Dual damascene fabrication with low k materials
First Claim
1. A method of forming a dual damascene structure on the surface of a substrate, comprising:
- depositing a dielectric film stack comprising a bottom barrier layer and a bulk dielectric insulating layer on the surface of the substrate;
applying a first resist material layer over the dielectric film stack;
performing trench lithography on the first resist material layer to form a trench pattern thereon;
etching the dielectric film stack until an desired etching depth to define one or more trenches therein according to the trench pattern on the first resist material layer;
removing the first resist material layer from the surface of the substrate;
filling the one or more trenches with an organic material;
depositing a mask layer over the organic material filling the one or more trenches;
applying a second resist material layer over the mask layer;
performing via lithography on the second resist material layer to form a via pattern thereon;
etching the mask layer to define one or more vias within the organic material filled trenches according to the via pattern on the second resist material layer;
etching the organic material to form the one or more vias therein according to the via pattern;
etching the bulk dielectric insulating layer to form the one or more vias therein according to the via pattern;
etching the bottom barrier layer to form the one or more vias therein according to the via pattern;
removing the organic material from the organic material filled trenches and the one or more vias; and
forming the one or more trenches and one or more vias therein the dielectric film stack on the surface of the substrate.
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Accused Products
Abstract
The invention provides methods and apparatuses for fabricating a dual damascene structure on a substrate. First, trench lithography and trench patterning are performed on the surface of a substrate to etch a low-k dielectric material layer to a desired etch depth to form a trench prior to forming of a via. The trenches can be filled with an organic fill material and a dielectric hard mask layer can be deposited. Then, via lithography and via resist pattering are performed. Thereafter, the dielectric hard mask and the organic fill material are sequentially etched to form vias on the surface of the substrate, where the trenches are protected by the organic fill material from being etched. A bottom etch stop layer on the bottom of the vias is then etched and the organic fill material is striped. As a result, the invention provides good patterned profiles of the via and trench openings of a dual damascene structure.
252 Citations
21 Claims
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1. A method of forming a dual damascene structure on the surface of a substrate, comprising:
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depositing a dielectric film stack comprising a bottom barrier layer and a bulk dielectric insulating layer on the surface of the substrate; applying a first resist material layer over the dielectric film stack; performing trench lithography on the first resist material layer to form a trench pattern thereon; etching the dielectric film stack until an desired etching depth to define one or more trenches therein according to the trench pattern on the first resist material layer; removing the first resist material layer from the surface of the substrate; filling the one or more trenches with an organic material; depositing a mask layer over the organic material filling the one or more trenches; applying a second resist material layer over the mask layer; performing via lithography on the second resist material layer to form a via pattern thereon; etching the mask layer to define one or more vias within the organic material filled trenches according to the via pattern on the second resist material layer; etching the organic material to form the one or more vias therein according to the via pattern; etching the bulk dielectric insulating layer to form the one or more vias therein according to the via pattern; etching the bottom barrier layer to form the one or more vias therein according to the via pattern; removing the organic material from the organic material filled trenches and the one or more vias; and forming the one or more trenches and one or more vias therein the dielectric film stack on the surface of the substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of forming a dual damascene structure on the surface of a substrate having a bottom barrier layer, a bulk dielectric insulating layer, and a first resist material layer deposited thereon, comprising:
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performing trench lithography on the first resist material layer to form a trench pattern thereon; etching the bulk dielectric insulating layer until an desired etching depth to define one or more trenches therein according to the trench pattern on the first resist material layer; filling the one or more trenches with an organic material; depositing a mask layer over the organic material and a second resist material layer over the mask layer; performing via lithography on the second resist material layer to form a via pattern thereon; etching the mask layer to define one or more vias within the organic material filled trenches according to the via pattern on the second resist material layer; etching the organic material and the bulk dielectric insulating layer to form the one or more vias therein according to the via pattern; etching the bottom barrier layer to form the one or more vias therein according to the via pattern; removing the organic material from the organic material filled trenches and the one or more vias; and forming the one or more trenches and one or more vias therein the dielectric film stack on the surface of the substrate. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A method of forming a dual damascene structure on the surface of a substrate having a bottom barrier layer, a bulk dielectric insulating layer, and a first resist material layer deposited thereon, comprising:
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performing trench lithography on the first resist material layer to form a trench pattern thereon prior to performing via lithography on a second resist material layer to form a via pattern thereon; etching the bulk dielectric insulating layer until an desired etching depth to define one or more trenches therein according to the trench pattern on the first resist material layer; filling the one or more trenches with an organic material, wherein the second resist material layer is applied over a mask layer deposited over the organic material; etching the mask layer, the organic material, and the bulk dielectric insulating layer to define one or more vias therein according to the via pattern on the second resist material layer; etching the bottom barrier layer to form the one or more vias therein according to the via pattern; removing the organic material from the organic material filled trenches and the one or more vias; and forming the one or more trenches and one or more vias therein the dielectric film stack on the surface of the substrate. - View Dependent Claims (19, 20, 21)
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Specification