The invention relates to a semiconductor electronic device primarily used for high-power and/or high-frequency electric/electronic circuit. More specifically, the invention relates to transistors using group III nitride semiconductor.
(Note: This patent application refers several publications and patents as indicated with numbers within brackets, e.g., [x]. A list of these publications and patents can be found in the section entitled “References.”)
Gallium nitride (GaN) and its related group III nitride alloys are the key semiconductor material for various electronic devices such as power switching transistors. Despite the fact that the maximum performance of GaN theoretically predicted with Baliga's Figure of Merit (BFOM) exceeds that of silicon carbide (SiC) by ˜5-fold, difficulties of device fabrication as well as lack of low-cost and low-defect GaN substrates impedes development of GaN-based power switching transistors having their full potential.
Currently, the majority of GaN-based devices are fabricated using a group III nitride film grown heteroepitaxially on a heterogeneous substrates, such as silicon (Si), SiC and sapphire. As for GaN-based power devices, horizontal field effect transistors (FETs) fabricated on Si are commercialized. However, due to a thin current channel for horizontal devices, attainable power is limited. Also, due to poor material quality of GaN grown on Si, the device cannot withstand voltages higher than 1500V.
Vertical GaN FET fabricated on GaN substrate is the ideal device for high-power, high-reliability applications. Due to low dislocation density of homoepitaxial GaN, the device is expected to show low leakage current, high linearity, and high reliability. Despite the many efforts of fabricating vertical GaN metal-oxide-semiconductor FETs (MOSFETs), the device has not reached its full potential. This is primarily due to difficulties in forming a three-dimensional structure of p-GaN necessary to avoid the concentration of the electric field.
Some of these devices and performance issues inherent in them are discussed below in greater detail.
The present invention discloses a GaN trench MOSFET and its fabrication method. The GaN trench MOSFET of the current invention has an n-GaN region having both Mg and donor impurities below a trench bottom and extending to an n−-GaN drift layer. By utilizing ion implantation, the n-type GaN region is formed in a Mg-doped p-GaN region and below the trench bottom of the MOSFET. Also, a dry etch removes a portion of ion-implanted trench sidewall and enables formation of an electron channel between an oxide layer and the Mg-doped p-GaN when forming a GaN trench MOSFET.
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
In the figure each number represents the following:
Note: the numbers “105” and “205” were not used to help illustrate one difference that conventional trench MOSFETS have from the GaN trench MOSFET of this invention, which has a feature “5” as illustrated in
In the figure each number represents the following:
In the figure each number represents the following:
1. Further Discussion of Known Trench MOSFETs and Some of their Problems
A. Conventional MOSFETs Formed with Non-GaN Semiconductors Such as Si and SiC
Various trench MOSFETs have been formed using Si or SiC semiconductors. Ref. 1 provides a review of trench MOSFETs, and
One of the key technologies to achieve a high breakdown voltage device in a conventional MOSFET involves deep p-type regions. Without deep p-type regions, the electric field concentrates at the bottom edge of the trench and physical breakdown occurs at the bottom edge of the trench 104c, damaging the trench catastrophically. To avoid this problem, deep p-type regions extend towards the substrate 101. Since the type of breakdown occurring at the interface of the deep p-type region and the drift layer is avalanche breakdown rather than physical breakdown, breakdown does not cause catastrophic damage, i.e., the device can be used again after recovery from the avalanche breakdown.
B. Conventional MOSFETs Formed with GaN Semiconductor
GaN is one of the wide bandgap semiconductors, and its material properties are superior to SiC. Thus, much research has been conducted to develop a GaN trench MOSFET. However, due to difficulties obtaining p-GaN by ion implantation of acceptors (typically Mg), the reported devices do not have the deep p-type region explained above, as Ref. [2] and [3] discuss.
In an attempt to form deep p regions, p-type formation of GaN by ion plantation of acceptors (e.g., Mg) has been researched. Mg implantation followed by high-pressure (˜1 GPa), high-temperature anneal (>1000° C.) was reported to form p-GaN; however, high-pressure, high-temperature anneal is not practical for mass production [4],[5].
