Methods of forming semiconductor device structures including linear structures substantially aligned with other structures

A method of forming a semiconductor device structure comprises forming a preliminary structure comprising a substrate, a photoresist material over the substrate, and a plurality of structures longitudinally extending through the photoresist material and at least partially into the substrate. The preliminary structure is exposed to electromagnetic radiation directed toward upper surfaces of the photoresist material and the plurality of structures at an angle non-orthogonal to the upper surfaces to form a patterned photoresist material. The patterned photoresist material is developed to selectively remove some regions of the patterned photoresist material relative to other regions of the patterned photoresist material. Linear structures substantially laterally aligned with at least some structures of the plurality of structures are formed using the other regions of the patterned photoresist material. Additional methods of forming a semiconductor device structure are also described.

TECHNICAL FIELD

Embodiments of the disclosure relate to the field of semiconductor device design and fabrication. More specifically, embodiments of the disclosure relate to methods of forming semiconductor device structures including linear structures substantially aligned with other structures.

BACKGROUND

Semiconductor device designers often desire to increase the level of integration, which may also be characterized in terms of density, of features within a semiconductor device by reducing the dimensions of the individual features and by reducing the separation distance between neighboring features. In addition, semiconductor device designers often desire to design architectures that are not only compact, but offer performance advantages, as well as simplified designs.

One example of a semiconductor device is a memory device. Memory devices are generally provided as internal integrated circuits in computers or other electronic devices. There are many types of memory including, but not limited to, random-access memory (RAM), read-only memory (ROM), dynamic random access memory (DRAM), synchronous dynamic random access memory (SDRAM), Flash memory, and resistance variable memory. Non-limiting examples of resistance variable memory include resistive random access memory (RRAM), conductive bridge random access memory (conductive bridge RAM), magnetic random access memory (MRAM), phase change material (PCM) memory, phase change random access memory (PCRAM), spin-torque-transfer random access memory (STT-RAM), oxygen vacancy-based memory, and programmable conductor memory.

Various semiconductor device structures (e.g., various memory device structures) are formed using a plurality of processing acts, which often include forming different features (e.g., contact structures, routing structures) aligned with one another over a substrate. Failure to achieve sufficient alignment of the features can render a semiconductor device including the misaligned features inoperative. A conventional way of providing requisite feature alignment is through the use of alignment marks (also referred to in the art as “registration marks”). For example, a mask including an integrated circuit pattern and an alignment mark pattern therein may be utilized in a photolithography process to transfer the integrated circuit pattern and the alignment mark pattern to a photoresist material overlying a substrate, wherein the substrate exhibits an additional alignment mark pattern thereon or therein. The photoresist material is then developed to form a patterned photoresist material exhibiting the integrated circuit pattern and the alignment mark pattern of the mask. Thereafter, the alignment mark pattern of the patterned photoresist material is inspected for alignment with the additional alignment mark pattern of the underlying substrate. If the alignment mark pattern of the patterned photoresist material is not sufficiently aligned with the additional alignment mark pattern of the underlying substrate, the patterned photoresist material is removed (e.g., stripped), re-applied, re-photoexposed, re-developed, and re-inspected for alignment mark pattern misalignment. Such additional, misalignment-imposed processing is inefficient and costly (e.g., increasing processing time as well as energy and material costs).

It would, therefore, be desirable to have new methods of forming semiconductor device structures having aligned features that mitigate one or more of the problems associated with conventional methods of forming such semiconductor device structures.

DETAILED DESCRIPTION

Methods of forming a semiconductor device structure including linear structures substantially aligned with other structures are described herein. The methods of the disclosure may utilize differences in the topography and/or transmissivity of different features (e.g., different materials and/or different structures) of a semiconductor device structure, in combination with or independent from an angle (e.g., a non-orthogonal angle) at which electromagnetic radiation is directed toward one or more upper surfaces of the semiconductor device structure (e.g., upper surfaces of the features), to facilitate the formation of one or more linear structures substantially aligned with one or more groups (e.g., rows, columns) of additional structures individually exhibiting different geometric configurations (e.g., different dimensions and/or different shapes) than the linear structures. The methods of the disclosure may facilitate the self-alignment of the linear structures with the groups of additional structures. The methods disclosed herein may decrease processing complexity, acts, and costs relative to conventional methods of forming semiconductor device structures and semiconductor devices.

The following description provides specific details, such as material types, material thicknesses, and processing conditions in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional fabrication techniques employed in the industry. In addition, the description provided below does not form a complete process flow for manufacturing a semiconductor device (e.g., a memory device). The semiconductor device structures described below do not form a complete semiconductor device. Only those process acts and structures necessary to understand the embodiments of the disclosure are described in detail below. Additional acts to form the complete semiconductor device from the semiconductor device structures may be performed by conventional fabrication techniques. Also note, any drawings accompanying the application are for illustrative purposes only, and are thus not drawn to scale. Additionally, elements common between figures may retain the same numerical designation.

As used herein, the term “pitch” refers to the distance between identical points in two adjacent structures. By way of non-limiting example, the pitch between centers of two adjacent cylindrical structures may be viewed as the sum of the radii of the adjacent cylindrical structures and any space between the adjacent cylindrical structures. Stated another way, the pitch in the foregoing example may be characterized as the distance between the centers of the adjacent cylindrical structures.

As used herein, the terms “longitudinal,” “vertical,” “lateral,” and “horizontal” are in reference to a major plane of a substrate (e.g., base material, base structure, base construction, etc.) in or on which one or more structures and/or features are formed and are not necessarily defined by earth's gravitational field. A “lateral” or “horizontal” direction is a direction that is substantially parallel to the major plane of the substrate, while a “longitudinal” or “vertical” direction is a direction that is substantially perpendicular to the major plane of the substrate. The major plane of the substrate is defined by a surface of the substrate having a relatively large area compared to other surfaces of the substrate.

FIGS. 1 through 5, includingFIGS. 2A through 2C, are perspective, partial cross-sectional (i.e.,FIGS. 1, 2A, and 3 through 5), side elevation (i.e.,FIG. 2B), and top-down (i.e.,FIG. 2C) views illustrating embodiments of a method of forming a semiconductor device structure, such as a structure of a memory device (e.g., a RAM device, a ROM device, a DRAM device, an SDRAM device, a FLASH memory device, a RRAM device, a conductive bridge RAM device, an MRAM device, a PCM memory device, a PCRAM device, an STT-RAM device, an oxygen vacancy-based memory device, a programmable conductor memory device, etc.). With the description provided below, it will be readily apparent to one of ordinary skill in the art that the methods described herein may be used in various devices (e.g., semiconductor devices, electronic devices, photonic devices, electronic-photonic devices, etc.). In other words, the methods of the disclosure may be used whenever it is desired to form a device including one or more linear structures substantially aligned with other structures.

Referring toFIG. 1, a semiconductor device structure100may include a substrate102, a photoresist material106on or over the substrate102, and structures108(e.g., contact structures, vertical interconnect structures, plug structures) longitudinally extending through the photoresist material106and at least partially (e.g., substantially) into the substrate102. Optionally, the semiconductor device structure100may also include at least one intervening material104positioned longitudinally between the substrate102and the photoresist material106. The intervening material104may, for example, be located on an upper surface of the substrate102, and the photoresist material106may be located on an upper surface of the intervening material104. If the intervening material104is present, the structures108may longitudinally extend completely through each of the photoresist material106and the intervening material104, and at least partially (e.g., substantially) into the substrate102.

The substrate102may comprise any base material or construction upon which additional materials may be formed. The substrate102may be a semiconductor substrate, a base semiconductor material on a supporting structure, a metal electrode, or a semiconductor substrate having one or more materials, structures, or regions formed thereon. The substrate102may be a conventional silicon substrate or other bulk substrate comprising a layer of semiconductive material. As used herein, the term “bulk substrate” means and includes not only silicon wafers, but also silicon-on-insulator (SOI) substrates, such as silicon-on-sapphire (SOS) substrates and silicon-on-glass (SOG) substrates, epitaxial layers of silicon on a base semiconductor foundation, and other semiconductor or optoelectronic materials, such as silicon-germanium, germanium, gallium arsenide, gallium nitride, and indium phosphide. The substrate102may be doped or undoped. By way of non-limiting example, a substrate102may comprise one or more of silicon, silicon dioxide, silicon with native oxide, silicon nitride, a carbon-containing silicon nitride, glass, semiconductor, metal oxide, metal, titanium nitride, carbon-containing titanium nitride, tantalum, tantalum nitride, carbon-containing tantalum nitride, niobium, niobium nitride, carbon-containing niobium nitride, molybdenum, molybdenum nitride, carbon-containing molybdenum nitride, tungsten, tungsten nitride, carbon-containing tungsten nitride, copper, cobalt, nickel, iron, aluminum, and a noble metal.

The intervening material104, if present, may comprise one or more of a conductive material, a dielectric material, and a semiconductive material. The material composition of the intervening material104may at least partially depend upon the material composition of the photoresist material106, and a selected process (e.g., a damascene process, a subtractive process) for patterning the intervening material104using a patterned photoresist material formed from the photoresist material106, as described in further detail below. In some embodiments, the intervening material104comprises at least one conductive material, such as one or more of a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, and a conductively doped semiconductor material. By way of non-limiting example, the intervening material104may comprise one or more of tungsten (W), tungsten nitride (WN), nickel (Ni), tantalum (Ta), tantalum nitride (TaN), tantalum silicide (TaSi), platinum (Pt), copper (Cu), silver (Ag), gold (Au), aluminum (Al), molybdenum (Mo), titanium (Ti), titanium nitride (TiN), titanium silicide (TiSi), titanium silicon nitride (TiSiN), titanium aluminum nitride (TiAlN), molybdenum nitride (MoN), iridium (Ir), iridium oxide (IrOx), ruthenium (Ru), ruthenium oxide (RuOx), and conductively doped silicon. In additional embodiments, the intervening material104comprises at least one dielectric material, such as one or more of an oxide material (e.g., silicon dioxide, phosphosilicate glass, borosilicate glass, borophosphosilicate glass, fluorosilicate glass, titanium dioxide, zirconium dioxide, hafnium dioxide, tantalum oxide, magnesium oxide, aluminum oxide, or a combination thereof), a nitride material (e.g., Si3N4), an oxynitride material (e.g., silicon oxynitride), amphorous carbon, or a combination thereof (e.g., a laminate of at least two of the foregoing). If present, the intervening material104may be selectively etchable relative to the substrate102. As used herein, a material is “selectively etchable” relative to another material if the material exhibits an etch rate that is at least about five times (5×) greater than the etch rate of another material, such as about ten times (10×) greater, about twenty times (20×) greater, or about forty times (40×) greater.

The photoresist material106may be formed of and include a conventional photoresist, such as a conventional positive tone photoresist, or a conventional negative tone photoresist. If the photoresist material106comprises a positive tone photoresist, the photoresist material106may be formulated such that regions thereof exposed to at least a minimum threshold dosage of electromagnetic radiation and, optionally, a post-exposure bake become at least partially soluble in a suitable developer (e.g., a positive tone developer). Photoexposed regions (e.g., regions exposed to the minimum threshold dosage of electromagnetic radiation) of the photoresist material106may be at least partially (e.g., substantially) removed by the developer while non-photoexposed regions (e.g., regions not exposed to the minimum threshold dosage of electromagnetic radiation) may remain substantially intact (e.g., not substantially removed), as described in further detail below. Alternatively, if the photoresist material106comprises a negative tone photoresist, the photoresist material106may be formulated such that regions thereof not exposed to at least a minimum threshold dosage of electromagnetic radiation are at least partially soluble in a suitable developer (e.g., a negative tone developer). Non-photoexposed regions of the photoresist material106may be at least partially (e.g., substantially) removed by the developer while photoexposed regions may remain substantially intact (e.g., not substantially removed), as also described in further detail below. The properties (e.g., tone) of the photoresist material106may be selected relative to material composition of the material(s) (e.g., intervening material104, if present) underlying the photoresist material106to facilitate desired patterning of the material(s), as described in further detail below. Suitable photoresist materials (e.g., positive tone photoresists, negative tone photoresists) are known in the art, and are, therefore, not described in detail herein. The photoresist material106may, for example, be compatible with 13.7 nm, 157 nm, 193 nm, 248 nm, or 365 nm wavelength systems; with 193 nm wavelength immersion systems; and/or with electron beam lithographic systems. The photoresist material106may exhibit any height H1(e.g., thickness) conducive to the formation of a patterned photoresist material from the photoresist material106through exposing the photoresist material106and the structures108to beams of electromagnetic radiation directed toward an upper surface of the semiconductor device structure100(e.g., upper surfaces of the photoresist material106and the structures108) at a non-orthogonal angle (e.g., a non-right angle, such as an acute angle) relative to the upper surface of the semiconductor device structure100, as described in further detail below.

The structures108may be formed of and include at least one material (e.g. one or more of a conductive material, a dielectric material, and a semiconductive material) having different electromagnetic radiation transmissivity than the photoresist material106. The structures108may impede the transmission of at least some electromagnetic radiation therethrough as compared to the photoresist material106. Put another way, the structures108may be less transmissive (e.g., more opaque) to electromagnetic radiation of one or more wavelengths than the photoresist material106. As described in further detail below, the transmissivity characteristics of the structures108may impede predetermined regions of the photoresist material106from being exposed to at least a minimum threshold dosage of electromagnetic radiation during subsequent processing to facilitate photoexposure of the predetermined regions. In some embodiments, the structures108comprise at least one conductive material less transmissive to one or more wavelengths of electromagnetic radiation than the photoresist material106, such as one or more of a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, and a conductively doped semiconductor material. By way of non-limiting example, the structures108may comprise one or more of W, WN, Ni, Ta, TaN, TaSi, Pt, Cu, Ag, Au, Al, Mo, Ti, TiN, TiSi, TiSiN, TiAlN, MoN, Ir, IrOx, Ru, RuOx, and conductively doped silicon. A material composition of the structures108may be substantially the same as or may be different than a material composition of the intervening material104(if present) and/or the substrate102. For example, if the intervening material104comprises a conductive material, the structures108may comprise the same conductive material as the intervening material104, or may comprise a different conductive material than the intervening material104. In some embodiments, the structures108and the intervening material104comprise substantially the same conductive material. As another example, if the intervening material104comprises a dielectric material (e.g., one or more of a dielectric oxide material, a dielectric nitride material, a dielectric oxynitride material, and amphorous carbon), the structures108may comprise a conductive material.

