An aluminum interconnection apparatus comprises a metal structure formed over a substrate, wherein the metal structure is formed of a copper and aluminum alloy, a first alloy layer formed underneath the metal structure and a first barrier layer formed underneath the first alloy layer, wherein the first barrier layer is generated by a reaction between the first alloy layer and an adjacent dielectric layer during a thermal process.

A method for forming a semiconductor structure includes following operations. A first metallization feature is formed, and a first cap layer is formed over the first metallization feature. A first insulating layer is formed over the first cap layer and the first metallization feature. A first dielectric structure is formed over the first insulating layer. A portion of the first dielectric structure and a portion of the first insulating layer are removed to expose the first cap layer. A second cap layer is formed over the first cap layer and the first metallization feature. A second insulating layer and a patterned second dielectric structure are formed over the substrate. The patterned second dielectric structure includes a trench and a via opening coupled to a bottom of the trench. A second metallization feature is formed in the trench, and a via structure is formed in the via opening.

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.

A semiconductor device manufacturing method includes a step of forming a hole reaching a first insulating layer over a first conductive member; a step of forming a trench reaching a second insulating layer and in communication with the hole; a step of forming an opening exposing the first conductive member in the hole; and a step of forming a second conductive member connected to the first conductive member by embedding a conductive material in the opening, the hole, and the trench. The trench is formed under an etching condition such that the etching rate with respect to the second insulating layer is lower than the etching rate with respect to the third insulating layer.

A method for bonding and interconnecting two or more IC devices arranged on substrates such as silicon wafers is disclosed. In one aspect, the wafers are bonded by a direct bonding technique to form a wafer assembly, and the multiple IC devices are provided with metal contact structures. A TSV (Through Semiconductor Via) is produced through the bonded wafer assembly. The IC device or devices in the upper wafer or wafers have contact structures that serve as masks for the etching of the TSV opening. A conformal isolation liner is deposited in the TSV opening, and subsequently removed from the bottom and any horizontal areas in the TSV opening, while maintaining the liner on the sidewalls, followed by deposition of a TSV plug in the TSV opening. The removal of the liner is done without applying a lithography step.

The present disclosure provides a semiconductor device structure with fine patterns and a method for forming the semiconductor device structure, which prevents the collapse of the fine patterns. The semiconductor device structure includes a first target structure and a second target structure disposed over a semiconductor substrate. The semiconductor device structure also includes a first spacer element disposed over the first target structure, wherein a topmost point of the first spacer element is between a central line of the first target structure and a central line of the second target structure in a cross-sectional view.

The present disclosure provides a semiconductor device structure with fine patterns and a method for forming the semiconductor device structure, which can prevent the collapse of the fine patterns. The semiconductor device structure includes a first target structure and a second target structure disposed over a semiconductor substrate. The semiconductor device structure also includes a first spacer element disposed over the first target structure, wherein a topmost point of the first spacer element is between a central line of the first target structure and a central line of the second target structure in a cross-sectional view.

Provided are conductive structures located within dielectric material, and methods for fabricating such structures and devices. A semiconductor structure includes a dielectric material; and a conductive structure located in the dielectric material, wherein the conductive structure has a bottom surface and a side surface that join at a corner at a first height, wherein the bottom surface includes a central portion at a second height greater than the first height.

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.