Method for fabricating bulbous-shaped vias
First Claim
1. A method for fabricating vias on a substrate having a surface, comprising:
- disposing, adjacent to said substrate, a polymerizable fluid composition;
contacting said polymerizable fluid composition with a mold having a relief structure, with said polymerizable fluid composition conforming to a profile of said mold;
subjecting said polymerizable fluid composition to conditions to polymerize said polymerizable fluid composition, forming a polymerized layer having a bi-level indentation including a nadir and shoulders spaced-apart from said nadir;
forming a relief pattern adjacent to said substrate having an opening extending toward said surface by selectively removing material adjacent to said substrate, with said material including a sub-section of said polymerized layer located proximate to said bi-level indentation; and
depositing a conductive layer to cover said relief pattern, thereby forming a contact having a shape defined by said relief pattern.
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Accused Products
Abstract
The present invention provides a method for fabricating bulbous-shaped vias on a substrate, having a surface, by disposing, on the substrate, a polymerizable fluid composition. A mold is placed in contact with the polymerizable fluid composition. The mold includes a relief structure on a surface thereof to create a recess in a layer of the polymerizable fluid composition. The polymerizable fluid composition is subjected to conditions to cause polymerization, forming a polymerized layer having a solidified indentation. An opening to the surface of the substrate is formed by removing material disposed on the substrate surface through etch processes. In a further embodiment a conductive layer may be disposed in the opening to form a gate. A lift-off process may be employed to remove the polymerized layer.
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Citations
28 Claims
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1. A method for fabricating vias on a substrate having a surface, comprising:
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disposing, adjacent to said substrate, a polymerizable fluid composition;
contacting said polymerizable fluid composition with a mold having a relief structure, with said polymerizable fluid composition conforming to a profile of said mold;
subjecting said polymerizable fluid composition to conditions to polymerize said polymerizable fluid composition, forming a polymerized layer having a bi-level indentation including a nadir and shoulders spaced-apart from said nadir;
forming a relief pattern adjacent to said substrate having an opening extending toward said surface by selectively removing material adjacent to said substrate, with said material including a sub-section of said polymerized layer located proximate to said bi-level indentation; and
depositing a conductive layer to cover said relief pattern, thereby forming a contact having a shape defined by said relief pattern. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method for fabricating vias on a substrate having a surface, comprising:
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disposing an etch-stop layer on said surface;
disposing, adjacent to said etch-stop layer, a polymerizable fluid composition;
contacting said polymerizable fluid composition with a mold with said polymerizable fluid composition conforming to a profile of said mold;
subjecting said polymerizable fluid composition to conditions to polymerize said polymerizable fluid composition, forming a polymerized layer having a solidified indentation including a nadir and shoulders spaced-apart form said nadir, with said etch-stop layer being positioned between said surface and said polymerized layer; and
defining an opening to said surface of said substrate by removing material disposed on said substrate, with said material including a sub-section of said polymerized layer positioned proximate to said solidified indentation and a sub-portion of said etch-stop layer in superimposition with said nadir. - View Dependent Claims (10, 11, 12)
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13. A method for fabricating vias on a substrate having a surface, comprising:
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disposing an etch-stop layer on said surface;
disposing a planarization layer onto said etch-stop layer;
disposing, on said planarization layer, a polymerizable fluid composition;
contacting said polymerizable fluid composition with a mold having a relief structure, with said polymerizable fluid composition conforming to a profile of said relief structure;
subjecting said polymerizable fluid composition to conditions to polymerize said polymerizable fluid composition, forming a polymerized layer having a solidified bi-level indentation including a nadir and shoulders spaced-apart from said nadir, with said etch-stop layer being positioned between said surface and said polymerized layer, said etch-stop, planarization and polymerized layers, defining a composite layer;
anisotropically etching said composite layer to form a relief pattern in said planarization layer, with said relief pattern matching a contour of said solidified bi-level indentation and having relief shoulders and a relief nadir, spaced-apart therefrom;
selectively etching said relief pattern to expose a sub-portion of said etch-stop layer in superimposition with said relief nadir; and
removing said sub-portion to expose a region of said surface in superimposition therewith. - View Dependent Claims (14, 15, 16, 17, 18)
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19. A method for fabricating vias on a substrate having a surface, comprising:
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disposing, adjacent to said substrate, a planarization layer;
forming, on said planarization layer, a polymerized layer having a bi-level indentation; and
etching said polymerized layer and said planarization layer to expose and form a relief pattern in said planarization layer, with said relief pattern having a curved bulb extending from a region of said planarization layer proximate to said polymerized layer and terminating in a narrow waist. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28)
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Specification