As shown inFIG. 1, the semiconductor device structure100may include rows of the structures108extending in an X-direction and columns of the structures108extending in a Y-direction. The X-direction may be substantially perpendicular to the Y-direction. The structures108within each row may be substantially aligned with one another, and the structures108within each column may also be substantially aligned with one another. For example, adjacent (i.e., neighboring) structures108most proximate one another in the X-direction may be substantially aligned with one another in the Y-direction, and other adjacent structures108most proximate one another in the Y-direction may be substantially aligned with one another in the X-direction. In additional embodiments, at least partially depending on a desired configuration of a patterned photoresist material to be formed using the structures108, at least some adjacent structures108most proximate one another in the X-direction may be unaligned with (e.g., offset from) one another in the Y-direction, and/or at least some adjacent structures108most proximate one another in the Y-direction may be unaligned with (e.g., offset from) one another in the X-direction.

The structures108may each individually exhibit any desired dimensions (e.g., length, width, diameter, height) and any desired shape. The dimensions and shapes of the structures108may be selected relative to one another and one or more dimensions (e.g., the height H1) of the photoresist material106to facilitate the formation of a patterned photoresist material exhibiting desired feature dimensions, shapes, and spacing by exposing the photoresist material106and the structures108to beams of electromagnetic radiation directed toward an upper surface of the semiconductor device structure100(e.g., upper surfaces of the photoresist material106and the structures108) at a non-orthogonal angle relative to the upper surface of the semiconductor device structure100, as described in further detail below. As shown inFIG. 1, in some embodiments, the structures108each exhibit a width W1(e.g., diameter), and each longitudinally extend (e.g., in a Z-direction) completely through the height H1of the photoresist material106to the upper surface of the photoresist material106(e.g., the upper surfaces of the structures108are substantially coplanar with the upper surface of the photoresist material106). In addition, as shown inFIG. 1, in some embodiments, the structures108exhibit cylindrical column shapes including substantially circular lateral cross-sectional geometries. In additional embodiments, one or more of the structures108may exhibit a different shape, such as a rectangular column shape, a tube shape, a fin shape, a pillar shape, a stud shape, dome shape, a cone shape, a frusto cone shape, a pyramid shape, a frusto pyramid shape, or an irregular shape. Each of the structures108may exhibit substantially the same dimensions and substantially the same shape as each other of the structures108, or one or more of the structures108may exhibit at least one different dimension and/or a different shape than one or more other of the structures108. In some embodiments, each of the structures108exhibits substantially the same dimensions and substantially the same shape as each other of the structures108.

The structures108may exhibit any desired spacing relative to one another. The spacing of the structures108may be selected relative to the dimensions and shapes of the structures108to facilitate the formation of a patterned photoresist material exhibiting desired feature dimensions, shapes, and spacing by exposing the photoresist material106and the structures108to beams of electromagnetic radiation directed toward an upper surface of the semiconductor device structure100(e.g., upper surfaces of the photoresist material106and the structures108) at a non-orthogonal angle relative to the upper surface of the semiconductor device structure100, as described in further detail below. As shown inFIG. 1, adjacent structures108within each row of the structures108may be substantially uniformly (e.g., substantially regularly) spaced apart from one another by a first distance D1, and adjacent structures108within each column of the structures108may be substantially uniformly (e.g., substantially regularly) spaced apart from one another by a second distance D2. The first distance D1may be substantially the same as the second distance D2, or the first distance D1may be different than the second distance D2. Accordingly, a pitch between centers of adjacent structures108within each of the rows may be substantially constant (e.g., non-variable), and a pitch between centers of adjacent structures108within each of the columns may also be substantially constant (e.g., non-variable). In additional embodiments, at least some adjacent structures108within at least one row of the structures108are spaced apart from one another by a different distance than at least some other adjacent structures108within the row, and/or at least some adjacent structures108within at least one column of the structures108are spaced apart from one another by a different distance than at least some other adjacent structures108within the column. Accordingly, a pitch between centers of at least some adjacent structures108within at least one row may be different than a pitch between centers of at least some other adjacent structures108within the row, and/or a pitch between centers of at least some adjacent structures108within at least one column may be different than a pitch between centers of at least some other adjacent structures108within the column.

Each of the substrate102, the intervening material104(if present), the photoresist material106, and the structures108may be formed using conventional processes including, conventional material deposition processes (e.g., conventional physical vapor deposition (“PVD”) processes, such as sputtering, evaporation, or ionized PVD; conventional chemical vapor deposition (“CVD”) processes; conventional atomic layer deposition (“ALD”) processes; conventional spin-coating processes), conventional photolithography processes, and conventional material removal processes (e.g., conventional etching processes, such as conventional dry etching processes and conventional wet etching processes; conventional polishing processes, such as conventional chemical-mechanical polishing (CMP) processes). Such processes are known in the art and, therefore, are not described in detail herein. In some embodiments, an initially-deposited (e.g., spin coated) photoresist material is reflowed to form the photoresist material106. Reflowing the initially-deposited photoresist material may provide the photoresist material106with an upper surface substantially coplanar with the surfaces of the structures108, and may also reduce defects in the photoresist material106relative to the initially-deposited photoresist material.

Referring next toFIG. 2A, the photoresist material106(FIG. 1) and the structures108are subjected to a photoexposure process wherein the photoresist material106and the structures108are exposed to beams (e.g., rays, waves) of electromagnetic radiation112directed toward upper surfaces of the photoresist material106and the structures108from one or more radiation sources at an angle θ non-orthogonal (e.g., non-perpendicular, non-normal) to the upper surfaces of the photoresist material106and the structures108to form a patterned photoresist material114including non-photoexposed regions116and photoexposed regions118.FIG. 2Bis a side elevation view of the semiconductor device structure100at the processing stage depicted inFIG. 2A.FIG. 2Cis a top-down view of the semiconductor device structure100at the processing stage depicted inFIG. 2A.

Depending at least on the tone (e.g., positive tone, or negative tone) of the photoresist material106(FIG. 1), the non-photoexposed regions116of the patterned photoresist material114comprise regions of the patterned photoresist material114not exposed to a sufficient dosage (e.g., at least a minimum threshold dosage) of electromagnetic radiation from the radiation sources to facilitate either the substantially complete removal of the regions upon subsequent development (e.g., if the photoresist material106comprises a positive tone photoresist material and the developer employed in the subsequent development comprises positive tone developer) or the at least partial (e.g., substantial) maintenance (e.g., preservation, non-removal) of the regions upon subsequent development (e.g., if the photoresist material106comprises a negative tone photoresist material and the developer employed in the subsequent development comprises negative tone developer). Accordingly, the photoexposed regions118of the patterned photoresist material114comprise additional regions of the patterned photoresist material114exposed to a sufficient dosage (e.g., at least a minimum threshold dosage) of electromagnetic radiation from the radiation sources to facilitate either the substantially complete removal of the additional regions upon subsequent development or the at least partial (e.g., substantial) maintenance of the additional regions upon subsequent development. Whether the non-photoexposed regions116comprise regions of the patterned photoresist material114to be substantially removed through subsequent development or comprise regions of the patterned photoresist material114to be substantially maintained through subsequent development may at least partially depend on the material composition of the intervening material104(if present) to facilitate desired patterning of the intervening material104through one or more subsequent processes (e.g., one or more subsequent subtractive processes, or one or more subsequent damascene processes), as described in further detail below.

Referring toFIG. 2B, during the photoexposure process, interactions between the structures108and some of the beams of electromagnetic radiation112from the radiation sources selectively form (e.g., cast, generate) penumbras120(e.g., shadows) within portions of the photoresist material106(FIG. 1). The penumbras120limit (e.g., obstruct, impede, restrict) electromagnetic radiation exposure within the portions of photoresist material106relative to other portions of the photoresist material106and form the patterned photoresist material114including the non-photoexposed regions116(i.e., corresponding to the portions of the photoresist material106wherein the penumbras120were formed during the photoexposure process) and the photoexposed regions118(FIG. 2A) (i.e., corresponding to the other portions of the photoresist material106wherein the penumbras120were not formed during the photoexposure process). The penumbras120may prevent the portions of the photoresist material106associated therewith from being exposed to a sufficient amount (e.g., dosage) of electromagnetic radiation to permit the non-photoexposed regions116of the patterned photoresist material114to have substantially the same solubility in a developer (e.g., a positive tone develop, a negative tone developer) as the photoexposed regions118of the patterned photoresist material114during subsequent development of the patterned photoresist material114.

With continued reference toFIG. 2B, the angle θ at which the beams of electromagnetic radiation112are directed toward the upper surfaces of the photoresist material106(FIG. 1) and the structures108may comprise any angle less than 90 degrees (e.g., within a range of from about 0 degrees to about 89 degrees, such as from about 0 degrees and to about 75 degrees, from about 0 degrees and to about 60 degrees, from about 0 degrees and to about 45 degrees, or from about 0 degrees and to about 30 degrees) permitting the penumbras120to laterally extend (e.g., in the X-direction; in the Y-direction; in an XY-direction angled relative to the X-direction and the Y-direction, such as a lateral direction oriented at an angle between 0 degree and 90 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 10 degrees and to about 80 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 30 degrees and to about 60 degrees relative to one or more of the X-direction and the Y-direction, or a lateral direction oriented at an angle of about 45 degrees relative to each of the X-direction and the Y-direction) completely between adjacent structures108(e.g., adjacent structures108of individual rows of the structures108; adjacent structures108of individual columns of the structures108; adjacent structures108diagonally laterally positioned relative to one another, such as diagonally adjacent structures108of adjacent columns of the structures108, or diagonally adjacent structures108of adjacent rows of the structures108) during the photoexposure process. Laterally extending the penumbras120completely between adjacent structures108permits the resulting non-photoexposed regions116to laterally extend continuously between the adjacent structures108. At a minimum, the angle θ of the beams of electromagnetic radiation112is selected such that a penumbra120laterally extends from a sidewall of one of the adjacent structures108to a sidewall of the other of the adjacent structures108in accordance with the following equation:

θ=tan-1⁡(HD)(1)
wherein D is the minimum distance (e.g., the first distance D1, or the second distance D2) between the adjacent structures108, and H is the height (e.g., the height H1) of the photoresist material106(and, hence, the height of the portions of the structures108longitudinally extending through the photoresist material106). However, the angle θ of the beams of electromagnetic radiation112may be selected such that the resulting penumbra120laterally extends beyond the minimum distance (e.g., beyond the first distance D1, or beyond the second distance D2) between the adjacent structures108. For example, the angle θ of the beams of electromagnetic radiation112may be selected such that one or more of the penumbras120overlap one or more other of the penumbras120. The angle θ of the beams of electromagnetic radiation112may be selected such that one or more of the penumbras120overlap one or more other of the penumbras120laterally adjacent (e.g., in the X-direction, in the Y-direction, in an XY-direction) thereto. Overlapping, adjacent penumbras120may form larger penumbras continuously laterally extending across and substantially aligned with individual rows of the structures108or individual columns of the structures108.

The penumbras120may exhibit maximum widths substantially corresponding to (e.g., substantially the same as) maximum widths (e.g., the widths W1) of the structures108casting the penumbras120. For example, if the penumbras120are formed to laterally extend in the X-direction, the maximum lateral dimensions (e.g., widths) in the Y-direction of the penumbras120may be substantially the same as the maximum lateral dimensions (e.g., the widths W1) in the Y-direction of the structures108casting the penumbras120. Outermost lateral boundaries in the Y-direction of the penumbras120may be substantially coplanar with outermost lateral boundaries in the Y-direction of the structures108casting the penumbras120. As another example, if the penumbras120are formed to laterally extend in the Y-direction, the maximum lateral dimensions (e.g., maximum widths) in the X-direction of the penumbras120may be substantially the same as the maximum lateral dimensions (e.g., the widths W1) in the X-direction of the structures108casting the penumbras120. Outermost lateral boundaries in the X-direction of the penumbras120may be substantially coplanar with outermost lateral boundaries in the X-direction of the structures108associated therewith. As a further example, if the penumbras120are formed to laterally extend in an XY-direction, the maximum lateral dimensions (e.g., widths) of the penumbras120in an additional XY-direction perpendicular to the XY-direction may be substantially the same as the maximum lateral dimensions in the additional XY-direction of the structures108casting the penumbras120. Outermost lateral boundaries of the penumbras120in the additional XY-direction may be substantially coplanar with outermost lateral boundaries in the additional XY-direction of the structures108casting the penumbras120. Each of the penumbras120may exhibit substantially the same maximum width (e.g., substantially the same width W1), or at least one of the penumbras120may exhibit a different maximum width than at least one other of the penumbras120. In addition, in embodiments wherein overlapping, adjacent penumbras120form larger penumbras continuously laterally extending across and substantially aligned with individual rows of the structures108or individual columns of the structures108, the larger penumbras may each exhibit a substantially uniform (e.g., non-variable) width, or one or more of the larger penumbras may exhibit a non-uniform (e.g., variable) width.

