Aperture size control for etched vias and metal contacts

Claim 1

A method for forming an aperture having a desired diameter D and a desired depth d in a layer of insulator material, the method comprising the steps of: providing an insulator layer on an electrically conductive underlayer, the insulator layer having an upper surface; forming a first aperture in the insulator layer to have sidewalls such that a major portion of the sidewalls has a diameter D' that is greater than the desired diameter D and to have a bottom surface such that the depth thereof relative to the upper surface of the insulator layer has a maximum value equal to the thickness of the insulator layer; depositing a uniform conformal layer of conformal insulating material in the first aperture at the bottom surface and sidewalls thereof such that the thickness of the conformal layer on each sidewall is approximately (D'-D)/2; and anisotropically etching the uniform conformal insulating material of the first aperture such that the resulting depth of the resulting aperture relative to the upper surface of the insulator layer is approximately d and a major portion of the sidewalls has a diameter D, thereby providing access to the electrically conductive underlayer.

Claim 2

A method for forming an aperture having a desired diameter D and a desired depth d in a layer of insulator material, the method comprising the steps of: providing an insulator layer on an electrically conductive underlayer, the insulator layer having an upper surface; forming a first aperture in the insulator layer to have sidewalls such that a major portion of the sidewalls has a diameter D' that is greater than the desired diameter D and to have a bottom surface such that the depth thereof relative to the upper surface of the insulator layer has a maximum value equal to the thickness of the insulator layer; depositing a uniform conformal layer of conformal insulating material in the first aperture at the bottom surface and sidewalls thereof such that the thickness of the conformal layer on each sidewall is approximately (D'-D)/2; and anisotropically etching the uniform conformal insulating material of the first aperture such that the resulting depth of the resulting aperture relative to the upper surface of the insulator layer is approximately d and a major portion of the sidewalls has a diameter D, thereby providing access to the electrically conductive underlayer.

Claim 6

A method for forming an aperture having a desired diameter D and a desired depth d in a layer of insulator material, the method comprising the steps of: providing an insulator layer on an electrically conductive underlayer, the insulator layer having a horizontal upper surface; selecting a value D" that is greater than the value D of the desired diameter; forming a first aperture in the insulator layer such that opposed sides of said aperture along a substantial portion of the height thereof are separated by a distance approximately equal to the value D" and such that said aperture has a horizontal bottom surface wherein in the distance from the horizontal upper surface to the horizontal bottom surface has a maximum value equal to the desired depth d; uniformly depositing a conformal layer of conformal insulating material onto the horizontal bottom surface and sides wherein the thickness of the conformal layer along the sides is based on the selectivity of etching the uniform conformal layer on the horizontal bottom surface relative to etching the uniform conformal layer on the sides; and anisotropically etching the uniform conformal layer on the horizontal bottom surface and sides to remove conformal insulating material at the horizontal bottom surface to expose the electrically conductive underlayer and to remove a fraction of the thickness of uniform conformal insulating material disposed on the sides so that a major portion of the sides has the desired diameter D.

Claim 7

A method for forming an aperture having a desired diameter D and a desired depth d in a layer of insulator material, the method comprising the steps of: providing an insulator layer on an electrically conductive underlayer, the insulator layer having a horizontal upper surface; selecting a value D" that is greater than the value D of the desired diameter; forming a first aperture in the insulator layer such that opposed sides of said aperture along a substantial portion of the height thereof are separated by a distance approximately equal to the value D" and such that said aperture has a horizontal bottom surface wherein in the distance from the horizontal upper surface to the horizontal bottom surface has a maximum value equal to the desired depth d; uniformly depositing a conformal layer of conformal insulating material onto the horizontal bottom surface and sides wherein the thickness of the conformal layer along the sides is based on the selectivity of etching the uniform conformal layer on the horizontal bottom surface relative to etching the uniform conformal layer on the sides; and anisotropically etching the uniform conformal layer on the horizontal bottom surface and sides to remove conformal insulating material at the horizontal bottom surface to expose the electrically conductive underlayer and to remove a fraction of the thickness of uniform conformal insulating material disposed on the sides so that a major portion of the sides has the desired diameter D.