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`EXHIBIT H
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`Case 2:20-cv-00048-JRG Document 1-8 Filed 02/21/20 Page 2 of 11 PageID #: 191
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`(12) United States Patent
`Ma et al.
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`USOO6544907B1
`(10) Patent No.:
`US 6,544,907 B1
`(45) Date of Patent:
`*Apr. 8, 2003
`
`(54) METHOD OF FORMING A HIGH QUALITY
`GATE OXDE LAYER HAVING A UNIFORM
`THICKNESS
`
`(75) Inventors: Yi Ma, Orlando, FL (US); Edith Yang,
`Orlando, FL (US)
`
`(*) Notice:
`
`(73) Assignee: Agere Systems Inc., Allentown, PA
`(US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 21 days.
`This patent is Subject to a terminal dis-
`claimer.
`
`(21) Appl. No.: 09/689,030
`
`(22) Filed:
`
`Oct. 12, 2000
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`5,940,736 A * 8/1999 Brady et al. ................ 438/787
`6,027,984 A 2/2000 Thakur et al.
`6,184.110 B1
`2/2001 Ono et al. .................. 438/513
`6,248,618 B1
`6/2001 Quek et al. ................. 438/199
`6,251,800 B1
`6/2001 Sun et al. ................... 438/736
`* cited b
`cited by examiner
`
`Primary Examiner-Caridad Everhart
`(57)
`ABSTRACT
`
`The present invention provides a method for manufacturing
`a high quality oxide layer having a uniform thickness. The
`method includes providing a Semiconductor Substrate, and
`
`(51)
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`
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`- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H01L 21/31
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`forming an oxide layer having a Substantially uniform
`
`O
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`- - - - - - - - - - - - - - - - - - - - - - - 438/787; 438/765; 438/770;
`
`(52)
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`427/2556; 427(255.19
`(58) Field of Search ................................. 438/239, 769,
`438/770, 773,774, 787, 765; 427/255.6,
`255.37, 255.23, 255.19
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`thickness on the Semiconductor Substrate, and in a Zone of
`
`pressure of less than about 4 Torr or greater than about 25
`Torr.
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`17 Claims, 5 Drawing Sheets
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`Case 2:20-cv-00048-JRG Document 1-8 Filed 02/21/20 Page 8 of 11 PageID #: 197
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`1
`METHOD OF FORMING A HIGH QUALITY
`GATE OXDE LAYER HAVING A UNIFORM
`THICKNESS
`
`TECHNICAL FIELD OF THE INVENTION
`The present invention is directed, in general, to integrated
`circuit fabrication and, more Specifically, to a method of
`forming a gate oxide layer having a Substantially uniform
`thickness.
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`US 6,544,907 B1
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`uniform gate oxides. In previous thicker gate oxide designs
`this non-uniformity was acceptable as discussed above. But,
`with the ultra thin gate oxides required by today's Semicon
`ductor devices. This non-uniformity is unacceptable because
`it can decrease the device's Overall quality and in Some
`instances can even cause complete failure of the device.
`Accordingly, what is needed in the art is a method of
`manufacturing a highly reliable, ultra thin and reliable oxide
`layer, that does not experience the problems associated with
`the prior art methods. The present invention addresses this
`need.
`
`BACKGROUND OF THE INVENTION
`Over the last Several decades, the electronics industry has
`undergone a revolution by the use of Semiconductor tech
`nology to fabricate Small, highly integrated electronic
`devices. Moreover, a large variety of Semiconductor devices
`having various applicability and numerous disciplines have
`been manufactured. One Such Silicon-based Semiconductor
`device that has wide use is a metal-oxide-Semiconductor
`(MOS) transistor.
