The present invention relates to image sensors formed of CMOS transistors and fabricated on a semiconductor-on-insulator (SOI) structures, and methods of manufacturing same.
CMOS image sensors are used for a variety of camera products such as digital still cameras, cell phone cameras, automotive cameras and security cameras. CMOS technology is attractive for use in such applications because CMOS transistors exhibit low power consumption characteristics and are fabricated at relatively low manufacturing costs. The achievable pixel size of CMOS image sensors has been steadily decreasing as the technology matures and, thus, higher resolution images are available from increasingly smaller camera product packages. As the pixel size decreases, however, there is a corresponding degradation in the photodiode sensitivity of each pixel, lowering of optical collection efficiency, and increased electrical crosstalk within and between pixels. In addition, the red/green/blue color filtering function (color separation) becomes more challenging as the pixel size decreases.
The above problems are typically associated with a conventional CMOS image sensor that has been fabricated in bulk silicon. There has been some effort in the prior art to develop CMOS image sensors having various pixel structures to address one or more of these problems. Such pixel structures include the use of silicon on a transparent insulator substrate to allow for reduced electrical crosstalk and improved optical collection efficiency. In another case, an improvement in resolution attributable to the color separation function was achieved using vertically stacked wavelength sensor layers in a bulk silicon wafer.
The prior art attempts to address the problems of lower photodiode sensitivity, lower optical collection efficiency, increased electrical crosstalk, and poor color separation in CMOS image sensors, while admirable, have not addressed enough of the problems in one, integrated solution. Thus, there are needs in the art for new methods and apparatus for fabricating CMOS image sensors.
In accordance with one or more embodiments disclosed herein, methods and apparatus result in novel CMOS pixel structures fabricated on SOI substrates, such as silicon on glass ceramic (SiOGC), a novel color separation technique, and an integrated retro-reflection technique, all of which collectively address the issues of photodiode sensitivity, optical collection efficiency, electrical crosstalk, and color separation.
Methods and apparatus provide for a CMOS image sensor, comprising: a glass or glass ceramic substrate having first and second spaced-apart major surfaces; a semiconductor layer disposed on the first surface of the glass or glass ceramic substrate; and a plurality of pixel structures formed in the semiconductor layer. Each pixel structure may include: at least first, second, and third semiconductor islands, each island operating as a color sensitive photo-detector and each being of a different thickness such that each is sensitive to a respective range of light wavelengths, and a fourth semiconductor island on which at least one transistor is disposed, the at least one transistor operating to at least one of buffer, select, and reset one or more of the photo-detectors.
The first semiconductor island may be of a first thickness, between about 0.05 um and about 1.80 um, for detecting blue light. The second semiconductor island may be of a second thickness between about 0.20 um and about 4.70 um for detecting composite blue and green light. The third semiconductor island may be of a third thickness between about 0.55 um and about 12.10 um for detecting composite blue and green and red light. These thicknesses assume that the light is absorbed by somewhere between about 10% on the low side and 90% on the high side in one pass of the light into the respective semiconductor islands.
A retro-reflector may be employed to reflect light that propagates through a second surface of the glass or glass ceramic substrate, opposite to the first surface thereof, and through at least one of the first, second, and third semiconductor islands, at least partially back therethrough. The retro-reflector improves light absorptions characteristics of the pixel structures and may, among other things, permit a reduction in the thicknesses of the first, second, and third semiconductor islands. For example, the above ranges of thickness may be reduced by a factor of about ½. The retro-reflector may be implemented via contact metallization layer(s) disposed on the first, second, and/or third semiconductor islands.
The semiconductor layer of the CMOS image sensor may be formed from a first semiconductor layer bonded to the first surface of the glass or glass ceramic substrate via anodic bonding and a second semiconductor layer formed on the first semiconductor layer via epitaxial growth.
The substrate of the CMOS image sensor may be a glass ceramic substrate, operating to withstand CMOS processing temperatures of at least 950° C. or more.
Other aspects, features, advantages, etc. will become apparent to one skilled in the art when the description of the invention herein is taken in conjunction with the accompanying drawings.
For the purposes of illustrating the various aspects of the invention, there are shown in the drawings forms that are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
A CMOS image sensor in accordance with various aspects of the present invention may be implemented in a semiconductor material, such as silicon, using CMOS very-large-scale-integration (VLSI) compatible fabrication processes. One or more embodiments disclosed herein contemplate the implementation of a CMOS image sensor on an SOG substrate, such as a silicon on glass ceramic (SiOGC) substrate. The SOG substrate is compatible with CMOS fabrication process steps, and permits color-selective sub-pixel photodetectors and readout transistor circuitry to be implemented in the semiconductor (e.g., silicon) layer. The transparent glass (or glass ceramic) portion of the SOG supports backside illumination and the benefits thereof.
