Patterning semiconductor materials using surface modification techniques

The method addresses the challenge of precise etch selectivity and contour control in semiconductor manufacturing by using a plasma-treated surface modification layer to achieve varying etch rates, reducing complexity and mitigating etch hysteresis without additional layers, enabling efficient formation of features with different critical dimensions.

TW202633394APending Publication Date: 2026-08-01TOKYO ELECTRON LTD
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Patent Information

Application Number
TW114136320
Authority / Receiving Office
TW · TW
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-09-26
Filing Date
2025-09-22
Publication Date
2026-08-01

AI Technical Summary

Technical Problem

The challenge in semiconductor manufacturing lies in achieving precise etch selectivity and contour control as feature sizes shrink, leading to complex patterning schemes and etching defects, necessitating multiple processes and additional layers that complicate and prolong the manufacturing process.

Method used

A method involving a plasma treatment to form a surface modification layer with enhanced etch selectivity, allowing different regions of the semiconductor layer to be removed at varying rates, thereby forming features of varying depths without the need for additional etch stop layers, and enabling precise control over etch resistance and selectivity.

Benefits of technology

This method achieves precise etch selectivity and contour control, mitigating etch hysteresis and reducing process complexity by allowing features of different critical dimensions to be formed efficiently, without requiring additional thin films or etch formulation changes, and can be tailored to adjust etch resistance and selectivity.

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Abstract

A method includes forming a mask over a semiconductor layer. The method includes first patterning the mask to form a first opening that exposes a first portion of the semiconductor layer. The method includes performing a plasma treatment to form a surface modification layer over the exposed first portion. The method includes second patterning the mask to form a second opening that exposes a second portion of the semiconductor layer, thereby forming a patterned mask that defines the first and second openings. The method includes performing an etching process to the semiconductor layer through the patterned mask to form a first trench extending from the first opening and a second trench extending from the second opening. The etching process removes the first portion at a first rate and the second portion at a second rate that is greater than the first rate.
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