The photoexposure process may expose the photoresist material106and the structures108to any wavelength(s) of electromagnetic radiation (e.g., ultraviolet (UV) radiation, infrared (IR) radiation, visible radiation) compatible with the photoresist material106, and capable of forming the penumbras120(and, hence, the non-photoexposed regions116and the photoexposed regions118) having maximum lateral dimensions (e.g., maximum widths) corresponding to the maximum lateral dimensions of the structures108. By way of non-limiting example, the beams of electromagnetic radiation112may each individually have a wavelength within a range of from about 10 nm to about 400 nm, such as 13.7 nm, 157 nm, 193 nm, 248 nm, or 365 nm. In some embodiments, each of the beams of electromagnetic radiation112has a wavelength of 13.7 nm. In additional embodiments, each of the beams of electromagnetic radiation112has a wavelength of 193 nm. The electromagnetic radiation may be polarized (e.g., S-polarized, P-polarized) or may be non-polarized. In addition, the photoexposure process may expose the photoresist material106and the structures108to a single (e.g., only one) dose of electromagnetic radiation, or may expose the photoresist material106and the structures108to multiple (e.g., more than one) doses of electromagnetic radiation. If multiple doses of electromagnetic radiation are utilized, each of the multiple doses of electromagnetic radiation may be substantially the same (e.g., substantially the same radiation wavelength(s) and duration), or at least one of the multiple doses of electromagnetic radiation may be different than (e.g., different radiation wavelength(s) and/or different durations) at least one other of the multiple doses of electromagnetic radiation.

The radiation sources may exhibit any configurations, positions (e.g., lateral positions, longitudinal positions), and orientations (e.g., in the X-, Y-, and Z-directions) capable of forming the penumbras120(and, hence, the non-photoexposed regions116and photoexposed regions118) to exhibit desired sizes, shapes, and orientations relative to one another and the structures108. As shown inFIGS. 2A through 2C, in some embodiments, the radiation sources are configured, positioned, and oriented to generate and direct the beams of electromagnetic radiation112toward the upper surfaces of the photoresist material106(FIG. 1) and the structures108in the X-direction and the Z-direction (FIGS. 2A and 2C) (e.g., an XZ-direction) at the angle θ to form the penumbras120(FIG. 2C), the non-photoexposed regions116, and the photoexposed regions118. In additional embodiments, the radiation sources are configured, positioned, and oriented to generate and direct the beams of electromagnetic radiation112toward the upper surfaces of the photoresist material106and the structures108in the Y-direction and the Z-direction (e.g., a YZ-direction) at the angle θ to form the penumbras120, the non-photoexposed regions116, and the photoexposed regions118. In further embodiments, the radiation sources are configured, positioned, and oriented to generate and direct the beams of electromagnetic radiation112toward the upper surfaces of the photoresist material106and the structures108in the X-direction, the Y-direction, and the Z-direction (e.g., an XYZ-direction) at the angle θ to form the penumbras120, the non-photoexposed regions116, and the photoexposed regions118.

Depending on the configurations, positions, and orientation of the radiation sources during the photoexposure process, the non-photoexposed regions116and photoexposed regions118of the patterned photoresist material114may extend in substantially the same lateral direction (e.g., in the X-direction; in the Y-direction; in an XY-direction angled relative to the X-direction and the Y-direction, such as a lateral direction oriented at an angle between 0 degree and 90 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 10 degrees and to about 80 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 30 degrees and to about 60 degrees relative to one or more of the X-direction and the Y-direction, or a lateral direction oriented at an angle of about 45 degrees relative to each of the X-direction and the Y-direction). In addition, the photoexposed regions118may laterally intervene (e.g., in the Y-direction if the non-photoexposed regions116and photoexposed regions118extend in the X-direction; in the X-direction if the non-photoexposed regions116and photoexposed regions118extend in the Y-direction; in an additional XY-direction extending perpendicular to an XY-direction if the non-photoexposed regions116and photoexposed regions118extend in the XY-direction) between the non-photoexposed regions116. As shown inFIG. 2C, in some embodiments, the non-photoexposed regions116are substantially laterally aligned (in the Y-direction) with rows of the structures108extending in the X-direction, and the photoexposed regions118are laterally offset (in the Y-direction) from the rows of the structures108. The non-photoexposed regions116may laterally extend in parallel with one another and the photoexposed regions118in the X-direction, and may laterally alternate with the photoexposed regions118in the Y-direction. In additional embodiments, the non-photoexposed regions116are substantially laterally aligned (in the X-direction) with columns of the structures108extending in the Y-direction, and the photoexposed regions118are laterally offset (in the X-direction) from the columns of the structures108. The non-photoexposed regions116may laterally extend in parallel with one another and the photoexposed regions118in the Y-direction, and may laterally alternate with the photoexposed regions118in the X-direction. In further embodiments, the non-photoexposed regions116are substantially laterally aligned (in an XY-direction) with adjacent structures108laterally diagonally positioned relative to one another. The non-photoexposed regions116may laterally extend in parallel with one another and the photoexposed regions118in an XY-direction, and may laterally alternate with the photoexposed regions118in an additional XY-direction oriented perpendicular to the XY-direction.

As shown inFIGS. 2A and 2C, portions of the non-photoexposed regions116of the patterned photoresist material114may laterally extend substantially continuously between adjacent structures108(e.g., adjacent structures108of individual rows of the structures108if the non-photoexposed regions116laterally extend in the X-direction, adjacent structures108of individual columns of the structures108if the non-photoexposed regions116laterally extend in the Y-direction, diagonally adjacent structures108if the non-photoexposed regions116laterally extend in an XY-direction). For example, the non-photoexposed regions116of the patterned photoresist material114may directly contact and extend continuously between sidewalls of adjacent structures108of individual rows of the structures108, of adjacent structures108of individual columns of the structures108, or of diagonally adjacent structures108of adjacent rows of the structures108or adjacent columns of the structures108. As shown inFIG. 2A, the non-photoexposed regions116of the patterned photoresist material114may at least partially (e.g., substantially) laterally surround the portions of the structures108longitudinally extending (e.g., in the Z-direction) through the patterned photoresist material114. Accordingly, at least in embodiments wherein the structures108are formed of and include a conductive material, the non-photoexposed regions116may facilitate the subsequent formation of conductive linear structures extending substantially continuously between and electrically connecting at least some (e.g., all) structures108of individual rows of the structures108, at least some (e.g., all) structures108of individual columns of the structures108, or at least some (e.g., all) diagonally adjacent structures108substantially aligned with one another in an XY-direction, as described in further detail below. In addition, the photoexposed regions118of the patterned photoresist material114may laterally extend substantially continuously across the patterned photoresist material114in the same direction (e.g., the X-direction, the Y-direction, or an XY-direction) as the non-photoexposed regions116.

Referring toFIG. 2C, the non-photoexposed regions116of the patterned photoresist material114may exhibit maximum widths substantially corresponding to (e.g., substantially the same as) maximum widths of the penumbras120(FIG. 2B) used to form the non-photoexposed regions116. Namely, the non-photoexposed regions116exhibit maximum widths substantially corresponding to maximum widths (e.g., the widths W1) of the structures108associated therewith (e.g., physically contacting the non-photoexposed regions116). For example, if the non-photoexposed regions116are formed to laterally extend in the X-direction, the maximum lateral dimensions (e.g., widths) in the Y-direction of the non-photoexposed regions116may be substantially the same as the maximum lateral dimensions (e.g., the widths W1) in the Y-direction of the structures108associated therewith. Outermost lateral boundaries in the Y-direction of each of the non-photoexposed regions116may be substantially coplanar with outermost lateral boundaries in the Y-direction of each of the structures108associated therewith. As another example, if the non-photoexposed regions116are formed to laterally extend in the Y-direction, the maximum lateral dimensions (e.g., maximum widths) in the X-direction of the non-photoexposed regions116may be substantially the same as the maximum lateral dimensions (e.g., the widths W1) in the X-direction of the structures108associated therewith. Outermost lateral boundaries in the X-direction of each of the non-photoexposed regions116may be substantially coplanar with outermost lateral boundaries in the X-direction of each of the structures108associated therewith. As a further example, if the non-photoexposed regions116are formed to laterally extend in an XY-direction, the maximum lateral dimensions (e.g., widths) of the non-photoexposed regions116in an additional XY-direction perpendicular to the XY-direction may be substantially the same as the maximum lateral dimensions in the additional XY-direction of the structures108associated therewith. Outermost lateral boundaries of the non-photoexposed regions116in the additional XY-direction may be substantially coplanar with outermost lateral boundaries in the additional XY-direction of the structures108associated therewith. Each of the non-photoexposed regions116may exhibit substantially the same maximum width (e.g., substantially the same width W1), or at least one of the non-photoexposed regions116may exhibit a different maximum width than at least one other of the non-photoexposed regions116.

The photoexposed regions118of the patterned photoresist material114may exhibit maximum widths substantially corresponding to (e.g., substantially the same as) distances (e.g., the second distances D2, or the first distances D1) between adjacent structures108of different rows of the structures108(e.g., if the photoexposed regions118laterally extend in the X-direction), between different columns of the structures108(e.g., if the photoexposed regions118laterally extend in the Y-direction), or between adjacent laterally diagonally oriented non-photoexposed regions116(e.g., if the photoexposed regions118and the non-photoexposed regions116laterally extend in an XY-direction). For example, if the photoexposed regions118(and, hence, the non-photoexposed regions116) are formed to laterally extend in the X-direction, the maximum lateral dimensions (e.g., widths) in the Y-direction of the photoexposed regions118may be substantially the same as the second distances D2between adjacent structures108in the Y-direction. Outermost lateral boundaries in the Y-direction of each of the photoexposed regions118may be substantially coplanar with outermost lateral boundaries in the Y-direction of each of the structures108laterally adjacent thereto in the Y-direction. As another example, if the photoexposed regions118(and, hence, the non-photoexposed regions116) are formed to laterally extend in the Y-direction, the maximum lateral dimensions (e.g., widths) in the X-direction of the photoexposed regions118may be substantially the same as the first distances D1between the adjacent structures108in the X-direction. Outermost lateral boundaries in the X-direction of each of the photoexposed regions118may be substantially coplanar with outermost lateral boundaries in the X-direction of each of the structures108laterally adjacent thereto in the X-direction. As a further example, if the photoexposed regions118(and, hence, the non-photoexposed regions116) are formed to laterally extend in an XY-direction, the maximum lateral dimensions (e.g., widths) in of the photoexposed regions118in an additional XY-direction oriented perpendicular to the XY-direction may be substantially the same as the distances between adjacent laterally diagonally oriented non-photoexposed regions116. Outermost lateral boundaries in the additional XY-direction of each of the photoexposed regions118may be substantially coplanar with outermost lateral boundaries in the additional XY-direction of each of the non-photoexposed regions116laterally adjacent thereto in the additional XY-direction. Each of the photoexposed regions118may exhibit substantially the same maximum width, or at least one of the photoexposed regions118may exhibit a different maximum width than at least one other of the photoexposed regions118.

Following the formation of the patterned photoresist material114including the non-photoexposed regions116and the photoexposed regions118, the patterned photoresist material114is subjected to at least one development process to selectively remove the non-photoexposed regions116relative to the photoexposed regions118, or to selectively remove the photoexposed regions118relative to the non-photoexposed regions116. Which of the non-photoexposed regions116and the photoexposed regions118is removed by the development process is selected at least partially based on the properties (e.g., material composition) of the structure(s) and/or material(s) (e.g., the intervening material104, if present) underlying (e.g., directly underlying) the patterned photoresist material114, and on predetermined processes (e.g., damascene processes, subtractive processes) of forming linear structures (e.g., conductive linear structures) substantially aligned with and connected to (e.g., electrically connected to, physically connected to) at least some adjacent structures108(e.g., adjacent structures108of rows of the structures108extending in the X-direction, adjacent structures108of columns of the structures108extending in the Y-direction, diagonally adjacent structures108of adjacent rows of the structures108or of adjacent columns of the structures108) based on the properties of the structure(s) and/or material(s) underlying the patterned photoresist material114, as described in further detail below.

As shown inFIG. 3, in some embodiments, the development process substantially removes the photoexposed regions118(FIGS. 2A and 2C) of the patterned photoresist material114(FIGS. 2A and 2C), while at least partially (e.g., substantially) maintaining (e.g., keeping, preserving) the non-photoexposed regions116. For example, if the patterned photoresist material114comprises a positive tone resist, the development process may include developing the patterned photoresist material114with a positive tone developer to selectively remove the photoexposed regions118relative to the non-photoexposed regions116. Optionally, the patterned photoresist material114may be subjected to at least one post-exposure bake to increase the solubility of the photoexposed regions118in the positive tone developer prior to the development process. Selectively removing the photoexposed regions118of the patterned photoresist material114relative to the non-photoexposed regions116may, for example, be performed when the material composition(s) of the material(s) (e.g., the intervening material104, if present) underlying (e.g., directly underlying) the patterned photoresist material114facilitate the subsequent formation of linear structures (e.g., conductive linear structures) through at least one subtractive process, as described in further detail below.

As shown inFIG. 4, in additional embodiments, the development process substantially removes the non-photoexposed regions116(FIGS. 2A and 2C) of the patterned photoresist material114(FIGS. 2A and 2C), while at least partially (e.g., substantially) maintaining (e.g., keeping, preserving) the photoexposed regions118. For example, if the patterned photoresist material114comprises a negative tone resist, the development process may include developing the patterned photoresist material114with a negative tone developer to selectively remove the non-photoexposed regions116relative to the photoexposed regions118. Optionally, the patterned photoresist material114may be subjected to at least one post-exposure bake to increase the insolubility of the photoexposed regions118in the negative tone developer prior to the development process. Selectively removing the non-photoexposed regions116of the patterned photoresist material114relative to the photoexposed regions118may, for example, be performed when the material composition(s) of the material(s) (e.g., the intervening material104, if present) underlying (e.g., directly underlying) the patterned photoresist material114facilitate the subsequent formation of linear structures (e.g., dielectric linear structures) through at least one damascene process, as described in further detail below.