Another potential route to form deep p regions is to etch down the n−-GaN drift layer followed by selective regrowth of p-GaN. However, the regrowth interface typically has an accumulation of silicon impurities, causing high leakage current under high voltage bias.
2. Current Invention
To provide a practical GaN trench MOSFET having deep p regions, this invention provides the novel structure and fabrication steps as explained below.
As shown in
To create the electron channel 7 on the facet of the p-GaN formed from the Mg-doped GaN layer 3, the p-GaN facet is formed by dry etching. The p-GaN facet is preferably a crystallographic plane selected from (101), (201), or (102) planes. The (101), (201), and (102) planes make angle of approximately 62°, 75°, and 43°, respectively. Since these crystallographic planes are stable planes, they are expected to create less surface state upon deposition of insulating layer. The details of the fabrication steps are explained below.
After the drift layer growth, Mg-doped GaN layer 3 is grown. It is preferable to grow Mg-doped GaN layer 3 without interruption after finishing the growth of n−-GaN drift layer 2 to avoid accumulation of silicon impurities at the interface between the n−-GaN drift layer 2 and the Mg-doped GaN layer 3 (
After growth, the wafer is taken out of the growth reactor and a trench 4 is formed by etching with an appropriate mask. Etching mask can be photoresist, a metal layer, or a dielectric layer. It is preferable to use dry etching because it can produce a trench with sidewalls closer to vertical angle. The trench 4 has a bottom 4a and sidewalls 4b (
Then, the donor impurities are implanted into the wafer. Although any donor impurities such as Si, O, and Ge can be used, it is preferable to use Si because Si is the most common donor in GaN. The dose amount is set so that the region below the bottom of the trench turns into n-GaN having an electron concentration close to that of the n−-GaN drift layer, within +/−50% difference of the carrier concentration of the n−-GaN drift layer. As explained above, the electron concentration is on the order of 1016 cm−3 or less, preferably less than 2×1016 cm−3, and more preferably les than 8×1015 cm−3. In this way, the region below the bottom of the trench is turned into n-type. (n-GaN region 5). Also, all regions near the exposed surfaces (trench sidewalls and n-GaN source regions) become n-type as shown in
To increase the electron concentration and form the n-GaN source 6, additional donor implantation is preferably conducted by covering the trench with a mask 6a (
To remove the n-GaN region formed at the surface of the sidewall and expose the p-GaN facet, a dry etch is conducted to remove the n-GaN region as shown in
Once the electron channel 7 is exposed, a gate insulator 8 is deposited as shown in
Gate contact 9 is deposited on the gate insulator 8 with a conventional semiconductor process (
Bulk crystals of GaN are grown with the near equilibrium ammonothermal method. A bulk crystal of GaN is grown on a c-plane GaN seed crystal. A c-plane 2″ GaN substrate having dislocation density of 2×105 cm−2, carrier concentration of 2×1018 cm−3, miscut orientation of 0.04 degree toward m-direction, and miscut orientation of 0.00 degree toward a-direction is produced by slicing the bulk GaN followed by grinding, lapping, polishing and chemical mechanical polishing.
A 10 micron-thick n−GaN drift layer and 0.9 micron-thick Mg-doped GaN layer are grown by MOCVD using trimethylgallium and ammonia. To dope the n−GaN drift layer slightly with Si, SiH4 gas diluted with hydrogen is introduced during drift layer growth. The electron concentration of the n−GaN drift layer is 1×1016 cm−3. To grow the Mg-doped GaN layer, bis(cyclopentadienyl) magnesium (Cp2Mg) carried by hydrogen gas is introduced into the MOCVD reactor. After the MOCVD growth, the wafer is taken out of the MOCVD reactor and annealed at 800° C. in nitrogen gas to activate the Mg dopant. Through this activation anneal, the Mg-doped GaN layer turns into p-GaN layer. The Mg concentration of the p-GaN layer is 2×1018 cm−3.
