Optical communication is becoming more prevalent in computer systems and network communications. Optical signals can propagate in a variety of different media, such as optical waveguides, between different computer systems and network devices. Modern Integrated Circuits (ICs) designed to facilitate optical devices have a profound impact on computing, electronics, and photonics.
Heteroepitaxy, also referred to as monolithic integration, is a powerful technique to integrate different materials on a same substrate for special functionalities or enhanced device performance. Heteroepitaxy is often used to grow crystalline films of materials for which crystals cannot otherwise be easily obtained and to fabricate integrated crystalline layers of different materials. Heteroepitaxy can be used to grow device materials in electronic and photonic devices.
The following detailed description references the drawings, wherein:
Heteroepitaxy is a powerful technique to integrate different materials together on a substrate for special functionalities or enhanced device performance. Heteroepitaxy is useful technique for the manufacture of various devices used in photonic and electronic computing applications. However, material property incompatibilities like differing lattice constants or thermal expansion coefficients (CTE) can result in defects in heteroepitaxially grown materials. Those defects may have a detrimental effect on microelectronic and photonic devices. These challenges contribute to the difficulty of manufacturing high-performance, reliable devices using direct bandgap compound semiconductors heteroepitaxially grown on silicon.
As a result, effort has been spent into developing ways to minimize defect formation and propagation. The use of intermediate layers, lateral overgrowth methods, and quantum dot active regions have been proposed. However, these solutions do not adequately eliminate defect formation at the heteroepitaxial interface, and they do not produce devices with adequate reliability. Another solution involves limiting functional layers to be within a critical thickness, under which defect formation is mostly mitigated. However, many functional layer thicknesses are above corresponding critical thickness. Furthermore, wafer bonding is a technique often used to join device layers. Wafer bonding, however, may result in extra fabrication cost and size mismatches with substrates can impact overall device yield.
Examples disclosed herein address these challenges by providing for devices having substrates with selective airgap regions for mitigating defects resulting from heteroepitaxial growth of device materials. Example devices may include a first semiconductor layer disposed on a substrate. The first semiconductor layer may have a window cut through a face, where etching a selective airgap region in the substrate is enabled via the window. A second semiconductor layer may be heteroepitaxially grown on the face of the first semiconductor layer so that at least a portion of the second semiconductor layer is aligned over the selective air gap region. The first semiconductor layer may be elastic enough, due to the selective air gap region, to allow elastic deformation caused by the heteroepitaxial (i.e. monolithic) growth of the second semiconductor layer, thereby mitigating the strain experienced by the second semiconductor layer. In this manner, example devices provide for mitigating of defects caused by heteroepitaxial growth of the second semiconductor layer without the use of wafer bonding and other limiting processes.
Referring now to the drawings,
Substrate 110 may be a wafer or solid substance onto which other substances are adhered. Substrate 110 may serve as a foundation for microelectronic and photonic devices, and may be the base that electronic and photonic devices are deposited. Substrate 110 may, in some examples, be a thin slice of material, which may include semiconductors such as silicon and germanium, compound semiconductors such as gallium arsenide (GaAs) and indium phosphide (InP), or dielectric insulators such as silicon oxide and aluminum oxide. In some examples, substrate 110 may include multiple materials, including but not limited to the examples listed above. Furthermore, in some examples, substrate 110 may include multiple layers, with each layer having a different material.
First semiconductor layer 120 may be disposed on the substrate 110. First semiconductor layer 120 may be a relatively thin device layer and may have a window cut through a face of the first semiconductor layer 120 to the substrate 110. The window may allow access to the underlying substrate 110 through the first semiconductor layer 120, and may be defined, for example, by lithography and cut out by etching. The etching may be a chemical hydrofluoric acid (HF) etch or it may be, for example, an anisotropic deep reactive ion etch (DRIE). For example, the first semiconductor layer 120 can be anisotropically etched with one or more plasma gases, such as carbon tetrafloride (CF4) containing fluorine ions, in a commercially available etcher, such as a parallel plate DRIE apparatus or, alternatively, an electron cyclotron resonance (ECR) plasma reactor to replicate the mask pattern of the window in first semiconductor layer 120. The first semiconductor layer may comprise a variety of semiconducting materials, including but not limited to silicon, germanium, and compound semiconductors such as GaAs and InP.
A selective airgap region may be etched out of the substrate 110 material between a portion of the substrate 110 and a portion of first semiconductor layer 120. In other words, the selective airgap region may be etched out of the portion of the substrate 110 that is directly coupled to first semiconductor layer 120. In some examples, the selective airgap is significantly larger across the width of the substrate 110 than it is deep into the substrate 110. The etching of the selective airgap region may be enabled by the window in first semiconductor layer 120. The window may allow etchants used in wet etching to access the substrate 110 to etch out the selective airgap region.
Furthermore, in some examples, substrate 110 may have a base layer and a dielectric layer. In such instances, the first semiconductor layer 120 and the substrate 110 together may represent a semiconductor-on-insulator substrate, such as silicon-on-insulator (SOI). For example, the base layer of substrate 110 and the first semiconductor layer 120 may sandwich the dielectric layer of substrate 110. In such examples, the selective airgap region may be etched out of the dielectric layer of the substrate 110. Example material configurations in such examples include GaAs—AlAs—GaAs, Si—SiO2—Si, and Si—Ge—GaAs.