Referring next toFIG. 5, following the removal of the photoexposed regions118(FIGS. 2A and 2C) or the non-photoexposed regions116(FIGS. 2A and 2C), the remaining non-photoexposed regions116(FIG. 3) or the remaining photoexposed regions118(FIG. 4) may be used to form linear structures122(e.g., line structures, linear routing structures) substantially aligned with, contacting (e.g., physically contacting, electrically contacting), and laterally extending between (e.g., in the X-direction, in the Y-direction, in an XY-direction) at least some adjacent structures108(e.g., adjacent structures108of rows of the structures108; adjacent structures108of columns of the structures108; adjacent structures108diagonally laterally positioned relative to one another, such as diagonally adjacent structures108of adjacent columns of the structures108, or diagonally adjacent structures108of adjacent rows of the structures108). The linear structures122may, for example, be electrically isolated from one another and may electrically connect at least some (e.g., all) structures108of individual rows of the structures108, at least some (e.g., all) structures108of individual columns of the structures108, or at least some (e.g., all) diagonally adjacent structures108substantially aligned with one another in an XY-direction. In some embodiments, the linear structures122each individually comprise at least one conductive material (e.g., one or more of a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, and a conductively doped semiconductor material). For example, if the structures108comprise a conductive material, the linear structures122may comprise the same conductive material as the structures108, or may comprise a different conductive material than the structures108. In some embodiments, the structures108and the linear structures122comprise substantially the same conductive material. In additional embodiments, one or more the linear structures122may comprise a different material, such as a semiconductive material or a dielectric material.

The linear structures122may exhibit lateral dimensions, lateral positions, and lateral orientations substantially corresponding to (e.g., substantially the same as) the lateral dimensions, lateral positions, and lateral orientations of the non-photoexposed regions116(FIGS. 2A and 2C) of the patterned photoresist material114(FIGS. 2A and 2C). Thus, the linear structures122may exhibit maximum widths substantially corresponding to maximum widths (e.g., the widths W1) of the structures108associated therewith. Accordingly, depending of the lateral orientations of the linear structures122, outermost lateral boundaries of the linear structures122in the Y-direction (e.g., if the linear structures122laterally extend between adjacent structures108in the X-direction), the X-direction (e.g., if the linear structures122laterally extend between adjacent structures108in the Y-direction), or an XY-direction (e.g., if the linear structures122laterally extend between adjacent structures108laterally diagonally positioned relative to one another) may be substantially coplanar with the outermost lateral boundaries in the Y-direction, the X-direction, or the XY-direction of the adjacent structures108connected thereto. In addition, the linear structures122may be substantially aligned with the adjacent structures108connected thereto. For example, as shown inFIG. 5, in some embodiments, individual linear structures122are substantially aligned in the Y-direction with adjacent structures108of individual rows of the structures108extending in the X-direction. In additional embodiments, individual linear structures122are substantially aligned in the X-direction with adjacent structures108of individual columns of the structures108extending in the Y-direction. In further embodiments, individual linear structures122are substantially aligned in an XY-direction with adjacent structures108laterally diagonally positioned relative to one another.

In embodiments wherein the non-photoexposed regions116(FIG. 3) remain following the development process, a subtractive process may be used to form the linear structures122. By way of non-limiting example, referring toFIG. 3, if the intervening material104is present and comprises a conductive material (e.g., a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, a conductively doped semiconductor material), the pattern defined by the remaining non-photoexposed regions116may transferred into the intervening material104using at least one anisotropic etching process (e.g., at least one anisotropic dry etching process, such as at least one of reactive ion etching, deep reactive ion etching, plasma etching, reactive ion beam etching, and chemically assisted ion beam etching; at least one anisotropic wet etching process). During the anisotropic etching process, the remaining non-photoexposed regions116, upper portions of the structures108longitudinally extending through the non-photoexposed regions116, and unprotected (e.g., exposed) portions of the intervening material104may be simultaneously removed. The etch rate of the non-photoexposed regions116and the upper portions of the structures108may be less than or equal to the etch rate of the intervening material104. The anisotropic etching process may substantially (e.g., completely) remove the unprotected (e.g., exposed) portions of the intervening material104, and the remaining portions of the intervening material104following the anisotropic etching process form the linear structures122(FIG. 5). The linear structures122may exhibit substantially the same lateral dimensions (e.g., lengths, widths) as the non-photoexposed regions116. Thereafter, an isolation material (e.g., a dielectric material) may be formed (e.g., deposited) between the linear structures122, and at least one polishing process (e.g., at least one chemical-mechanical polishing (CMP) process) may be employed to remove portions of the non-photoexposed regions116, the structures108, and the isolation material positioned longitudinally above upper surfaces of the linear structures122.

In embodiments wherein the photoexposed regions118(FIG. 4) remain following the development process, a damascene process may be used to form the linear structures122. By way of non-limiting example, referring toFIG. 4, if the intervening material104is present and comprises a dielectric material (e.g., a dielectric oxide material, a dielectric nitride material, a dielectric oxynitride material, amphorous carbon, combinations thereof), at least one material removal process (e.g., at least one of a wet etching process and a dry etching process) may be used to transfer the pattern defined by the remaining photoexposed regions118into the intervening material104to form trenches therein. The material removal process may at least partially (e.g., substantially) remove the unprotected (e.g., exposed) portions of the intervening material104. Thereafter, the trenches may be filled (e.g., through one or more material deposition processes, such as a blanket material deposition process) with a conductive material (e.g., a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, a conductively doped semiconductor material), and at least one polishing process (e.g., at least one CMP process) may be used to remove portions of the conductive material, the photoexposed regions118, and the structures108positioned longitudinally above upper boundaries of the trenches to form the linear structures122. The linear structures122may exhibit substantially the same lateral dimensions (e.g., lengths, widths) as the non-photoexposed regions116(FIGS. 2A and 2C) of the patterned photoresist material114(FIGS. 2A and 2C).

Following the formation of the linear structures122, the semiconductor device structure100may be subjected to additional processing (e.g., additional deposition processes, additional material removal processes), as desired. The additional processing may be conducted by conventional processes and conventional processing equipment, and is not illustrated or described in detail herein.

Thus, in accordance with embodiments of the disclosure, a method of forming a semiconductor device structure comprises forming a preliminary structure comprising a substrate, a photoresist material over the substrate, and a plurality of structures longitudinally extending through the photoresist material and at least partially into the substrate. The preliminary structure is exposed to electromagnetic radiation directed toward upper surfaces of the photoresist material and the plurality of structures at an angle non-orthogonal to the upper surfaces to form a patterned photoresist material. The patterned photoresist material is developed to selectively remove some regions of the patterned photoresist material relative to other regions of the patterned photoresist material. Linear structures substantially laterally aligned with at least some structures of the plurality of structures are formed using the other regions of the patterned photoresist material.

FIGS. 6 through 10, includingFIGS. 7A through 7C, 8A and 8B, and 9A and 9B, are perspective, partial cross-sectional (i.e.,FIGS. 6, 7A, 8A, 9A, and 10), side elevation (i.e.,FIG. 7B), and top-down (i.e.,FIGS. 7C, 8B, and 9B) views illustrating embodiments of another method of forming a semiconductor device structure, such as a structure of a memory device (e.g., a RAM device, a ROM device, a DRAM device, an SDRAM device, a Flash memory device, a RRAM device, a conductive bridge RAM device, an MRAM device, a PCM memory device, a PCRAM device, an STT-RAM device, an oxygen vacancy-based memory device, a programmable conductor memory device, etc.). With the description provided below, it will be readily apparent to one of ordinary skill in the art that the method described herein may be used in various devices (e.g., photonic devices, electronic devices, electronic-photonic devices, semiconductor devices). In other words, the methods of the disclosure may be used whenever it is desired to form a device including one or more linear structures substantially aligned with other structures.

Referring toFIG. 6, a semiconductor device structure200may include a substrate202, a photoresist material206on or over the substrate202, and structures208(e.g., contact structures, vertical interconnect structures, plug structures) longitudinally extending from a lower boundary (e.g., a lower surface) of the photoresist material206and at least partially (e.g., substantially) into the substrate202. Optionally, the semiconductor device structure200may also include at least one intervening material204positioned longitudinally between the substrate202and the photoresist material206. The intervening material204may, for example, be located on an upper surface of the substrate202, and the photoresist material206may be located on an upper surface of the intervening material204. If the intervening material204is present, the structures208may longitudinally extend from an interface of the intervening material204and the photoresist material206, completely through the intervening material204, and at least partially (e.g., substantially) into the substrate202. The substrate202, the intervening material204(if present), and the photoresist material206may respectively have material compositions substantially similar to the those of the substrate102, the intervening material104, and the photoresist material106previously described with reference toFIG. 1.

The structures208may be formed of and include at least one material (e.g. one or more of a conductive material, a dielectric material, and a semiconductive material) reflective to one or more wavelengths of electromagnetic radiation to which the semiconductor device structure200is subsequently exposed to pattern the photoresist material206. As described in further detail below, the reflectivity characteristics of the structures208may permit predetermined regions of the photoresist material206to be exposed to at least a minimum threshold dosage of electromagnetic radiation to facilitate desired photoexposure of the predetermined regions relative to other regions of the photoresist material206. In some embodiments, the structures208comprise at least one conductive material reflective to one or more wavelengths of electromagnetic radiation to which the semiconductor device structure200is subsequently exposed, such as one or more of a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, and a conductively doped semiconductor material. By way of non-limiting example, the structures208may comprise one or more of W, WN, Ni, Ta, TaN, TaSi, Pt, Cu, Ag, Au, Al, Mo, Ti, TiN, TiSi, TiSiN, TiAlN, MoN, Ir, IrOx, Ru, RuOx, and conductively doped silicon. A material composition of the structures208may be substantially the same as or may be different than a material composition of the intervening material204(if present) and/or the substrate202.

As shown inFIG. 6, upper surfaces of the structures208may be substantially coplanar with lower surfaces of the photoresist material206and upper surfaces of the intervening material204(if present). Put another way, the photoresist material206may be substantially free of portions of the structures208longitudinally extending (e.g., in the Z-direction) at least partially therethrough. Aside from the longitudinal dimensions of the structures208, the structures208each individually exhibit dimensions (e.g., lateral dimensions, such as lengths and widths) and shapes substantially similar to one or more of the dimensions and the shapes of the structures108previously described with reference toFIG. 1. Each of the structures208may exhibit substantially the same dimensions and substantially the same shape as each other of the structures208, or one or more of the structures208may exhibit at least one different dimension and/or a different shape than one or more other of the structures208. As shown inFIG. 6, in some embodiments, each of the structures208exhibit a width W2(e.g., diameter) and a cylindrical column shape including a substantially circular lateral cross-sectional geometry.

The alignment and spacing of the structures208may be substantially similar to the alignment and spacing of the structures108previously described with reference toFIG. 1. As shown inFIG. 6, in some embodiments, the semiconductor device structure200includes rows of the structures208extending in an X-direction and columns of the structures208extending in a Y-direction substantially perpendicular to the X-direction. The structures208within each row may be substantially aligned with one another, and the structures208within each column may also be substantially aligned with one another. In addition, adjacent structures208within each row of the structures208may be substantially uniformly (e.g., substantially regularly) spaced apart from one another by a first distance D3, and adjacent structures208within each column of the structures208may be substantially uniformly (e.g., substantially regularly) spaced apart from one another by a second distance D4(seeFIG. 7C). In additional embodiments, at least partially depending on a desired configuration of a patterned photoresist material to be formed using the structures208, at least some adjacent structures208most proximate one another in the X-direction may be unaligned with (e.g., offset from) one another in the Y-direction, and/or at least some adjacent structures208most proximate one another in the Y-direction may be unaligned with (e.g., offset from) one another in the X-direction. In further embodiments, at least some adjacent structures208within at least one row of the structures208may be spaced apart from one another by a different distance than at least some other adjacent structures208within the row, and/or at least some adjacent structures208within at least one column of the structures208may be spaced apart from one another by a different distance than at least some other adjacent structures208within the column.

Each of the substrate202, the intervening material204(if present), the photoresist material206, and the structures208may be formed using conventional processes including, conventional material deposition processes (e.g., conventional PVD processes, such as sputtering, evaporation, or ionized PVD; conventional CVD processes; conventional ALD processes; conventional spin-coating processes), conventional photolithography processes, and conventional material removal processes (e.g., conventional etching processes, such as conventional dry etching processes and conventional wet etching processes; conventional polishing processes, such as conventional CMP processes). Such processes are known in the art and, therefore, are not described in detail herein.

Referring next toFIG. 7A, the semiconductor device structure200is subjected to a photoexposure process wherein the photoresist material206(FIG. 6) is exposed to beams (e.g., rays, waves) of electromagnetic radiation212directed toward an upper surface of the photoresist material206from one or more radiation sources at an angle θ non-normal (e.g., non-perpendicular, non-orthogonal) to the upper surface of the photoresist material206to form a patterned photoresist material214including non-photoexposed regions216and photoexposed regions218. As described in further detail below, the photoexposed regions218comprise regions of the photoresist material206photoexposed by reflected electromagnetic radiation.FIG. 7Bis a side elevation view of the semiconductor device structure200at the processing stage depicted inFIG. 7A.FIG. 7Cis a top-down view of the semiconductor device structure200at the processing stage depicted inFIG. 7A.

