Method for Manufacturing a Semiconductor Device Utilizing a Self-Aligned Contact Process

1. A method for forming a semiconductor device which comprises a plurality of segment separation oxide layers formed on a silicon substrate, with each segment separation oxide layer being spaced apart relative to each other; a plurality of MOSFETs formed on the silicon substrate in which each MOSFET includes a plurality of diffusion regions formed into the silicon substrate between the segment separation oxide layers, with each diffusion region being spaced apart relative to each other and having a lightly doped diffusion region, a gate oxide layer formed on the silicon substrate extending between the spaced apart segment separation oxide layers, and a plurality of gate electrodes formed on the gate oxide layer, with each gate electrode being spaced apart relative to each other and relative to each segment separation oxide layer; a plurality of gate electrode lines formed on each segment separation oxide layer with oxide spacers formed on each side of each gate electrode and each gate electrode line; and a first insulating layer formed on each gate electrode and each gate electrode line, wherein the improvement for forming the semiconductor device to selectively connect a conducting layer to each diffusion region positioned between MOSFETs of the plurality of MOSFETs, and to each gate electrode line by utilizing a self-aligned contact process, comprises: sequentially depositing an undoped polysilicon layer, a nitride layer and a photoresistive layer on the entire surface of the resulting semiconductor device; removing the photoresist layer except for those portions of the photoresist layer positioned above each gate electrode lines and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes of the plurality of gate electrodes to thereby define contact regions positioned over each diffusion region which is positioned between the gate electrodes of the MOSFETs of the plurality of MOSFETs, and over each gate electrode lines, respectively, thereby exposing the nitride layer except for those portions of the nitride layer positioned at the contact regions; removing the nitride layer except for those portions of the nitride layer positioned at the defined contact regions, thereby exposing portions of the undoped polysilicon layer; performing an ion-implantation process on the exposed portions of the undoped polysilicon layer to thereby form the exposed portions of the undoped polysilicon layer into a doped polysilicon layer; removing the photoresist layer remaining above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes, thereby exposing the nitride layer remained at the contact regions; thermally oxidizing the exposed doped polysilicon layer, thereby forming a thermal oxide layer on and into the exposed dope polysilicon layer; sequentially removing the exposed nitride layer and the exposed underlying undoped polysilicon layer remaining at the defined contact regions to thereby expose the first insulating layer formed on each gate electrode line and to expose the gate oxide layer formed on each gate electrode line and to expose the gate oxide layer formed over the diffusion region positioned between the gate electrodes, respectively; forming a contact hole at each contact region by etching the thermal oxide layer, the exposed gate oxide layer positioned over the diffusion region and the first insulating layer positioned on the each gate electrode lines and a surface of each diffusion region positioned between gate electrodes of the plurality of gate electrodes, respectively; depositing a conducting layer on the entire surface of the resulting structure comprising the thermal oxide layer and the contact holes; and removing the conducting layer except for those portions of the conducting layer deposited in and proximate to each contact hole such that each portion of the conducting layer forms a contact at each gate electrode lines, respectively, and a contact at each diffusion region positioned between MOSFETs of the plurality of MOSFETs, thereby enabling a selective connection to be made at each diffusion region positioned between MOSFETs of the plurality of MOSFETs and at each gate electrode line, respectively.

2. The method of claim 1 wherein the first insulating layer is formed with oxide.

3. The method of claim 1 wherein the ion-implantation of the exposed undoped polysilicon layer is performed utilizing a dopant source selected from the group consisting of: B(Boron), BF.sub.2 (Boron-Fluorine), P(Phosphorus) or As (Arsenic), to thereby form the exposed portion of the undoped polysilicon layer into a doped polysilicon layer having an impurity-concentration of 1.times.10.sup.18 -5.times.10.sup.21 cm.sup.-3.

4. The method of claim 1 wherein the thermal oxidation of the exposed doped polysilicon layer is performed by thermally oxidizing the exposed doped polysilicon layer at a temperature of 200-1000 degree Celsius for a period of 10-120 minutes.

