Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
   The present application claims priority to and is a divisional of parent application Ser. No. 10/295,062, filed Nov. 15, 2002, now U.S. Pat. No. 6,917,109 which is hereby incorporated by reference. The parent application is related to the following applications: Air Gap for Dual Damascene applications Ser. No. 10/295,795, filed Oct. 15, 2002, and Air Gap for Tungsten/Aluminum Plug applications Ser. No. 10,295,080 filed Oct. 15, 2002. The aforementioned are hereby incorporated by reference as if fully set forth herein. 

   FIELD OF THE INVENTION 
   The present invention relates, in general, to the field of integrated circuit (“IC”) device structures and methods of forming the same. More particularly, the present invention relates to an air gap structure and formation method for reducing undesired capacitive coupling between interconnects and/or other elements in an integrated circuit device. 
   BACKGROUND OF THE INVENTION 
   As integrated circuit transistor densities increase, and feature sizes shrink, capacitive coupling between adjacent interconnects, metal lines or other elements also increases. The increased capacitive coupling results in increased parasitic capacitance, which undesirably slows circuit speeds and negatively impacts overall device performance. 
   Current attempts to improve electrical isolation in high density integrated circuits involve the implementation of low K dielectric materials such as hydrogen silsesquioxane (HSQ), SiLK™ (a trademark of The Dow Chemical Company) resin, Black Diamond™ (a trademark of Applied Materials company) low K film, Coral™ (a trademark of Novellus System Inc.) carbonaceous oxide film and several other exotic materials. While these materials have a relatively low dielectric constant, they are not normally used in semiconductor manufacturing and therefore increase manufacturing complexity and costs. Much work remains to effectively integrate these materials into conventional semiconductor manufacturing processes. 
   Some disadvantages of current low K materials include incompatible thermal coefficient of expansion, low mechanical strength and poor thermal diffusivity. 
   Another manner of improving electrical isolation between interconnects is to use an integrated air gap structure because of the extremely low dielectric constant of air. Previous attempts at air gap structures were hard to manufacture and also did not completely isolate adjacent metal lines due to fringing fields above and below the air gap itself. 
   For example, U.S. Pat. No. 6,177,329 to Pang (and particularly at col. 7, ll. 46+) illustrates one conventional approach in which an additional mask is used to pattern the underlying layers to form the air gaps. This is both inefficient and imprecise for extremely small geometries. U.S. Pat. No. 5,847,439 to Reinberg illustrates another approach in which a combination of a low melting point dielectric, photoresist, a heat cycle and surface tension interact to form a void between two adjacent metal lines. This technique is clearly not suitable for precise control of air gap sizes, and is further disadvantageous because it cannot be used to form gaps which extend above a metal line. The latter may be desirable in some applications. Finally, U.S. Pat. No. 5,949,143 to Bang depicts a rather complex process in which a small opening is made in an etch stop layer and then a selective isotropic etch is used to remove dielectric between two metal lines. 
   Clearly, while portions of the aforementioned references are useful in forming air gap structures, and could be used in many applications, their overall approach is not optimal from a manufacturing perspective. 
   What is desired, therefore, is an easily manufacturable integrated air gap structure that substantially electrically isolates adjacent interconnects, metal lines or other IC elements. 
   SUMMARY OF THE INVENTION 
   In accordance with the structure and method disclosed herein, a first method for forming a device having an air gap structure includes forming a device layer, which can include first level metal, capacitors, transistors, or other integrated circuit devices, as well as previously formed air gap structures fabricated according to the method of the present invention. A dual damascene structure with a plurality dual damascene opening is formed over the device layer, including first and second patterned dielectric layers. A copper or other conductive layer is formed to fill the dual damascene opening. An adjustable-depth trench is formed between the conductive pattern at least down to the surface of the device layer. The dual damascene structure itself is used as a hard mask in the etching of the trench. Finally, a third dielectric layer is formed onto the trench to form at least one air gap, the air gap optionally extending above the top surface of the dual damascene structure. If desired, the depth of the trench can be extended below the surface of the device layer. 
   A second method for forming an air gap structure in an integrated circuit according to the present invention includes forming an interconnect structure on the device layer including, for example, an patterned aluminum or aluminum alloy (conductive aluminum with or without minor amounts of another element or elements) conductive layer overlaying a tungsten conductive plug layer. 
   An adjustable-depth trench is formed between the patterned interconnect structure at least down to the surface of the device layer. A dielectric layer is formed over the trench to form an air gap therein, the air gap optionally extending above the top surface of the interconnect structure. If desired, the depth of the trench can be etched to extend below the surface of the device layer. 
