Method of decreased interlayer dielectric constant in a multilayer interconnect structure to increase device speed performance

Claim 1

A process for fabricating a semiconductor device comprising source and drain regions contacted by source and drain contacts, respectively, and each source and drain region separated by a gate region contacted by a gate electrode through a gate oxide, said source and drain contacts and said gate electrode separated by a first oxide layer, with a first level patterned interconnect contacting said source and drain contacts and said gate electrode in a desired pattern and with a second level patterned interconnect contacting said first level patterned interconnect by a plurality of metal lines, said metal lines separated by an interlevel dielectric layer, comprising the steps of: (a) prior to forming source and drain contacts and gate electrode, forming an etch stop layer on said first oxide layer; (b) forming said source and drain contacts to respective source and drain regions and gate electrodes over said gate oxide; (c) forming and patterning said first interconnect layer contacting said source and drain contacts and said gate electrodes; (d) forming on said patterned first interconnect layer said interlevel dielectric layer comprising a first dielectric material having a first dielectric constant; (e) etching vias through said interlevel dielectric layer and forming metal lines therein contacting portions of said first interconnect layer; (f) forming and patterning said second interconnect layer contacting said metal lines; (g) removing at least a portion of said interlevel dielectric layer, thereby forming air spaces between said metal lines which connect said first interconnect layer and said second interconnect layer; (h) partially filling said air spaces between said metal lines with a second dielectric material having a second dielectric constant, said second dielectric constant lower than that of said first dielectric constant; and (i) depositing a passivation layer which partially fills said air spaces between said metal lines and which leaves voids in said passivation layer or between said passivation layer and said metal lines thereby providing said interlevel dielectric layer with an effective dielectric constant that is lower than that of said first dielectric constant.