Some embodiments relate to a semiconductor device manufacturing process. In the process, a substrate is provided, and a sacrificial layer is formed over the substrate. An opening is patterned through the sacrificial layer, and the opening is filled with conductive material. The sacrificial layer is removed while the conductive material is left in place. A first dielectric layer is formed along sidewalls of the conductive material that was left in place.

A semiconductor structure includes a first metallization feature, a first dielectric structure over the first metallization feature, a second metallization feature embedded in the first dielectric structure, a via structure between the first metallization feature and the second metallization feature, and a first insulating layer between the first dielectric structure and the first metallization feature, and between the first dielectric structure and the via structure. The first metallization feature extends along a first direction, and the second metallization feature extends along a second direction different from the first direction. The first insulating layer covers first sidewalls of the via structure along the second direction.

An interconnection structure includes a non-insulator structure, a dielectric structure, a conductive structure and a first dielectric protective layer. The dielectric structure is present on the non-insulator structure. The dielectric structure has a trench opening and a via opening therein. The via opening is present between the trench opening and the non-insulator structure. The conductive structure is present in the trench opening and the via opening and electrically connected to the non-insulator structure. The first dielectric protective layer is present between the conductive structure and at least one sidewall of the trench opening.

An integrated circuit product includes two laterally spaced-apart transistors, wherein each of the two laterally spaced-apart transistors includes a gate structure, a gate cap layer positioned above the gate structure, and a sidewall spacer positioned adjacent to sidewalls of the gate structure. A source/drain region is positioned between the two laterally spaced-apart transistors, and a conformal etch stop layer is positioned on and in contact with an upper surface of the source/drain region and on and in contact with a sidewall surface of the sidewall spacer of each of the two laterally spaced-apart transistors. A self-aligned conductive contact extends through an opening in the conformal etch stop layer and is conductively coupled to the source/drain region.

An interconnection structure includes a non-insulator structure, a dielectric structure, a conductive structure and a first dielectric protective layer. The dielectric structure is present on the non-insulator structure. The dielectric structure has a trench opening and a via opening therein. The via opening is present between the trench opening and the non-insulator structure. The conductive structure is present in the trench opening and the via opening and electrically connected to the non-insulator structure. The first dielectric protective layer is present between the conductive structure and at least one sidewall of the trench opening.

Described herein are IC devices include vias deposited in a regular array, e.g., a hexagonal array, and processes for depositing vias in a regular array. The process includes depositing a guiding pattern over a metal grating, depositing a diblock copolymer over the guiding pattern, and causing the diblock copolymer to self-assemble such one polymer forms an array of cylinders over metal portions of the metal grating. The polymer layer can be converted into a hard mask layer, with one hard mask material forming the cylinders, and a different hard mask material surrounding the cylinders. A cylinder can be selectively etched, and a via material deposited in the cylindrical hole to form a via.

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.

One illustrative method disclosed includes, among other things, forming a silicon dioxide etch stop layer on and in contact with a source/drain region and adjacent silicon nitride sidewall spacers positioned on two laterally spaced-apart transistors having silicon dioxide gate cap layers, performing a first etching process through an opening in a layer of insulating material to remove the silicon nitride material positioned above the source/drain region, performing a second etching process to remove a portion of the silicon dioxide etch stop layer and thereby expose a portion of the source/drain region, and forming a conductive self-aligned contact that is conductively coupled to the source/drain region.

The present disclosure relates to a method of forming a masking structure having a trench with a high aspect ratio, and an associated structure. In some embodiments, the method is performed by forming a first material over a substrate. The first material is selectively etched and a second material is formed onto the substrate at a position abutting sidewalls of the first material, resulting in a pillar of sacrificial material surrounded by a masking material. The pillar of sacrificial material is removed, resulting in a masking layer having a trench that extends into the masking material. Using the pillar of sacrificial material during formation of the trench allows the trench to have a high aspect ratio. For example, the sacrificial material allows for a plurality of masking layers to be iteratively formed to have laterally aligned openings that collectively form a trench extending through the masking layers.

A field effect transistor comprising a substrate, at least one gate stack structure, source and drain regions and an interconnect structure is described. The interconnect structure comprises a metal interconnect connected to a conductive region, an adhesion sheath structure and a cap layer. The adhesion sheath structure is disposed between the metal interconnect and inter-dielectric layers and surrounds the metal interconnect. The cap layer is disposed on the metal interconnect and covers a gap between the metal interconnect and the inter-dielectric layer.