   A third method for forming an air gap structure for an integrated circuit according to the present invention includes forming an interconnect structure on the device layer including an aluminum alloy interconnect layer overlaying an aluminum alloy plug layer. The conductive plug layer and interconnect layer can be formed simultaneously, thus eliminating at least two processing steps as compared to the second method of the present invention. An adjustable-depth trench is formed between the patterned interconnect structure at least down to the surface of the device layer. A dielectric layer is formed on the trench to form an air gap therein, the air gap optionally extending above the top surface of the interconnect structure. If desired, the depth of the trench can be etched to extend below the surface of the device layer. 
   It is an advantage of the present invention that the low dielectric constant of air is used to provide maximum electrical isolation by extending the air gap both below and above the adjacent isolated interconnects, or metal lines, while still ensuring that physical dielectric support is provided beneath the interconnects themselves. 
   It is a further advantage of the present invention that the air gap isolation structure is readily manufacturable and compatible with existing semiconductor manufacturing techniques. 
   It is a still further advantage of the present invention that exotic low K dielectric materials need not be used, thus saving costs and minimizing manufacturing complexity. 
   It is a still further advantage of the present invention that the existence of the air gaps is to release most of the system stress generated by subsequent thermal treatments. 
   It is a still further advantage of the present invention that the network structure using conventional dielectric layers encompassing the interconnects provides good thermal dissipation. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The aforementioned and other features and objects of the present invention and the manner of attaining them will become more apparent and the invention itself will be best understood by reference to the following description of a preferred embodiment taken in conjunction with the accompanying drawings, wherein: 
       FIGS. 1-12  are cross-sectional views of sequential integrated circuit processing steps for forming an air gap isolation structure according to a first embodiment of the present invention, using one of several acceptable dual-damascene metal interconnect processes; 
       FIG. 13  is a cross-sectional view of a resulting air gap isolation structure according to the present invention, accommodating the use of multiple levels of a dual-damascene metal interconnect process; 
       FIGS. 14-24  are cross-sectional views of sequential integrated circuit processing steps for forming an air gap isolation structure according to a second embodiment of the present invention using one of several acceptable conventional metal interconnect processes; 
       FIGS. 25-33  are cross-sectional views of sequential integrated circuit processing steps for forming an air gap isolation structure according to a third embodiment of the present invention using a conventional metal interconnect process; 
       FIG. 34  is a cross-sectional view of an air gap isolation structure according to the second/third embodiments of the present invention, accommodating the use of multiple levels of a conventional metal interconnect process; and 
       FIGS. 35-38  are cross-sectional views of sequential integrated circuit processing steps for forming an air gap isolation structure according to a fourth embodiment of the present invention, which is a variant of the first embodiment in which an etch stop layer between a line dielectric and a via dielectric is eliminated to further reduce the effective dielectric constant of the inter-metal dielectric layer; and 
       FIGS. 39-40  are cross-sectional views of sequential integrated circuit processing steps for forming an air gap isolation structure according to a fifth embodiment of the present invention, which is a variant of the first embodiment in which a first etch is performed only as far as a first etch stop layer. 
   

   DESCRIPTION OF PREFERRED EMBODIMENTS 
   First Embodiment 
   Referring generally now to  FIGS. 1-13 , a method for forming an integrated circuit device having an air gap structure is shown for a dual damascene-type metal interconnect structure. 
   In  FIG. 1 , a device layer  10  is formed, which may be a simple silicon substrate and first-level metal, for example. The device layer  10  may nonetheless also include multiple levels of metal, transistors, capacitors, or other devices, including previously manufactured integrated air gap structures built according to the method of the present invention. Thus, device layer  10  is meant to represent that portion of the previously formed integrated circuit device on which the air gap structure is to be built, but it is not limited to any particular form, structure or circuitry. 
   Similarly, as used herein, the terms “on” or “onto” or “above” when used in connection with various thin film layers are merely intended to denote a physical spatial relationship, and not necessarily a direct physical or electrical contact. It will be understood therefore by those skilled in the art that in embodiments of the invention, a first layer may be “on” or “above” a second layer, even if there are other intervening layers present. 
   In a first embodiment, a first etch stop layer  12  is formed on the upper surface of the device layer  10 . The etch stop layer  12  is ideally formed of silicon nitride (SiNx), silicon oxynitride (SiNxOy), silicon carbide (SiCx), or the like, and is deposited to a thickness of about 100 to 1500 Angstroms using any of a number of known conventional mechanisms. The particular material for any application of course can be determined by one skilled in the art by coordinating such selection with an etch chemistry/mechanism to be employed in a later etch operation. Thus, so long as such first etch stop layer is otherwise compatible with other materials and processes described herein, the present invention is not limited to any particular material. 
