A method for etching contact/via openings in low-k dielectric layers is described.
The method introduces a carbon deficient ARL which is compatible with the acidic
photoresists used by DUV photolithography. The carbon deficiency of the ARL permits
the use of fluorocarbon plasma etching ambients to etch the openings in the low-k
layers without excessive polymer formation, thereby eliminating polymer pinch-off
during the etching of deep, high aspect ratio contacts and vias in sub-tenth micron
integrated circuit technology. Vertical walled contact and via openings may be
formed using a DUV photoresist mask and non-oxygen containing fluorocarbon etching
plasmas. An additional hardmask is therefore not needed. For non-carbon containing
low-k dielectric layers the openings may be etched in simple fluorocarbon plasmas
without excessive polymer formation. For low carbon low-k dielectric materials
such as alky and aryl polysilsesquioxanes and some organosilicate glasses, the
method provides a regimen of hydrogen addition to the etching plasma in order to
sufficiently control polymer formation during the contact/via etch to obtain high
quality vertical walled openings.