5. A method for forming a semiconductor device which comprises a plurality of segment separation oxide layers formed on a silicon substrate, with each segment separation oxide layer being spaced apart relative to each other; a plurality of MOSFETs formed on the silicon substrate in which each MOSFET includes a plurality of diffusion regions formed into the silicon substrate between the segment separation oxide layers, with each diffusion region being spaced apart relative to each other and having a lightly doped diffusion region, a gate oxide layer formed on the silicon substrate extending between the spaced apart segment separation oxide layers, and a plurality of gate electrodes formed on the gate oxide layer, with each gate electrode being spaced apart relative to each other and relative to each segment separation oxide layer; a plurality of gate electrode lines formed on each segment separation oxide layer with oxide spacers formed on each side of each gate electrode and each gate electrode line; and a first insulating layer formed on each gate electrode and each gate electrode line, wherein the improvement for forming the semiconductor device to selectively connect a conducting layer to each diffusion region positioned between MOSFETs of the plurality of MOSFETs, and to each gate electrode line by utilizing a self-aligned contact process, comprises: sequentially depositing an undoped polysilicon layer, a nitride layer and a photoresistive layer on the entire surface of the resulting semiconductor device; removing the photoresist layer except for those portions of the photoresist layer positioned above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes of the plurality of gate electrodes to thereby define contact regions positioned over each diffusion region which is positioned between the gate electrodes of the MOSFETs of the plurality of MOSFETs, and over each gate electrode lines, respectively, thereby exposing the nitride layer except for those portions of the nitride layer positioned at the contact regions; removing the nitride layer except for those portions of the nitride layer positioned at the defined contact regions, thereby exposing portions of the undoped polysilicon layer; performing an ion-implantation process on the exposed portions of the undoped polysilicon layer utilizing a dopant source selected form the group consisting of: B(Boron), BF.sub.2 (Boron-Fluorine), P(Phosphorus) or As(Arsenic), the thereby form the exposed portions of the undoped polysilicon layer into a doped polysilicon layer having an impurity-concentration of 1.times.10.sup.18 -5.times.10.sup.21 cm.sup.-3 ; removing the photoresist layer remaining above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes, thereby exposing the nitride layer remained at the contact regions; thermally oxidizing the exposed doped polysilicon layer at a temperature of 200-1000 degree Celsius for a period of 10-120 minutes thereby forming a thermal oxide layer on and into the exposed doped polysilicon layer; sequentially removing the exposed nitride layer and the exposed underlying undoped polysilicon layer remaining at the defined contact regions to thereby expose the first insulating layer formed on each gate electrode line and to expose the gate oxide layer formed on each gate electrode line and to expose the gate oxide layer formed over the diffusion region positioned between the gate electrodes, respectively; forming a contact hole at each contact region by etching the thermal oxide layer, the exposed gate oxide layer positioned over the diffusion region and the first insulating layer positioned on the each gate electrode line to expose a surface of each gate electrode lines and a surface of each diffusion region positioned between gate electrodes of the plurality of gate electrodes, respectively; depositing a conducting layer on the entire surface of the resulting structure comprising the thermal oxide layer and the contact holes; and removing the conducting layer except for those portions of the conducting layer deposited in and proximate to each contact hole such that each portion of the conducting layer forms a contact at each diffusion region positioned between MOSFETs of the plurality of MOSFETs, thereby enabling a selective connection to be made at each diffusion region positioned between MOSFETs of the plurality of MOSFETs and at each gate electrode line, respectively.

