Semiconductor devices having bit line contact plugs and methods of manufacturing the same

A semiconductor device including active regions defined in a semiconductor substrate to be non-parallel with a first direction and a second direction which are perpendicular to each other, word lines intersecting active regions and extending in first directions to be spaced apart from each other in the second direction, bit lines crossing over word lines and extending in second directions to be spaced apart from each other in the first direction, first impurity regions disposed in respective ones of central portions of active regions to non-overlap with the word lines, second impurity regions disposed in both ends of each of the active regions to non-overlap with the word lines, and bit line contact plugs disposed between the first impurity regions and the bit lines. The bit line contact plugs having longish shapes including major axes substantially parallel with the second direction and minor axes substantially parallel with the first direction.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority under 35 U.S.C 119(a) to Korean Application No. 10-2012-0096287, filed on Aug. 31, 2012, in the Korean Intellectual Property Office, which is incorporated herein by reference in its entirety as set forth in full.

BACKGROUND

Embodiments of the present disclosure generally relate to semiconductor devices and methods of manufacturing the same and, more particularly, to semiconductor devices having bit line contact plugs and methods of manufacturing the same.

In general, a dynamic random access memory (DRAM) device may include a plurality of memory cells, and each of the DRAM cells may include a cell transistor and a cell capacitor electrically connected to the cell transistor to store a data therein. The cell transistors may be formed in and/or on active regions which are defined in a semiconductor substrate, and the cell capacitors may be electrically connected to the cell transistors through contact pads and contact plugs. Recently, as semiconductor devices having unit cells become more highly integrated, areas (planar areas) that the unit cells occupy have been abruptly reduced. Thus, various process technologies for forming fine patterns as well as various cell layouts for obtaining compact cell structures have been proposed to realize highly integrated semiconductor devices. A semiconductor device including active regions, word lines and bit lines extending in different directions form each other is taught in U.S. Pat. No. 6,809,364 B2 to Matsuoka et al., entitled “Semiconductor Integrated Circuit Device and A Method of Manufacture Thereof”.

According to the U.S. Pat. No. 6,809,364 B2, the semiconductor device includes word lines extending in a first direction, bit lines extending in a second direction perpendicular to the first direction, and active region disposed to extend in a diagonal direction that is non-parallel with both the word lines and the bit lines. In such a case, bit line contact plugs may be disposed to be adjacent to storage node contact plugs. Thus, there may be every probability of electrical shortage between the bit line contact plugs and the storage node contact plugs. This electrical shortage phenomenon may occur due to a short distance between the bit line contact plugs and the storage node contact plugs. Accordingly, various cell structures and/or various process techniques are still required to realize highly integrated semiconductor devices.

SUMMARY

Various embodiments are directed to semiconductor devices having bit line contact plugs and methods of manufacturing the same.

According to various embodiments, a semiconductor device includes active regions defined in a semiconductor substrate to be non-parallel with a first direction and a second direction which are perpendicular to each other, word lines intersecting the active regions and extending in the first direction to be spaced apart from each other in the second direction, bit lines crossing over the word lines and extending in the second direction to be spaced apart from each other in the first direction, first impurity regions disposed in respective ones of central portions of the active regions to non-overlap with the word lines, second impurity regions disposed in both ends of each of the active regions to non-overlap with the word lines, and bit line contact plugs disposed between the first impurity regions and the bit lines. Each of the bit line contact plugs has a longish shape including a major axis substantially parallel with the second direction and a minor axis substantially parallel with the first direction.

In various embodiments, each of the bit line contact plugs may include a pair of first sidewalls opposite to each other and a pair of second sidewalls opposite to each other. Further, the first sidewalls of the bit line contact plugs may be in contact with a first insulation layer and a second insulation layer which are stacked, and the second sidewalls of the bit line contact plugs may be in contact with only the second insulation layer. In addition, the first insulation layer may be an oxide layer when the second insulation layer is a nitride layer, or the first insulation layer may be a nitride layer when the second insulation layer is an oxide layer.

In various embodiments, the semiconductor device may further include bit line spacers between the first sidewalls of the bit line contact plugs and the first and second insulation layers.

In some embodiments, each of the bit line contact plugs may have an oval shape which is parallel with the second direction when viewed from a plan view.