In some examples, a dielectric layer of the substrate 110 may have a lower refractive index than the first semiconductor layer 120. In such instances, the first semiconductor layer 120, which is directly disposed on the dielectric layer of substrate 110, may act as a waveguide layer for photonic communications. Because the first semiconductor layer 120 may have a higher refractive index than the dielectric layer of the substrate, an optical signal propagating within first semiconductor layer 120 above a total internal reflection angle associated with the first semiconductor layer 120 and the dielectric layer of substrate 110 may experience total internal reflection within first semiconductor layer 120, which thereby serves as a waveguide.
Continuing to refer to
The presence of the selective airgap region aligned with the second semiconductor layer 130 may mitigate the formation and propagation of defects in the second semiconductor layer 130. For example, selective airgap region may allow the freestanding portions of the first semiconductor layer 120 to elastically deform to accommodate for stress generated by mismatch between first semiconductor layer 120 and second semiconductor layer 130. For example, the mismatch may be between lattice constants and CTEs. By concentrating the stress on first semiconductor layer 120, the freestanding portions of second semiconductor 130—that is portions of the layer 130 that is aligned over the selective airgap region—may be less prone to defect formation and propagation.
Furthermore, the thickness of first semiconductor layer 120 may, in some examples, be below a critical thickness, under which defect formation is largely reduced. As a result, defect formation within first semiconductor 120 may also be mitigated.
Substrate 210 may be a foundation on which electronic and photonic devices are deposited. As illustrated by
First semiconductor layer 220 may be disposed on the dielectric layer 214 of substrate 210. First semiconductor layer 220 may be a relatively thin device layer comprising a semiconductor such as Si, Ge, GaAs, and InP. In some examples, base layer 212 of substrate 210, dielectric layer 214 of substrate 210, and first semiconductor layer 220 may represent a semiconductor-on-insulator substrate.
Although not shown in
Second semiconductor layer 230 may be heteroepitaxially grown on a face of the first semiconductor layer 220 so that a portion of the second semiconductor layer 230 is aligned over selective airgap region 215 of substrate 210. Example materials for second semiconductor layer 130 include GaAs and InP. In some examples, the second semiconductor layer 130 may include a layered stack of multiple layers, such as Ge—GaAs or Ge—GaAs—AlGaAs—GaAs. Additional example materials for the second semiconductor layer 130 include other group III-V and II-VI direct bandgap semiconductors.
The presence of the selective airgap region 215 aligned with the second semiconductor layer 230 may mitigate the formation and propagation of defects 232 in a freestanding region 235 of first semiconductor layer 220 and second semiconductor layer 230. For example, selective airgap region 215 may allow the freestanding portions of the first semiconductor layer 220 to elastically deform to accommodate for stress generated by mismatch between first semiconductor layer 220 and second semiconductor layer 230. By concentrating the stress on first semiconductor layer 220, the freestanding portions of second semiconductor layer 230 may be less prone to defect formation and propagation. However, as illustrated in
First semiconductor layer 220 may have a plurality of windows 225 cut into its face. The windows 225 may allow access to the underlying dielectric layer of the substrate through the first semiconductor layer 220. In some examples, first semiconductor layer 220 may have one window, while in other examples, such as that shown in
The windows 225 may enable the etching of the selective airgap region in the dielectric layer of the substrate underneath. The selective airgap region 215 under first semiconductor layer 220 may be emphasized in
In an operation 310, a first semiconductor layer may be deposited on a substrate. In
In an operation 320, a window may be cut through a face of the first semiconductor layer to the substrate. In
In an operation 330, a selective airgap region may be etched, via the window, between a portion of the substrate and a portion of the first semiconductor layer. In
In an operation 340, a dielectric mask may be deposited on portions of the first semiconductor layer where the first semiconductor layer is directly coupled to the substrate. In other words, the dielectric mask is deposited on the portions of the first semiconductor layer where there is no selective airgap region in the parts of the substrate directly below the portions of the first semiconductor layer. This is illustrated in
In an operation 350, a second semiconductor layer may be heteroepitaxially grown on the face of the first semiconductor layer. In
In an operation 510, a first semiconductor layer is deposited on a substrate. In an operation 520, a plurality of windows may be cut through a face of the first semiconductor layer to the substrate. In an operation 530, a plurality of selective airgap regions may be etched in the substrate via the windows cut in operation 520.
In an operation 540A, a dielectric mask may be deposited on portions of the first semiconductor layer where a second semiconductor layer is not to be grown. This is illustrated in
In an operation 550A, the second semiconductor layer is heteroepitaxially grown on the face of the first semiconductor layer. In
Similarly, in an operation 540B, a dielectric mask may be deposited on portions of the first semiconductor layer where a third semiconductor layer is not to be grown. This is illustrated in
In an operation 550B, the third semiconductor layer is heteroepitaxially grown on the face of the first semiconductor layer. In
The final diagram in
The foregoing describes a number of examples for devices having substrates with selective airgap regions. It should be understood that the examples described herein may include additional components and that some of the components described herein may be removed or modified without departing from the scope of the examples or their applications. It should also be understood that the components depicted in the figures are not drawn to scale, and thus, the components may have different relative sizes with respect to each other than as shown in the figures.
Further, the sequence of operations described in connection with
It should further be noted that, as used in this application and the appended claims, the singular forms “a,” “an,” and “the” include plural elements unless the context clearly dictates otherwise.
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PCT/US2016/024823 | 3/30/2016 | WO | 00 |
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