   A first dielectric layer  14  (designated generally herein as a “via” dielectric layer because the body of a via contact is later formed therein) is formed on etch stop layer  12 . The first dielectric layer  14  is ideally silicon dioxide or undoped silicate glass (USG) but can also be fluorinated silicate glass (FSG), or borophosphorus silicate glass (BPSG), phosphorus silicate glass (PSG), or the like and is deposited to a thickness of about 1000 to 10000 Angstroms using well-known processing tools. Moreover, first dielectric layer  14  can include combinations and/or composites of individual thin film layers. Again, the particular formulation for this layer will depend on desired performance characteristics and process requirements, and thus a variety of materials are expected to be suitable for such layer. 
   In  FIG. 2 , an additional second etch stop layer  16  is deposited onto the upper surface of via dielectric layer  14 . As with etch stop layer  12 , the particular composition of etch stop layer  16  is not critical, and can be determined without undue experimentation by one skilled in the art based on the present teachings and objectives defined herein for the inventions presented. 
   A second dielectric layer  18  (designated generally herein as a “line” dielectric layer because portions of a conductive line are later formed therein) is deposited onto the surface of etch stop layer  16 . The line dielectric is also ideally silicon dioxide or a similar dielectric as via dielectric layer  14  and is deposited to a thickness of about 1000 to 10000 Angstroms. The selection of materials for this layer will again be a routine design choice based on lithographic and etching requirements associated with a particular manufacturing process. 
   A third etch stop and/or an anti-reflecting layer  20  is subsequently deposited on the line dielectric layer  18 . Etch stop and/or anti-reflecting layer  20  is preferably SiNx, SiNxOy, silicon riched oxide (SRO), SiCx or the like and is deposited to a thickness of about 100 to 500 Angstroms. As with the other etch stop layers, the particular material for any application of course can be determined by one skilled in the art by coordinating such selection with an etch chemistry/mechanism to be employed in a later etch operation. 
   In general, the overall composition of the structure shown in  FIG. 2  can be constructed with conventional and well-known manufacturing equipment suitable for wafer processing operations. The particular selection of materials for the thin film layers is directed primarily by concerns of reliability, reproducibility and lithographic constraints in small scale geometries, and so it is expected that a wide variety of combinations will be suitable for use in the present invention. 
   In  FIG. 3 , a photoresist layer  22  is formed on third etch stop and/or anti-reflecting layer  20  to a thickness of about 1000 to 10000 Angstroms. Photoresist layer  22  is patterned to form metal contacts or a via pattern  24 A by any conventional photolithography process. The particular resist formulation and lithography process are again not material to the present teachings, so any suitable combination may be employed. 
   In  FIG. 4 , line dielectric layer  18  is anisotropically etched using via pattern  24 A as a mask to form a metal contact or via opening  24 B. A conventional oxide etch such as reactive ion etch (RIE) can be used for this step, which is terminated upon reaching first etch stop layer  12 , or some other point before this. Other techniques will be apparent to those skilled in the art. It should be noted, of course, that etch stop layer  12  can also be removed in those areas (not shown) where it may be desirable to make a conductive contact to some portion of device layer portion  10 . 
   In  FIG. 5 , after removing the resist layer  22 , another photoresist layer  32  is processed to form a metal line pattern  24 C by photolithography processes. Again, the particular resist formulation and lithography process for layer  32  are again not material to the present teachings, so any suitable combination may be employed. 
   In  FIG. 6 , both line dielectric layer  18  and via dielectric layer  14  are etched to form an opening  24 D for subsequent processing of the dual damascene structure. This etching operation is also done with a conventional etch such as reactive ion etch (RIE) can be used for this step, which is preferably terminated upon reaching second etch stop layer  16 . Other techniques will be apparent to those skilled in the art. Thus, both photoresist layer  32  and the patterned etch stop layer  16  act as a form of mask for this operation. 
   It should be noted that the upper portion of opening  24 D serves as an interconnect line while the bottom portion of opening  24 D functions as a conductive pillar to the device portion. The result is a conductive line  28  with a cross section in some areas that resembles a T-shape as seen in the Figures. 
   In  FIG. 7 , resist layer  32  is stripped using a conventional process and a composite copper barrier/seed layer (shown as a single integrated layer  26  for simplicity) is deposited using conventional means. The first portion of copper barrier/seed layer is a barrier layer selected from a group of conductive materials that can prevent Cu from diffusing into adjacent dielectric layers, such as Ta, TaN, TiN, TiW, WN, Mo, W, etc. These are examples known to the inventors at this time, and it is possible of course that later developed materials unforeseen and as yet undiscovered may prove to be suitable for this purpose. 
   A seed layer portion of composite barrier/seed layer  26  is typically Cu or Cu alloy, again deposited using known means. 
   In a preferred embodiment, the copper barrier layer portion is deposited to a thickness of about 50 to 500 Angstroms, and the seed layer portion is deposited to a thickness of about 300 to 2000 Angstroms to form combined layer  26 . It will be understood by those skilled in the art that these values are merely exemplary for the geometries described therein, and that the final values for any particular embodiment of the invention may deviate from such figures. 