Depending at least on the tone (e.g., positive tone, or negative tone) of the photoresist material206(FIG. 6), the non-photoexposed regions216of the patterned photoresist material214comprise regions of the patterned photoresist material214not exposed to a sufficient dosage (e.g., at least a minimum threshold dosage) of electromagnetic radiation from the radiation sources to facilitate either the substantially complete removal of the regions upon subsequent development (e.g., if the photoresist material206comprises a positive tone photoresist material and the developer employed in the subsequent development comprises positive tone developer) or the at least partial (e.g., substantial) maintenance (e.g., preservation, non-removal) of the regions upon subsequent development (e.g., if the photoresist material206comprises a negative tone photoresist material and the developer employed in the subsequent development comprises negative tone developer). Accordingly, the photoexposed regions218of the patterned photoresist material214comprise additional regions of the patterned photoresist material214exposed to a sufficient dosage (e.g., at least a minimum threshold dosage) of electromagnetic radiation from the radiation sources (e.g., through a combination of beams of electromagnetic radiation and reflected beams of electromagnetic radiation) to facilitate either the substantially complete removal of the additional regions upon subsequent development or the at least partial (e.g., substantial) maintenance of the additional regions upon subsequent development. Whether the non-photoexposed regions216comprise regions of the patterned photoresist material214to be substantially removed through subsequent development or comprise regions of the patterned photoresist material214to be substantially maintained through subsequent development may at least partially depend on the material composition of the intervening material204(if present) to facilitate desired patterning of the intervening material204through one or more subsequent processes (e.g., one or more subsequent subtractive processes, or one or more subsequent damascene processes), as described in further detail below.

During the photoexposure process, as the beams of electromagnetic radiation212from the radiation sources are transmitted through the photoresist material206(FIG. 6), interactions between the structures208and a portion of the beams of electromagnetic radiation212reflect the portion of the beams of electromagnetic radiation212back into the photoresist material206as the reflected beams of electromagnetic radiation213to selectively dose portions of the photoresist material206with additional radiation. The reflected beams of electromagnetic radiation213enhance electromagnetic radiation exposure within the portions of photoresist material206relative to other portions of the photoresist material206and form the patterned photoresist material214including the photoexposed regions218(i.e., corresponding to the portions of the photoresist material206wherein the reflected beams of electromagnetic radiation213were directed back through the photoresist material206during the photoexposure process) and the non-photoexposed regions216(i.e., corresponding to the other portions of the photoresist material206wherein radiation was not directed back through the photoresist material206during the photoexposure process). The reflected beams of electromagnetic radiation213expose the portions of the photoresist material206associated therewith to a sufficient amount (e.g., dosage) of radiation to permit the photoexposed regions218of the patterned photoresist material214to have a different solubility in a developer (e.g., a positive tone develop, a negative tone developer) than the non-photoexposed regions216of the patterned photoresist material214during subsequent development of the patterned photoresist material214.

Referring toFIG. 7B, the angle θ at which the beams of electromagnetic radiation212are directed toward the upper surfaces of the photoresist material206(FIG. 6) may comprise any angle less than 90 degrees (e.g., between 0 degrees and 90 degrees, such as greater than 0 degrees and less than or equal to 75 degrees, greater than 0 degrees and less than or equal to 60 degrees, greater than 0 degrees and less than or equal to 45 degrees, or greater than 0 degrees and less than or equal to 30 degrees) permitting the formation of the photoexposed regions218by the combination of the beams of electromagnetic radiation212and the reflected beams of electromagnetic radiation213. As shown inFIG. 7B, the angle θ permits paths of the reflected beams of electromagnetic radiation213to intersect with paths of the beams of electromagnetic radiation212, such that portions of the photoresist material206receive a double dosage of radiation and form the photoexposed regions218. The double dosage of electromagnetic radiation may permit the portions of the photoresist material206to be exposed to at least a minimum threshold dosage of electromagnetic radiation permitting the resulting photoexposed regions218to have a different solubility in a developer than the non-photoexposed regions216. The angle θ may permit the resulting photoexposed regions218to be substantially aligned with and continuously laterally extend between adjacent structures208(e.g., adjacent structures208of individual rows of the structures208; adjacent structures208of individual columns of the structures208; adjacent structures208diagonally laterally positioned relative to one another, such as diagonally adjacent structures208of adjacent columns of the structures208, or diagonally adjacent structures208of adjacent rows of the structures208) of the semiconductor device structure200. At a minimum, the angle θ of the beams of electromagnetic radiation212is selected such that some of the reflected beams of electromagnetic radiation213laterally extend from a sidewall of one of the adjacent structures208to a sidewall of another of the adjacent structures208. However, the angle θ of the beams of electromagnetic radiation212may be selected such that the resulting reflected beams of electromagnetic radiation213laterally extend beyond the minimum distance (e.g., beyond the first distance D3, or beyond the second distance D4) (FIG. 6) between the adjacent structures208.

The photoexposure process may expose the semiconductor device structure200to any wavelength(s) of electromagnetic radiation (e.g., UV radiation, IR radiation, visible radiation) compatible with the photoresist material206, and capable of forming the photoexposed regions218to exhibit maximum lateral dimensions (e.g., maximum widths) corresponding to the maximum lateral dimensions of the structures208. By way of non-limiting example, the beams of electromagnetic radiation212may each individually have a wavelength within a range of from about 10 nm to about 400 nm, such as 13.7 nm, 157 nm, 193 nm, 248 nm, or 365 nm. In some embodiments, each of the beams of electromagnetic radiation212has a wavelength of 13.7 nm. In additional embodiments, each of the beams of electromagnetic radiation212has a wavelength of 193 nm. The electromagnetic radiation may be polarized (e.g., S-polarized, P-polarized) or may be non-polarized. In addition, the radiation sources may exhibit configurations, positions (e.g., lateral positions, longitudinal positions), and orientations (e.g., in the X-, Y-, and Z-directions) substantially similar to those of the radiation source previously described with reference toFIGS. 2A through 2C. The radiation sources may exhibit configurations, positions, and orientations capable of forming the non-photoexposed regions216and photoexposed regions218of the patterned photoresist material214to exhibit desired sizes, shapes, and orientations relative to one another and the structures208.

Depending on the configurations, positions, and orientation of the radiation sources during the photoexposure process, the non-photoexposed regions216and photoexposed regions218of the patterned photoresist material214may extend in substantially the same lateral direction (e.g., in the X-direction; in the Y-direction; in an XY-direction angled relative to the X-direction and the Y-direction, such as a lateral direction oriented at an angle between 0 degree and 90 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 10 degrees and to about 80 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 30 degrees and to about 60 degrees relative to one or more of the X-direction and the Y-direction, or a lateral direction oriented at an angle of about 45 degrees relative to each of the X-direction and the Y-direction). In addition, the non-photoexposed regions216may laterally intervene (e.g., in the Y-direction if the non-photoexposed regions216and photoexposed regions218extend in the X-direction; in the X-direction if the non-photoexposed regions216and photoexposed regions218extend in the Y-direction; in an additional XY-direction extending perpendicular to an XY-direction if the non-photoexposed regions216and photoexposed regions218extend in the XY-direction) between the photoexposed regions218. As shown inFIG. 7C, in some embodiments, the photoexposed regions218are substantially laterally aligned (in the Y-direction) with rows of the structures208extending in the X-direction, and the non-photoexposed regions216are laterally offset (in the Y-direction) from the rows of the structures208. The photoexposed regions218may laterally extend in parallel with one another and the non-photoexposed regions216in the X-direction, and may laterally alternate with the non-photoexposed regions216in the Y-direction. In additional embodiments, the photoexposed regions218are substantially laterally aligned (in the X-direction) with columns of the structures208extending in the Y-direction, and the non-photoexposed regions216are laterally offset (in the X-direction) from the columns of the structures208. The photoexposed regions218may laterally extend in parallel with one another and the non-photoexposed regions216in the Y-direction, and may laterally alternate with the non-photoexposed regions216in the X-direction. In further embodiments, the photoexposed regions218are substantially laterally aligned (in an XY-direction) with adjacent structures208laterally diagonally positioned relative to one another. The photoexposed regions218may laterally extend in parallel with one another and the non-photoexposed regions216in an XY-direction, and may laterally alternate with the non-photoexposed regions216in an additional XY-direction oriented perpendicular to the XY-direction.

As shown inFIGS. 7A and 7C, the photoexposed regions218of the patterned photoresist material214may longitudinally overly (e.g., in the Z-direction) and laterally extend substantially continuously between adjacent structures208(e.g., adjacent structures208of individual rows of the structures208if the photoexposed regions218laterally extend in the X-direction, adjacent structures208individual columns of the structures208if the photoexposed regions218laterally extend in the Y-direction, diagonally adjacent structures208if the photoexposed regions218laterally extend in an XY-direction). For example, the photoexposed regions218of the patterned photoresist material214may directly contact and extend continuously between of adjacent structures208of individual rows of the structures108, adjacent structures108of individual columns of the structures108, or diagonally adjacent structures208of adjacent rows of the structures208or of adjacent columns of the structures208. The photoexposed regions218of the patterned photoresist material214may laterally extend substantially continuously across the patterned photoresist material214in the same direction as individual rows of the structures208thereunder, in the same direction as individual columns of the structures208thereunder, or in the same direction as diagonally adjacent structures108thereunder. Accordingly, at least in embodiments wherein the structures208are formed of and include a conductive material, the photoexposed regions218may facilitate the subsequent formation of conductive linear structures extending substantially continuously between and electrically connecting at least some (e.g., all) structures208of individual rows of the structures208, at least some (e.g., all) structures208of individual columns of the structures208, or at least some (e.g., all) diagonally adjacent structures208substantially aligned with one another in an XY-direction, as described in further detail below. In addition, the non-photoexposed regions216of the patterned photoresist material214may laterally extend substantially continuously across the patterned photoresist material214in the same direction (e.g., the X-direction, the Y-direction, an XY-direction) as the photoexposed regions218.

Referring toFIG. 7C, the photoexposed regions218of the patterned photoresist material214may exhibit maximum widths substantially corresponding to (e.g., substantially the same as) maximum widths (e.g., the widths W2) of the structures208associated therewith (e.g., laterally aligned with and longitudinally underlying the photoexposed regions218). For example, if the photoexposed regions218are formed to laterally extend in the X-direction, the maximum lateral dimensions (e.g., widths) in the Y-direction of the photoexposed regions218may be substantially the same as the maximum lateral dimensions (e.g., the widths W2) in the Y-direction of the structures208associated therewith. Outermost lateral boundaries in the Y-direction of each of the photoexposed regions218may be substantially coplanar with outermost lateral boundaries in the Y-direction of each of the structures208associated therewith. As another example, if the photoexposed regions218are formed to laterally extend in the Y-direction, the maximum lateral dimensions (e.g., maximum widths) in the X-direction of the photoexposed regions218may be substantially the same as the maximum lateral dimensions (e.g., the widths W2) in the X-direction of the structures208associated therewith (e.g., laterally aligned with and longitudinally underlying the photoexposed regions218). Outermost lateral boundaries in the X-direction of each of the photoexposed regions218may be substantially coplanar with outermost lateral boundaries in the X-direction of each of the structures208associated therewith. As a further example, if the photoexposed regions218are formed to laterally extend in an XY-direction, the maximum lateral dimensions (e.g., widths) of the photoexposed regions218in an additional XY-direction perpendicular to the XY-direction may be substantially the same as the maximum lateral dimensions in the additional XY-direction of the structures208associated therewith. Outermost lateral boundaries of the photoexposed regions218in the additional XY-direction may be substantially coplanar with outermost lateral boundaries in the additional XY-direction of the structures208associated therewith. Each of the photoexposed regions218may exhibit substantially the same maximum width (e.g., substantially the same width W2), or at least one of the photoexposed regions218may exhibit a different maximum width than at least one other of the photoexposed regions218.

The non-photoexposed regions216of the patterned photoresist material214may exhibit maximum widths substantially corresponding to (e.g., substantially the same as) distances (e.g., the second distances D4, or the first distances D3) between adjacent structures208of different rows of the structures208(e.g., if the non-photoexposed regions216laterally extend in the X-direction), different columns of the structures208(e.g., if the non-photoexposed regions216laterally extend in the Y-direction), or between adjacent laterally diagonally oriented photoexposed regions218(e.g., if the photoexposed regions218and the non-photoexposed regions216laterally extend in an XY-direction). For example, if the non-photoexposed regions216(and, hence, the photoexposed regions218) are formed to laterally extend in the X-direction, the maximum lateral dimensions (e.g., widths) in the Y-direction of the non-photoexposed regions216may be substantially the same as the second distances D4between adjacent structures208in the Y-direction. Outermost lateral boundaries in the Y-direction of each of the non-photoexposed regions216may be substantially coplanar with outermost lateral boundaries in the Y-direction of each of the structures208laterally adjacent thereto in the Y-direction. As another example, if the non-photoexposed regions216(and, hence, the photoexposed regions218) are formed to laterally extend in the Y-direction, the maximum lateral dimensions (e.g., widths) in the X-direction of the non-photoexposed regions216may be substantially the same as the first distances D3between the adjacent structures208in the X-direction. Outermost lateral boundaries in the X-direction of each of the non-photoexposed regions216may be substantially coplanar with outermost lateral boundaries in the X-direction of each of the structures208laterally adjacent thereto in the X-direction. As a further example, if the non-photoexposed regions216(and, hence, the photoexposed regions218) are formed to laterally extend in an XY-direction, the maximum lateral dimensions (e.g., widths) in of the non-photoexposed regions216in an additional XY-direction oriented perpendicular to the XY-direction may be substantially the same as the distances between adjacent laterally diagonally oriented photoexposed regions218. Outermost lateral boundaries in the additional XY-direction of each of the non-photoexposed regions216may be substantially coplanar with outermost lateral boundaries in the additional XY-direction of each of the photoexposed regions218laterally adjacent thereto in the additional XY-direction. Each of the non-photoexposed regions216may exhibit substantially the same maximum width, or at least one of the non-photoexposed regions216may exhibit a different maximum width than at least one other of the non-photoexposed regions216.

