International Business Machines Corporation

Globalfoundries Inc.

Stmicroelectronics Gmbh

Brown Cornelius Peethala

Shariq Siddiqui

Frank Wilhelm Mont

Douglas M Trickett

Mark L Lenhardt

Jessica P Striss

Yann Mignot

Raghuveer Reddy Patlolla

Joe Lee

Jassem Ahmed Abdallah

Son Van Nguyen

Christopher J Penny

Stephen McConnell Gates

Elbert Emin Huang

Xunyuan Zhang

Deepika Priyadarshini

Spyridon Skordas

Kevin R Winstel

Allan Ward Upham

Da Song

Han You

Chamferless via structures and methods of manufacture are provided. The method includes: forming at least one self-aligned via within at least dielectric material; plugging the at least one self-aligned via with material; forming a protective sacrificial mask over the material which plugs the at least one self-aligned via, after a recessing process; forming at least one trench within the dielectric material, with the protective sacrificial mask protecting the material during the trench formation; removing the protective sacrificial mask and the material within the at least one self-aligned via to form a wiring via; and filling the wiring via and the at least one trench with conductive material.

Chamferless via structures

Chamferless via structures and methods of manufacture are provided. The method includes: forming at least one non-self-aligned via within at least dielectric material; plugging the at least one non-self-aligned via with material; forming a protective sacrificial mask over the material which plugs the at least one non-self-aligned via, after a recessing process; forming at least one trench within the dielectric material, with the protective sacrificial mask protecting the material during the trench formation; removing the protective sacrificial mask and the material within the at least one non-self-aligned via to form a wiring via; and filling the wiring via and the at least one trench with conductive material.

One illustrative method disclosed includes, among other things, forming a first dielectric layer and forming first and second conductive structures comprising cobalt embedded in the first dielectric layer. A second dielectric layer is formed above and contacting the first dielectric layer. The first and second dielectric layers comprise different materials, and a portion of the second dielectric layer comprises carbon or nitrogen. A first cap layer is formed above the first and second conductive structures and the second dielectric layer.

Methods of mitigating cobalt diffusion in contact structures and the resulting devices

A method utilizing a chemical mechanical polishing process to remove a patterned material stack comprising at least one pattern transfer layer and a template layer during a rework process or during a post pattern transfer cleaning process is provided. The pattern in the patterned material stack is formed by pattern transfer of a directed self-assembly pattern generated from microphase separation of a self-assembly material.

Rework and stripping of complex patterning layers using chemical mechanical polishing

A method includes, for example, providing an intermediate semiconductor structure comprising a metallic layer, a patternable layer disposed over the metallic layer, and a hard mask disposed over the patternable layer, the intermediate semiconductor structure comprising a plurality of vias extending through the hard mask onto the metallic layer, depositing a sacrificial barrier layer over the intermediate semiconductor structure and in the plurality of vias, removing a portion of the sacrificial barrier layer between the plurality of vias while maintaining a portion of the sacrificial barrier layer in the plurality of vias, forming a trench in the patternable layer between the removed portion of the sacrificial barrier layer and the plurality of vias, and removing the remaining portions of the sacrificial barrier layer from the plurality of vias.

Methods employing sacrificial barrier layer for protection of vias during trench formation

A method that allows effective removal of a silicon-containing antireflective coating (SiARC) layer in a block mask after defining an unblock area in a sidewall image transfer (SIT) patterning process without causing a height loss of the SIT spacers is provided. The method includes first modifying the SiARC layer with a dry etch utilizing an etching gas comprising a nitrogen gas followed by treating the modified SiARC layer with a wet chemical etch utilizing an aqueous solution including dilute hydrofluoric acid and citric acid.

SiARC removal with plasma etch and fluorinated wet chemical solution combination

A selective wet etching process is used, prior to air gap opening formation, to remove a sacrificial nitride layer from over a first region of an interconnect dielectric material containing a plurality of first conductive metal structures utilizing a titanium nitride hard mask portion located over a second region of the interconnect dielectric material as an etch mask. The titanium nitride hard mask portion located over the second region of the interconnect dielectric material is thereafter removed, again prior to air gap opening formation, utilizing another wet etch process. The wet etching processes are used instead of reactive ion etching.

Method for residue-free block pattern transfer onto metal interconnects for air gap formation

A method of preparing an etch solution and thinning semiconductor wafers using the etch solution is proposed. The method includes steps of creating a mixture of hydrofluoric acid, nitric acid, and acetic acid in a solution container in an approximate 1:3:5 ratio; causing the mixture to react with portions of one or more silicon wafers, the portions of the one or more silicon wafers are doped with boron in a level no less than 1&#xd7;10atoms/cm; collecting the mixture after reacting with the boron doped portions of the one or more silicon wafers; and adding collected mixture back into the solution container to create the etch solution.

Selective etching of silicon wafer

A method includes forming a stack of materials including a first dielectric layer having a conductive feature positioned therein, and a second dielectric layer positioned above the first dielectric layer. An etch mask including a plurality of spaced apart mask elements is formed above the second dielectric layer. The mask elements define at least a first via opening exposing the second dielectric layer. A patterning layer is formed above the etch mask. A second via opening is formed in the patterning layer to expose the first via opening in the etch mask. The second dielectric layer is etched through the second via opening to define a third via opening in the second dielectric layer exposing the conductive feature. The patterning layer and the etch mask are removed. A conductive via contacting the conductive feature is formed in the third via opening.

Forming interconnect features with reduced sidewall tapering

After forming a manganese (Mn)-containing cap layer over interconnects embedded in an interlevel dielectric (ILD) layer, a lithographic stack is formed over the Mn-containing cap layer. The lithographic stack is subsequently patterned to expose a portion of the Mn-containing cap layer that overlies a subset of the interconnects between which the air gaps are to be formed. A portion of the ILD layer located between the subset of the interconnects is damaged through the exposed portion of the Mn-containing cap layer. The damaged portion of the ILD layer is subsequently removed to form openings between the subset of the interconnects. The Mn-containing cap layer acts as a temporary protection layer preventing erosion of the underlying interconnects during the air gap formation.

Growing community of inventors

Albany, NY, United States of America

Brown Cornelius Peethala