   In  FIG. 8 , opening  24 D is then filled with a copper layer  28 . Copper is deposited to a thickness of about 2000 to 10000 Angstroms using any well-known conventional tools, which preferably completely fills opening  24 D and provides an excess copper layer. It will be understood, of course, that the deposition of this layer may be achieved in a single step, or multiple steps to provide a graded and/or composite copper layer within opening  24 D. 
   In  FIG. 9 , any excess copper on top of line dielectric  18  is removed preferably using chemical-mechanical polishing (CMP) with a suitable polish pad, slurry, recipe, etc. as is known to those skilled in the art. In self-limiting growth processes, this type of CMP operation may be minimized or reduced. The above steps for defining the openings and forming the Cu lines within such openings  24 D are merely an example of the preferred technique known to the inventors at this time, and it is possible of course that later developed processes unforeseen and as yet undiscovered may prove to be suitable for such purposes. 
   In  FIG. 10 , a plurality of dual damascene metal conductive lines  28  form an interconnect structure  28 ′. Each dual damascene metal interconnect line  28  is isolated primarily at this point by a combination of dielectric layers  14  and  18 . 
   Other cross-sectional portions of a wafer are illustrated in  FIG. 10A  to show some additional examples of structures/relationships that may exist. For example, in some areas an conductive line  29  may not extend down to device layer  10  (the most likely case for a metal line); in other areas  29 ′ the position of the via is not symmetric about the metal line. In other areas  29 ″ the via part of the dual damascene structure may extend to the device portion  10  and may be contacted to the substrate. In other area  29 ′″, the metal line part of the dual damascene structure is about the same width as that of via parts. Thus, a variety of cross-sectional patterns will result. It will be understood by those skilled in the art that these are merely exemplary, and that other portions of a wafer are likely to contain additional variants of those illustrated depending on interconnect/masking requirements. 
   As alluded to earlier, at least some of the conductive lines  28  may be included as part of a so-called “dummy” pattern so as to make the interconnection patterns more uniform across the surface of a wafer. This also facilitates the manufacturing process because the resulting surface is more uniform. 
   In  FIG. 10B , a side perspective can be seen of another exemplary conductive line  28  viewed lengthwise as it may be formed for an integrated circuit. At individual points across the surface, a lower portion of conductive line  28  extends (in some instances) as a type of conductive pillar  11  to form an electrical contact at selective points to device layer  10 . These conductive pillars are formed from a combination of material from conductive line  28  that is surrounded by dielectric material  14  for additional support. 
   In  FIG. 11 , dielectric layers  14  and  18  from  FIG. 10  are preferably-anisotropically etched using copper layer  28  as a hard mask. A conventional dielectric etch is used to form trenches  30  into dielectric layers  14  and  18 . The form and depth of trenches  30  is adjustable and can extend down to the upper surface of the device layer  10 , or can be etched further to extend down below etch stop layer  12  and below the surface of device layer  10  (not shown in  FIG. 11 ). 
   For reasons that are explained in more detail below, an anisotropic etch (or an etch type with reduced isotropic behavior) is preferred over a “wet” isotropic etch at this point, because it is desirable to leave some small amount of dielectric on the sidewalls of interconnect  18 , underneath the overhang areas as seen in  FIG. 11 . Of course, in some cases it may be desirable to remove such remaining material (from layer  14 ) and replace it with another material (i.e., through another spin on deposition/plasma deposition and subsequent etch. An isotropic etch could then be used on layer  14 . While this would require additional processing steps, it is conceivable that the dielectric constant could be improved in this fashion, as well as reliability, yield etc. of the overall process. 
   The depth of trenches  30  is preferably controlled through a timed etch, and it will be apparent to those skilled in the art that the duration of such etch will be a function of the dielectric layer composition, the etch process chemistry, the thickness of layers  14 ,  18 , etc., etc. The etch time will thus vary from application to application, and can be determined with routine simulations and testings. 
   Alternatively it is possible instead to use either etch stop layer  12  to control the end of the etch, and/or to provide yet another etch stop layer (not shown) within layer  14  at any optimally determined etch depth. In such instance, of course, layer  14  would be a composite layer deposited in separate steps, and thus this option is not as attractive from a throughput perspective. 
   As noted above, a preferred approach uses copper conductive lines  28  as a mask, but it those skilled in the art will appreciate that an additional masking step could be employed should it be necessary to make the air gaps more narrow. Again, this is not optimal from a control and throughput perspective, so it is probably not desirable except in limited cases. 
   In contrast, in the present invention, it should be relatively simple and easy to control the size of such air gaps both by controlling the spacing between the conductive lines  28 , as well as tailoring the size/shape of the top portion of the conductive line. This is true since the latter effectuate the hard mask used for etching dielectric layers  14 ,  18  to form the air gaps. 
