This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2010-269673, filed on Dec. 2, 2010, the entire contents of which are incorporated herein by reference.
The present invention relates to a compound semiconductor device and a method of manufacturing the compound semiconductor device.
There have been active developments in compound semiconductor devices in which a GaN layer and an AlGaN layer are formed over a substrate and the GaN layer functions as an electron transport layer. An example of such compound semiconductor devices is a GaN-based high electron mobility transistor (HEMT). The GaN-based HEMTs use a two-dimensional electron gas (2DEG) formed in a high concentration at an AlGaN/GaN heterojunction interface.
GaN has a higher bandgap (3.4 eV) than Si (1.1 eV) or GaAs (1.4 eV). That is, GaN exhibits a high breakdown field strength. GaN also has a high saturated electron velocity. Thus, GaN is a potential material for compound semiconductor devices capable of high-voltage operation and high output. GaN-based HEMTs are expected to serve as high-efficiency switching elements and high-voltage power devices in electric vehicles and the like.
GaN-based HEMTs which utilize a high-concentration 2DEG are usually normally-on transistors. That is, an electric current flows when there is no gate voltage applied. This current flow is because of a large number of electrons that are present in the channel. Meanwhile, GaN-based HEMTs used in high-voltage power devices are designed with the highest priority placed on a normally-off operation for failsafe reasons.
A variety of studies have been carried out on normally-off GaN-based HEMTs.
In a GaN-based HEMT illustrated in
In the GaN-based HEMT illustrated in
However, the GaN-based HEMTs illustrated in
The related technologies are described in WO 2007/108055, Toshihiro Ohki, “An over 100 W AlGaN/GaN enhancement-mode HEMT power amplifier with piezoelectric-induced cap structure”, Phys. Status Solidi C 6, No. 6, 1365-1368, 2009, and Masahito Kanamura, “A Normally-Off GaN HEMT with Large Drain Current”, IEEJ Trans. Els, Vol. 130, No. 6, 2010.
According to an aspect of the invention, a compound semiconductor device includes: a substrate; an electron transport layer formed over the substrate; an electron supply layer formed over the electron transport layer; and a cap layer formed over the electron supply layer; the cap layer includes a first compound semiconductor layer containing GaN; a second compound semiconductor layer containing AlN, which is formed over the first compound semiconductor layer; a third compound semiconductor layer containing GaN, which is formed over the second compound semiconductor layer; and at least one of a first AlGaN-containing layer and a second AlGaN-containing layer, with the first AlGaN-containing layer formed between the first compound semiconductor layer and the second compound semiconductor layer and in which the Al content increases toward the second compound semiconductor layer, and the second AlGaN-containing layer formed between the second compound semiconductor layer and the third compound semiconductor layer and in which the Al content increases toward the second compound semiconductor layer.
According to another aspect of the invention, a method of manufacturing a compound semiconductor device, includes: forming an electron transport layer over a substrate; forming an electron supply layer over the electron transport layer; and forming a cap layer over the electron supply layer; wherein the forming of the cap layer includes: forming a first compound semiconductor layer containing GaN; forming a second compound semiconductor layer containing AlN over the first compound semiconductor layer; forming a third compound semiconductor layer containing GaN over the second compound semiconductor layer; and forming at least one of a first AlGaN-containing layer between the first compound semiconductor layer and the second compound semiconductor layer, the first AlGaN-containing layer having an Al content which increases toward the second compound semiconductor layer, and a second AlGaN-containing layer between the second compound semiconductor layer and the third compound semiconductor layer, the second AlGaN-containing layer having an Al content which increases toward the second compound semiconductor layer.
The object and advantages of the invention will be realized and attained by at least those elements, features, and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
The GaN-based HEMTs as noted earlier and illustrated in
The present inventors further studied the causes of current collapse in a GaN-based HEMT illustrated in
Hereinbelow, embodiments will be described in detail with reference to the attached drawings.