The wafer goes through a photolithography step followed by dry etching to form trenches on the wafer. Inductively coupled plasma (ICP) etching with Cl2 gas using photoresist mask is conducted to obtain trenches having virtually vertical sidewalls, as known in the art. Looking at the wafer from the top, the trenches are hexagonally shaped with point-to-point dimension of approximately 1 microns. The sides of the trenches are aligned to m-planes of GaN. The depth of the trench is approximately 0.7 microns. The dry etching ends prior to exposing the n−GaN drift layer 2, leaving approximately a 0.2 micron-thick p-GaN region between the bottom of the trench and the interface between the n−GaN drift layer and the p-GaN layer.
Ion implantation of Si is performed without masking the wafer to convert the p-GaN region between the bottom of the trench and the interface between the n−GaN drift layer and the p-GaN layer. After the ion implantation, the wafer is annealed at 800° C. in nitrogen gas to activate the Si. The resulting electron concentration in the region is approximately 1×1016 cm−3, which matches the electron concentration of the n−GaN drift layer. It is preferable to have the electron concentration in the region to be within +/−50% difference of the carrier concentration of the n−GaN drift layer.
To increase the electron concentration in the source region, additional Si implantation is conducted with covering the trench bottoms and trench walls with a dielectric mask. The electron concentration of the n-GaN source region is approximately 5×10 18 cm−3. After the implantation, the dielectric mask is removed by e.g., wet etching.
To expose p-GaN facet that will form the electron channel, inductively-coupled plasma (ICP) etching with photoresist mask is performed. In this case, by using different photoresist thickness and material, (101) plane of p-GaN is exposed. The angle of the facet is about 62° to the basal (002) plane. The details of controlling the facet angle are outlined in Ref. [6]. In this way the portion of n-GaN on the sidewalls of the trenches is removed, exposing p-GaN facet. Then, alumina layer and SiO2 layer are each deposited as gate dielectric, followed by deposition of a Ti/Al gate contact. The conventional semiconductor process is used for the patterning of the gate contact.
Similarly, by using the conventional semiconductor process, body contacts are made by dry etching of the n-GaN source followed by patterned deposition of Ni/Au to p-GaN layer. Finally, source contact of Ti/Al and drain contact of Ti/Al are formed to complete the GaN MOSFET structure.
The completed GaN MOSFET structure has a deep p-region. The breakdown voltage is over 1000 V and the breakdown occurs in a region other than the trench because the bottom of the trench is farther from the substrate than the interface between the p-GaN and the n−-GaN drift layer. The inventive device is not catastrophically (physically) damaged even after the breakdown because the breakdown occurring at the interface between p-GaN and the n−-GaN drift layer is avalanche mode, not physically destructive mode. By avoiding the physical breakdown occurring under the trench as occurs in the conventional device of
Possible Modifications
Although the preferred embodiment describes usage of GaN substrate produced by the ammonothermal method, GaN substrates produced by other methods such as HVPE can also be used.
Although the preferred embodiment describes usage of MOCVD as layer growth method, other methods such as HVPE, and molecular beam epitaxy can also be used.
Although the preferred embodiment describes ICP etching to form trenches, other dry etching method such as reactive ion etching (RIE) can also be used.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
The following references are incorporated by reference herein:
Each of the references above is incorporated by reference in its entirety as if put forth in full herein, and particularly with respect to description of methods of making trench GaN MOSFETs, activating Mg-implanted p-type GaN, and making angled wall etches by selection of mask material and process parameters.
