Air gap integration
First Claim
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1. A method to form an air gap interconnect structure comprising:
- forming a multi-layer interconnect adjacent a substrate layer, the interconnect comprising conductive layers positioned in at least two conductive vertical series, the conductive vertical series isolated from each other by sacrificial dielectric material;
forming a protective layer adjacent the interconnect;
patterning the protective layer to expose portions of the sacrificial dielectric material;
decomposing portions of the sacrificial dielectric material to form a sacrificial dielectric decomposition product;
removing portions of the sacrificial dielectric decomposition product to form air gaps between the conductive layers; and
wherein forming a multi-layer interconnect comprises;
forming a first layer of sacrificial dielectric material, forming trenches in the first layer, and filling the trenches with conductive material to form at least two conductive layers isolated from each other by the sacrificial dielectric material; and
forming a second layer of sacrificial dielectric material adjacent the at least two conductive layers and fist layer, forming trenches in the second layer in substantial vertical alignment with the trenches of the first layer, and filling the trenches with conductive material to form at least two additional conductive layers isolated from each other by the second sacrificial dielectric material and forming vertical support structures peripheral to the conductive vertical series, wherein removing portions of the sacrificial dielectric decomposition product further forms air gaps between the vertical support structures and the conductive vertical series.
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Abstract
Method and structure for integrating conductive and dielectric materials in a microelectronic structure having air gaps are disclosed. Certain embodiments of the invention comprise isolating dielectric layers from conductive layers using an etch stop layer to facilitate controlled removal of portions of the dielectric layers and formation of air gaps or voids. Capping and peripheral structural layers may be incorporated to increase the structural integrity of the integration subsequent to removal of sacrificial material.
207 Citations
25 Claims
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1. A method to form an air gap interconnect structure comprising:
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forming a multi-layer interconnect adjacent a substrate layer, the interconnect comprising conductive layers positioned in at least two conductive vertical series, the conductive vertical series isolated from each other by sacrificial dielectric material; forming a protective layer adjacent the interconnect; patterning the protective layer to expose portions of the sacrificial dielectric material; decomposing portions of the sacrificial dielectric material to form a sacrificial dielectric decomposition product; removing portions of the sacrificial dielectric decomposition product to form air gaps between the conductive layers; and wherein forming a multi-layer interconnect comprises; forming a first layer of sacrificial dielectric material, forming trenches in the first layer, and filling the trenches with conductive material to form at least two conductive layers isolated from each other by the sacrificial dielectric material; and forming a second layer of sacrificial dielectric material adjacent the at least two conductive layers and fist layer, forming trenches in the second layer in substantial vertical alignment with the trenches of the first layer, and filling the trenches with conductive material to form at least two additional conductive layers isolated from each other by the second sacrificial dielectric material and forming vertical support structures peripheral to the conductive vertical series, wherein removing portions of the sacrificial dielectric decomposition product further forms air gaps between the vertical support structures and the conductive vertical series. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. An air gap interconnect structure comprising:
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a. a substrate layer; b. at least two conductive vertical series adjacent the substrate layer, each conductive vertical series comprising a plurality of conductive layers, wherein the conductive vertical series are isolated from each other by air gaps defined by side walls of the conductive vertical series; c. vertical support structures peripheral to the conductive vertical series and isolated from the conductive vertical series by air gaps wherein none of the peripheral vertical support structures are between the at least two conductive vertical series; and d. a capping layer adjacent to and above upper surfaces of the vertical support structures and the conductive vertical series. - View Dependent Claims (13, 14, 15)
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16. An air gap interconnect structure comprising:
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a substrate layer; a first conductive vertical series adjacent the substrate layer having a plurality of conductive layers, and having a first side wall and a second side wall, each side wall extending substantially perpendicularly from the substrate layer; a second conductive vertical series adjacent the substrate layer having a plurality of conductive layers, and having a first side wall and a second side wall, each side wall extending substantially perpendicularly from the substrate layer; layers of silicon nitride on each of the first and second side walls of the first conductive vertical series and the first and second side walls of the second conductive vertical series; and at least one peripheral vertical support structure, wherein no peripheral vertical support structure is between the first and second conductive vertical series.
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17. A method to form an air gap interconnect structure comprising:
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forming a first layer of sacrificial dielectric material, forming trenches in the first layer, and filling the trenches with conductive material to form at least two conductive layers isolated from each other by remaining portions of the first layer of sacrificial dielectric material; forming a second layer of sacrificial dielectric material adjacent the at least two conductive layers and the remaining portions of the first layer of sacrificial dielectric material, forming trenches in the second layer in substantial vertical alignment with the trenches of the first layer, and filling the trenches with conductive material to form at least two additional conductive layers isolated from each other by remaining portions of the second layer of sacrificial dielectric material; and removing, after forming the first and second layers, at least some of the remaining portions of the first layer of sacrificial dielectric material and at least some of the remaining portions of the second layer of sacrificial dielectric material to form air gaps between the conductive layers positioning a first capping layer adjacent to the surfaces of the two additional conductive layers and applying a tensile load in a direction substantially parallel to a substrate layer to the first capping layer such that the first capping layer is adhered to the two additional conductive layers separated by the air gap. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25)
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Specification