In various embodiments, the semiconductor device may further include storage node contact plugs which are disposed between the bit lines and which are electrically connected to respective ones of the second impurity regions.

According to various embodiments, a method of manufacturing a semiconductor device includes defining an active region in a semiconductor substrate, forming line-shaped first insulation patterns on the semiconductor substrate to intersect the active region and to extend in a first direction, forming a second insulation layer on the first insulation patterns to fill spaces between the first insulation patterns, and patterning the second insulation layer and the first insulation patterns to form a contact hole exposing a portion of the active region. The contact hole is formed to include a pair of first opposite sidewalls exposing the first insulation patterns and the second insulation layer and a pair of second opposite sidewalls exposing only the second insulation layer. The second insulation layer is isotropically etched to enlarge the contact hole in a second direction substantially perpendicular to the first direction, and a conductive contact plug is formed to fill the enlarged contact hole. The first opposite sidewalls of the contact hole are substantially parallel with the second direction and the second opposite sidewalls of the contact hole are substantially parallel with the first direction.

In various embodiments, the first insulation patterns may have a different etch rate from the second insulation layer while the second insulation layer is isotropically etched to enlarge the contact hole in substantially the second direction.

In various embodiments, the contact hole may be formed by etching the second insulation layer and the first insulation patterns using an anisotropic etch process that exhibits substantially the same etch rate with respect to the second insulation layer and the first insulation patterns.

In various embodiments, isotropically etching the second insulation layer to enlarge the contact hole in the second direction may be performed by an isotropic etch process exhibiting an etch condition that an etch rate of the second insulation layer is faster than that of the first insulation patterns.

In various embodiments, the isotropic etch process may be a dry etch process performed using plasma or a wet etch process performed using an etchant.

According to various embodiments, a method of manufacturing a semiconductor device includes defining active regions in a semiconductor substrate, forming line-shaped first insulation patterns on the semiconductor substrate to intersect the active regions and to extend in a first direction, forming a second insulation layer on the first insulation patterns to fill spaces between the first insulation patterns, and patterning the second insulation layer and the first insulation patterns to form contact holes exposing respective ones of central portions of the active regions. Each of the contact holes is formed to include a pair of first opposite sidewalls exposing two adjacent ones of the first insulation patterns and the second insulation layer and a pair of second opposite sidewalls exposing only the second insulation layer. The second insulation layer is isotropically etched to enlarge the contact holes in a second direction perpendicular to the first direction. Contact patterns are formed to fill respective ones of the enlarged contact holes. A conductive layer is formed on the second insulation layer and the contact patterns. The conductive layer is patterned to form bit lines that extend in the second direction and contact the contact patterns. The contact patterns are etched using the bit lines as etch masks to form bit line contact plugs vertically aligned with the bit lines. Insulation spacers are formed on sidewalls of the bit lines and sidewalls of the bit line contact plugs. Storage node contact plugs, which are separated from the bit lines and the bit line contact plugs by the insulation spacers, are formed. The storage node contact plugs are formed to be connected to both ends of the active regions. The first opposite sidewalls of the contact holes are substantially parallel with the second direction and the second opposite sidewalls of the contact holes are substantially parallel with the first direction.

In various embodiments, the first insulation patterns may be mask patterns for defining regions where word lines are formed.

In various embodiments, the first insulation patterns may have a different etch rate from the second insulation layer while the second insulation layer is isotropically etched to enlarge the contact holes in the second direction.

In various embodiments, the contact holes may be formed by etching the second insulation layer and the first insulation patterns using an anisotropic etch process that exhibits substantially the same etch rate with respect to the second insulation layer and the first insulation patterns.

In various embodiments, isotropically etching the second insulation layer to enlarge the contact hole in the second direction may be performed by an isotropic etch process exhibiting an etch condition that an etch rate of the second insulation layer is faster than that of the first insulation patterns.

In various embodiments, the isotropic etch process may be a dry etch process performed using plasma or a wet etch process performed using an etchant.

In various embodiments, the first insulation patterns may be formed of an oxide layer and the second insulation layer may be formed of a nitride layer.

In various embodiments, isotropically etching the second insulation layer to enlarge the contact holes in the second direction may be performed under a pressure of about 5 mTorr to about 100 mTorr and a bias power of about 0 watt to about 150 watts using an inductively coupled plasma (ICP) apparatus or an electron cyclotron resonance (ECR) apparatus.

