Method for manufacturing static random access memory device

Patent metadata

Field	Value
Publication number	US-9842843-B2
Application number	US-201514958592-A
Country	US
Kind code	B2
Filing date	Dec 3, 2015
Priority date	Dec 3, 2015
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

In a method of manufacturing an SRAM device, an insulating layer is formed over a substrate. First dummy patterns are formed over the insulating layer. Sidewall spacer layers, as second dummy patterns, are formed on sidewalls of the first dummy patterns. The first dummy patterns are removed, thereby leaving the second dummy patterns over the insulating layer. After removing the first dummy patterns, the second dummy patterns are divided. A mask layer is formed over the insulating layer and between the divided second dummy patterns. After forming the mask layer, the divided second dummy patterns are removed, thereby forming a hard mask layer having openings that correspond to the patterned second dummy patterns. The insulating layer is formed by using the hard mask layer as an etching mask, thereby forming via openings in the insulating layer. A conductive material is filled in the via openings, thereby forming contact bars.

First claim

What is claimed is:

1. A method of manufacturing a static random access memory (SRAM) device including a plurality of SRAM cells, the method comprising:
forming an insulating layer over a substrate;
forming first dummy patterns over the insulating layer;
forming sidewall spacer layers, as second dummy patterns, on sidewalls of the first dummy patterns;
removing the first dummy patterns, thereby leaving the second dummy patterns over the insulating layer;
after removing the first dummy patterns, dividing each of the second dummy patterns into plural pieces of the second dummy patterns;
forming a mask layer over the insulating layer and between the plural pieces of the second dummy patterns;
after forming the mask layer, removing the plural pieces of the second dummy patterns, thereby forming a hard mask layer having openings that correspond to the plural pieces of the second dummy patterns;
patterning the insulating layer by using the hard mask layer as an etching mask, thereby forming via openings in the insulating layer; and
filling a conductive material in the via openings, thereby forming contact bars.

2. The method of claim 1 , wherein:
the forming first dummy patterns includes:
forming a first material layer over the insulating layer;
forming a resist layer over the first material layer;
patterning the resist layer by using a first photo mask; and
patterning the first material layer by using the patterned resist layer as an etching mask, thereby forming the first dummy pattern, and

in the first photo mask, only one rectangular pattern extending in a row direction of the SRAM device is included in an area corresponding to each of the plurality of SRAM unit cells.

3. The method of claim 1 , wherein in an area corresponding to each of the plurality of SRAM unit cells, one second dummy pattern is disposed in the area and two second dummy patterns are disposed on upper and lower boundaries of the area extending in a row direction.

4. The method of claim 1 , wherein:
each of the SRAM unit cells includes six fin field effect transistors (Fin FETs), and
the contact bars are connected to sources and drains of the Fin FETs.

5. The method of claim 1 , wherein the first dummy patterns are made of a different material than the second dummy patterns.

6. The method of claim 1 , wherein the second dummy patterns are made of a different material than the mask layer.

7. The method of claim 1 , wherein the via openings are formed by using two photo masks in two lithography operations.

8. A method of manufacturing a static random access memory (SRAM) device including a plurality of SRAM cells, the method comprising:
forming an insulating layer over a substrate;
forming a first mask layer over the insulating layer;
forming first dummy patterns over the first mask layer;
forming sidewall spacer layers, as second dummy patterns, on sidewalls of the first dummy patterns;
removing the first dummy patterns, thereby leaving the second dummy patterns over the first mask layer;
after removing the first dummy patterns, dividing each of the second dummy patterns into plural pieces of the second dummy patterns;
forming a second mask layer over the first mask layer and between the plural pieces of the second dummy patterns;
after forming the second mask layer, removing the plural pieces of the second dummy patterns, thereby forming a first hard mask layer having openings that correspond to the plural pieces of the second dummy patterns;
patterning the first mask layer by using the first hard mask layer as an etching mask, thereby forming a second mask layer;
patterning the insulating layer by using the second hard mask layer as an etching mask, thereby forming via openings in the insulating layer; and
filling a conductive material in the via openings, thereby forming contact bars.

9. The method of claim 8 , wherein:
the forming first dummy patterns includes:
forming a first material layer over the first mask layer;
forming a resist layer over the first material layer;
patterning the resist layer by using a first photo mask; and
patterning the first material layer by using the patterned resist layer as an etching mask, thereby forming the first dummy pattern, and

in the first photo mask, only one rectangular pattern extending in a row direction of the SRAM device is included in an area corresponding to each of the plurality of SRAM unit cells.

10. The method of claim 8 , wherein in an area corresponding to each of the plurality of SRAM unit cells, one second dummy pattern is disposed in the area and two second dummy patterns are disposed on upper and lower boundaries of the area extending in a row direction.

11. The method of claim 8 , wherein:
each of the SRAM unit cells includes six fin field effect transistors (Fin FETs), and
the contact bars are connected to sources and drains of the Fin FETs.

12. The method of claim 8 , wherein the first dummy patterns are made of a different material than the second dummy patterns.

13. The method of claim 8 , wherein the second dummy patterns are made of a different material than the first mask layer.

14. The method of claim 8 , wherein the first mask layer is made of a different material than the second mask layer.

15. The method of claim 8 , wherein the via openings are formed by using two photo masks in two lithography operations.

16. A method of manufacturing a static random access memory (SRAM) device including a plurality of SRAM cells, the method comprising:
forming a first insulating layer over a substrate;
forming a first layer over the first insulating layer;
forming first dummy patterns over the first layer;
forming sidewall spacer layers, as second dummy patterns, on sidewalls of the first dummy patterns;
removing the first dummy patterns, thereby leaving the second dummy patterns over the first layer;
dividing each of the second dummy patterns into plural pieces of the second dummy patterns; and
patterning the first layer by using the plural pieces of the second dummy patterns as an etching mask, thereby forming gate patterns.

17. The method of claim 16 , wherein:
the forming first dummy patterns includes:
forming a first material layer over the first layer;
forming a resist layer over the first material layer;
patterning the resist layer by using a first photo mask; and
patterning the first material layer by using the patterned resist layer as an etching mask, thereby forming the first dummy pattern, and

in the first photo mask, only one rectangular pattern extending in a row direction of the SRAM device is included in an area corresponding to each of the plurality of SRAM unit cells.

18. The method of claim 16 , wherein in an area corresponding to each of the plurality of SRAM unit cells, only one first dummy pattern is disposed on a center line of the area extending in a row direction.

19. The method of claim 16 , wherein the first layer, first dummy patterns and the second dummy patterns are made of different materials from each other.

20. The method of claim 17 , further comprising:
before forming the first material layer, forming fin structures over the substrate;
after forming the gate electrode:
forming source/drain regions in the fin structures;
forming a second insulating layer over the gate electrodes and the source/drain regions;
forming a first mask layer over the second insulating layer;
forming third dummy patterns over the first mask layer;
forming sidewall spacer layers, as fourth dummy

Assignees

• Taiwan Semiconductor Mfg Co Ltd

Inventors

• Liaw Jhon Jhy

Classifications

• H10P76/4088

  Processes for improving the resolution of the masks · CPC title

• H10P76/4085

  characterised by the processes involved to create the masks · CPC title

• H10P76/2041

  Photolithographic processes · CPC title

• H10P50/73

  using masks for insulating materials · CPC title

• H10D64/01328

  by defining the conductor using a sidewall spacer mask, a transformation under a mask or a plating at a sidewall · CPC title