   In this respect, those skilled in the art will appreciate that shapes and sizes of the interconnect structures shown in the figures are only approximate, and not intended to be to scale. Other variations are expected to be beneficially employed in accordance with the present teachings. 
   In  FIG. 12 , a copper barrier layer  44  such as SiNx, SiC, or the like is deposited to a thickness of about 50 to 500 Angstroms. Again, these are materials particularly suited for copper, and other compositions may be needed for other types of conductive line metals. For some metals, of course, a barrier layer may not be needed in the first place. 
   A silicon-dioxide dielectric layer, or the like  32  is then deposited to a thickness of about 2000 to 10000 Angstroms. Poor step coverage by the deposition of dielectric layer  32 , such as conventional plasma enhanced chemical vapor deposition (PECVD), results in the formation of intra-metal line air gaps  34 . In other words, the present invention exploits the basically conformal growth nature of this type of process to intentionally form gaps between the metal lines. By controlling the deposition parameters, and the thickness of the deposited layer, the size, shape and height of air gaps  34  can be customized for any particular line interconnect geometry. 
   In lieu of a PECVD process, other similar techniques that are characterized by poor step coverage could be used to form air gaps  34 . For example, a series of HDPCVD depositions could be used. As those skilled in the art will appreciate, the above are merely examples of techniques for achieving poor step coverage that are known to the inventors at this time, and it is possible of course that later developed processes unforeseen and as yet undiscovered may prove to be suitable for such purposes. 
   As previously discussed, the inclusion of air gaps  34  provides superior electric isolation due to the low dielectric constant of air. The size and shape of air gaps  34  may also vary across the surface of a wafer, as illustrated generally in  FIG. 12A . It can be seen in such picture that the width of any air gaps (W 1  or W 2 ) are not necessarily uniform across the surface of the wafer, nor are they required to be for purposes of the present invention. It is simply desirable, of course, to ensure that at least some air filled gap is provided between two adjacent signal lines. 
   Thus, as seen in  FIG. 12A , one useful benchmark is to consider the relative ratio of the airgap width (W 1 , W 2 ) to an overall line spacing (WS 1 , WS 2 ). In general, the closer W 1 /WS 1  and W 2 /WS 2  are to unity, the lower the capacitance, so it is preferable to maximize this value to the extent consistent with other processing requirements. 
   In addition, the height by which the air gaps  34  extend above interconnect layer  28 , or below such layer, is controlled both by the trench sizing noted earlier, as well as the details of the conformal dielectric deposition noted earlier. Thus, they may also vary in vertical size as seen in  FIG. 12B , where two different heights (H 1  and H 2 ) are provided. Again it is understood that the height of any air gaps (H 1  or H 2 ) are not necessarily uniform across the surface of the wafer, nor are they required to be for purposes of the present invention. Nonetheless, for reasons well understood in the art, it is preferable (to the exent possible within available process constraints) to maximize such air gap heights (in relation to the height HL of the conductive lines  28 ) by extending them above and below an interconnect structure  28  to reduce the capacitance between adjacent lines. 
   In summary, an inter-line interconnect structure as shown in  FIG. 12  typically includes a metal line  28 , an conductive line sidewall dielectric portion  14 ′, a second dielectric filler  32 , and air gap  34 . The sidewall dielectric portion  14 ′ left underneath metal line  28  provides structural support and additional process window margin when the present invention is used in small scale line width geometries. 
   Those skilled in the art will further appreciate that the above are merely examples of what might be present in any section of the wafer, and that other air gap structures will inevitably result as part of any conventional manufacturing process employing the present teachings. 
   As further noted, to reduce non-uniformities for such air gaps, dummy metal lines can be added to an interconnect pattern to ensure that no large flat spaces are left between adjacent conductive lines. Thus, for example, in  FIG. 12 , for some instances across the surface of the wafer, the middle metal line  28  may be carrying an actual signal, and in other instances, a “dummy” metal line  28  may be simply added so as to create a uniform capacitance everywhere for the metal lines adjacent thereto. 
   In  FIG. 13 , a composite drawing is shown of two dual damascene structures fabricated in sequence according to the method of the present invention. A device layer  10  includes a silicon substrate and a portion of first level of metal interconnect  28  extends herein as well. In a first level of interconnect structure according to the present invention, copper metal layer  28  and air gaps  34  are shown extending in and to the top of dielectric layers  14  and  18 . Note that air gaps  34  are shown to extend below the level of the upper surface of the device layer  10  as well as above the upper surface of metal lines  28 , thus providing the maximum electrical isolation between adjacent metal structures. 
   Also shown in  FIG. 13  is a second level of metal interconnect that includes an additional metal interconnect  38  and a dielectric layer  36  with air gaps  40  and  42 . Air gap  40  provides intra-level metal isolation and extends to the surface of device layer including layers  10 ,  14 , and  18 , as well as above the upper surface of metal lines  38 . Air gaps  42  extend below the surface of the device layer including layers  10 ,  14 , and  18 , and thus provide electrical intra-metal isolation for both metal layers  38  and  28 . 
