Structure and method for manufacturing interconnect structures having self-aligned dielectric caps

1. A method of forming a device, comprising:

providing a substrate;

forming a first ILD layer above the substrate, wherein the first ILD layer has a top surface and a first opening;

depositing a first metal liner in the first opening;

forming a first metallization level in the first opening;

forming a first cap layer on the top surface of the first ILD layer;

forming a second ILD layer above the first cap layer, wherein the second ILD layer has a top surface and a second opening extending into the first metallization level;

depositing a second metal liner on the top surface and in the second opening;

forming a second metallization level in the second opening;

performing a CMP of the second metallization level, wherein a top of the second metallization level is co-planar with a top of the second metal liner;

forming a second cap layer on the second metallization level, wherein the forming of said second cap layer on the second metallization level comprises selectively depositing a dielectric cap selected from the group consisting of: silicon carbon nitride (SiCN), silicon nitride (SiN) and silicon carbide (SiC);

forming a recess in the second metallization level below a top surface of the second ILD layer before the forming said second cap layer on the second metallization level; and

removing the second metal liner from the top surface of the second ILD layer.

2. The method according to claim 1 , wherein the dielectric cap is selectively deposited by one of chemical vapor deposition (CVD) and atomic layer deposition (ALD).

3. The method according to claim 1 , wherein the removing the second metal liner from the top surface of the second ILD layer step comprises performing one of a carbon tetra fluoride (CF4) reactive ion etch (RIE) and a xenon fluoride (XeF) gas etch.

4. The method according to claim 1 , wherein the second ILD layer is selected from the group consisting of: carbon doped silicon oxide (SiCOH), porous SiCOH and silicon oxide (SiO).

5. The method according to claim 1 , wherein the second metal liner is one of a stack of tantalum nitride (TaN) and tantalum (Ta).

6. The method according to claim 1 , wherein the second metallization level is copper.

7. The method according to claim 1 , further comprising forming spacers adjacent to the second cap layer.

8. The method according to claim 1 , further comprising forming at least one trench in the second ILD layer.

9. The method according to claim 8 , wherein the forming at least one trench in the second ILD layer step comprises performing a selective etch of the second ILD layer.

10. A device, comprising:

a substrate;

a first ILD layer formed above the substrate, wherein the first ILD layer has a top surface and a first opening;

a first metal liner deposited in the first opening;

a first metallization level formed in the first opening;

a first cap layer formed on the top surface of the first ILD layer;

a second ILD layer formed above the first cap layer, wherein the second ILD layer has a top surface and a second opening extending into the first metallization level;

a second metal liner deposited in the second opening;

a second metallization level formed in the second opening, wherein the second metallization level is recessed below the top surface of said second ILD layer; and

a second cap layer formed on the second metallization level, wherein the second cap layer is selected from the group consisting of: silicon carbon nitride (SiCN), silicon nitride (SiN) and silicon carbide (SiC).

11. The device according to claim 10 , wherein the second metallization level comprises copper.

12. The device according to claim 10 , further comprising spacers formed adjacent to the second cap layer.

13. The device according to claim 10 , further comprising at least one trench formed in the second ILD layer.