Highly porous, low-k dielectric materials are mechanically reinforced to
enable the use of these low-k materials as intralayer and interlayer
dielectrics in advanced integrated circuits such as those which
incorporate highly porous materials in a Cu damascene interconnect
technology. An integrated circuit, embodying such a mechanically
reinforced dielectric layer generally includes a substrate having
interconnected electrical elements therein, a copper-diffusion barrier or
etch stop layer disposed over the substrate, the copper-diffusion barrier
or etch stop layer being patterned so as to provide a plurality of
electrically insulating structures, and a low-k dielectric layer disposed
around the plurality of structures. A process, for making a mechanically
reinforced, highly porous, low-k dielectric layer, generally includes
forming a copper-diffusion or etch stop layer on a substrate, patterning
the copper-diffusion or etch stop layer such that a plurality of
structures are formed, the structures each having a top surface, forming
a low-k dielectric layer over and adjacent to the structures, the low-k
dielectric layer having a top surface, and polishing the low-k dielectric
layer such that its top surface is substantially even with the top
surfaces of the structures. The structures may be rectangular posts, or
more geometrically complex forms. The structures may be identical, or a
combination of various forms.