Following the formation of the patterned photoresist material214including the non-photoexposed regions216and the photoexposed regions218, the patterned photoresist material214is subjected to at least one development process to selectively remove the photoexposed regions218relative to the non-photoexposed regions216, or to selectively remove the non-photoexposed regions216relative to the photoexposed regions218. Which of the non-photoexposed regions216and the photoexposed regions218is removed by the development process is selected at least partially based on the properties (e.g., material composition) of the structure(s) (e.g., the structures208) and/or material(s) (e.g., the intervening material204, if present) underlying (e.g., directly underlying) the patterned photoresist material214, and on predetermined processes (e.g., damascene processes, subtractive processes) of forming linear structures (e.g., conductive linear structures) substantially aligned with and connected to (e.g., electrically connected to, physically connected to) at least some adjacent structures208(e.g., adjacent structures208of rows of the structures208extending in the X-direction, adjacent structures208of columns of the structures208extending in the Y-direction, diagonally adjacent structures208of adjacent rows of the structures208or of adjacent columns of the structures208) based on the properties of the structure(s) and/or material(s) underlying the patterned photoresist material214, as described in further detail below.

As shown inFIG. 8A, in some embodiments, the development process substantially removes the non-photoexposed regions216(FIGS. 7A and 7C) of the patterned photoresist material214(FIGS. 7A and 7C), while at least partially (e.g., substantially) maintaining (e.g., keeping, preserving) the photoexposed regions218. For example, if the patterned photoresist material214comprises a negative tone resist, the development process may include developing the patterned photoresist material214with a positive tone developer to selectively remove the non-photoexposed regions216relative to the photoexposed regions218. Optionally, the patterned photoresist material214may be subjected to at least one post-exposure bake to increase the insolubility of the photoexposed regions218in the negative tone developer prior to the development process. Selectively removing the non-photoexposed regions216of the patterned photoresist material214relative to the photoexposed regions218may, for example, be performed when the material composition(s) of the structure(s) (e.g., the structures208) and/or material(s) (e.g., the intervening material204, if present) underlying (e.g., directly underlying) the patterned photoresist material214facilitate the subsequent formation of linear structures (e.g., conductive linear structures) through at least one subtractive process, as described in further detail below.FIG. 8Bis a top-down view of the semiconductor device structure200at the processing step depicted inFIG. 8A, wherein lateral boundaries of the structures208underlying the remaining photoexposed regions218are depicted with dashed lines.

As shown inFIG. 9A, in additional embodiments, the development process substantially removes the photoexposed regions218(FIGS. 7A and 7C) of the patterned photoresist material214(FIGS. 7A and 7C), while at least partially (e.g., substantially) maintaining (e.g., keeping, preserving) the non-photoexposed regions216. For example, if the patterned photoresist material214comprises a positive tone resist, the development process may include developing the patterned photoresist material214with a positive tone developer to selectively remove the photoexposed regions218relative to the non-photoexposed regions216. Optionally, the patterned photoresist material214may be subjected to at least one post-exposure bake to increase the solubility of the photoexposed regions218in the positive tone developer prior to the development process. Selectively removing the photoexposed regions218of the patterned photoresist material214relative to the non-photoexposed regions216may, for example, be performed when the material composition(s) of the structure(s) (e.g., the structures208) and/or material(s) (e.g., the intervening material204, if present) underlying (e.g., directly underlying) the patterned photoresist material214facilitate the subsequent formation of linear structures (e.g., conductive linear structures) through at least one damascene process, as described in further detail below.FIG. 9Bis a top-down view of the semiconductor device structure200at the processing step depicted inFIG. 9A.

Referring next toFIG. 10, following the removal of the non-photoexposed regions216(FIGS. 7A and 7C) or the photoexposed regions218(FIGS. 7A and 7C), the remaining photoexposed regions218(FIGS. 8A and 8B) or the remaining non-photoexposed regions216(FIGS. 9A and 9B) may be used to form linear structures222(e.g., line structures, linear routing structures) substantially aligned with, contacting (e.g., physically contacting, electrically contacting), and laterally extending between (e.g., in the X-direction, in the Y-direction, in an XY-direction) at least some adjacent structures208(e.g., adjacent structures208of rows of the structures208; adjacent structures208of columns of the structures208; adjacent structures208diagonally laterally positioned relative to one another, such as diagonally adjacent structures208of adjacent columns of the structures208, or diagonally adjacent structures208of adjacent rows of the structures208). The linear structures222may, for example, be electrically isolated from one another and may electrically connect at least some (e.g., all) structures208of individual rows of the structures208, at least some (e.g., all) structures208of individual columns of the structures208, or at least some (e.g., all) diagonally adjacent structures208substantially aligned with one another in an XY-direction. In some embodiments, the linear structures222each individually comprise at least one conductive material (e.g., one or more of a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, and a conductively doped semiconductor material). For example, if the structures208comprise a conductive material, the linear structures222may comprise the same conductive material as the structures208, or may comprise a different conductive material than the structures208. In some embodiments, the structures208and the linear structures222comprise substantially the same conductive material. In additional embodiments, one or more the linear structures222may comprise a different material, such as a semiconductive material or a dielectric material.

The linear structures222may exhibit lateral dimensions, lateral positions, and lateral orientations substantially corresponding to (e.g., substantially the same as) the lateral dimensions, lateral positions, and lateral orientations of the photoexposed regions218(FIGS. 7A and 7C) of the patterned photoresist material214(FIGS. 7A and 7C). Thus, the linear structures222may exhibit maximum widths substantially corresponding to maximum widths (e.g., the widths W2) of the structures208associated therewith. Accordingly, depending of the lateral orientations of the linear structures222, outermost lateral boundaries of the linear structures222in the Y-direction (e.g., if the linear structures222laterally extend between adjacent structures208in the X-direction), the X-direction (e.g., if the linear structures222laterally extend between adjacent structures208in the Y-direction), or an XY-direction (e.g., if the linear structures122laterally extend between adjacent structures108laterally diagonally positioned relative to one another) may be substantially coplanar with outermost lateral boundaries in the Y-direction, the X-direction, or the XY-direction of the adjacent structures208connected thereto. In addition, the linear structures222may be substantially aligned with the adjacent structures208connected thereto. For example, as shown inFIG. 10, in some embodiments, individual linear structures222are substantially aligned in the Y-direction with adjacent structures208of individual rows of the structures208extending in the X-direction. In additional embodiments, individual linear structures222are substantially aligned in the X-direction with adjacent structures208of individual columns of the structures208extending in the Y-direction. In further embodiments, individual linear structures222are substantially aligned in an XY-direction with adjacent structures208laterally diagonally positioned relative to one another.

In embodiments wherein the photoexposed regions218(FIGS. 8A and 8B) remain following the development process, a subtractive process may be used to form the linear structures222. By way of non-limiting example, referring toFIGS. 8A and 8B, if the intervening material204is present and comprises a conductive material (e.g., a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, a conductively doped semiconductor material), the pattern defined by the remaining photoexposed regions218may transferred into the intervening material204using at least one anisotropic etching process (e.g., at least one anisotropic dry etching process, such as at least one of reactive ion etching, deep reactive ion etching, plasma etching, reactive ion beam etching, and chemically assisted ion beam etching; at least one anisotropic wet etching process). During the anisotropic etching process, the remaining photoexposed regions218and unprotected (e.g., exposed) portions of the intervening material204may be simultaneously removed. The etch rate of the photoexposed regions218may be less than or equal to the etch rate of the intervening material204. The anisotropic etching process may substantially (e.g., completely) remove the unprotected (e.g., exposed) portions of the intervening material204, and the remaining portions of the intervening material204following the anisotropic etching process form the linear structures222(FIG. 10). The linear structures222may exhibit substantially the same lateral dimensions (e.g., lengths, widths) as the photoexposed regions218. Thereafter, an isolation material (e.g., a dielectric material) may be formed (e.g., deposited) between the linear structures222, and at least one polishing process (e.g., at least one CMP process) may be employed to remove portions of the photoexposed regions218and the isolation material positioned longitudinally above upper surfaces of the linear structures222.

In embodiments wherein the non-photoexposed regions216(FIGS. 9A and 9B) remain following the development process, a damascene process may be used to form the linear structures222. By way of non-limiting example, referring toFIGS. 9A and 9B, if the intervening material204is present and comprises a dielectric material (e.g., a dielectric oxide material, a dielectric nitride material, a dielectric oxynitride material, amphorous carbon, combinations thereof), at least one material removal process (e.g., at least one of a wet etching process and a dry etching process) may be used to transfer the pattern defined by the remaining non-photoexposed regions216into the intervening material204to form trenches therein. The material removal process may at least partially (e.g., substantially) remove the unprotected (e.g., exposed) portions of the intervening material204. Thereafter, the trenches may be filled (e.g., through one or more material deposition processes, such as a blanket material deposition process) with a conductive material (e.g., a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, a conductively doped semiconductor material), and at least one polishing process (e.g., at least one CMP process) may be used to remove portions of the conductive material, the non-photoexposed regions216, and the structures208positioned longitudinally above upper boundaries of the trenches to form the linear structures222. The linear structures222may exhibit substantially the same lateral dimensions (e.g., lengths, widths) as the photoexposed regions218(FIGS. 7A and 7C) of the patterned photoresist material214(FIGS. 7A and 7C).

Following the formation of the linear structures222, the semiconductor device structure200may be subjected to additional processing (e.g., additional deposition processes, additional material removal processes), as desired. The additional processing may be conducted by conventional processes and conventional processing equipment, and is not illustrated or described in detail herein.

Thus, in accordance with embodiments of the disclosure, a method of forming a semiconductor device structure comprises forming a preliminary structure comprising a substrate, a photoresist material over the substrate, and structures longitudinally extending from a lower surface of the photoresist material and at least partially into the substrate. The preliminary structure is exposed to electromagnetic radiation directed toward an upper surface of the photoresist material at an angle non-orthogonal to the upper surface to form a patterned photoresist material. At least a portion of the electromagnetic radiation is transmitted through the photoresist material and is reflected off upper surfaces of the structures to transmit the portion of the electromagnetic radiation back through regions of the photoresist material. The patterned photoresist material is developed to selectively remove some regions of the patterned photoresist material relative to other regions of the patterned photoresist material. Linear structures substantially laterally aligned with at least some of the structures are formed using the other regions of the patterned photoresist material.

FIGS. 11 through 13, includingFIGS. 12A and 12B, are perspective, partial cross-sectional (i.e.,FIGS. 11, 12A, and 13), and top-down (i.e.,FIG. 12B) views illustrating embodiments of another method of forming a semiconductor device structure, such as a structure of a memory device (e.g., a RAM device, a ROM device, a DRAM device, an SDRAM device, a Flash memory device, a RRAM device, a conductive bridge RAM device, an MRAM device, a PCM memory device, a PCRAM device, an STT-RAM device, an oxygen vacancy-based memory device, a programmable conductor memory device, etc.). With the description provided below, it will be readily apparent to one of ordinary skill in the art that the method described herein may be used in various devices (e.g., photonic devices, electronic devices, electronic-photonic devices, semiconductor devices). In other words, the methods of the disclosure may be used whenever it is desired to form a device including one or more linear structures substantially aligned with other structures.

Referring toFIG. 11, a semiconductor device structure300may include a substrate302, a thermoresist material306on or over the substrate302, and structures308(e.g., contact structures, vertical interconnect structures, plug structures) longitudinally extending from a lower boundary (e.g., a lower surface) of the thermoresist material306and at least partially (e.g., substantially) into the substrate302. Optionally, the semiconductor device structure300may also include at least one intervening material304positioned longitudinally between the substrate302and the thermoresist material306. The intervening material304may, for example, be located on an upper surface of the substrate302, and the thermoresist material306may be located on an upper surface of the intervening material304. If the intervening material304is present, the structures308may longitudinally extend from an interface of the intervening material304and the thermoresist material306, completely through the intervening material304, and at least partially (e.g., substantially) into the substrate302. In additional embodiments, the structures308may at least partially longitudinally extend through the thermoresist material306. By way of non-limiting example, the structures308may longitudinally extend completely through each of the thermoresist material306and the intervening material304, and at least partially (e.g., substantially) into the substrate302. The substrate302and the intervening material304(if present) may respectively have material compositions substantially similar to the those of the substrate102and the intervening material104previously described with reference toFIG. 1.

