For simplifying the dual-damascene formation steps of a multilevel Cu interconnect, a formation step of an antireflective film below a photoresist film is omitted. Described specifically, an interlayer insulating film is dry etched with a photoresist film formed thereover as a mask, and interconnect trenches are formed by terminating etching at the surface of a stopper film formed in the interlayer insulating film. The stopper film is made of an SiCN film having a low optical reflectance, thereby causing it to serve as an antireflective film when the photoresist film is exposed.

A semiconductor device includes a first interlayer insulating film on a substrate, a via which penetrates the first interlayer insulating film, a first etching stop film which extends along an upper surface of the first interlayer insulating film, a second interlayer insulating film on the first etching stop film, the second interlayer insulating film including a plurality of periodically arranged air gaps, a first wiring pattern in the second interlayer insulating film, the first wiring pattern penetrating the first etching stop film and is connected to the via, and a capping film which covers an upper surface of the second interlayer insulating film and an upper surface of the first wiring pattern, each of the plurality of air gaps in the second interlayer insulating film extending from the first etching stop film to the capping film.

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.

Embodiments of the present disclosure provide semiconductor devices having conductive features with reduced height and increased width, and methods for forming the semiconductor devices. Particularly, sacrificial self-aligned contact (SAC) layer and sacrificial metal contact etch stop layer (M-CESL) are used to form conductive features with reduced resistance. After formation of the conductive features, the sacrificial SAC and sacrificial M-CESL are removed and replaced with a low-k material to reduce capacitance in the device. As a result, performance of the device is improved.

A method of manufacturing a semiconductor device includes forming a first recess in a first wafer. The first recess is at a first front-side surface of the first wafer and exposes a first interconnect structure in the first wafer. A second recess is formed in a second wafer. The second recess is at a second front-side surface of the second wafer. The first recess is filled with a first polymer. The second recess is filled with a second polymer. The first front-side surface of the first wafer is bonded with the second front-side surface of the second wafer such that the first polymer is bonded to the second polymer. The first polymer in the first recess and the second polymer in the second recess are removed. A metal is deposited in the first recess and the second recess.

Interconnect structures including super vias are formed during back-end-of-line processing using sacrificial placeholders to protect the bottom portions of the super vias while upper portions of the super vias are formed. The sacrificial placeholders are removed and replaced by metal conductors that fill the bottom and upper portions of the super vias.

Embodiments disclosed herein include edge placement error mitigation processes and structures fabricated with such processes. In an embodiment, a method of fabricating an interconnect layer over a semiconductor die comprises forming a patterned layer over a substrate, disposing a resist layer over the patterned layer and patterning the resist layer to expose portions of the patterned layer. In an embodiment, overlay misalignment during the patterning results in the formation of edge placement error openings. In an embodiment, the method further comprises correcting the edge placement error openings, and patterning an opening into the substrate after correcting edge placement error openings.

An integrated circuit structure includes a first interconnect layer including a first dielectric material. The first dielectric material has a first recess therein, the first recess having a first opening. The integrated circuit structure further includes a second interconnect layer above the first interconnect layer. The second interconnect layer includes a second dielectric material that has a second recess therein. The second recess has a second opening. In an example, at least a portion of the first opening of the first recess abuts and overlaps with at least a portion of the second opening of the second recess. In an example, a continuous conformal layer is on walls of the first and second recesses, and a continuous body of conductive material is within the first and second recesses.

In a method of manufacturing a semiconductor device, a first conductive pattern is formed in a first interlayer dielectric (ILD) layer disposed over a substrate, a second ILD layer is formed over the first conductive pattern and the first ILD layer, a via contact is formed in the second ILD layer to contact an upper surface of the first conductive pattern, a second conductive pattern is formed over the via contact wherein a part of an upper surface of the via contact is exposed from the second conductive pattern in plan view, a part of the via contact is etched by using the second conductive pattern as an etching mask, thereby forming a space between the via contact and the second ILD layer, and a third ILD layer is formed over the second ILD layer.

A semiconductor device includes an integrated circuit (IC) and an interlayer dielectric layer on the substrate, a contact through the interlayer dielectric layer and electrically connected to the IC, a wiring layer on the interlayer dielectric layer with a wiring line electrically connected to the contact, a first passivation layer on the wiring layer, first and second pads on the first passivation layer, and a through electrode through the substrate, the interlayer dielectric layer, the wiring layer, and the first passivation layer to connect to the first pad. The first pad includes a first head part on the first passivation layer, and a protruding part that extends into the first passivation layer from the first head part, the protruding part surrounding a lateral surface of the through electrode in the first passivation layer, and the second pad is connected to the IC through the wiring line and the contact.