In an embodiment illustrated in
A cap layer 21 is formed over the electron supply layer 5. The cap layer 21 includes an n-type n-GaN layer 6 formed over the electron supply layer 5. The cap layer 21 further includes an AlGaN-containing layer 7 which is formed over the n-type n-GaN layer 6 and in which the Al content changes in the thickness direction, a non-doped i-AlN layer 8 formed over the AlGaN-containing layer 7, an AlGaN-containing layer 9 which is formed over the i-AlN layer 8 and in which the Al content changes in the thickness direction, and an n-GaN layer 10 formed over the AlGaN-containing layer 9. The n-GaN layer 6 and the n-GaN layer 10 each have a thickness of, for example, about 1 nm to 5 nm (for example, 2 nm). The AlGaN-containing layer 7 and the AlGaN-containing layer 9 each have a thickness of, for example, about 1 nm to 5 nm (for example, 1 nm). The i-AlN layer 8 has a thickness of, for example, about 1 nm to 5 nm (for example, 1 nm).
The cap layer 21 includes an opening 11g for a gate electrode. The opening 11g penetrates into the electron supply layer 5. That is, the opening 11g extends to a depth so as to penetrate the electron supply layer 5. In the cap layer 21, an opening 11s for a source electrode and an opening 11d for a drain electrode are formed with the opening 11g therebetween. A source electrode 12s is formed in the opening 11s, and a drain electrode 12d is formed in the opening 11d. In the opening 11g, an insulating layer 13 is formed which extends over the n-GaN layer 10. A gate electrode 12g is formed over the insulating layer 13 so as to fill the opening 11g. The gate electrode 12g includes, for example, a Ni layer about 30 nm in thickness and a Au layer about 400 nm in thickness formed thereover. The source electrode 12s and the drain electrode 12d each include, for example, a Ta layer about 20 nm in thickness and an Al layer about 200 nm in thickness formed thereover. The source electrode 12s and the drain electrode 12d are in ohmic contact with the electron supply layer 5. The thickness of the insulating layer 13 is, for example, about 2 nm to 200 nm (for example, 10 nm). The insulating layer 13 may be made of, for example, an oxide, nitride or oxynitride of Si, Al, Hf, Zr, Ti, Ta or W, and particularly preferably alumina.
A passivation layer 14 covers the gate electrode 12g, the source electrode 12s and the drain electrode 12d. The passivation layer 14 is, for example, a silicon nitride layer. In the insulating layer 13 and the passivation layer 14, openings are formed for the connection of external terminals or the like.
According to this embodiment, the AlGaN-containing layer 7 between the n-GaN layer 6 and the i-AlN layer 8 reduces the piezoelectric effect due to the lattice mismatch between the n-GaN layer 6 and the i-AlN layer 8. As a result, the conduction band energy between the n-GaN layer 6 and the i-AlN layer 8 is further from the Fermi level than in the GaN-based HEMT illustrated in
Further, the AlGaN-containing layer 9 between the i-AlN layer 8 and the n-GaN layer 10 reduces the elastic strain due to the lattice mismatch between the i-AlN layer 8 and the n-GaN layer 10. As a result, lattice defects such as dislocation and point defects are less likely to occur. Accordingly, the n-GaN layer 10/insulating layer 13 interface state density in a region between the gate electrode 12g and the drain electrode 12d is lower than that of the GaN-based HEMT illustrated in
Next, there will be described a method of manufacturing GaN-based HEMTs (compound semiconductor devices) according to the aforementioned embodiment.
As illustrated in
In the formation of the AlGaN-containing layer 7, the TMA flow rate is gradually increased while the TMG flow rate is gradually lowered so that the Al content in the AlGaN-containing layer 7 will increase from the interface between the AlGaN-containing layer 7 and the n-GaN layer 6 toward the interface between the AlGaN-containing layer 7 and the i-AlN layer 8. In an embodiment, the Al content in the AlGaN-containing layer 7 is changed continuously from 0 at the interface of the AlGaN-containing layer 7 and the n-GaN layer 6 to 1 at the interface of the AlGaN-containing layer 7 and the i-AlN layer 8. In the formation of the AlGaN-containing layer 9, the TMA flow rate is gradually lowered while the TMG flow rate is gradually increased so that the Al content in the AlGaN-containing layer 9 will decrease from the interface between the AlGaN-containing layer 9 and the i-AlN layer 8 toward the interface between the AlGaN-containing layer 9 and the n-GaN layer 10. In an embodiment, the Al content in the AlGaN-containing layer 9 is changed continuously from 1 at the interface of the AlGaN-containing layer 9 and the i-AlN layer 8 to 0 at the interface of the AlGaN-containing layer 9 and the n-GaN layer 10.
