Process for and structure of high density VLSI circuits, having inherently self-aligned gates and contacts for FET devices and conducting lines

A process for forming very large scale integrated circuits on a monocrystalline silicon semiconductor substrate having field oxide regions surrounding and isolating at least a first selected area in which a field effect semiconductor device is to be formed and at least a second selected area in which a diffused conducting line is to be formed and having polysilicon line conductors disposed on said field oxide and for providing self-aligned contacts to at least selected ones of said conductors comprising the steps of:

• thermally growing a first silicon dioxide layer on each of said first and second selected areas,
• forming a first silicon nitride layer on said first silicon dioxide layer,
• forming a silicon oxynitride layer on said first silicon nitride layer,
• forming a polysilicon layer on said silicon oxynitride layer extending over said selected areas and said field oxide region,
• forming a second silicon nitride layer on said polysilicon layer,
• forming a second silicon oxynitride layer on said second silicon nitride layer,
• retaining a selected portion of said second silicon oxynitride and second silicon nitride layers overlying said field region as a button having a width dimension larger than the width of a polysilicon line conductor to be formed from said polysilicon layer on said field region and removing remaining portions of said second silicon oxynitride and silicon nitride layers,
• defining a polysilicon gate electrode, extending transversly and centrally of said selected area for said active device, and a polysilicon line conductor, extending at least in part over said field region, of lesser width dimension than said button and intersecting same in an intersection region, to be formed from said polysilicon layer,
• removing portions of said second silicon oxynitride and silicon nitride layers of said button to conform the width of said button to that of said intersection region with said defined polysilicon lend conductor,
• delineating said polysilicon layer to form said line conductor with said conformed button juxtaposed thereon and to form said gate electrode,
• protecting the portions of said first silicon oxynitride and nitride layers on said source and drain regions and on a selected contact area of said diffused conducting line and removing all unprotected portions of said first silicon oxynitride and silicon nitride layers,
• removing the silicon dioxide layer portions exposed by removal of said first nitride layer portions, and removing said second oxynitride layer of said button,
• forming a thermal oxide on exposed surfaces of said gate polysilicon layer, of said polysilicon line conductor, and of said diffused line, and, in sequence,
• removing exposed portions of said first and second oxynitride layers and the thereby exposed portions of said first and second nitride layers,
• removing the exposed portions of said silicon dioxide layer exposed by removal of said portions of said first silicon nitride layer and any oxide on the exposed contact surface of said polysilicon line conductor, thereby to expose said contact surfaces of said source and drain regions, of said diffused conducting line, and of said polysilicon line conductor.

A process for fabricating a field effect semiconductor device having source, drain, and gate regions on a selected area of a first surface of a monocrystalline silicon substrate comprising the steps of:

• thermally growing a silicon dioxide layer on said selected area of said first surface of a thickness suitable for the gate insulator layer of said field effect device,
• forming a first silicon nitride layer on said silicon dioxide layer,
• forming a first silicon oxynitride layer on said first silicon nitride layer,
• forming a polysilicon layer on said first silicon oxynitride layer,
• forming a second silicon nitride layer on said polysilicon layer,
• removing said second nitride layer except for retaining a gate contact surface defining portion thereof extending transversly of said selected area in the region of a gate to be defined,
• protecting said retained portion of said second silicon nitride layer while delineating said polysilicon layer to define a gate polysilicon layer electrode extending transversly of said selected area of said active device of greater width than and in alignment with said retained portion of said second silicon nitride layer, said gate polysilicon layer electrode defining first and second remaining portions of said selected area corresponding to source and drain regions of said device,
• thermally oxidizing the surface of said gate polysilicon layer electrode while retaining said first silicon nitride and silicon oxynitride layers over said source and drain regions of said active device to prevent formation of any substantial amount of oxide thereon,
• removing said retained, second silicon oxynitride layer portion from said gate polysilicon layer electrode and simultaneously removing the portions of said first silicon oxynitride layer from said source and drain regions,
• removing said retained second nitride layer portion from said gate polysilicon layer electrode and simultaneously removing the portions of said first nitride layer portions from said source and drain regions, and
• removing any silicon dioxide from said gate polysilicon electrode exposed by removal of said second silicon nitride and silicon oxynitride layer portions therefrom, to expose the underlying contact surface of said gate polysilicon layer electrode defined thereby, and simultaneously removing said silicon dioxide layer from said source and drain region sources, thereby to provide a direct contact to said gate polysilicon layer electrode.

