Process for making air gap containing semiconducting devices and resulting semiconducting device

1. A method of forming at least a partial air gap within a semiconducting device comprising the steps of: (a) depositing a sacrificial polymeric composition in one or more layers of the device during its formation; (b) coating the device with one or more layers of a relatively non-porous, organic, polymeric, insulating dielectric material (hardmask) having a density less than 2.2 g/cm 3 ; and (c) decomposing the sacrificial polymeric composition such that the decomposition products permeate at least partially through the one or more hardmask layers, thereby forming at least a partial air gap within the device.

2. The method of claim 1 , wherein the sacrificial polymer is a copolymer of a first monomer selected from the group consisting of acrylates, vinylaromatics, norbomenes, and alkyldiol diacrylates with a second monomer selected from the group consisting of vinylbenzocyclobutenes and 1,3 bis 2[4-benzocyclobutenyl(ethenyl)]benzene.

3. The method of claim 1 , wherein the sacrificial polymer is a copolymer of (a) 5-ethylidene-2-norbornene and vinylbenzocyclobutene (or a vinylbenzocyclobutene derivative); (b) 5-ethylidene-2-norbomene and 5-(3-benzocyclobutylidene)-2-norbornene; (c) styrene (or a styrene derivative) and 5-(3-benzocyclobutylidene)-2-norbornene; (d) styrene (or a derivative of styrene) and vinylbenzocyclobutene (or a vinylbenzocyclobutene derivative); or (e) bis[3-(4-benzocyclobutenyl)]1,n (n=2-12)alkyldiol diacrylate and 1,3 bis 2[4-benzocyclobutenyl(ethenyl)]benzene.

4. The method of claim 1 , wherein the sacrificial polymer is a copolymer comprising from 99 to 40 mole percent styrene or a styrene derivative and from 1 to 60 mole percent vinylbenzocyclobutene or a vinylbenzocyclobutene derivative based on total moles of incorporated monomers in the polymer.

5. The method of claim 1 , wherein the sacrificial polymer is a copolymer of α-methylstyrene and vinylbenzocyclobutene.

6. The method of claim 1 wherein the hard mask is the cured product formed from the hydrolyzed or partially hydrolyzed reaction products of substituted alkoxysilanes or substituted acyloxysilanes.

7. The method of claim 6 wherein the hard mask comprises the hydrolyzed reaction product of a substituted alkoxy or acyloxy silane of the formula:

wherein R is C 1 -C 6 alkylidene, C 1 -C 6 alkylene, arylene, or a direct bond; Y is C 1 -C 6 alkyl, C 2 -C 6 alkenyl, a C 2-6 alkynyl, a C 6 -C 20 aryl, 3-methacryloxy, 3-acryloxy, 3-aminoethyl-amino, 3-amino, —SiZ 2 OR′, or —OR′; R′ is independently, in each occurrence, a C 1 -C 6 alkyl or C 2 -C 6 acyl; and Z is C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2-6 alkynyl, C 6-20 aryl, or —OR′.

8. The method of claim 1 wherein the dielectric material comprises a polyarylene resin.

9. The method of any of claims 1 - 8 wherein the dielectric material comprises a pore forming substance that is activated or removed, either simultaneously with or prior to decomposition of the sacrificial material, thereby introducing pores or voids in the layer.

10. The method of claim 9 wherein the pore forming substance is a crosslinked emulsion polymerized copolymer.

11. A semiconducting device comprising an air gap prepared by a method according to any one of claims 1 - 8 .

12. A semiconducting device comprising an air gap prepared by a method according to claim 9 .

13. A semiconductor device comprising a substrate layer, one or more conductive layers, at least one layer of a relatively non-porous, organic polymeric insulating dielectric material having a density less than 2.2 g/cm 3 , and optionally an impermeable organic or inorganic sealing layer, wherein at least some portion of the conductive layer is separated from another portion thereof by at least a partial air gap.