Method for manufacturing a multi-level interconnect structure
First Claim
1. A method for manufacturing a multi-level interconnect structure, comprising:
- applying a mandrel material to a substrate;
removing portions of the mandrel material to form trenches;
removing portions of the mandrel material to form vias, the trenches opening onto the underlying vias;
filling the vias and the trenches with a conductive material to create a plurality of features having the mandrel material disposed between adjacent features;
forming at least one layer overlying the features and the mandrel material;
defining at least one passageway leading to the mandrel material through the layer; and
removing the mandrel material by introducing an isotropic etchant into the passageway, the isotropic etchant selectively etching the mandrel material to leave an air void between adjacent features.
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Accused Products
Abstract
A method for forming interlevel dielectric layers in multilevel interconnect structures using air as the constituent low-k dielectric material that is compatible with damascene processes without introducing additional process steps. The conductive features characteristic of the damascene process are formed by standard lithographic and etch processes in the mandrel material for each level of the interconnect structure. The conductive features in each level are surrounded by the mandrel material. After all levels of the interconnect structure are formed, a passageway is provided to the mandrel material. An isotropic etchant is introduced through the passageway that selectively etches and removes the mandrel material. The spaces formerly occupied by the mandrel material in the levels of the interconnect structure are filled by air, which operates as a low-k dielectric material.
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Citations
39 Claims
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1. A method for manufacturing a multi-level interconnect structure, comprising:
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applying a mandrel material to a substrate;
removing portions of the mandrel material to form trenches;
removing portions of the mandrel material to form vias, the trenches opening onto the underlying vias;
filling the vias and the trenches with a conductive material to create a plurality of features having the mandrel material disposed between adjacent features;
forming at least one layer overlying the features and the mandrel material;
defining at least one passageway leading to the mandrel material through the layer; and
removing the mandrel material by introducing an isotropic etchant into the passageway, the isotropic etchant selectively etching the mandrel material to leave an air void between adjacent features. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for manufacturing a multi-level interconnect structure, comprising:
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forming a first layer of a mandrel material on a substrate;
removing portions of the first layer of the mandrel material to form first trenches;
removing portions of the first layer of the mandrel material to form first vias, the first trenches opening onto the underlying first vias;
filling the first vias and the first trenches with a conductive material to create a plurality of first features having the mandrel material horizontally separating adjacent first features;
forming a second layer of the mandrel material overlying the first features;
removing portions of the second layer of the mandrel material to form second trenches;
removing portions of the second layer of the mandrel material to form second vias, the second trenches opening onto the underlying second vias;
filling the second vias and the second trenches with the conductive material to create a plurality of second features having the mandrel material horizontally separating adjacent second features, the mandrel material separating the second features being coextensive with the mandrel material separating the first features;
forming at least one layer overlying the second features;
defining at least one passageway leading to the mandrel material through the layer; and
removing the mandrel material by introducing an isotropic etchant into the passageway, the isotropic etchant selectively etching the mandrel material to leave an air void between adjacent first features and between adjacent second features. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A method for manufacturing a multi-level interconnect structure, comprising:
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applying a mandrel material to a substrate, the mandrel material being selected from the group consisting of amorphous silicon, amorphous germanium, and amorphous silicon-germanium;
removing portions of the mandrel material to form trenches;
removing portions of the mandrel material to form vias, the trenches opening onto the underlying vias;
filling the vias and the trenches simultaneously with a conductive material to create a plurality of features having the mandrel material disposed between adjacent features;
forming at least one layer overlying the features and the mandrel material;
defining at least one passageway leading to the mandrel material through the layer; and
removing the mandrel material by introducing an isotropic etchant into the passageway, the isotropic etchant selectively etching the mandrel material to leave an air void between adjacent features. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32)
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33. A multi-level interconnect structure produced by the process comprising:
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applying a mandrel material to a substrate;
removing portions of the mandrel material to form trenches;
removing portions of the mandrel material to form vias, the trenches opening onto the underlying vias;
filling the vias and the trenches with a conductive material to create a plurality of features having the mandrel material disposed between adjacent features;
forming at least one layer overlying the features and the mandrel material;
defining at least one passageway leading to the mandrel material through the layer; and
removing the mandrel material by introducing an isotropic etchant into the passageway, the isotropic etchant selectively etching the mandrel material to leave an air void between adjacent features. - View Dependent Claims (34, 35, 36, 37, 38, 39)
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Specification