Patent ID: 6930038

Claim:
A dual damascene partial gap fill polymer fabrication process, comprising: providing a substrate having a conductive layer therein; forming a dielectric layer over the substrate and conductive layer; forming at least one via hole in the dielectric layer, to expose a portion of the conductive layer; covering the dielectric layer with a gap fill polymer, to fill the via hole; performing a chemical mechanical polishing step to remove the gap fill polymer layer on the outside of the via hole; performing an etching step to remove a portion of the gap fill polymer layer remaining on the inside of the via hole, forming a partial gap fill polymer, while the dielectric layer is substantially not etched in this etching step; performing a lithographic process to form a photoresist layer having an opening above the dielectric layer, wherein the opening exposes the via hole and the partial gap fill polymer; etching a portion of the dielectric layer exposed in the opening, to form a trench in the dielectric layer; removing the photoresist layer and the partial gap fill polymer, to expose a portion of the conductive layer; and filling the via hole and the trench with a metal material, to simultaneously form a plug and a first conductive line.