Patent ID: 6373135
Filing Date: 2002-04-16
Classification: H01L

Abstract:
A method of forming aluminum conductors over a semiconductor structure comprising a semiconductor body having defined therein and formed on a top surface thereof contact regions to which electrical contacts are to be made, a first plurality of electrical conductors which have first ends that contact the contact regions, which extend above the top surface of the semiconductor body and are electrically isolated from each other by portions of a first insulating layer, and which have second ends which are in an essentially common plane, the method comprising the steps of:forming a second insulating layer over the first insulating layer; forming vias through the second insulating layer with each via being in communication with one of the first plurality of electrical conductors; overfilling each of the vias through the second insulating layer with physical vapor deposited aluminum deposited at a first temperature below the melting point of aluminum but close enough thereto such that the deposited aluminum fills the vias through the second insulating layer and forms a first blanket layer of aluminum above a top surface of the second insulating layer; forming a second blanket layer of physical vapor deposited aluminum over the first blanket layer of aluminum at a second temperature below the first temperature; applying a patterning layer over the second blanket layer of aluminum which leaves surface portions uncovered; removing portions of the second blanket aluminum layer not covered by the patterning layer and portions of the second blanket aluminum layer therebelow to leave columns of aluminum which include the portions of the second blanket layer of aluminum and the first blanket layer of aluminum which extend into the vias of the second insulating layer; and forming a third insulating layer around the columns of aluminum.