   Furthermore it will be apparent that this overall process could be repeated as needed to form additional interconnect layers, and the present invention is by no means limited to any particular number of such layers. 
   Another important observation about the present invention that can be gleaned from  FIG. 13 , is that in some instances an air gap for a second level interconnect may be formed on top of a first level interconnect. In other instances a single air gap can be extended in height so that it serves to reduce capacitance for more than one interconnect layer. For example, the air gap  42  shown in the middle of  FIG. 13  serves as an air gap for two separate metal interconnect levels; this same principle could be extended as needed for additional levels. Thus by appropriate “stacking” and arrangement of interconnect layers, a single air gap can be formed between adjacently located conductive lines in more than one layer of metal. 
   As illustrated herein, the dielectric material  14  underneath the conductive lines further functions to provide some measure of structural support for the latter. This feature can be enhanced or reduced in other embodiments by structural variations so that more or less dielectric is left on the sidewalls, or under the top portions of the conductive lines. The dielectric also functions as a heat dissipator, and further reduces electromigration. Accordingly, the amount of dielectric left on the sidewalls can be tailored for any particular environment, so that it might be used extensively in some applications (thicker layers), and not used in others (thin layers, or no layers at all). 
   Second Embodiment 
   Referring generally now to  FIGS. 14-24 , a method for forming an integrated circuit device having at least one air gap structure is shown for a conventional metal interconnect structure of the type having aluminum alloy metal interconnect layers and tungsten metal plugs. Except where otherwise noted, like numerals are intended to represent like structures and materials already identified in connection with  FIGS. 1-13 . 
   In  FIG. 14 , a device layer  10  is formed as before. 
   A contact/via dielectric layer  14  is formed on device layer  10 . As before, dielectric layer  14  is ideally silicon dioxide but can also be USG, FSG, PSG, BPSG, or the like and is deposited to a thickness of about 1000 to 10000 Angstroms. It will be understood, of course, that layer  14  may be comprised of a combination of layers, and formed in more than one processing step, but for purposes of the present discussion, it will be referred to as a single layer. 
   In  FIG. 15 , a photoresist layer  22  is formed on dielectric layer  14  to a thickness of about 1000 to 10000 Angstroms. Photoresist layer  22  is patterned to form metal contact or via pattern  56 A by photolithography processes as before. 
   In  FIG. 16 , as noted before, openings  56 B are etched into the contact/via dielectric layer  52  in a similar fashion to that already described for  FIG. 4 . 
   In  FIG. 17 , resist layer  22  is stripped and a tungsten barrier layer  92  (such as Ti/TiN, Ta, TaN etc.) is deposited on the surface of dielectric layer  52  and in openings  56 . Again, these are merely examples of those known at this time to be particularly suited for Tungsten, and other compositions may be needed for other types of conductive line metals. For some metals, of course, a barrier layer may not be needed in the first place. 
   A layer of Tungsten  58  is then preferably deposited to a thickness of about 500 to 8000 Angstroms, which completely fills openings  56 . Again, for other processes, materials other than Tungsten may be more suitable. 
   In  FIG. 18 , any excess tungsten is removed using tungsten CMP or tungsten etch back, which results in a structure that includes dielectric layer  14  and tungsten metal plugs  58 . In self-limiting growth processes, this type of CMP operation may be minimized or reduced. 
   In  FIG. 19 , an aluminum alloy (or the like) interconnect layer  60  is deposited on combined metal plug/dielectric layer  14 / 58  to a thickness of about 2000 to 10000 Angstroms. Again, for other processes, materials other than an aluminum alloy may be more suitable. For example, doped polycrystalline silicon is also well-known as an effective conductive interconnect/gate material. 
   In  FIG. 20 , a resist layer  62  is formed on the metal layer  60  in any conventional manner to a thickness of preferably about 2000 to 15000 Angstroms and followed preferably by a photolithography process to result in metal line pattern  64 A. 
   In  FIG. 21 , an intra-metal spacing  64 B is formed by etching metal layer  60  using a conventional metal etching process to form an interconnect structure consisting of patterned metal layer  60  and spacings  64 B. Again, the particular etch chemistry and technique will depend on the particular material selected for layer  60 . 
   In  FIG. 22 , the metal interconnect structure of  FIG. 21  is shown in conjunction with several other metal plugs  58 , each capped by a section of metal interconnect layer  60 . It will be understood, of course, that it is not necessary to locate every interconnect line above a metal plug. 
   In a preferred first processing option, any material in spacings  64 B is removed and etched down to the surface of the device layer  50  with the resist layer  62  intact to form trenches  64 C. As explained in connection with  FIG. 11  as well, the depth of trenches  64 C is adjustable and can be made down to and even below the upper surface of the device layer  10  (not shown in  FIG. 22 ). 