In various embodiments, isotropically etching the second insulation layer to enlarge the contact holes in the second direction may be performed under a pressure of about 15 mTorr to about 100 mTorr and a bias power of about 0 watt to about 500 watts using a capacitively coupled plasma (CCP) apparatus.

In various embodiments, isotropically etching the second insulation layer to enlarge the contact holes in the second direction may be performed using a main etch gas and a subsidiary gas, the main etch gas may include at least one of a CxFygas where x is a whole number greater than or equal to one and less than or equal to five and y is a whole number greater than or equal to two and less than or equal to eight, a CkHFsgas where k and s are whole numbers greater than or equal to one and less than or equal to three, a NF3gas and a SF6gas, and the subsidiary gas may include at least one of an oxygen (O2) gas, a CO gas, a COS gas, a nitrogen (N2) gas, a CH4gas, an argon (Ar) gas and a helium (He) gas.

In various embodiments, isotropically etching the second insulation layer to enlarge the contact holes in the second direction may be performed using a wet etch process that employs a phosphoric acid solution as an etchant.

In various embodiments, the method may further include applying an additional etch process to the substrate including the enlarged contact holes to control sizes and sidewall profiles of the enlarged contact holes before the contact patterns are formed. The additional etch process may be a wet etch process.

In various embodiments, forming the insulation spacers may include depositing a nitride layer on the substrate having the bit lines contact plugs to a thickness of about 20 angstroms to about 400 angstroms and anisotropically etching or etching back the nitride layer.

In various embodiments, the conductive layer may be formed of a polysilicon layer. Patterning the conductive layer to form the bit lines may be performed using an etch process that utilizes a main etch gas and a subsidiary gas. The main etch gas may include at least one of a chlorine (Cl2) gas and a hydrogen bromide (HBr) gas, and the subsidiary gas may include at least one of an oxygen (O2) gas, a nitrogen (N2) gas, an argon (Ar) gas, a helium (He) gas, a methane (CH4) gas and a silicon tetrachloride (SiCl4) gas.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1is a plan view illustrating an example of layouts of various semiconductor devices.

Referring toFIG. 1, a plurality of active regions12may be disposed in a semiconductor substrate to extend in a first direction which is substantially parallel with a surface of the semiconductor substrate. Word lines20may be disposed to intersect the active regions12. The word lines20may extend in a second direction different from the first direction. Impurity regions acting as source/drain regions of cell transistors may be disposed in portions of the active regions, which are non-overlapping with the word lines20. Bit lines30may be disposed to cross over the word lines20and may be electrically connected to the impurity regions acting as the drain regions (e.g., common drain regions) of the cell transistors. The bit lines30may extend in a third direction which is substantially perpendicular to the word lines20and may intersect central regions

(e.g., the common drain regions of the cell transistors) of the active regions12. Cell capacitors (not shown) for storing data may be disposed over the bit lines30, and storage nodes (e.g., storage electrodes) of the cell capacitors may be electrically connected to respective ones of the impurity regions (e.g., the source regions of the cell transistors) of the active regions12through storage node contact plugs50. The bit lines30may be electrically connected to the common drain regions of the active regions12through bit line contact plugs40.

InFIG. 1, the storage node contact plugs50may be self-aligned with the bit lines30and may be disposed between the bit lines30. Thus, the storage node contact plugs50and the bit line contact plugs40may be disposed to be very close to each other in a plan view. As a result, the probability of electrical shortage between the storage node contact plugs50and the bit line contact plugs40may increase.

To reduce the probability of the electrical shortage between the storage node contact plugs50and the bit line contact plugs40, the bit line contact plugs40may be designed to have longish shapes, for example, oval shapes which are substantially parallel with the third direction (e.g., the bit lines30). However, as a minimum size of the bit line contact plugs40is reduced to several tens of nanometers, it may be difficult to form the bit line contact plugs40having oval shapes using only a photolithography process. This may be due to a resolution limit of an exposure step of a photolithography process. According to the following embodiments, longish bit line contact plugs may be fabricated by forming circle-shaped bit line contact holes using a photo mask and by enlarging the circle-shaped bit line contact holes in a specific direction using a selective etch process. For example, each of the circle-shaped bit line contact holes may be formed to have a pair of first sidewalls opposite to each other and a pair of second sidewalls opposite to each other. The first sidewalls may correspond to surfaces of a nitride layer, and the second sidewalls may correspond to surfaces of an oxide layer having an etch selectivity with respect to the nitride layer. Thus, if the nitride layer (or the oxide layer) is isotropically etched after formation of the circle-shaped bit line contact holes, the circle-shaped bit line contact holes may be enlarged in one direction (including a positive direction and a negative direction opposite to the positive direction). As a result, the circle-shaped bit line contact holes may be deformed to have oval shapes when viewed from a plan view.