The thermoresist material306may be formed of and include a conventional thermoresist, such as a conventional positive tone thermoresist, or a conventional negative tone thermoresist. If the thermoresist material306comprises a positive tone thermoresist, the thermoresist material306may be formulated such that regions thereof heated to at least a minimum threshold temperature become at least partially soluble in a suitable developer (e.g., a positive tone developer). Thermally exposed regions (e.g., regions heated to the minimum threshold temperature) of the thermoresist material306may be at least partially (e.g., substantially) removed by the developer while non-thermally exposed regions (e.g., regions not heated to the minimum threshold temperature) may remain substantially intact (e.g., not substantially removed), as described in further detail below. Alternatively, if the thermoresist material306comprises a negative tone thermoresist, the thermoresist material306may be formulated such that regions thereof not heated to a minimum threshold temperature are at least partially soluble in a suitable developer (e.g., a negative tone developer). Non-thermally exposed regions of the thermoresist material306may be at least partially (e.g., substantially) removed by the developer while thermally exposed regions may remain substantially intact (e.g., not substantially removed), as also described in further detail below. The properties (e.g., tone) of the thermoresist material306may be selected relative to material composition of the structure(s) (e.g., the structures308) and/or material(s) (e.g., intervening material304, if present) underlying the thermoresist material306to facilitate desired patterning of the structure(s) and/or material(s), as described in further detail below. Suitable thermoresist materials (e.g., positive tone thermoresists, negative tone thermoresists) are known in the art, and are, therefore, not described in detail herein. The thermoresist material306may exhibit any thickness conducive to the formation of a patterned thermoresist material from the thermoresist material306through exposing the thermoresist material306and the structures308to beams of radiation, as described in further detail below.

The structures308may be formed of and include at least one material (e.g. one or more of a conductive material, a dielectric material, and a semiconductive material) that absorbs one or more wavelengths of electromagnetic radiation to which the semiconductor device structure300is subsequently exposed to generate and emit thermal radiation. The thermal radiation emitted from the structures308patterns the thermoresist material306. As described in further detail below, the electromagnetic radiation absorption and surface emissivity characteristics of the structures308may permit predetermined regions of the thermoresist material306to be heated to at least a minimum threshold temperature facilitating desired thermal exposure of the predetermined regions relative to other regions of the thermoresist material306. In some embodiments, the structures308comprise at least one conductive material, such as one or more of a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, and a conductively doped semiconductor material. By way of non-limiting example, the structures308may comprise one or more of W, WN, Ni, Ta, TaN, TaSi, Pt, Cu, Ag, Au, Al, Mo, Ti, TiN, TiSi, TiSiN, TiAlN, MoN, Ir, IrOx, Ru, RuOx, and conductively doped silicon. A material composition of the structures308may be substantially the same as or may be different than a material composition of the intervening material304(if present) and/or the substrate302.

As shown inFIG. 11, upper surfaces of the structures308may be substantially coplanar with lower surfaces of the thermoresist material306and upper surfaces of the intervening material304(if present). Put another way, the thermoresist material306may be substantially free of portions of the structures308longitudinally extending (e.g., in the Z-direction) at least partially therethrough. In additional embodiments, upper surfaces of the structures308may be non-coplanar with lower surfaces of the thermoresist material306and upper surfaces of the intervening material304(if present). Put another way, the structures308may at least partially (e.g., substantially) longitudinally extend (e.g., in the Z-direction) through the thermoresist material306. Aside from the longitudinal dimensions of the structures308, the structures308each individually exhibit dimensions (e.g., lateral dimensions, such as lengths and widths) and shapes substantially similar to one or more of the dimensions and shapes of the structures108previously described with reference toFIG. 1. Each of the structures308may exhibit substantially the same dimensions and substantially the same shape as each other of the structures308, or one or more of the structures308may exhibit at least one different dimension and/or a different shape than one or more other of the structures308. As shown inFIG. 11, in some embodiments, each of the structures308exhibits a width W3(e.g., diameter) and a cylindrical column shape including a substantially circular lateral cross-sectional geometry.

The alignment of the structures308may be substantially similar to the alignment of the structures108previously described with reference toFIG. 1. As shown inFIG. 11, in some embodiments, the semiconductor device structure300includes rows of the structures308extending in an X-direction and columns of the structures308extending in a Y-direction substantially perpendicular to the X-direction. The structures308within each row may be substantially aligned with one another, and the structures308within each column may also be substantially aligned with one another. In additional embodiments, at least partially depending on a desired configuration of a patterned thermoresist material to be formed using the structures308, at least some adjacent structures308most proximate one another in the X-direction may be unaligned with (e.g., offset from) one another in the Y-direction, and/or at least some adjacent structures308most proximate one another in the Y-direction may be unaligned with (e.g., offset from) one another in the X-direction.

The structures308may exhibit any desired spacing relative to one another facilitating the formation of a patterned thermoresist material exhibiting desired feature dimensions, shapes, and spacing by exposing the semiconductor device structure300to beams of electromagnetic radiation (e.g., beams of IR radiation), as described in further detail below. As shown inFIG. 11, adjacent structures308within each row of the structures308may be substantially uniformly (e.g., substantially regularly) spaced apart from one another by a first distance D5, and adjacent structures308within each column of the structures308may be substantially uniformly (e.g., substantially regularly) spaced apart from one another by a second distance D6. The first distance D5may be substantially the same as the second distance D6, or the first distance D5may be different than the second distance D6. Accordingly, a pitch between centers of adjacent structures308within each of the rows may be substantially constant (e.g., non-variable), and a pitch between centers of adjacent structures308within each of the columns may also be substantially constant (e.g., non-variable). In additional embodiments, at least some adjacent structures308within at least one row of the structures308are spaced apart from one another by a different distance than at least some other adjacent structures308within the row, and/or at least some adjacent structures308within at least one column of the structures308are spaced apart from one another by a different distance than at least some other adjacent structures308within the column. Accordingly, a pitch between centers of at least some adjacent structures308within at least one row may be different than a pitch between centers of at least some other adjacent structures308within the row, and/or a pitch between centers of at least some adjacent structures308within at least one column may be different than a pitch between centers of at least some other adjacent structures308within the column.

Each of the substrate302, the intervening material304(if present), the thermoresist material306, and the structures308may be formed using conventional processes including, conventional material deposition processes (e.g., conventional PVD processes, such as sputtering, evaporation, or ionized PVD; conventional CVD processes; conventional ALD processes; conventional spin-coating processes), conventional photolithography processes, and conventional material removal processes (e.g., conventional etching processes, such as conventional dry etching processes and conventional wet etching processes; conventional polishing processes, such as conventional CMP processes). Such processes are known in the art and, therefore, are not described in detail herein.

Referring next toFIG. 12A, the semiconductor device structure300is selectively exposed to beams (e.g., rays, waves) of electromagnetic radiation312directed through at least one mask324from one or more radiation sources to form a patterned thermoresist material314including non-thermally exposed regions316and thermally exposed regions318.FIG. 12Bis a top-down view of the semiconductor device structure300at the processing stage depicted inFIG. 12A, wherein lateral boundaries of the structures308underlying the patterned thermoresist material314and the mask324are depicted with dashed lines.

Depending at least on the tone (e.g., positive tone, or negative tone) of the thermoresist material306(FIG. 11), the non-thermally exposed regions316of the patterned thermoresist material314comprise regions of the patterned thermoresist material314not heated to at least a minimum threshold temperature to facilitate either the substantially complete removal of the regions upon subsequent development (e.g., if the thermoresist material306comprises a positive tone thermoresist material and the developer employed in the subsequent development comprises positive tone developer) or the at least partial (e.g., substantial) maintenance (e.g., preservation, non-removal) of the regions upon subsequent development (e.g., if the thermoresist material306comprises a negative tone thermoresist material and the developer employed in the subsequent development comprises negative tone developer). Accordingly, the thermally exposed regions318of the patterned thermoresist material314comprise additional regions of the patterned thermoresist material314heated to at least a minimum threshold temperature to facilitate either the substantially complete removal of the additional regions upon subsequent development or the at least partial (e.g., substantial) maintenance of the additional regions upon subsequent development. Whether the non-thermally exposed regions316comprise regions of the patterned thermoresist material314to be substantially removed through subsequent development or comprise regions of the patterned thermoresist material314to be substantially maintained through subsequent development may at least partially depend on the material composition of the intervening material304(if present) to facilitate desired patterning of the intervening material304through one or more subsequent processes (e.g., one or more subsequent subtractive processes, or one or more subsequent damascene processes), as described in further detail below.

The mask324may comprise a conventional mask exhibiting a desired pattern to be transferred to the thermoresist material306(FIG. 11). The mask324may, for example, include features (e.g., apertures, regions) having lateral dimensions, shapes, positions, and orientations facilitating desired lateral dimensions, shapes, positions, and orientations of the non-thermally exposed regions316and thermally exposed regions318of the patterned thermoresist material314. As shown inFIGS. 12A and 12B, in some embodiments, the mask324includes apertures sized, shaped, oriented, and positioned to expose at least some (e.g., all) adjacent structures308of individual rows of the structures308extending in the X-direction to the beams of electromagnetic radiation312transmitted therethrough. In additional embodiments, the mask324includes apertures sized, shaped, oriented, and positioned to expose at least some (e.g., all) adjacent structures308of individual columns of the structures308extending in the Y-direction to the beams of electromagnetic radiation312transmitted therethrough. In further embodiments, the mask324includes apertures sized, shaped, oriented, and positioned to expose at least some (e.g., all) diagonally adjacent structures108substantially aligned with one another in an XY-direction to the beams of electromagnetic radiation312transmitted therethrough. The mask324having the desired pattern may be formed and positioned by conventional processes, which are not described in detail herein.

Referring toFIG. 12B, as the beams of electromagnetic radiation312exiting the mask324are transmitted through the thermoresist material306(FIG. 11), a portion of the beams of electromagnetic radiation312are absorbed by and heat the structures308. Thermal radiation326is then isotropically emitted from surfaces of the structures308into portions of the thermoresist material306adjacent thereto to selectively heat the portions of the thermoresist material306. The thermal radiation326isotropically emitted from the surfaces of the structures308enhances thermal exposure within the portions of thermoresist material306relative to other portions of the thermoresist material306and forms the patterned thermoresist material314including the thermally exposed regions318(i.e., corresponding to the portions of the thermoresist material306receiving the thermal radiation326from the structures308) and the non-thermally exposed regions316(i.e., corresponding to the other portions of the thermoresist material306that do not receive the thermal radiation326from the structures308). The thermal radiation326isotropically emitted from the structures308heats the portions of the thermoresist material306adjacent thereto to at least the minimum threshold temperature permitting the thermally exposed regions318of the patterned thermoresist material314to have a different solubility in a developer (e.g., a positive tone develop, a negative tone developer) than the non-thermally exposed regions316of the patterned thermoresist material314during subsequent development of the patterned thermoresist material314.

With continued reference toFIG. 12B, as the thermal radiation326is isotropically emitted from the structures308at least some paths of the thermal radiation326emitted by adjacent structures308(e.g., adjacent structures308of individual rows of the structures308, or adjacent structures of individual columns of the structures) intersect with one another. The intersecting paths of the emitted thermal radiation326(and, hence, thermal exposure) may permit the thermally exposed regions318of the patterned thermoresist material314to be substantially aligned with and continuously laterally extend between the adjacent structures308.

The semiconductor device structure300, including the thermoresist material306and the structures308, may be exposed to any wavelength(s) of electromagnetic radiation (e.g., UV radiation, IR radiation, visible radiation) from the radiation sources that can be substantially transmitted through the thermoresist material306, and that can be at least partially (e.g., substantially) absorbed by the structures308exposed thereto to generate and emit the thermal radiation326. By way of non-limiting example, the beams of electromagnetic radiation312may each individually have a wavelength within the IR spectrum, such as a wavelength within a range of from about 700 nm to about 1 mm. In addition, the semiconductor device structure300may be exposed to a single (e.g., only one) dose of electromagnetic radiation, or may be exposed to multiple (e.g., more than one) doses of electromagnetic radiation. If multiple doses of electromagnetic radiation are utilized, each of the multiple doses of electromagnetic radiation may be substantially the same (e.g., substantially the same radiation wavelength(s) and duration), or at least one of the multiple doses of electromagnetic radiation may be different than (e.g., different radiation wavelength(s) and/or different durations) at least one other of the multiple doses of electromagnetic radiation.

Depending on the configurations and positions of the mask324and the structures308, the non-thermally exposed regions316and thermally exposed regions318of the patterned thermoresist material314may extend in substantially the same lateral direction (e.g., in the X-direction; in the Y-direction; in an XY-direction angled relative to the X-direction and the Y-direction, such as a lateral direction oriented at an angle between 0 degree and 90 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 10 degrees and to about 80 degrees relative to one or more of the X-direction and the Y-direction, a lateral direction oriented at an angle within a range of from about 30 degrees and to about 60 degrees relative to one or more of the X-direction and the Y-direction, or a lateral direction oriented at an angle of about 45 degrees relative to each of the X-direction and the Y-direction). In addition, the non-thermally exposed regions316may laterally intervene (e.g., in the Y-direction if the non-thermally exposed regions316and the thermally exposed regions318extend in the X-direction; in the X-direction if the non-thermally exposed regions316and the thermally exposed regions318extend in the Y-direction; in an additional XY-direction extending perpendicular to an XY-direction if the non-thermally exposed regions316and the thermally exposed regions318extend in the XY-direction) between the thermally exposed regions318. As shown inFIG. 12B, in some embodiments, the thermally exposed regions318are substantially laterally aligned (in the Y-direction) with rows of the structures308extending in the X-direction, and the non-thermally exposed regions316are laterally offset (in the Y-direction) from the rows of the structures308. The thermally exposed regions318may laterally extend in parallel with one another and the non-thermally exposed regions316in the X-direction, and may laterally alternate with the non-thermally exposed regions316in the Y-direction. In additional embodiments, the thermally exposed regions318are substantially laterally aligned (in the X-direction) with columns of the structures308extending in the Y-direction, and the non-thermally exposed regions316are laterally offset (in the X-direction) from the columns of the structures308. The thermally exposed regions318may laterally extend in parallel with one another and the non-thermally exposed regions316in the Y-direction, and may laterally alternate with the non-thermally exposed regions316in the X-direction. In further embodiments, the thermally exposed regions318are substantially laterally aligned (in an XY-direction) with adjacent structures308laterally diagonally positioned relative to one another. The thermally exposed regions318may laterally extend in parallel with one another and the non-thermally exposed regions316in an XY-direction, and may laterally alternate with the non-thermally exposed regions316in an additional XY-direction oriented perpendicular to the XY-direction.