A process for fabricating a field effect semiconductor device having source, drain, and gate regions on a selected area of a first surface of a monocrystalline silicon substrate comprising the steps of:

• thermally growing a silicon dioxide layer on said selected area of said first surface of a thickness suitable for the gate insulator layer of said field effect device,
• forming a first silicon nitride layer on said silicon dioxide layer,
• forming a first silicon oxynitride layer on said first silicon nitride layer,
• forming a polysilicon layer on said first silicon oxynitride layer,
• forming a protection layer on said polysilicon layer, said protection layer being substantially non-oxidizable by thermal oxidation and being removable by a material-selective removal process having no substantial effect on silicon and silicon dioxide surfaces,
• removing said protection layer except for retaining a gate contact surface defining portion thereof extending transversly of said selected area in the region of a gate to be defined,
• protecting said retained portion of said protection layer while delineating said polysilicon layer to define a gate polysilicon layer electrode extending transversly of said selected area of said active device of greater width than and in alignment with said retained portion of said protection layer, said gate polysilicon layer electrode defining first and second remaining portions of said selected area corresponding to source and drain regions of said device,
• thermally oxidizing the surface of said gate polysilicon layer electrode while retaining said first silicon nitride and silicon oxynitride layers over said source and drain regions of said active device to prevent formation of any substantial amount of oxide thereon,
• removing said retained, protection layer portion from said gate polysilicon layer electrode and removing said first silicon oxynitride and silicon nitride layers from said source and drain regions, and
• removing any silicon dioxide from said gate polysilicon electrode exposed by removal of said protection layer portion therefrom, to expose the underlying contact surface of said gate polysilicon layer electrode defined by said protection layer portion, and simultaneously removing said silicon dioxide layer from said source and drain region sources, thereby to provide a direct contact to said gate polysilicon layer electrode.

A process for forming a self-aligned contact with polysilicon line conductor to be formed at least in part on the field oxide of a semiconductor substrate, comprising:

• forming a polysilicon layer on said substrate extending at least over said field oxide,
• forming a protective button on said polysilicon layer, juxtaposed on the location of a corresponding said polysilicon line conductor to be formed, and of greater width than said line conductor,
• defining said polysilicon line conductor,
• delineating said button to conform in width and location to said defined line conductor,
• delineating said polysilicon layer to form said line conductor with said conformed button juxtaposed thereon, and to form said gate electrode,
• thermally oxidizing said polysilicon line to form an insulating oxide layer thereon while said button prevents thermal oxidation of the line conductor portion on which it is juxtaposed, and
• removing said button by a selective material removal process which does not affect said insulating thermal oxide, thereby to expose the underlying surface portion of said polysilicon line conductor as a contact.

A process for forming very large scale integrated circuits on a monocrystalline silicon semiconductor substrate having field oxide surrounding and isolating at least one selected area in which a field effect semiconductor device is to be formed and having at least one polysilicon line conductor disposed at least in part on said field oxide and for providing self-aligned contacts to at least the source and drain regions of said device and to said polysilicon line conductor at a selected location thereof, comprising the steps of:

• thermally oxidizing the surface of said semiconductor substrate in said selected area to form a first silicon dioxide layer thereon,
• forming a first silicon nitride layer on said first silicon dioxide layer,
• forming a first silicon oxynitride layer on said first silicon nitride layer,
• forming a layer of polysilicon on said first silicon oxynitride layer and on said field oxide,
• forming a protective button on said polysilicon layer, juxtaposed over the location of the corresponding said polysilicon line conductor to be formed, and of greater width and said line conductor,
• defining a polysilicon line conductor to be formed from said polysilicon layer in accordance with the said juxtaposed position of said button and defining a polysilicon gate electrode to be formed in said polysilicon layer, said gate electrode extending transversely and centrally of said selected area for said active device,
• delineating said button to conform in width and location to that of said line,
• delineating said polysilicon layer to provide said polysilicon line conductor and said polysilicon gate electrode,
• thermally oxidizing said polysilicon line conductor and said polysilicon gate electrode to form an insulating oxide on exposed surfaces thereof while said button prevents thermal oxidation of the line portion on which it is juxtaposed and said first silicon nitride and oxynitride layer prevent thermal oxidation of said source and drain regions,
• removing said button and said first silicon oxynitride and nitride layers overlying said source and drain regions of said device,
• removing the silicon dioxide layer portions exposed by removal of said first silicon oxynitride and nitride layers and removing any oxide on the surface of said polysilicon line conductor exposed by removal of said button, thereby to expose said contact surfaces of said source and drain regions and of said diffused conducting line.