Various embodiments will be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments are shown. In the drawings, like reference designators denote like or corresponding elements.

FIG. 2is a plan view illustrating a layout of a semiconductor device according to various embodiments. Further,FIG. 3Ais a cross sectional view taken along a line A-A′ ofFIG. 2, andFIG. 3Bis a cross sectional view taken along a line B-B′ ofFIG. 2. InFIG. 2, the line A-A′ may correspond to a substantially straight line which is substantially parallel with an X-axis and the line B-B′ may correspond to a substantially straight line which is substantially parallel with a Y-axis.

Referring toFIGS. 2,3A and3B, a semiconductor device according to the embodiment may include word lines110disposed to extend in a first direction and arrayed to be spaced apart from each other in a second direction which is substantially perpendicular to the first direction, bit lines142disposed to extend in the second direction and arrayed to be spaced apart from each other in the first direction, active regions102disposed to be substantially parallel with a third direction which is non-parallel with both the first and second directions, and bit line contact plugs134disposed between the bit lines142and the active region102. Each of the active regions102may intersect two of the word lines110. Further, a first impurity region120may be disposed in a central portion of each active region102, and a pair of second impurity regions122may be disposed in both edges of each active region102, respectively. That is, the word lines110may overlap with the active regions102between the first and second impurity regions120and122when viewed from a plan view. Moreover, the bit line contact plugs134may be disposed between the bit lines142and the first impurity regions120to electrically connect the bit lines142to the first impurity regions120. Each of the bit line contact plugs134may have a longish shape which is substantially parallel with the bit lines142in a plan view. For example, each of the bit line contact plugs134may substantially have an oval shape that includes a major axis substantially parallel with the second direction and a minor axis substantially parallel with the first direction.

The active regions102may be defined by an isolation layer104formed in a semiconductor substrate100and may be arrayed to be substantially parallel with a diagonal direction in an X-Y plane. The first impurity region120(e.g., a central portion) of one of the active regions102may be disposed between the second impurity regions122of two other active regions102. The word lines110may cross over the active regions102and may extend in the first direction. The first impurity regions120may act as common drain regions of cell transistors and the second impurity regions122may act as source regions of the cell transistors. Thus, a pair of cell transistors may be formed in each of the active regions102.

The bit lines142may cross over the word lines110, and the first impurity regions120of the active regions102may be electrically connected to the bit lines142. The bit lines142may intersect the word lines110at substantially a right angle in a plan view, as illustrated inFIG. 2. In addition, the bit lines142may be disposed to overlap with the first impurity regions120of the active regions102in a plan view. Call capacitors (not shown) for storing data may be disposed over the bit lines142, and storage nodes (or storage electrodes) of the call capacitors may be electrically connected to respective ones of the second impurity regions122of the active regions102. Specifically, the storage electrodes of the call capacitors may be electrically connected to respective ones of the second impurity regions122of the active regions102through storage node contact plugs146formed on the second impurity regions122. The storage node contact plugs146may extend into spaces between the bit lines142, and the storage electrodes may be formed on top surfaces of the storage node contact plugs146opposite to the semiconductor substrate100.

The bit line contact plugs134may be disposed between the first impurity regions120(formed in the central portions of the active regions102) and the bit lines142to electrically connect the first impurity regions120to the bit lines142. Each of the bit line contact plugs134may have a longish shape extending in the second direction which is substantially parallel with the Y-axis. For example, each of the bit line contact plugs134may have a major axis substantially parallel with the second direction and a minor axis substantially parallel with the first direction when viewed from a plan view. Thus, a distance between the bit line contact plugs134and the storage node contact plugs146adjacent thereto may increase as compared with the general semiconductor device illustrated inFIG. 1. As a result, the probability of electrical shortage between the storage node contact plugs146and the bit line contact plugs134may be reduced. Further, since the bit line contact plugs134extend in the second direction, contact areas between the bit line contact plugs134and the bit lines142may increase. Hence, the contact resistance of the bit lines142may be reduced.

