A method of forming via-first, dual damascene interconnect structures by
using a gap-filling, bottom anti-reflective coating material whose
thickness is easily controlled by a solvent is provided. After
application to a substrate, the bottom anti-reflective coating is
partially cured by baking at a low temperature. Next, a solvent is
dispensed over the coated wafer and allowed to contact the coating for a
period of time. The solvent removes the bottom anti-reflective coating at
a rate controlled by the bottom anti-reflective coating's bake
temperature and the solvent contact time to yield a bottom
anti-reflective coating thickness that is thin, while maintaining optimum
light-absorbing properties on the dielectric stack. In another possible
application of this method, sufficient bottom anti-reflective coating may
be removed to only partially fill the vias in order to protect the
bottoms of the vias during subsequent processing. The solvent is removed
from the wafer, and the bottom anti-reflective coating is cured
completely by a high-temperature bake. The wafer is then coated with
photoresist, and the trench pattern exposed. The bottom anti-reflective
coating material used maintains a greater planar topography for trench
patterning, eliminates the need for an inorganic light-absorbing material
layer on the top of the dielectric stack, protects the bottom of the vias
during the trench etch, and prevents the formation of fencing problems by
using a solvent to control the thickness in the vias.