   In a second processing variation of this embodiment (shown in  FIG. 23 ), resist layer  62  is first stripped and previously etched metal layer  60  is used as a hard mask to etch trenches  64 C. The choice between these two variations can be made on a case by case basis in accordance with conventional and well-known process requirements. 
   In  FIG. 24  air gaps are formed in substantially the same manner as depicted earlier for  FIG. 12 . That is, a silicon-dioxide or the like dielectric layer  66  is deposited onto the surface to a thickness of about 2000 to 10000 Angstroms. Poor step coverage by the deposition of dielectric layer  66  results in the formation of intra-metal line air gaps  68 . Air gaps  68  provide superior electric isolation due to the low dielectric constant of air as previously discussed. 
   It will be appreciated by those skilled in the art that this second embodiment can also be used to create structures that are similar to those already illustrated in  FIGS. 12A and 12B , including air gaps of different height, width, etc. Moreover, the above steps can be sequenced again to form multi-level interconnect structures in the same manner as previously described for  FIG. 13 . Thus, air gaps can be used as an insulation layer between inter-metal or intra-metal layers formed of Al, Al alloys, polycrystalline silicon, etc. 
   Third Embodiment 
   Referring generally now to  FIGS. 25-33 , a third embodiment of a method for forming an integrated circuit device having at least an air gap structure is shown for a conventional metal interconnect structure of the type having aluminum alloy metal interconnect layers and aluminum alloy metal plugs. The primary difference to the second embodiment is in the use of a different type of a barrier metal layer for the interlayer plugs. 
   In  FIG. 25 , a contact/via dielectric layer  14  is formed on device layer  10  as before. 
   In  FIG. 26 , a photoresist layer  22  is formed and patterned on dielectric layer  14  as before to form a pattern of openings  86 A. 
   In  FIG. 27 , openings  86 B are etched into contact/via dielectric layer  14  as before. 
   In  FIG. 28 , resist layer  22  is stripped and an aluminum barrier layer  94  (such as Ti/TiN, Ta, TaN or Aluminum oxide) is deposited on the surface of dielectric layer  82  and in openings  86 . Again, these are merely examples of those known at this time to be particularly suited for Aluminum, and other compositions may be needed for other types of conductive line metals. For some metals, of course, a barrier layer may not be needed in the first place. 
   An aluminum alloy layer  90  (preferably Aluminum with some small percentage of Cu and/or Si) is then deposited to a thickness of about 500 to 8000 Angstroms, which completely fills contact/via openings  86 B and provides an aluminum alloy interconnect layer coupled to aluminum alloy plugs  88 . 
   This embodiment, therefore, is distinguished from the second embodiment noted earlier in that the plug and interconnect layer can be formed in a single step, thus improving throughput for those applications where it is acceptable to use something other than a Tungsten based plug. 
   In  FIG. 29 , as before a resist layer  92  is formed on the metal layer to a thickness of about 2000 to 15000 Angstroms followed by a photolithography process. 
   In  FIG. 30 , an intra-metal spacing  74 B is formed by etching the aluminum metal layer  90  using a conventional metal etching process as noted earlier for  FIG. 21 . 
   In  FIG. 31 , the metal interconnect structure of  FIG. 30  is shown in conjunction with several other metal plugs  88 , each capped by a section of aluminum alloy metal interconnect layer  90 . As before, it will be understood, of course, that it is not necessary to locate every interconnect line above a metal plug. 
   In a preferred first processing option, any material in intra-metal spacings  74 B is removed and etched down to the surface of the device layer  10  with the resist layer  92  intact to form trenches  74 C. As explained in connection with  FIG. 11  as well, the depth of trenches  74 C is adjustable and can be made down to and even below the upper surface of the device layer  10  (not shown in  FIG. 31 ). 
   In a second processing variation shown in  FIG. 32 , resist layer  92  is first stripped and previously etched metal layer  90  is used as a hard mask to etch trenches  74 . Again the choice between these two variations can be made on a case by case basis in accordance with conventional and well-known process requirements. 
   In  FIG. 33  air gaps are formed in substantially the same manner as depicted earlier for  FIG. 12 . That is, a silicon-dioxide dielectric layer or the like  78  is deposited to fill the trenches  74  and cover the metal pattern  90  to a thickness of about 1000 to 8000 Angstroms. Poor step coverage by the deposition of dielectric layer  78  results in the formation of intra-metal line air gaps  76 . Air gaps  76  provide superior electric isolation due to the low dielectric constant of air as previously discussed. 
   It will be appreciated by those skilled in the art that this third embodiment can also be used to create structures that are similar to those already illustrated in  FIGS. 12A and 12B , including air gaps of different height, width, etc. 