FIGS. 4C to 10Care plan views illustrating a method of manufacturing a semiconductor device according to various embodiments.FIGS. 4A to 10Aare cross sectional views taken along lines A-A′ ofFIGS. 4C to 10C, respectively. In addition,FIGS. 4B to 10Bare cross sectional views taken along lines B-B′ ofFIGS. 4C to 10C, respectively. The term “first direction” used herein denotes a direction which is substantially parallel with the line A-A′ ofFIG. 4C, and the term “second direction” used herein denotes a direction which is substantially parallel with the line B-B′ ofFIG. 4C.

Referring toFIGS. 4A,4B and4C, an isolation layer104may be formed in a semiconductor substrate100such as a silicon wafer, thereby defining active regions102. The isolation layer104may be formed using, for example, a shallow trench isolation process. The isolation layer104may be formed to include an oxide layer such as a silicon oxide layer or a nitride layer such as a silicon nitride layer. The active regions102may be defined to extend in a diagonal direction which is non-parallel with both the lines A-A′ and B-B′ in a plan view, as illustrated inFIG. 4C. Each of the active regions102may include a central portion and both end portions. That is, each of the active regions102may be defined such that both end portions are substantially point symmetric with respect to the central portion.

Referring toFIGS. 5A,5B and5C, a hard mask pattern106for forming buried gates may be formed on the substrate including the isolation layer104. The hard mask pattern106may be formed by depositing an oxide layer on the substrate using a low pressure chemical vapor deposition (LPCVD) process and by patterning the oxide layer. The hard mask pattern106may be formed to have line-shaped openings that intersect the active regions102to be substantially parallel with the line A-A′ ofFIG. 4C. Subsequently, portions of the active regions102and the isolation layer104exposed by the hard mask pattern106may be etched to form trenches having a predetermined depth, and a gate oxide layer (not shown) may be formed on inner surfaces of the trenches. A gate conductive layer may be formed on the substrate including the gate oxide layer to fill the trenches. The gate conductive layer may be formed to include a single layer of a titanium nitride (TiN) material or a double layered structure having a titanium nitride (TiN) material and a tungsten (W) material. The gate conductive layer may be planarized to expose the hard mask pattern106, and the planarized gate conductive layer may be recessed to form buried gates110(e.g., word lines) remaining in lower portions of the trenches. Subsequently, a capping layer114may be formed to fill the trenches on the buried gates110and to cover the hard mask pattern106. The capping layer114may be formed of a nitride layer.

As described above, the buried gates110may act as word lines. The word lines may be formed to extend in the first direction which is non-parallel with the active regions102and may be formed to intersect the active regions102. Each of the active regions102may intersect two of the word lines. That is, one of the pair of adjacent word lines may cross a region between a central portion and one end portion of the active region102, and the other of the pair of adjacent word lines may cross a region between the central portion and the other end portion of the active region102. Subsequently, first impurity regions120and second impurity regions122may be formed in the central portions of the active regions102and the edge portions of the active regions102, respectively. The word lines110, the first impurity regions120and the second impurity regions122may constitute a plurality of cell transistors. In various embodiments, the first and second impurity regions120and122may be formed by implanting impurity ions into the active regions102using the word lines110as implantation masks prior to formation of the capping layer114. The first and second impurity regions120and122may function as source/drain regions of the cell transistors. Accordingly, a pair of cell transistors may be formed in each active region102, and one of the pair of cell transistors may share the first impurity region120with the other of the pair of cell transistors.

As described later, bit line contact plugs may be formed on respective ones of the first impurity regions120to electrically connect the first impurity region120to bit lines formed in a subsequent process. Accordingly, each of the bit line contact plugs may be formed to have a longish shape in a plan view. In more detail, the longish bit line contact plugs may be formed by patterning a plurality of stacked material layers having different etch rates to form substantially circle-shaped bit line contact holes, isotropically etching one or more of the stacked material layers to enlarge the substantially circle-shaped bit line contact holes in one direction, and filling the enlarged bit line contact holes with a conductive layer. For example, the bit line contact plugs may be formed in respective ones of bit line contact holes penetrating the capping layer114, the hard mask pattern106and the isolation layer104. Thus, the capping layer114may be formed of a material having an etch selectivity with respect to the hard mask pattern106and the isolation layer104. In various embodiments, the capping layer114may be formed of a nitride layer such as a silicon nitride layer, and the hard mask pattern106and the isolation layer104may be formed of an oxide layer such as a silicon oxide layer.