`An important Step in the manufacturing of a MOS device
`is the formation of the gate oxide layer. The quality and
`uniformity of the gate oxide is critical to the proper opera
`tion of any MOS transistor. The gate oxide layer is typically
`grown in active regions of the device. In order to obtain
`reliable, high-quality gate oxides, the Surface of the active
`area is often wet-etched to remove any residual oxide. The
`gate oxide is then grown slowly, typically through a wet
`oxidation in an oxygen, hydrogen and nitrogen ambient
`atmosphere or a dry oxidation in an oxygen and nitrogen
`ambient atmosphere. It is important to carefully control the
`growth of the gate oxide layer because the thickness and
`uniformity of the gate oxide layer can Significantly impact
`the overall operation of the device being formed. For
`example, the drain current in a MOS transistor is inversely
`proportional to the gate oxide thickness at a given set of
`terminal Voltages. In order to maintain proper transistor
`operation, which have shrunk well into the Submicron range,
`the thickness of the gate oxide has shrunk in a corresponding
`fashion to maintain optimal and efficient operation of the
`transistors. Thus, it is highly desirable to make the gate
`oxide as thin as possible, taking into consideration the oxide
`breakdown and reliability considerations of the process and
`technology being used, while maintaining the robustneSS
`and electrical isolation integrity of the gate oxide.
`AS the Overall thickness of the gate oxide layer continues
`to decrease (e.g., currently it is less than 1.7 nm), the
`thickness uniformity of the gate oxide layer (e.g., SiO2)
`becomes ever more critical and at the same time, more
`problematic. In the past when the gate oxide layer had a
`thickness of greater than about 10.0 nm, a 0.3 nm variation
`in gate oxide thickness over the Surface of the gate oxide
`layer amounted to less than a 3 percent variation. However,
`as mentioned above, gate oxide thicknesses of less than
`about 1.7 nm are currently being manufactured, and this
`Same 0.3 nm variation in thickness amounts to about a 17
`percent variation. Such Substantial variations in thickneSS
`over the Surface of the gate oxide layer are highly undesir
`able and known to be quite problematic.
`To overcome the above mentioned gate dielectric non
`uniformity issues, the Semiconductor manufacturing indus
`try developed new gate oxide layer manufacturing tech
`niques. Currently, the Semiconductor manufacturing
`industry manufactures gate oxide layers at preSSures ranging
`from about 10 Torr to about 15 Torr. However, forming gate
`oxides within these pressure ranges produce very non
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`SUMMARY OF THE INVENTION
`To address the above-discussed deficiencies of the prior
`art, the present invention provides a method for manufac
`turing a high quality oxide layer having a uniform thickness.
`In one embodiment, the method includes providing a Semi
`conductor Substrate, and forming a gate oxide layer having
`a Substantially uniform thickness on the Semiconductor
`Substrate and in a Zone of pressure of less than about 4 Torr
`or greater than about 25 Torr.
`It has been unexpectedly found that if the gate oxide layer
`is formed within these pressure ranges, a Substantially
`uniform gate oxide layer can be formed. Thus, the unifor
`mity problems associated with the prior art methods can be
`avoided. In fact, the flexibility in processing conditions,
`including the range of temperatures, range of fluid flows and
`type of fluid used, may be altered without Substantially
`affecting the quality, thickneSS or uniformity of the oxide
`layer.
`Another aspect of the invention provides a method of
`manufacturing an integrated circuit. The method of manu
`facturing the integrated circuit consists of (1) forming a
`transistor device over a Substrate, including: forming a gate
`oxide layer having a Substantially uniform thickneSS on the
`Semiconductor Substrate and in a Zone of pressure of leSS
`than about 4 Torr or greater than about 25 Torr, and forming
`a transistor gate layer over the gate oxide layer, and (2)
`forming interconnect Structures in dielectric layers located
`over the transistor device, the interconnect Structures con
`tacting the transistor device to form a completed integrated
`circuit.
`The foregoing has outlined, rather broadly, preferred and
`alternative features of the present invention So that those
`skilled in the art may better understand the detailed descrip
`tion of the invention that follows. Additional features of the
`invention will be described hereinafter that form the subject
`of the claims of the invention. Those skilled in the art should
`appreciate that they can readily use the disclosed conception
`and Specific embodiment as a basis for designing or modi
`fying other Structures for carrying out the same purposes of
`the present invention. Those skilled in the art should also
`realize that Such equivalent constructions do not depart from
`the Spirit and Scope of the invention in its broadest form.
