the first stop layer203, and the mask structure may be removed.

The present disclosure also provides a semiconductor structure.FIG.13illustrates a corresponding structure.

As shown inFIG.13, the semiconductor structure includes a to-be-etched layer200and a plurality of first sacrificial layers218formed on the to-be-etched layer200. The semiconductor structure may also include a plurality of third sidewall spacers220formed on the sidewall surfaces of the first sacrificial layers218. The to-be-etched layer200may include a substrate202, a mask structure including a first mask layer204and a second mask layer205on the substrate202, and a first stop layer203on the mask structure. The detailed structures and intermediate structures are described above with respect to the fabrication processes.

The technical solutions of the present disclosure may have at least the following beneficial effects.

In the disclosed fabrication method, in a multiple patterning process, a second sidewall spacer may be used to fill the first sidewall trench to merge the first sidewall spacers at two sides of the first sidewall trench. In the following pattern transfer process, and the portion of the to-be-etched layer corresponding to the merged first sidewall spacers and the second sidewall spacers may not form a fin. Thus, the process for subsequently removing a portion of the fins by a photolithography process may be omitted. Accordingly, the production time and the production cost may be reduced.