6. The method of claim 5 wherein the first insulating layer is formed with oxide.

7. A method for forming a semiconductor device which comprises a plurality of segment separation oxide layers formed on a silicon substrate, with each segment separation oxide layer being spaced apart relative to each other; a plurality of MOSFETs formed on the silicon substrate in which each MOSFET includes a plurality of diffusion regions formed into the silicon substrate between the segment separation oxide layers, with each diffusion region being spaced apart relative to each other and having a lightly doped diffusion region, a gate oxide layer formed on the silicon substrate extending between the spaced apart segment separation oxide layers, and a plurality of gate electrodes formed on the gate oxide layer, with each gate electrode being spaced apart relative to each other and relative to each segment separation oxide layer; a plurality of gate electrode lines formed on each segment separation oxide layer with oxide spacers formed on each side of each gate electrode and each gate electrode line; and a first insulating layer formed on each gate electrode and each gate electrode line, wherein the improvement for forming the semiconductor device to selectively connect a conducting layer to each diffusion region positioned between MOSFETs of the plurality of MOSFETs, and to each gate electrode line by utilizing a self-aligned contact process, comprises: depositing an undoped polysilicon layer on the entire surface of the resulting semiconductor device; doping the undoped polysilicon layer to form a doped polysilicon layer; sequentially depositing a nitride layer and a photoresistive layer over the doped polysilicon layer; removing the photoresist layer except for those portions of the photoresist layer positioned above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes of the plurality of gate electrodes to thereby define contact regions positioned over each diffusion region which is positioned between the gate electrodes of the MOSFETs of the plurality of MOSFETs, and over each gate electrode lines, respectively, thereby exposing the nitride layer except for those portions of the nitride layer positioned at the contact regions; removing the nitride layer except for those portions of the nitride layer positioned at the defined contact regions, thereby exposing portions of the undoped polysilicon layer; removing the photoresist layer remaining above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes, thereby exposing the nitride layer remained at the contact regions; thermally oxidizing the exposed doped polysilicon layer, thereby forming a thermal oxide layer on and into the exposed doped polysilicon layer; sequentially removing the exposed nitride layer and the exposed underlying undoped polysilicon layer remaining at the defined contact regions to thereby expose the first insulating layer formed on each gate electrode line and to expose the gate oxide layer formed over the diffusion region positioned between the gate electrodes, respectively; forming a contact hole at each contact region by etching the thermal oxide layer, the exposed gate oxide layer positioned over the diffusion region and the first insulating layer positioned on the each gate electrode line to expose a surface of each gate electrode lines and a surface of each diffusion region positioned between gate electrodes of the plurality of gate electrodes, respectively; depositing a conducting layer on the entire surface of the resulting structure comprising the thermal oxide layer and the contact holes; and removing the conducting layer except for those portions of the conducting layer deposited in and proximate to each contact hole such that each portion of the conducting layer forms a contact at each gate electrode lines, respectively, and a contact at each diffusion region positioned between MOSFETs of the plurality of MOSFETs, thereby enabling a selective connection to be made at each diffusion region positioned between MOSFETs of the plurality of MOSFETs and at each gate electrode line, respectively.

8. The method of claim 7 wherein the first insulating layer is formed with oxide.

9. The method of claim 7 wherein the doping process of the undoped polysilicon layer is performed by heating the undoped polysilicon layer at a temperature of 700-1000 C degree Celsius for a period of 10-100 minutes simultaneously with application of POCl.sub.3 (Phosphorus-Oxygen-Chlorine) gas, to thereby diffuse the impurity contained the gas into the undoped polysilicon layer, in order to form a doped polysilicon layer having an impurity-concentration of 1.times.10.sup.18 -5.times.10.sup.21 cm.sup.-3.

10. The method of claim 7 wherein the doping process of the undoped polysilicon layer is performed by depositing on the undoped polysilicon layer a solid dopant source selected from the group consisting of: BN (Boron-Nitride), BSG (Boro-Silicate-Glass), BPSG (Boro-Phospho-Silicate-Glass) or PSG (Phospho-Silicate-Glass), having a thickness of 100-2000 Angstroms, and heating the solid dopant source deposited on the undoped polysilicon layer at a temperature of 700-1000 degree Celsius for a period of 10-100 minutes, to thereby diffuse the impurity contained the solid dopant source into the undoped polysilicon layer, in order to form a doped polysilicon having an impurity-concentration of 1.times.10.sup.18 -5.times.10.sup.21 cm.sup.-3.

11. The method of claim 7 wherein the thermal oxidation of the doped polysilicon layer is performed by thermally oxidizing the exposed doped polysilicon layer at a temperature of 200-1000 degree Celsius for a period of 10-120 minutes.