Referring toFIGS. 6A,6B and6C, a hard mask layer and an anti-reflection layer128may be sequentially formed on the capping layer114. The hard mask layer may be formed by sequentially stacking a first hard mask layer124and a second hard mask layer126. The first hard mask layer124may be formed of an amorphous carbon layer, and the second hard mask layer126may be formed of a silicon oxynitride (SiON) layer.

A photoresist pattern130may be formed on the anti-reflection layer128. The photoresist pattern130may be formed to include circle-shaped openings for defining regions where bit line contact holes are formed. The circle-shaped openings of the photoresist pattern130may be located on respective ones of the first impurity regions120, as illustrated inFIGS. 6A,6B and6C.

Referring toFIGS. 7A,7B and7C, the hard mask layers124and126and the anti-reflection layer128may be etched using the photoresist pattern130as an etch mask. Subsequently, the photoresist pattern130, the etched anti-reflection layer128and the etched second hard mask layer126may be removed to expose the etched first hard mask layer124. The capping layer114and the hard mask pattern106may then be etched using the exposed first hard mask layer124as an etch mask, thereby forming first bit line contact holes132a. The first bit line contact holes132amay be formed by etching the capping layer114and the hard mask pattern106without removal of the photoresist pattern130, the etched anti-reflection layer128and the etched second hard mask layer126.

The first bit line contact holes132amay be formed to have circular shapes in a plan view as illustrated inFIG. 7Cand to expose respective ones of the first impurity regions120as illustrated inFIGS. 7A and 7B. In such a case, each of the first bit line contact holes132amay be formed to include a pair of first sidewalls exposing the isolation layer104, the hard mask pattern106and the capping layer114, and a pair of second sidewalls exposing only the capping layer114(seeFIGS. 7A and 7B).

The first bit line contact holes132amay be formed using an anisotropic etch process. The anisotropic etch process for forming the first bit line contact holes132amay be performed using at least one of a CxFygas (where, 1≦x≦5 and 2≦y≦8), a CxHFygas (where, 1≦x≦3 and 1≦y≦3), a NF3gas and a SF6gas as a main etch gas in order to etch the isolation layer104(e.g., a nitride layer), the hard mask pattern106(e.g., an oxide layer) and the capping layer114(e.g., a nitride layer) at substantially the same etch rate. Further, the anisotropic etch process for forming the first bit line contact holes132amay be performed with a subsidiary gas in addition to the main etch gas. The subsidiary gas may include at least one of an oxygen (O2) gas, a CO gas, a COS gas, a nitrogen (N2) gas, a CH4gas, an argon (Ar) gas and a helium (He) gas. Moreover, the anisotropic etch process for forming the first bit line contact holes132amay be performed with a chlorine (Cl2) gas or a hydrogen bromide (HBr) gas in addition to the main etch gas and the subsidiary gas. In such a case, the semiconductor substrate100(e.g., the first impurity regions120) may be over-etched during the anisotropic etch process for forming the first bit line contact holes132a.

Referring toFIGS. 8A,8B and8C, an isotropic etch process may be applied to the substrate including the first hard mask layer124to isotropically etch only the capping layer114formed of a nitride layer. That is, the isotropic etch process may be performed to selectively etch the capping layer114. As a result, the first bit line contact holes132amay be enlarged in one direction (e.g., the second direction) which is substantially parallel with the line B-B′ ofFIG. 8C. Thus, the first bit line contact holes132ahaving circular shapes may be deformed into bit line contact holes132bhaving longish shapes, as illustrated in a plan view ofFIG. 8C. Specifically, the isotropic etch process may be performed under a pressure of about 5 mTorr to about 100 mTorr and a bias power of about 0 watt to about 150 watts using an inductively coupled plasma (ICP) apparatus or an electron cyclotron resonance (ECR) apparatus. Alternatively, the isotropic etch process may be performed under a pressure of about 15 mTorr to about 100 mTorr and a bias power of about 0 watt to about 500 watts using a capacitively coupled plasma (CCP) apparatus. When the isotropic etch process is performed, the main etch gas may include at least one of a CxFygas (where, 1≦x≦5 and 2≦y≦8), a CxHFygas (where, 1≦x≦3 and 1≦y≦3), a NF3gas and a SF6gas, and the subsidiary gas may include at least one of an oxygen (O2) gas, a CO gas, a COS gas, a nitrogen (N2) gas, a CH4gas, an argon (Ar) gas and a helium (He) gas. In various embodiments, the isotropic etch process for selectively etching the capping layer114may be performed using a wet etch process that employs a phosphoric acid (H3PO4) solution or the like as an etchant.

