A method of forming an interconnect structure for an integrated circuit device is provided. The method includes forming a wiring layer having a metal line, and forming a patterned disposable material layer over the wiring layer and having an opening aligned with the metal line. The method also includes depositing a first dielectric film in the opening and in contact with the metal line, and removing the patterned disposable material layer to leave the first dielectric film. The method further includes depositing a second dielectric film over the first dielectric film, and etching the second dielectric film to form a trench above the first dielectric film. In addition, the method includes removing a portion of the first dielectric film to form a via hole under the trench, and depositing a conductive material in the trench and the via hole.

A method of manufacturing a semiconductor device includes forming a first dielectric layer and a through hole passing through the first dielectric layer over a substrate; forming a plurality of dummy contacts in the through hole; forming a plurality of first dummy wires on the plurality of dummy contacts; filling a second dielectric layer between the plurality of first dummy wires, wherein the second dielectric layer has a first air gap; removing the dummy contacts and the first dummy wires to expose the through hole, thereby forming a first wiring trench over the through hole; and forming a contact and a first wire in the through hole and the first wiring trench.

A semiconductor device includes a conductive line and a conductive via contacting the conductive line. A first dielectric material contacts a first sidewall surface of the conductive via. A second dielectric material contacts a second sidewall surface of the conductive via. The first dielectric material includes a first material composition, and the second dielectric material includes a second material composition different than the first material composition.

A semiconductor device includes a first conductive structure. The semiconductor device includes a first dielectric structure. The semiconductor device includes a second conductive structure. The first dielectric structure is positioned between a first surface of the first conductive structure and a surface of the second conductive structure. The semiconductor device includes an etch stop layer overlaying the first conductive structure. The semiconductor device includes a first spacer structure overlaying the first dielectric structure. The semiconductor device includes a second dielectric structure overlaying the first spacer structure and the etch stop layer.

Systems and methods for maskless gap (for example, air gap) integration into multilayer interconnects having one or more interconnect lines (for example, metal interconnect lines) embedded in a dielectric layer of the interconnects are described. In various embodiments, the described systems and methods may serve to reduce electrical shorting between adjacent vias in the interconnects. In one embodiment, a spacer layer may be provided to mask portions of an interlayer dielectric (ILD) in the interconnect. These masked portions of the ILD can protect regions between adjacent interconnect lines (for example, metal interconnect lines) from electrical shorting during subsequent metal layer depositions, for example, during a fabrication sequence of the interconnects. Further, the vias may enclose a gap (for example, an air gap) without the need for additional masking steps. Further, such gaps may be inherently self-aligned to the vias and/or spacer layers. Moreover, the gaps may act to reduce capacitance and thereby increase the performance (circuit timing, power consumption, etc.) of the interconnect.

A semiconductor device includes a conductive line and a conductive via contacting the conductive line. A first dielectric material contacts a first sidewall surface of the conductive via. A second dielectric material contacts a second sidewall surface of the conductive via. The first dielectric material includes a first material composition, and the second dielectric material includes a second material composition different than the first material composition.

Apparatuses and methods to provide a fully self-aligned via are described. A first metallization layer comprises a set of first conductive lines extending along a first direction on a first insulating layer on a substrate, the set of first conductive lines recessed below a top portion of the first insulating layer. A capping layer is on the first insulating layer, and a second insulating layer is on the capping layer. A second metallization layer comprises a set of second conductive lines on the second insulating layer and on a third insulating layer above the first metallization layer. The set of second conductive lines extend along a second direction that crosses the first direction at an angle. At least one via is between the first metallization layer and the second metallization layer. The via is self-aligned along the second direction to one of the first conductive lines. The tapering angle of the via opening may be in a range of from about 60 to about 120.

Certain aspects of the present disclosure generally relate to integration of a hybrid conductor material in power rails of a semiconductor device. An example semiconductor device generally includes an active electrical device and a power rail. The power rail is electrically coupled to the active electrical device, disposed above the active electrical device, and embedded in at least one dielectric layer. The power rail comprises a first conductive layer, a barrier layer, and a second conductive layer comprising copper. The barrier layer is disposed between the first conductive layer and the second conductive layer.

2D self-aligned contact structures (both gate contact and source/drain contact) are provided that can improve the process control and push further scaling. The 2D self-aligned contact structures can enable tighter process control which can lead to further device scaling. In accordance with the present application, the gate contact structure is confined in one direction by a sacrificial spacer structure that is present in a dielectric material layer, and in another direction by an edge of a metallization structure that is located above the gate contact structure.

2D self-aligned contact structures (both gate contact and source/drain contact) are provided that can improve the process control and push further scaling. The 2D self-aligned contact structures can enable tighter process control which can lead to further device scaling. In accordance with the present application, the gate contact structure is confined in one direction by a sacrificial spacer structure that is present in a dielectric material layer, and in another direction by an edge of a metallization structure that is located above the gate contact structure.