12. A method for manufacturing a semiconductor device, comprising: forming a plurality of segment separation oxide layers on a silicon substrate, with each segment separation oxide layer being spaced apart relative to one another; depositing a gate oxide layer on the silicon substrate extending between the spaced apart segment separation oxide layers; depositing a first conductive layer over the entire surface of the resulting structure; removing portions of the first conducting layer to form a plurality of gate electrodes on the gate oxide layers and to form a plurality of gate electrode lines on the segment separation oxide layers, with each gate electrode being spaced apart relative to one another; forming a plurality of lightly doped diffusion regions into portions of the silicon substrate between the spaced apart segment separation oxide layers and the gate electrodes; depositing an spacer oxide layer on the entire surface of the resulting structure and forming from the spacer oxide layer a plurality of oxide spacers with an oxide spacer being formed on each side of each gate electrode of the plurality of gate electrodes and on each side of each gate electrode line of the plurality of gate electrode lines; forming a plurality of diffusion regions through each lightly doped diffusion region of the plurality of lightly doped diffusion regions into the silicon substrate with each diffusion region of the plurality of diffusion regions functioning, in use, as a drain electrode or a source electrode; forming a plurality of MOSFETs by depositing a first insulating layer on each gate electrode, each gate electrode line and each oxide spacer of the plurality of oxide spacers; depositing an undoped polysilicon layer on the entire surface of the resulting structure; sequentially depositing a nitride layer and a photoresist layer over the undoped polysilicon layer; removing the photoresist layer except for those portions of the photoresist layer positioned above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes of the plurality of gate electrodes to thereby define contact regions positioned over each diffusion region positioned between the gate electrodes of the MOSFETs of the plurality of MOSFETs, and over each gate electrode lines, respectively, thereby exposing the nitride layer except for those portions of the nitride layer positioned at the contact regions; removing the nitride layer except for those portions of the nitride layer positioned at the defined contact regions, thereby exposing portions of the undoped polysilicon layer; performing an ion-implantation process on the exposed portions of the undoped polysilicon layer to thereby form the exposed portions of the undoped polysilicon layer into a doped polysilicon layer; removing the photoresist layer remaining above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes, thereby exposing the nitride layer remaining at the contact regions; thermally oxidizing the exposed doped polysilicon layer, thereby forming a thermal oxide layer on and into the exposed doped polysilicon layer; sequentially removing the exposed nitride layer and the exposed underlying undoped polysilicon layer remaining at the defined contact regions to thereby expose the first insulating layer formed on each gate electrode line and to expose the gate oxide layer formed over the diffusion region positioned between the gate electrode, respectively; forming a contact hole at each contact region by etching the thermal oxide layer, the exposed gate oxide layer positioned over the diffusion region and the first insulating layer positioned on the each gate electrode line to expose a surface of each gate electrode lines and a surface of each diffusion region positioned between gate electrodes of the plurality of gate electrodes, respectively; depositing a second conducting layer on the entire surface of the resulting structure comprising the thermal oxide layer and the contact holes; and removing the second conducting layer except for those portions of the second conductive layer deposited in and proximate to each contact hole such that each portion of the conducting layer forms a contact at each gate electrode lines, respectively, and a contact at each diffusion region positioned between MOSFETs of the plurality of MOSFETs, thereby enabling a selective connection to be made at each diffusion region positioned between MOSFETs of the plurality of MOSFETs and at each gate electrode line, respectively.

13. The method for manufacturing a semiconductor of claim 12 wherein the ion-implantation process utilized a dopant source selected from the group consisting of: B(Boron), BF.sub.2 (Boron-Fluorine), P(Phosphorus) or As(Arsenic), to thereby form the exposed portion of the undoped polysilicon layer into a doped polysilicon layer 8A having an impurity-concentration of 1.times.10.sup.18 -5.times.10.sup.21 cm.sup.-3.

14. The method of claim 12 wherein the thermal oxidation of the exposed doped polysilicon layer is performed by thermally oxidizing the exposed polysilicon layer at a temperature of 200-1000 degree Celsius for a period of 10-120 minutes.