As shown inFIGS. 12A and 12B, the thermally exposed regions318of the patterned thermoresist material314may longitudinally overly (e.g., in the Z-direction) and laterally extend substantially continuously between adjacent structures308(e.g., adjacent structures308of individual rows of the structures308if the thermally exposed regions318laterally extend in the X-direction, adjacent structures308individual columns of the structures308if the thermally exposed regions318laterally extend in the Y-direction, diagonally adjacent structures308if the thermally exposed regions318laterally extend in an XY-direction). For example, the thermally exposed regions318of the patterned thermoresist material314may directly contact and extend continuously between of adjacent structures308of individual rows of the structures308, adjacent structures308of individual columns of the structures308, or diagonally adjacent structures308of adjacent rows of the structures308or of adjacent columns of the structures308. The thermally exposed regions318of the patterned thermoresist material314may laterally extend substantially continuously across the patterned thermoresist material314in the same direction as individual rows of the structures308thereunder, in the same direction as individual columns of the structures308thereunder, or in the same direction as diagonally adjacent structures308thereunder. Accordingly, at least in embodiments wherein the structures308are formed of and include a conductive material, the thermally exposed regions318may facilitate the subsequent formation of conductive linear structures extending substantially continuously between and electrically connecting at least some (e.g., all) structures308of individual rows of the structures308, at least some (e.g., all) structures308of individual columns of the structures308, or at least some (e.g., all) diagonally adjacent structures308substantially aligned with one another in an XY-direction, as described in further detail below. In addition, the non-thermally exposed regions316of the patterned thermoresist material314may laterally extend substantially continuously across the patterned thermoresist material314in the same direction (e.g., the X-direction, the Y-direction, and XY-direction) as the thermally exposed regions318.

Referring toFIG. 12B, in some embodiments, the thermally exposed regions318of the patterned thermoresist material314exhibit widths W4greater than the widths W3of the structures308associated therewith (e.g., laterally aligned with and longitudinally underlying the thermally exposed regions318). For example, if the thermally exposed regions318are formed to laterally extend in the X-direction, the maximum lateral dimensions (e.g., the widths W4) in the Y-direction of the thermally exposed regions318may be greater than the maximum lateral dimensions (e.g., the widths W3) in the Y-direction of the structures308associated therewith. As another example, if the thermally exposed regions318are formed to laterally extend in the Y-direction, the maximum lateral dimensions (e.g., the widths W4) in the X-direction of the thermally exposed regions318may be greater than the maximum lateral dimensions (e.g., the widths W3) in the X-direction of the structures308associated therewith (e.g., laterally aligned with and longitudinally underlying the thermally exposed regions318). As a further example, if the thermally exposed regions318are formed to laterally extend in an XY-direction, the maximum lateral dimensions (e.g., widths) in an additional XY-direction perpendicular to the XY-direction may be greater than the maximum lateral dimensions in the additional XY-direction of the structures308associated therewith. In additional embodiments, the widths W4of the thermally exposed regions318of the patterned thermoresist material314are substantially the same as the widths W3of the structures308associated therewith. Outermost lateral boundaries in the X-direction, the Y-direction, or an XY-direction of each of the thermally exposed regions318may be substantially coplanar with outermost lateral boundaries in the X-direction, the Y-direction, or the XY-direction of each of the structures308associated therewith. The thermally exposed regions318may be formed to exhibit desired widths W4by controlling the configuration and position of the mask324(including the dimensions and positions of the features thereof) relative to the configurations and positions of at least the structures308and the thermoresist material306(FIG. 11) and the properties of the beams of electromagnetic radiation312emitted from the radiation sources. Each of the thermally exposed regions318may exhibit substantially the same maximum width (e.g., substantially the same width W4), or at least one of the thermally exposed regions318may exhibit a different maximum width than at least one other of the thermally exposed regions318.

Following the formation of the patterned thermoresist material314including the non-thermally exposed regions316and the thermally exposed regions318, the patterned thermoresist material314is subjected to at least one development process to selectively remove the thermally exposed regions318relative to the non-thermally exposed regions316, or to selectively remove the non-thermally exposed regions316relative to the thermally exposed regions318. Which of the non-thermally exposed regions316and the thermally exposed regions318is removed by the development process is selected at least partially based on the properties (e.g., material composition) of the structure(s) (e.g., the structures308) and/or material(s) (e.g., the intervening material304, if present) underlying (e.g., directly underlying) the patterned thermoresist material314, and on predetermined processes (e.g., damascene processes, subtractive processes) of forming linear structures (e.g., conductive linear structures) substantially aligned with and connected to (e.g., electrically connected to, physically connected to) at least some adjacent structures308(e.g., adjacent structures308of rows of the structures308extending in the X-direction, adjacent structures308of columns of the structures308extending in the Y-direction, diagonally adjacent structures308of adjacent rows of the structures308or of adjacent columns of the structures308) based on the properties of the structure(s) and/or material(s) underlying the patterned thermoresist material314, as described in further detail below.

In some embodiments, the development process substantially removes the non-thermally exposed regions316of the patterned thermoresist material314, while at least partially (e.g., substantially) maintaining (e.g., keeping, preserving) the thermally exposed regions318. For example, if the patterned thermoresist material314comprises a negative tone resist, the development process may include developing the patterned thermoresist material314with a negative tone developer to selectively remove the non-thermally exposed regions316relative to the thermally exposed regions318. Selectively removing the non-thermally exposed regions316of the patterned thermoresist material314relative to the thermally exposed regions318may, for example, be performed when the material composition(s) of the structure(s) (e.g., the structures308) and/or material(s) (e.g., the intervening material304, if present) underlying (e.g., directly underlying) the patterned thermoresist material314facilitate the subsequent formation of linear structures (e.g., conductive linear structures) through at least one subtractive process, as described in further detail below.

In additional embodiments, the development process substantially removes the thermally exposed regions318of the patterned thermoresist material314, while at least partially (e.g., substantially) maintaining (e.g., keeping, preserving) the non-thermally exposed regions316. For example, if the patterned thermoresist material314comprises a positive tone resist, the development process may include developing the patterned thermoresist material314with a positive tone developer to selectively remove the thermally exposed regions318relative to the non-thermally exposed regions316. Selectively removing the thermally exposed regions318of the patterned thermoresist material314relative to the non-thermally exposed regions316may, for example, be performed when the material composition(s) of the structure(s) (e.g., the structures308) and/or material(s) (e.g., the intervening material304, if present) underlying (e.g., directly underlying) the patterned thermoresist material314facilitate the subsequent formation of linear structures (e.g., conductive linear structures) through at least one damascene process, as described in further detail below.

Referring next toFIG. 13, following the removal of the non-thermally exposed regions316(FIGS. 12A and 12B) or the thermally exposed regions318(FIGS. 12A and 12B), the remaining thermally exposed regions318or the remaining non-thermally exposed regions316may be used to form linear structures322(e.g., line structures, linear routing structures) substantially aligned with, contacting (e.g., physically contacting, electrically contacting), and laterally extending between (e.g., in the X-direction, in the Y-direction, in an XY-direction) at least some adjacent structures308(e.g., adjacent structures308of rows of the structures308; adjacent structures308of columns of the structures308; adjacent structures308diagonally laterally positioned relative to one another, such as diagonally adjacent structures308of adjacent columns of the structures308, or diagonally adjacent structures308of adjacent rows of the structures308). The linear structures322may, for example, be electrically isolated from one another and may electrically connect at least some (e.g., all) structures308of individual rows of the structures308, at least some (e.g., all) structures308of individual columns of the structures308, or at least some (e.g., all) diagonally adjacent structures308substantially aligned with one another in an XY-direction. In some embodiments, the linear structures322each individually comprise at least one conductive material (e.g., one or more of a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, and a conductively doped semiconductor material). For example, if the structures308comprise a conductive material, the linear structures322may comprise the same conductive material as the structures308, or may comprise a different conductive material than the structures308. In some embodiments, the structures308and the linear structures322comprise substantially the same conductive material. In additional embodiments, one or more the linear structures322may comprise a different material, such as a semiconductive material or a dielectric material.

The linear structures322may exhibit lateral dimensions, lateral positions, and lateral orientations substantially corresponding to (e.g., substantially the same as) the lateral dimensions, lateral positions, and lateral orientations of the thermally exposed regions318(FIGS. 12A and 12B) of the patterned thermoresist material314(FIGS. 12A and 12B). In addition, the linear structures322may be substantially aligned with the adjacent structures308connected thereto. For example, as shown inFIG. 13, in some embodiments, individual linear structures322are substantially aligned in the Y-direction with adjacent structures308of individual rows of the structures308extending in the X-direction. In additional embodiments, individual linear structures322are substantially aligned in the X-direction with adjacent structures308of individual columns of the structures308extending in the Y-direction. In further embodiments, individual linear structures322are substantially aligned in an XY-direction with adjacent structures308laterally diagonally positioned relative to one another.

In embodiments wherein the thermally exposed regions318(FIGS. 12A and 12B) remain following the development process, a subtractive process may be used to form the linear structures322. By way of non-limiting example, if the intervening material304is present and comprises a conductive material (e.g., a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, a conductively doped semiconductor material), the pattern defined by the remaining thermally exposed regions318may transferred into the intervening material304using at least one anisotropic etching process (e.g., at least one anisotropic dry etching process, such as at least one of reactive ion etching, deep reactive ion etching, plasma etching, reactive ion beam etching, and chemically assisted ion beam etching; at least one anisotropic wet etching process). During the anisotropic etching process, the remaining thermally exposed regions318and unprotected (e.g., exposed) portions of the intervening material304may be simultaneously removed. The etch rate of the thermally exposed regions318may be less than or equal to the etch rate of the intervening material304. The anisotropic etching process may substantially (e.g., completely) remove the unprotected (e.g., exposed) portions of the intervening material304, and the remaining portions of the intervening material304following the anisotropic etching process form the linear structures322. The linear structures322may exhibit substantially the same lateral dimensions (e.g., lengths, widths) as the thermally exposed regions318of the patterned thermoresist material314(FIGS. 12A and 12B). Thereafter, an isolation material (e.g., a dielectric material) may be formed (e.g., deposited) between the linear structures322, and at least one polishing process (e.g., at least one CMP process) may be employed to remove portions of the thermally exposed regions318and the isolation material positioned longitudinally above upper surfaces of the linear structures322.

In embodiments wherein the non-thermally exposed regions316(FIGS. 12A and 12B) remain following the development process, a damascene process may be used to form the linear structures322. By way of non-limiting example, if the intervening material304is present and comprises a dielectric material (e.g., a dielectric oxide material, a dielectric nitride material, a dielectric oxynitride material, amphorous carbon, combinations thereof), at least one material removal process (e.g., at least one of a wet etching process and a dry etching process) may be used to transfer the pattern defined by the remaining non-thermally exposed regions316into the intervening material304to form trenches therein. The material removal process may at least partially (e.g., substantially) remove the unprotected (e.g., exposed) portions of the intervening material304. Thereafter, the trenches may be filled (e.g., through one or more material deposition processes, such as a blanket material deposition process) with a conductive material (e.g., a metal, a metal alloy, a conductive metal oxide, a conductive metal nitride, a conductive metal silicide, a conductively doped semiconductor material), and at least one polishing process (e.g., at least one CMP process) may be used to remove portions of the conductive material, the non-thermally exposed regions316, and the structures308positioned longitudinally above upper boundaries of the trenches to form the linear structures322. The linear structures322may exhibit substantially the same lateral dimensions (e.g., lengths, widths) as the thermally exposed regions318of the patterned thermoresist material314(FIGS. 12A and 12B).

Following the formation of the linear structures322, the semiconductor device structure300may be subjected to additional processing (e.g., additional deposition processes, additional material removal processes), as desired. The additional processing may be conducted by conventional processes and conventional processing equipment, and is not illustrated or described in detail herein.

Thus, in accordance with embodiments of the disclosure, a method of forming a semiconductor device structure comprises forming a preliminary structure comprising a substrate, a thermoresist material over the substrate, and structures longitudinally extending from a lower surface of the thermoresist material and at least partially into the substrate. The preliminary structure is exposed to electromagnetic radiation through a mask to form a patterned thermoresist material. At least a portion of the electromagnetic radiation is transmitted through the thermoresist material and is absorbed by a portion of the structures to produce heat that is then emitted from the portion of the structures into regions of the thermoresist material adjacent thereto. The patterned thermoresist material is developed to selectively remove some regions of the patterned thermoresist material relative to other regions of the patterned thermoresist material. Linear structures substantially laterally aligned with at least some of the structures are formed using the other regions of the patterned thermoresist material.

The methods of the disclosure facilitate the simple, efficient, and cost-effective formation of a variety of semiconductor device structures, such as memory device structures. The methods facilitate self-alignment of linear structures (e.g., the linear structures122,222,322) with multiple other structures (e.g., the structures108,208,308), and may avoid or relax overlay constraints as compared to conventional methods of forming similar line-structures over similar non-linear structures. The methods of the disclosure may reduce the number of processing acts (e.g., alignment and masking acts), materials, and structures required to form the semiconductor device structures as compared to conventional methods of forming the semiconductor device structures, and may facilitate improved pattern quality, lower costs, greater packaging density, and increased miniaturization of components as compared to conventional methods. Semiconductor device structures formed by the methods of the disclosure may exhibit feature dimensions at least equivalent to those of semiconductor device structures formed by conventional methods.