After the n-GaN layer 10 is formed, a periphery of an active region 30 is deactivated. In the formation of the inactive regions, for example, the multilayer structure may be mesa-etched with a chlorine-containing gas through a photolithographically patterned resist to create grooves, or may be implanted with ions such as Ar.
Next, a resist pattern is formed which has openings exposing regions where a source electrode 12s and a drain electrode 12d will be formed. Thereafter, the n-GaN layer 10, the AlGaN-containing layer 9, the i-AlN layer 8, the AlGaN-containing layer 7 and the n-GaN layer 6 are etched using the resist pattern as a mask. As a result, an opening 11s for a source electrode and an opening 11d for a drain electrode are formed in the n-GaN layer 10, the AlGaN-containing layer 9, the i-AlN layer 8, the AlGaN-containing layer 7 and the n-GaN layer 6 as illustrated in
Next, as illustrated in
After forming the source electrode 12s and the drain electrode 12d, a resist pattern is formed which has an opening exposing a region where an opening 11g for a gate electrode will be formed. Etching is then performed using the resist pattern as a mask to create an opening 11g in the n-GaN layer 10, the AlGaN-containing layer 9, the i-AlN layer 8, the AlGaN-containing layer 7 and the n-GaN layer 6 as illustrated in
Thereafter, an insulating layer 13 is formed so as to cover the entire surface as illustrated in
As illustrated in
A passivation layer 14 is formed over the entire surface so as to cover the gate electrode 12g, the source electrode 12s and the drain electrode 12d as illustrated in
Thereafter, a gate wire 25g, a source wire 25s and a drain wire 25d are formed which mutually connect a plurality of the gate electrodes 12g, a plurality of the source electrodes 12s and a plurality of the drain electrodes 12d, respectively (see
Components such as resistors and capacitors may be mounted over the substrate 1, thus manufacturing a monolithic microwave integrated circuit (MMIC).
It is not necessary that the cap layer 21 include both the AlGaN-containing layer 7 and the AlGaN-containing layer 9. Even when the AlGaN-containing layer 9 is not included as illustrated in
The GaN-based HEMT according to the aforementioned embodiment may be used as, for example, a high-output amplifier.
Further, the GaN-based HEMT according to the aforementioned embodiment may be used as a power device.
As illustrated in
As illustrated in
It is also possible to constitute a power device which is similar to the server power supply 100 but is capable of higher speed operation. Switch elements similar to the switch element 94 may be used in switch power supplies or electronic devices. Further, these semiconductor devices may be used as components in a full bridge power circuit such as a server power circuit.
In any embodiments, the substrate may be a silicon carbide (SiC) substrate, a sapphire substrate, a silicon substrate, a GaN substrate or a GaAs substrate. The substrate may be conductive, semi-insulating, or insulating.
The structures of the gate electrode, the source electrode and the drain electrode are not limited to those described in the aforementioned embodiments. For example, they may be each composed of a single layer. Further, the electrode-forming method is not limited to the lift-off process. Furthermore, the heat treatment after forming the source electrode and the drain electrode may be omitted as long as ohmic characteristics are obtained without the heat treatment. Still further, the heat treatment may be performed for the gate electrode.
The thicknesses, the materials and other conditions for the layers are not limited to those described in the above embodiments.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Although the embodiments in accordance with aspects of the present invention have been described in detail, it should be understood that various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
Number | Date | Country | Kind |
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2010-269673 | Dec 2010 | JP | national |
Number | Name | Date | Kind |
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6787820 | Inoue et al. | Sep 2004 | B2 |
7838904 | Nakazawa et al. | Nov 2010 | B2 |
20090008677 | Kikkawa | Jan 2009 | A1 |
20090045438 | Inoue et al. | Feb 2009 | A1 |
Number | Date | Country |
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WO-2007108055 | Sep 2007 | WO |
Entry |
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Kanamura, Masahito et al., “A Normally-Off GaN HEMT with Large Drain Current”, IEEJ Trans. Els, vol. 130, No. 6, Mar. 3, 2010, pp. 929-933. |
Ohki, Toshihiro et al., “An over 100 W AlGaN/GaN enhancement-mode HEMT power amplifier with piezoelectric-induced cap structure”, Phys. Status Solidi C 6 No. 6, Apr. 20, 2009, pp. 1365-1368. |
Number | Date | Country | |
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20120138948 A1 | Jun 2012 | US |