`BRIEF DESCRIPTION OF THE DRAWINGS
`The invention is best understood from the following
`detailed description when read with the accompanying FIG
`URES. It is emphasized that in accordance with the standard
`practice in the Semiconductor industry, various features are
`not drawn to Scale. In fact, the dimensions of the various
`features may be arbitrarily increased or reduced for clarity of
`discussion. Reference is now made to the following descrip
`tions taken in conjunction with the accompanying drawings,
`in which:
`FIG. 1 illustrates a partial Sectional view of an exemplary
`embodiment of a Semiconductor feature formed in accor
`dance with the principals of the present invention;
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`Turning to FIGS. 2-4, illustrated are graphical represen
`tations illustrating the benefits of forming the oxide layer
`120 at pressures of less than about 4 Torr, or pressures of
`greater than about 25 Torr. Traditionally, gate oxides are
`presently formed at pressures ranging from about 10 Torr to
`about 18 Torr, and any variation in the processing
`conditions, including fluid mixture content, fluid mixture
`temperature and flow rate, caused the Surface of the gate
`oxide to be substantially nonuniform.
`FIG. 2 illustrates a thickness versus pressure profile 200
`for three different mixtures, each containing differing
`amounts of oxygen and hydrogen. In the illustrated thick
`ness versus pressure profile 200, it should be understood that
`the other processing parameters, for example mixture tem
`perature and mixture flow rate, are held constant. A first line
`210 represents a gate oxide layer formed using a first
`mixture, wherein the first mixture comprises 1 liter of
`oxygen and 0.33 liters of hydrogen. Similarly, a Second line
`220 represents a gate oxide layer formed using a Second
`mixture, wherein the Second mixture comprises 2 liters of
`oxygen and 0.66 liters of hydrogen. Likewise, a third line
`230 represents a gate oxide layer formed using a third
`mixture, wherein the third mixture comprises 3 liters of
`oxygen and 0.99 liters of hydrogen.
`AS can be determined from the thickneSS verSuS preSSure
`profile 200 illustrated in FIG. 2, at pressures of less than
`about 1 Torr, and independent of the variations in mixture
`content, oxide layerS 120 having Substantially similar thick
`nesses are formed. Furthermore, it is believed that the first
`line 210, second line 220 and third line 230 may be
`extrapolated and that at a pressure of greater than about 25
`Torr, oxide layers 120 having substantially similar thick
`nesses will also be formed.
`In contrast, pressures between about 5 Torr and 18 Torr do
`not provide Substantially similar thicknesses for each of the
`three examples. For example, it can be observed at a
`preSSure of about 5 Torr, that the thickness of the gate oxide
`formed with the mixture represented by the first line 210 is
`about 2.5 nm, the thickness of the gate oxide formed by the
`mixture represented by the second line 220 is about 2.9 nm,
`and the thickness of the mixture represented by the third line
`230 is about 3.3 nm. What may be understood from the
`results of the thickness versus pressure profile 200 illustrated
`in FIG. 2, is that at pressures of less than about 1 Torr and
`greater than about 25 Torr, the mixture of the forming gas
`may vary without Substantially changing the thickness of the
`gate oxide layer 120. It should be noted, however, that even
`though the mixture of the forming gas was varied in the
`thickness versus pressure profile 200 illustrated in FIG. 2, at
`preSSures of less than about 1 Torr and greater than about 25
`Torr, Varying the mixture temperature or mixture flow rate
`would provide Substantially the same results, which is
`indicated by the convergence of the three different Sample
`lines 210, 220, 230.
`Turning to FIG. 3, illustrated is a percent standard devia
`tion versus pressure profile 300. This percent standard
`deviation versus pressure profile 300 illustrates variations in
`thickness of the gate oxide layer 120, while being formed at
`the three previously mentioned mixtures and various pres
`Sures. Generally, less than a 1 percent Standard deviation in
`thickness across the gate oxide layer 120 is desired.
`However, even more desirable is a percent Standard devia
`tion in thickness acroSS the gate oxide layer 120 of less than
`about 0.5. AS can be seen by the percent Standard deviation
`versus pressure profile 300, at pressures less than about 3 or
`4 Torr the percent Standard deviation is Substantially leSS
`than about 1 percent, and more specifically, at about 0.5
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`FIG. 2 illustrates a thickness verSuS pressure profile;
`FIG. 3 illustrates a percent standard deviation versus
`preSSure profile;
`FIG. 4 illustrates range of thickneSS verSuS pressure
`profile; and
`FIG. 5 illustrates a sectional view of a conventional
`integrated circuit that might be manufactured according to
`the principles of the present invention.
