A method for producing self-aligned line end vias and the resulting device are provided. Embodiments include forming trenches in a dielectric layer; filling the trenches with a sacrificial layer; forming and etching a block mask over sacrificial layers to form a cut area over a portion of the trenches; forming spacers at sides of the cut area; removing the sacrificial layer from the portion of the trenches; forming a mask in the cut area and the portion of trenches, the mask selected from a HDP oxide, SiC or SiCNH; selectively etching the spacers; and selectively etching the sacrificial layer and the dielectric layer by RIE to form SAVs.

A method of fabricating a wiring structure for a semiconductor device may include forming a lower wiring in a lower insulating layer, forming an etch stop layer covering the lower insulating layer and the lower wiring, forming an interlayer insulating layer on the etch stop layer, forming a preliminary via-hole through the interlayer insulating layer, partially etching the interlayer insulating layer to form a trench partially merged with the preliminary via-hole and a via-hole defined by a remaining portion of the preliminary via-hole, removing the etch stop layer exposed by the via-hole to expose the lower wiring, partially etching a contact area at which the trench and the via-hole are in contact with each other and forming an upper wiring in the via-hole and the trench to be electrically connected to the lower wiring.

An interconnection and a method for manufacturing thereof are provided. The interconnection includes a first conductive layer, a dielectric layer, a second conductive layer, an insulation layer, and a plurality of air gaps. The first conductive layer is disposed over a semiconductor substrate. The dielectric layer is disposed over the first conductive layer. The second conductive layer penetrates through the dielectric layer to electrically connect with the first conductive layer. The insulation layer is located between a portion of the dielectric layer and the second conductive layer, and a material of the insulation layer and a material of the dielectric layer are different. The air gaps are located between another portion of the dielectric layer and the second conductive layer.

A method of forming an interconnect to an electrical device is provided. The structure produced by the method may include a plurality of metal lines in a region of a substrate positioned in an array of metal lines all having parrallel lengths; and a plurality of air gaps between the metal lines in a same level as the metal lines, wherein an air gap is present between each set of adjacent metal lines. A plurality of interconnects may be present in electrical communication with said plurality of metal lines, wherein an exclusion zone for said plurality of interconnects is not present in said array of metal lines.

In a method of manufacturing a semiconductor device, a first insulating interlayer and a sacrificial layer is sequentially formed on a substrate. The sacrificial layer is partially removed to form a first opening exposing an upper surface of the first insulating interlayer. An insulating liner including silicon oxide is conformally formed on the exposed upper surface of the first insulating interlayer and a sidewall of the first opening. At least a portion of the insulating liner on the upper surface of the first insulating interlayer and a portion of the first insulating interlayer thereunder are removed to form a second opening connected to the first opening. A self-forming barrier (SFB) pattern is formed on a sidewall of the second opening and the insulating liner. A wiring structure is formed to fill the first and second openings. After the sacrificial layer is removed, a second insulating interlayer is formed.

A via opening is provided in an interconnect dielectric material. Prior to line opening formation, a continuous layer of a sacrificial material is formed lining the entirety of the via opening. An organic planarization layer (OPL) and a photoresist that contains a line pattern are formed above the interconnect dielectric material. The line pattern is then transferred into an upper portion of the interconnect dielectric material, while maintaining a portion of the OPL and a portion of the continuous layer of sacrificial material within a lower portion of the via opening. The remaining portions of the OPL and the sacrificial material are then removed from the bottom portion of the via opening. A combined via opening/line opening is provided in which the via opening has a well controlled profile/geometry. An interconnect metal or metal alloy can then be formed into the combined via opening/line opening.

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.

Approaches based on differential hardmasks for modulation of electrobucket sensitivity for semiconductor structure fabrication, and the resulting structures, are described. In an example, a method of fabricating an interconnect structure for an integrated circuit includes forming a hardmask layer above an inter-layer dielectric (ILD) layer formed above a substrate. A plurality of dielectric spacers is formed on the hardmask layer. The hardmask layer is patterned to form a plurality of first hardmask portions. A plurality of second hardmask portions is formed alternating with the first hardmask portions. A plurality of electrobuckets is formed on the alternating first and second hardmask portions and in openings between the plurality of dielectric spacers. Select ones of the plurality of electrobuckets are exposed to a lithographic exposure and removed to define a set of via locations.

An embodiment includes a method. The method includes: forming a first conductive line over a substrate; depositing a first dielectric layer over the first conductive line; depositing a second dielectric layer over the first dielectric layer, the second dielectric layer including a different dielectric material than the first dielectric layer; patterning a via opening in the first dielectric layer and the second dielectric layer, where the first dielectric layer is patterned using first etching process parameters, and the second dielectric layer is patterned using the first etching process parameters; patterning a trench opening in the second dielectric layer; depositing a diffusion barrier layer over a bottom and along sidewalls of the via opening, and over a bottom and along sidewalls of the trench opening; and filling the via opening and the trench opening with a conductive material.

A method for forming a via in an integrated circuit comprises patterning a first opening in a first hardmask, the first hardmask disposed on a first organic self-planarizing polymer (OPL) layer, removing an exposed portion of the first OPL layer to define a cavity, removing an exposed portion of a second hardmask in the cavity, removing an exposed portion of a first dielectric layer disposed under the second hardmask to further define the cavity, removing an exposed portion of a first cap layer in the cavity, removing an exposed portion of a second dielectric layer to further define the cavity, removing an exposed portion of a second cap layer to further define the cavity, removing an exposed portion of a liner layer over a second conductive material in the cavity, and depositing a conductive material in the cavity.