The isotropic etch process for selectively etching the capping layer114may be performed without removal of the photoresist pattern130or the first hard mask layer124after forming the first bit line contact holes132a. Alternatively, the isotropic etch process for selectively etching the capping layer114may be performed after all the photoresist pattern130, the anti-reflection layer128, the second hard mask layer126and the first hard mask layer124are removed. In this case, the upper corners of the bit line contact holes132bmay be formed to have rounded shapes. In various embodiments, an additional etch process for partially etching the hard mask pattern106may be performed to control the sidewall profiles of the bit line contact holes132bafter the isotropic etch process is performed. The additional etch process may be performed using an oxide etchant such as a buffered oxide etchant (BOE).

During the isotropic etch process, the capping layer114may be selectively etched. Thus, only an upper width of each first bit line contact hole132amay be enlarged when viewed from a cross sectional view taken along the line A-A′ ofFIG. 8C(seeFIG. 8A), and a total width of each first bit line contact hole132amay be enlarged when viewed from a cross sectional view taken along the line B-B′ ofFIG. 8C(seeFIG. 8B). The capping layer114on the hard mask pattern106may be partially removed in a subsequent process. Accordingly, a width of the final bit line contact holes132bin the first direction substantially parallel with the X-axis may be substantially equal to that of the first bit line contact holes132ain the first direction, and a width of the final bit line contact holes132bin the second direction substantially parallel with the Y-axis may be greater than that of the first bit line contact holes132ain the second direction. Hence, the final bit line contact holes132bmay be formed to have longish shapes, for example, oval shapes which are parallel with the second direction, as illustrated in a plan view ofFIG. 8C.

Referring toFIGS. 9A,9B and9C, a conductive layer, for example, a doped polysilicon layer may be formed on the capping layer114to fill the oval-shaped bit line contact holes132b. The conductive layer may be planarized to form contact patterns134(e.g., bit line contact patterns) in respective ones of the oval-shaped bit line contact holes132b.

Subsequently, a bit line conductive layer and a bit line hard mask layer140may be sequentially formed on the substrate including the bit line contact patterns134. In various embodiments, the bit line conductive layer may be formed by sequentially stacking a titanium nitride (TiN) layer136and a tungsten (W) layer138, and the bit line hard mask layer140may be formed of a silicon nitride layer. A barrier layer for preventing metal diffusion may be additionally formed before the bit line conductive layer is formed. The barrier layer may be formed by a stack layer of a metal layer and a metal compound layer. For example, the barrier layer may be formed by a stack layer of a titanium (Ti) layer and a titanium nitride (TiN) layer.

A photoresist pattern (not shown) for defining bit lines may be formed on the bit line hard mask layer140, and the bit line hard mask layer140may be etched and patterned using the photoresist pattern as an etch mask. After the photoresist pattern is removed using a photoresist strip process, the bit line conductive layer (138+136) may be etched and patterned using the patterned bit line hard mask layer140as an etch mask to form bit lines142. While the bit line conductive layer (138+136) is etched and patterned, both sides of each of the bit line contact patterns134in the bit line contact holes may be etched if a width of the patterned bit line hard mask layer140is less than a width of the bit line contact holes in the first direction parallel with the line A-A′, as illustrated inFIG. 9A. Thus, the width of the bit line contact patterns134in the first direction may be reduced to form bit line contact plugs134vertically self-aligned with the bit lines142. The bit lines142including the patterned bit line conductive layer (138+136) and the patterned bit line hard mask layer140may be formed to extend in the second direction which is substantially perpendicular to the word lines110and to intersect the central portions of the active regions102, as illustrated in a plan view ofFIG. 9C. That is, the bit lines142may be formed to cross over the first impurity regions120in the active regions102.