`DETAILED DESCRIPTION
`Referring initially to FIG. 1, illustrated is a partial sec
`tional view of an exemplary embodiment of a Semiconductor
`feature 100 formed in accordance with the principals of the
`present invention. The semiconductor feature 100 includes a
`semiconductor Substrate 110. The semiconductor Substrate
`110 may be any layer located in the semiconductor feature
`100, including a wafer itself or a layer located above the
`wafer.
`Formed over the semiconductor Substrate 110 is a high
`quality gate oxide layer 120. The gate oxide layer 120, as a
`result of the method covered by the present invention and
`used to form Such a layer, has a Substantially uniform
`thickness. The gate oxide layer 120, in a preferred
`embodiment, has a thickness of less than about 5.0 nm, and
`even more preferably, a thickness of less than about 2.0 nm.
`It should be noted that the gate oxide layer 120 may have a
`thickneSS Substantially greater than about 5.0 nm, but its use
`is particularly advantageous in Submicron technologies of
`0.25 um or less.
`A method for forming the gate oxide layer 120 on the
`semiconductor Substrate 110 will now be discussed. To form
`the gate oxide layer 120, the semiconductor substrate 110, in
`an advantageous embodiment is Subjected to an oxidation
`process, typically by placing the Semiconductor wafer
`within a vacuum chamber. In one particular example, the
`gate oxide layer 120 may be grown using a wet oxidation
`process, however, in should be noted that the gate oxide
`layer 120 may also be formed using a dry oxidation process.
`For example, in one particularly advantageous embodiment,
`the gate oxide layer 120 may be grown by flowing a mixture
`of gases, including hydrogen and oxygen, Over the Semi
`conductor Substrate 110 surface. It should be noted, though,
`that the present invention is not limited to the oxygen and
`hydrogen gases, and that other gases, for example nitrogen,
`may be contained within the mixture. The flow rates of the
`various gases may vary dramatically, however, an oxygen
`flow rate ranging from about 0.5 SLM to about 5 SLM, a
`hydrogen flow rate ranging from about 1.0 Scem to about 2
`SLM and a nitrogen flow rate ranging from about 1.0 SLM
`to about 20 SLM, may be used in one exemplary embodi
`50
`ment. It should be further noted that other similar oxide
`forming gases may be used in place of those mentioned
`above, and thus, are also within the Scope of the present
`invention. In a preferred embodiment, the temperature of the
`mixture ranges from about 700° C. to about 1250° C., but
`other temperatures mayS also be used.
`During the formation of the oxide layer 120 the chamber
`should be maintained at a pressure of less than about 4 Torr
`or a pressure of greater than about 25 Torr. In another
`advantageous embodiment, the pressure may be less than
`about 1 Torr or greater than about 25 Torr. These pressures
`provide unexpected results over conventional formation
`preSSures, mainly, it has been found that forming the oxide
`layer 120 within either of these preSSure ranges produces a
`much more uniform oxide layer acroSS the Semiconductor
`Substrate than a layer that is formed using the conventional
`preSSures discussed above.
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`parameter within the window does not substantially effect
`the quality, thickness or uniformity of the gate oxide layer
`120. From the above-mentioned graphs, it can be seen that
`a pressure of less than about 4 Torr or a pressure of about 25
`Torr, provides Such a processing window. These results are
`quite unexpected in View of the conventional preSSures at
`which gate oxides are typically formed. In an alternative
`embodiment, a preSSure ranging from about 1 mTorr to
`about 1 Torr or a pressure ranging from about 25 Torr to
`about 500 Torr, also provides Such a processing window.
`Such preSSures also lead to process robustness and much
`better proceSS repeatability.
`Turning briefly to FIG. 5, there is illustrated a sectional
`view of a conventional integrated circuit 500 that might be
`manufactured according to the principles of the present
`invention. The integrated circuit 500 may include a CMOS
`device, a BiCMOS device, a Bipolar device, or other type of
`integrated circuit device. Shown in FIG. 5 are components
`of the conventional integrated circuit 500, including: tran
`sistors 510, including the gate oxide layer 120, and dielectric
`layers 520, in which interconnect structures 530 are formed
`(together forming interconnect layers). In the embodiment
`shown in FIG. 5, the interconnect structures 530 connect the
`transistors 510 to other areas of the integrated circuit 500.