   Moreover, the above steps can be sequenced again to form multi-level interconnect structures in the same manner as previously described for  FIG. 13 , and as shown generally in  FIG. 34 . 
   In  FIG. 34 , a composite drawing is shown of two metal interconnect structures fabricated according to the third (and second) air gap method of the present invention. In a first level of interconnect structure according to the present invention, metal interconnect  60 , metal plugs  58 , and air gaps  68  are shown embedded in dielectric layer  14  above device layer  10 . 
   Note that as with  FIG. 13 , the resulting structure of  FIG. 34  shows that that air gaps  68  can extend below the level of the upper surface of device layer  50  and above the upper surface of metal lines  60 , thus providing maximum electrical isolation. Also shown in  FIG. 34  is a second level of metal interconnect layer  80  that includes an additional metal level  86 , metal plugs  84 , and air gaps  88 . Air gap  88  provides intra-level metal isolation and extends to layers  50 ,  52 , and  60 . 
   Fourth Embodiment 
   A fourth embodiment is now described with reference to  FIGS. 35-38 . This embodiment is a variant of the first embodiment in which an etch stop layer between a line dielectric and a via dielectric is eliminated to further reduce the effective dielectric constant of the inter-metal dielectric layer. 
   Thus, in  FIG. 35 , the second etch stop layer  16  between the via and line dielectric layers  14  and  18  ( FIG. 2 ) has been eliminated to further reduce the effective dielectric constant of the inter-metal dielectric layer. In lieu of two dielectric layers separated by an etch stop layer, a single dielectric layer  15  is deposited onto the surface of etch stop layer  12 . The single dielectric layer  15  is also ideally silicon dioxide or the like and is deposited to a thickness of about 1000 to 10000 Angstroms in a manner similar to that already described for via dielectric layer  14 . 
   An etch stop and/or anti-reflecting layer  20  is subsequently deposited on the line dielectric layer  15  as discussed before in connection with  FIG. 2 . 
   In  FIG. 36 , a photoresist layer  22  is formed on etch stop and/or anti-reflecting layer  20  to a thickness of about 1000 to 10000 Angstroms as already described in  FIG. 3 . 
   In  FIG. 37 , using metal contact or via pattern  24 A as a mask, the dielectric layer  15  is anisotropically etched to form metal contact or via opening  24 B as already described in  FIG. 4 . The primary difference from  FIG. 4  is that, as generally illustrated, dielectric layer  15  is only partially etched, in this case, to a depth of approximately slightly more than half the thickness of such layer. 
   In  FIG. 38 , after removing the resist layer  22 , another photoresist layer  32  is processed to form metal line pattern  24 C by photolithography processes as generally already described in  FIG. 5 . 
   From this point forward, processing takes place in substantially the same fashion as already illustrated above in connection with  FIGS. 6-13 , thus resulting in a single or multi-level air gap interconnect structure, albeit with slightly modified layer compositions as noted here. 
   Fifth Embodiment 
   A fifth embodiment is now described with reference to  FIGS. 39-40 . This embodiment is also a variant of the first embodiment in which a first etching operation is performed only as far as a first etch stop layer. 
   Accordingly,  FIG. 39  illustrates a variation in which given the structure shown in  FIG. 3 , an etching operation is conducted in a similar fashion to that already describe in  FIG. 4 , except that such etch is stopped upon reaching second etch stop layer  16 . In all other respects, this operation is the same, in that line dielectric layer  18  is anisotropically etched using via pattern  24 A as a mask to form a metal contact or via opening  24 B. It is only the case, therefore, that these openings do not extend as far down as those illustrated in  FIG. 4 . 
   In  FIG. 40 , after removing the resist layer  22 , another photoresist layer  32  is formed. A subsequent etch transfers the upper profile of opening  24 C to the bottom of the openings, so that a deeper enlarged opening  24 D results that is substantially the same as shown in  FIG. 6 . 
   From this point forward, processing takes place in substantially the same fashion as already illustrated above in connection with  FIGS. 7-13 , thus resulting in a single or multi-level air gap interconnect structure, albeit with slightly modified layer compositions as noted here. 
   While there have been described above the principles of the present invention in conjunction with specific circuit implementations and applications it is to be clearly understood that the foregoing description is made only by way of example and not as a limitation to the scope of the invention. Particularly, it is recognized that the teachings of the foregoing disclosure will suggest other modifications to those persons skilled in the relevant art. Such modifications may involve other features which are already known and which may be used instead of or in addition to features already described herein. Although claims have been formulated in this application to particular combinations of features, it should be understood that the scope of the disclosure herein also includes any novel feature or any novel combination of features disclosed either explicitly or implicitly or any generalization or modification thereof which would be apparent to persons skilled in the relevant art, whether or not such relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as confronted by the present invention. The applicants hereby reserve the right to formulate new claims to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.

Technology Category: 5