Method for forming controlled voids in interlevel dielectric

摘要

A method of forming a thick interlevel dielectric layer containing sealed voids formed in a controlled manner, over a substantially planar surface in semiconductor device structure, and the semiconductor structure formed according to such a method. The sealed voids are used to reduce interlevel capacitance. A plurality of metal signal lines are formed over a globally planarized insulator. A thick layer of first conformal interlevel dielectric is deposited over the metal signal lines and over the intermetal spacings formed between the metal signal lines. Because of the thickness, flow properties, and manner of deposition of the interlevel dielectric and the aspect ratio the intermetal spacings, voids are formed in the first conformal interlevel dielectric, in the intermetal spacings. This interlevel dielectric is then etched or polished back to the desired thickness, which exposes the voids in the wider intermetal spacings, but does not expose voids in the narrower intermetal spacings. An etchback may be chosen so that all voids are exposed. The exposed voids are filled with a flowable dielectric which can be then etched back to leave the flowable dielectric in the exposed voids. A second conformal interlevel dielectric layer is formed over the first conformal interlevel dielectric to further bury the sealed voids, insuring that they do not get exposed in further process steps. The second conformal interlevel dielectric may be formed in a thin layer to allow the flowable dielectric to remain near the top of the interlevel dielectric structure to reduce the possibility of poisoned vias.