`Also shown in the integrated circuit 500 shown in FIG. 5, are
`conventionally formed tubs, 540, 545, and source regions
`550 and drain regions 555.
`Although the present invention has been described in
`detail, those skilled in the art should understand that they can
`make various changes, Substitutions and alterations herein
`without departing from the Spirit and Scope of the invention
`in its broadest form.
`What is claimed is:
`1. A method for manufacturing a high quality oxide layer
`having a uniform thickness, comprising:
`providing a Semiconductor Substrate, and
`forming a gate oxide layer having a Substantially uniform
`thickness on the Semiconductor Substrate, the gate
`Oxide layer having a range of thicknesses that varies by
`less than about 0.2 nm.
`2. The method as recited claim 1 wherein forming a gate
`oxide layer includes growing a gate oxide layer in the
`presence of oxygen, hydrogen or nitrogen.
`3. The method as recited in claim 2 wherein forming a
`gate oxide layer in the presence of oxygen includes forming
`a gate oxide layer in the presence of oxygen having a flow
`rate ranging from about 0.5 SLM to about 5 SLM.
`4. The method as recited in claim 2 wherein forming a
`gate oxide layer in the presence of hydrogen includes
`forming a gate oxide layer in the presence of hydrogen
`having a flow rate ranging from about 1.0 ScCm to about 2
`SLM.
`5. The method as recited in claim 2 wherein forming a
`gate oxide layer in the presence of nitrogen includes forming
`a gate oxide layer in the presence of nitrogen having a flow
`rate ranging from about 1.0 SLM to about 20 SLM.
`6. The method as recited in claim 1 wherein forming a
`gate oxide layer includes forming a gate oxide layer at a
`temperature ranging from about 750° C. to about 1250 C.
`7. The method as recited in claim 1 wherein forming a
`gate oxide layer includes forming a gate oxide layer having
`a thickness of less than about 5.0 nm.
`8. A method of manufacturing an integrated circuit, com
`prising:
`forming a transistor device over a Substrate, including:
`forming a gate oxide layer having a Substantially uni
`form thickness on the Semiconductor Substrate, the
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`percent. It is also believed that if the first line 210, the second
`line 220 and the third line 230 were extrapolated to a
`pressure of about 25 Torr, the same would hold true. Thus,
`at preSSures less than about 3 or 4 Torr and greater than about
`25 Torr, the percent standard deviation is in the desired
`range, independent of variations of mixture, mixture tem
`perature and gas flow rate.
`In contrast, it can be observed that at preSSures ranging
`from about 5 Torr to about 18 Torr, the percent standard
`deviation is Substantially higher than 1 percent, which as
`previously mentioned is undesirable. For example, it can be
`observed at a pressure of about 10 Torr, that the percent
`standard deviation of the gate oxide formed with the mixture
`represented by the first line 210 is about 2.8, the percent
`Standard deviation of the gate oxide formed by the mixture
`represented by the second line 220 is about 3.7, and the
`percent Standard deviation of the mixture represented by the
`third line 230 is about 4.5. Thus, at pressures such as 10 Torr,
`not only is the percent Standard deviation much higher than
`1 percent, but the percent Standard deviation varies from
`about 2.8 to about 4.5 with variations in the fluid mixture. It
`should be noted, however, that the mixture of the oxidizing
`agent was varied in the percent Standard deviation verSuS
`pressure profile 300 illustrated in FIG.3, but that varying the
`mixture temperature or mixture flow rate would provide
`Substantially the same results, if using pressures of less than
`about 3 or 4 Torr and greater than about 25 Torr.
`Turning to FIG. 4, illustrated is a range verSuS pressure
`profile 400. This range versus pressure profile 400 illustrates
`the range of thicknesses in angstroms (A) that may occur for
`the three given mixtures, at various preSSures. AS can be seen
`from the range verSuS pressure profile 400, at pressures leSS
`than about 3 or 4 Torr, and independent of the mixture of gas
`used to form the gate oxide layer 120, less than about a 2 A
`variation in thickneSS occurs in the gate oxide layer 120.