With reference to the drawings, wherein like numerals indicate like elements, there is shown in
By way of example, and not limitation, a circuit diagram of a pixel structure 106 suitable for implementing a given one of the pixel structures 106 is illustrated in
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The first, second, third, and fourth semiconductor islands 104A, 104B, 104C, and 104D are isolated from one another via physical trenches A, B, C, which may include a dielectric material, such as silica, disposed therein. The particular thicknesses of the first, second, and third semiconductor islands 104A, 104B, and 104C are established to create color sensitivity in the photo-detection function. The first semiconductor island 104A may be of a first thickness, between about 0.05 um and about 1.80 um, for detecting blue light. The second semiconductor island 104B may be of a second thickness between about 0.20 um and about 4.70 um for detecting composite blue and green light. The third semiconductor island 104C may be of a third thickness between about 0.50 um and about 12.10 um for detecting composite blue and green and red light. These thicknesses assume that the light is absorbed by somewhere between about 10% on the low side and 90% on the high side in one pass of the light into the respective semiconductor islands.
With the above configuration, light is received into the pixel structure 106 via the second surface 102B of the glass or glass ceramic substrate 102. The light then enters into the respective first, second, and third semiconductor islands (photo-detectors) 104A, 104B, 104C and is absorbed and sensed. Electrical connections to the respective photo-detectors 104A, 104B, 104C is achieved by respective contact metallization 112A, 112B, 112C disposed thereon. Electrical connections to the contact metallization 112 and the transistors 108 is achieved via one or more layers of interconnection metallization 114A, 114B, 114C, including further dielectric material layers 110A, 110B, 110C therebetween.
In one or more embodiments, one or more of the contact metallization 112A, 112B, 112C may operate as a retro-reflector. The retro-reflector reflects light that has propagated through the second surface 102B of the glass or glass ceramic substrate 102, and through at least one of the first, second, and third semiconductor islands 104A, 104B, 104C at least partially back therethrough. Using this configuration, the light absorption characteristics of the photo-detectors is improved and the thicknesses of the semiconductor islands 104A, 104B, 104C may be reduced (by somewhere up to about ½) without sacrificing sensing quality. For example, using a retro-reflector, the first semiconductor island 104A may be between about 0.025 um and about 0.90 um thick and detect blue light. The second semiconductor island 104B may be between about 0.10 um and about 2.35 um thick and detect composite blue and green light. The third semiconductor island 104C may be between about 0.25 um and about 6.0 um thick and detect composite blue and green and red light.
In one or more embodiments, the substrate 102 is a glass ceramic substrate. The glass ceramic substrate 102 is alkali-free, and expansion-matched to the semiconductor layer 104. The glass-ceramic substrate 102 possess excellent thermal stability, and maintains transparency and dimensional stability for many hours at temperatures in excess of 950° C., which is desirable for relatively high temperature CMOS processes. The material also provides excellent chemical durability to resist the etchants used in the CMOS fabrication process. Additionally, any metal ions in the glass ceramic substrate 102 pose a negligible contamination threat during the CMOS fabrication process at elevated temperatures. Modifier ions are also trapped in the glass ceramic substrate 102 and cannot migrate into the semiconductor layer 104, which might otherwise degrade the electrical and/or optical characteristics of the pixel structures 106.
It is noted that lower temperature CMOS processes are available, which may be used when certain glass substrates 102 are employed that are less stable at higher CMOS processing temperatures, such as 950° C. or greater. Such glasses include EAGLE XG™ and JADE™ available from Corning Incorporated, Corning, N.Y., each of which have strain points of less than about 700° C. The lower temperature CMOS processes, however, usually result in lower electrical and/or optical performance.
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The semiconductor layer 104 may be bonded to the glass substrate 102 using any of the existing techniques. Among the suitable techniques is bonding using an electrolysis process. A suitable electrolysis bonding process is described in U.S. Pat. No. 7,176,528, the entire disclosure of which is hereby incorporated by reference. Portions of this process are discussed below.