During the etch process for patterning the bit line conductive layer (138+136), at least one of a chlorine (Cl2) gas and a hydrogen bromide (HBr) gas may be used as a main etch gas of the etch process and at least one of an oxygen (O2) gas, a nitrogen (N2) gas, an argon (Ar) gas, a helium (He) gas, a methane (CH4) gas and a silicon tetrachloride (SiCl4) gas may be used as a subsidiary gas of the etch process. In addition, the etch process may be performed using a pulsed power. This etch recipe may prevent conductive tails from being formed at interfaces between the bit lines142and the bit line contact plugs134.

Referring toFIGS. 10A,10B and10C, a spacer insulation layer may be formed on an entire surface of the substrate including the bit lines142. The spacer insulation layer may be formed by depositing a nitride layer to a thickness of about 20 angstroms to about 400 angstroms. The spacer insulation layer may be anisotropically etched or etched back to form bit line spacers144on sidewalls of the bit lines142. The patterned bit line hard mask layer140and the bit line spacers144may electrically insulate the patterned bit line conductive layer (138+136) from storage node contact plugs formed in a subsequent process. That is, the patterned bit line conductive layer (138+136) may be electrically isolated by the patterned bit line hard mask layer140and the bit line spacers144.

An interlayer insulation layer may be formed on an entire surface of the substrate including the bit line spacers144to fill spaces between the bit lines142. A photoresist pattern may be formed on the interlayer insulation layer. The interlayer insulation layer, the capping layer114and the hard mask pattern106may be etched using the photoresist pattern as an etch mask, thereby forming storage node contact holes that expose respective ones of the second impurity regions122. The photoresist pattern may be removed, and a conductive layer may be formed on the interlayer insulation layer to fill the storage node contact holes. The conductive layer may then be planarized to expose the interlayer insulation layer and to form storage node contact plugs146in respective ones of the storage node contact holes. The storage node contact plugs146may be separated from the bit lines142by the bit line spacers144and may be disposed between the bit lines142. Further, the storage node contact plugs146may be electrically connected to respective ones of the second impurity regions122which are formed in both ends of the active regions102.

Although not shown in the drawings, storage electrodes may be formed on respective ones of the storage node contact plugs146, and a capacitor dielectric layer and a plate electrode may be sequentially formed on the storage electrodes to complete cell capacitors.

According to the embodiments described above, each of the first bit line contact holes may be formed to have a pair of first opposite sidewalls exposing a first oxide layer (e.g., the isolation layer104), a second oxide layer (e.g., the hard mask pattern106) and a nitride layer (e.g., the capping layer114) which are sequentially stacked and a pair of second opposite sidewalls exposing only the nitride layer (e.g., the capping layer114). The first opposite sidewalls may be substantially parallel with the second direction, and the second opposite sidewalls may be substantially parallel with the first direction. Thus, if the nitride layer is isotropically etched, the first bit line contact holes may be enlarged in one direction (including a positive direction and a negative direction opposite to the positive direction). As a result, longish bit line contact holes can be formed when viewed from a plan view. However, the above embodiments are merely some examples of the embodiments and may be deformed in many different forms. For example, each of the first bit line contact holes may be formed to have a pair of first opposite sidewalls exposing a first nitride layer (e.g., the isolation layer104), a second nitride layer (e.g., the hard mask pattern106) and an oxide layer (e.g., the capping layer114) which are sequentially stacked and a pair of second opposite sidewalls exposing only the oxide layer (e.g., the capping layer114). Thus, if the oxide layer is isotropically etched, the first bit line contact holes may be enlarged in one direction (including a positive direction and a negative direction opposite to the positive direction). As a result, longish bit line contact holes can be formed when viewed from a plan view.

According to the embodiments described above, contact holes may be formed in a plurality of material layers which are stacked, and each of the contact holes may be formed to include a pair of first opposite sidewalls exposing the plurality of material layers having different etch rates from each other and a pair of second opposite sidewalls exposing only one of the plurality of material layers. Thus, if one of the plurality of material layers is selectively etched using an isotropic etch process, longish contact holes such as oval contact holes that are difficult to define using only an exposure process can be formed when viewed from a plan view.