`35
`Likewise, it is believed that if the first line 210, second line
`220 and third line 230 were extrapolated past about 25 Torr,
`the same would hold true. Thus, at pressures less than about
`3 or 4 Torr and greater than about 25 Torr, the range of
`thickness within a given gate oxide layer 120 is less than
`about 2 A (0.2 nm), independent of variations of mixture,
`mixture temperature and gas flow rate.
`In contrast, it can be observed that at preSSures ranging
`from about 5 Torr to about 18 Torr, the range of thicknesses
`are substantially higher than 2 A (0.2 nm), which with the
`ever decreasing thicknesses of gate oxides, is undesirable.
`Take for example a pressure of about 10 Torr, wherein the
`variation in thickness of the gate oxide formed with the
`mixture represented by the first line 210 is about 7.5 A (0.75
`nm), the variation in thickness of the gate oxide formed by
`the mixture represented by the second line 220 is about 9.9
`A (0.99 nm), and the variation in thickness of the mixture
`represented by the third line 230 is about 11.7 A (1.17 nm).
`Not only is the range Substantially larger than 2 A, it is not
`constant for the different fluid mixtures represented by the
`three lines 210, 220, 230. It should also be noted that the
`mixture of the forming gas was varied in the range verSuS
`pressure profile 400 illustrated in FIG. 4, but that at pres
`Sures of less than about 3 or 4 Torr and greater than about
`25 Torr, Varying the mixture temperature or mixture flow
`rate would provide Substantially the same results.
`What may be derived from the three profiles 200, 300,
`400, illustrated in FIGS. 2-4, is an optimal range of pres
`Sures at which to form the gate oxide layer 120 having a
`Substantially uniform thickness. Moreover, a range of pres
`Sures may be determined to provide a wide processing
`parameter window, wherein changing any processing
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`gate oxide layer having a range of thicknesses that
`varies by less than about 0.2 nm, and
`forming a transistor gate layer over the gate oxide
`layer; and
`forming interconnect Structures located over the transistor
`device, the interconnect Structures contacting the tran
`Sistor device to form a completed integrated circuit.
`9. The method as recited in claim 8 wherein forming a
`gate oxide layer includes growing a gate oxide layer in the
`presence of oxygen, hydrogen or nitrogen.
`10. The method as recited in claim 9 wherein forming a
`gate oxide layer in the presence of oxygen includes forming
`a gate oxide layer in the presence of oxygen having a flow
`rate ranging from about 0.5 SLM to about 5 SLM.
`11. The method as recited in claim 9 wherein forming a
`gate oxide layer in the presence of hydrogen includes
`forming a gate oxide layer in the presence of hydrogen
`having a flow rate ranging from about 1.0 ScCm to about 2
`SLM.
`12. The method as recited in claim 9 wherein forming a
`gate oxide layer in the presence of nitrogen includes forming
`a gate oxide layer in the presence of nitrogen having a flow
`rate ranging from about 1.0 SLM to about 20 SLM.
`13. The method as recited in claim 8 wherein forming a
`gate oxide layer includes forming a gate oxide layer at a
`temperature ranging from about 750° C. to about 1250 C.
`
`1O
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`15
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`25
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`US 6,544,907 B1
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`8
`14. The method as recited in claim 8 wherein forming a
`gate oxide layer includes forming a gate oxide layer having
`a thickness of less than about 5.0 nm.
`15. The method as recited in claim 8 wherein the com
`pleted integrated circuit includes devices Selected from the
`group consisting of
`CMOS devices,
`BiCMOS devices, and
`Bipolar devices.
`16. A Semiconductor device, comprising:
`a Substrate;
`a gate oxide layer located over the Substrate and having a
`thickness of less than about 5 nm and wherein a range
`of thickness layer varies by less than about 0.2 nm.
`17. A Semiconductor device, comprising:
`a Substrate;
`a gate oxide layer located over the Substrate and having a
`thickness of less than about 5 nm and that has less than
`a 1 percent deviation in the thickness across the gate
`Oxide layer.
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