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The semiconductor material of the semiconductor donor wafer 120 (and thus the semiconductor layer 104) may be in the form of a substantially single-crystal material. The term “substantially” is used to take account of the fact that semiconductor materials normally contain at least some internal or surface defects either inherently or purposely added, such as lattice defects or a few grain boundaries. The term substantially also reflects the fact that certain dopants may distort or otherwise affect the crystal structure of the semiconductor material.
For the purposes of discussion, it is assumed that the semiconductor material of the semiconductor donor wafer 120 (and thus the semiconductor layer 104) is formed from silicon. It is understood, however, that the semiconductor material may be a silicon-based semiconductor or any other type of semiconductor, such as, the III-V, II-IV, II-IV-V, etc. classes of semiconductors. Examples of these materials include: silicon (Si), germanium-doped silicon (SiGe), silicon carbide (SiC), germanium (Ge), gallium arsenide (GaAs), GaP, GaN, and InP.
The substrate 102 may be formed from an oxide glass or an oxide glass-ceramic. By way of example, the glass substrate 102 may be formed from glass substrates containing alkaline-earth ions and may be silica-based, such as, substrates made of CORNING INCORPORATED GLASS COMPOSITION NO. 1737 or CORNING INCORPORATED GLASS COMPOSITION NO. EAGLE 2000®. The glass or glass-ceramic substrate 102 may be designed to match a coefficient of thermal expansion (CTE) of one or more semiconductor materials (e.g., silicon, germanium, etc.) of the layer 104 that are bonded together. The CTE match ensures desirable mechanical properties during heating cycles of the deposition process.
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In the case of glass substrates 102, the application of the electrolysis bonding process causes alkali or alkaline earth ions in the glass substrate 102 to move away from the semiconductor/glass interface further into the glass substrate 102. More particularly, positive ions of the glass substrate 102, including substantially all modifier positive ions, migrate away from the higher voltage potential of the semiconductor/glass interface, forming: (1) a reduced positive ion concentration layer in the glass substrate 102 adjacent the semiconductor/glass interface; and (2) an enhanced positive ion concentration layer of the glass substrate 102 adjacent the reduced positive ion concentration layer. This accomplishes a number of features: (i) an alkali or alkaline earth ion free interface (or layer) is created in the glass substrate 102; (ii) an alkali or alkaline earth ion enhanced interface (or layer) is created in the glass substrate 102; (iii) an oxide layer is created between the exfoliation layer 122 and the glass substrate 102; and (iv) the glass substrate 102 becomes very reactive and bonds to the exfoliation layer 122 strongly with the application of heat at relatively low temperatures. Additionally, relative degrees to which the modifier positive ions are absent from the reduced positive ion concentration layer in the glass substrate 102, and the modifier positive ions exist in the enhanced positive ion concentration layer are such that substantially no ion re-migration from the glass substrate 102 into the exfoliation layer 122 (and thus into any of the structures later formed thereon or therein).
An alternative embodiment may include further processing steps to transform a glass substrate into a glass-ceramic substrate 102. In this regard, the structure of
As a result of the above-described heat-treatment, a portion of the precursor glass substrate 102 remains glass and a portion is converted to a glass-ceramic structure. Specifically, the portion which remains an oxide glass is that portion of the precursor glass substrate 102 closest to the semiconductor exfoliation layer 122, the aforementioned reduced positive ion concentration layer. This is due to the fact that there is a lack of spinel forming cations Zn, Mg in this portion of the precursor glass substrate 102 (because the positive modifier ions moved away from the interface during the bonding process). At some depth into the precursor glass substrate 102 (specifically that portion of the precursor glass substrate 102 with an enhanced positive ion concentration) there are sufficient ions to enable crystallization and to form a glass-ceramic layer with an enhanced positive ion concentration.
It follows that the remaining precursor glass portion 102 (a bulk glass portion at still further depths into the substrate 102 away from the interface) also possesses sufficient spinel forming cations to achieve crystallization. The resultant glass-ceramic substrate structure is thus a two layer glass-ceramic portion comprised of a layer having an enhanced positive ion concentration, which is adjacent the remaining oxide glass layer, and a bulk glass-ceramic layer.
Irrespective of whether one employs a glass substrate 102 or a cerammed substrate, the cleaved surface 123 of the SOI structure just after exfoliation may exhibit excessive surface roughness, implantation damage, etc. Post processing may be carried out to correct the roughness, implantation damage, etc.
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In summary, embodiments disclosed herein may be directed to CMOS image sensor applications. Among the advantages of at least some of the embodiments disclosed herein include:
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.