15. A method for manufacturing a semiconductor device, comprising: forming a plurality of segment separation oxide layers on a silicon substrate, with each segment separation oxide layer being spaced apart relative to one another; depositing a gate oxide layer on the silicon substrate extending between the spaced apart segment separation oxide layers; depositing a first conducting layer over the entire surface of the resulting structure; removing portions of the first conducting layer to form a plurality of gate electrodes on each portion of the gate oxide layer and to form a plurality of gate electrode lines with each gate electrode line formed on a portion of each segment separation oxide layer and with each gate electrode being spaced apart relative to one another; forming a plurality of lightly doped diffusion regions into portions of the silicon substrate between the spaced apart segment separation oxide layers and the gate electrodes; depositing an spacer oxide layer on the entire surface of the resulting structure and forming from the spacer oxide layer a plurality of oxide spacers with an oxide spacer being formed on each side of each gate electrode of the plurality of gate electrodes and on each side of each gate electrode line of the plurality of gate electrode lines; forming a plurality of diffusion regions through each lightly doped diffusion region of the plurality of lightly doped diffusion regions into the silicon substrate with each diffusion region of the plurality of diffusion regions functioning, in use, as a drain electrode or a source electrode; forming a plurality of MOSFETs by depositing a first insulating layer on each gate electrode, each gate electrode line and each oxide spacer of the plurality of oxide spacers; depositing an undoped polysilicon layer on the entire surface of the resulting structure; doping the undoped polysilicon layer on the entire surface of the resulting structure; doping the undoped polysilicon layer to form a doped polysilicon layer; sequentially depositing a nitride layer and a photoresist layer over the doped polysilicon layer; removing the photoresist layer except for those portions of the photoresist layer positioned above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes of the plurality of gate electrodes to thereby define contact regions positioned over each diffusion region positioned between the gate electrodes of the MOSFETs of the plurality of MOSFETs, and over each gate electrode lines, respectively, thereby exposing the nitride layer except for those portions of the nitride layer positioned at the contact regions; removing the nitride layer except for those portions of the nitride layer positioned at the defined contact regions, thereby exposing portions of the doped polysilicon layer; removing the photoresist layer remaining above each gate electrode line and above each diffusion region of the plurality of diffusion regions positioned between adjacent gate electrodes, thereby exposing the nitride layer remaining at the contact regions; thermally oxidizing the exposed doped polysilicon layer, thereby forming a thermal oxide layer on and into the exposed doped polysilicon layer; sequentially removing the exposed nitride layer and the exposed underlying doped polysilicon layer remaining at the defined contact regions to thereby expose the first insulating layer formed on each gate electrode line and to expose the gate oxide layer formed over the diffusion region positioned between the gate electrodes, respectively; forming a contact hole at each contact region by etching the thermal oxide layer, the exposed gate oxide layer positioned over the diffusion region and the first insulating layer positioned on the each gate electrode line to expose a surface of each gate electrode lines and a surface of each diffusion region positioned between gate electrodes of the plurality of gate electrodes, respectively; depositing a second conducting layer on the entire surface of the resulting structure comprising the thermal oxide layer and the contact holes; and removing the second conducting layer except for those portions of the conducting layer deposited in and proximate to each contact hole such that each portion of the second conducting layer forms a contact at each gate electrode lines, respectively, and a contact at each diffusion region positioned between MOSFETs of the plurality of MOSFETs, thereby enabling a selective connection to be made at each diffusion region positioned between MOSFETs of the plurality of MOSFETs and at each gate electrode line, respectively.

16. The method of claim 15 wherein the undoped polysilicon is doped by heating the undoped polysilicon layer at a temperature of 700-1000 degrees Celsius for a period of 10-100 minutes with the simultaneously application of POCl.sub.3 (Phosphorus-Oxygen-Chlorine) gas, to thereby diffuse the impurity contained the gas into the undoped polysilicon such that a doped polysilicon layer is formed.

17. The method of claim 16 wherein the doped polysilicon layer has an impurity-concentration of about 1.times.10.sup.18 -5.times.10.sup.21 cm.sup.-3.

18. The method of claim 16 wherein the undoped polysilicon layer is doped by depositing on the undoped polysilicon layer a solid dopant source selected from the group consisting of: BN(Boro-Nitride), BSG(Boro-Silicate-Glass)m, BPSG(Boro-Phospho-Silicate-Glass) or PSG(Phospho-Silicate-Glass), having a thickness of 100-2000 Angstroms, and heating the solid dopant source deposited on the undoped polysilicon layer at a temperature of 700-1000 degrees Celsius for a period of 10-100 minutes, to diffuse the impurity contained the solid dopant source into the undoped polysilicon layer in order to form a doped polysilicon layer.

19. The method of claim 18 wherein the doped polysilicon layer has an impurity-concentration of about 1.times.10.sup.18 -5.times.10.sup.21 cm.sup.-3.

20. The method of claim 15 wherein the thermal oxidation of the exposed doped polysilicon layer is performed by thermally oxidizing the exposed doped polysilicon layer at a temperature of 200-1000 degrees Celsius for a period of 10-120 minutes.