This patent application claims the benefit of priority to U.S. Provisional Patent Application 63/389,363 filed Jul. 14, 2022, with title “GaN TRENCH MOSFET AND FABRICATION METHOD” and inventor Tadao Hashimoto, which application is incorporated by reference in its entirety as if put forth in full below. This application is related to the following patent applications: PCT Utility Patent Application Serial No. US2005/024239, filed on Jul. 8, 2005, by Kenji Fujito, Tadao Hashimoto and Shuji Nakamura, entitled “METHOD FOR GROWING GROUP III-NITRIDE CRYSTALS IN SUPERCRITICAL AMMONIA USING AN AUTOCLAVE,” attorneys' docket number 30794.0129-WO-01 (2005-339-1); U.S. Utility patent application Ser. No. 11/784,339, filed on Apr. 6, 2007, by Tadao Hashimoto, Makoto Saito, and Shuji Nakamura, entitled “METHOD FOR GROWING LARGE SURFACE AREA GALLIUM NITRIDE CRYSTALS IN SUPERCRITICAL AMMONIA AND LARGE SURFACE AREA GALLIUM NITRIDE CRYSTALS,” attorneys docket number 30794.179-US-U1 (2006-204), which application claims the benefit under 35 U.S.C. Section 119(e) of U.S. Provisional Patent Application Ser. No. 60/790,310, filed on Apr. 7, 2006, by Tadao Hashimoto, Makoto Saito, and Shuji Nakamura, entitled “A METHOD FOR GROWING LARGE SURFACE AREA GALLIUM NITRIDE CRYSTALS IN SUPERCRITICAL AMMONIA AND LARGE SURFACE AREA GALLIUM NITRIDE CRYSTALS,” attorneys docket number 30794.179-US-P1 (2006-204); United States Utility Patent Application Ser. No. 60/973,602, filed on Sep. 19, 2007, by Tadao Hashimoto and Shuji Nakamura, entitled “GALLIUM NITRIDE BULK CRYSTALS AND THEIR GROWTH METHOD,” attorneys docket number 30794.244-US-P1 (2007-809-1); U.S. Utility patent application Ser. No. 11/977,661, filed on Oct. 25, 2007, by Tadao Hashimoto, entitled “METHOD FOR GROWING GROUP III-NITRIDE CRYSTALS IN A MIXTURE OF SUPERCRITICAL AMMONIA AND NITROGEN, AND GROUP III-NITRIDE CRYSTALS GROWN THEREBY,” attorneys docket number 30794.253-US-U1 (2007-774-2); U.S. Utility patent application Ser. No. 12/392,960, filed on Feb. 25, 2009, by Tadao Hashimoto, Edward Letts, Masanori Ikari, entitled “METHOD FOR PRODUCING GROUP III-NITRIDE WAFERS AND GROUP III-NITRIDE WAFERS,” attorneys docket number SIXPOI-003US; U.S. Utility patent application Ser. No. 12/455,760, filed on Jun. 4, 2009, by Edward Letts, Tadao Hashimoto, Masanori Ikari, entitled “METHODS FOR PRODUCING IMPROVED CRYSTALLINITY GROUP III-NITRIDE CRYSTALS FROM INITIAL GROUP III-NITRIDE SEED BY AMMONOTHERMAL GROWTH,” attorneys docket number SIXPOI-002US; U.S. Utility patent application Ser. No. 12/455,683, filed on Jun. 4, 2009, by Tadao Hashimoto, Edward Letts, Masanori Ikari, entitled “HIGH-PRESSURE VESSEL FOR GROWING GROUP III NITRIDE CRYSTALS AND METHOD OF GROWING GROUP III NITRIDE CRYSTALS USING HIGH-PRESSURE VESSEL AND GROUP III NITRIDE CRYSTAL,” attorneys docket number SIXPOI-005US; U.S. Utility patent application Ser. No. 12/455,181, filed on Jun. 12, 2009, by Tadao Hashimoto, Masanori Ikari, Edward Letts, entitled “METHOD FOR TESTING III-NITRIDE WAFERS AND III-NITRIDE WAFERS WITH TEST DATA,” attorneys docket number SIXPOI-001US; U.S. Utility patent application Ser. No. 12/580,849, filed on Oct. 16, 2009, by Tadao Hashimoto, Masanori Ikari, Edward Letts, entitled “REACTOR DESIGN FOR GROWING GROUP III NITRIDE CRYSTALS AND METHOD OF GROWING GROUP III NITRIDE CRYSTALS,” attorneys docket number SIXPOI-004US; U.S. Utility patent application Ser. No. 13/781,509, filed on Feb. 28, 2013, by Tadao Hashimoto, entitled “COMPOSITE SUBSTRATE OF GALLIUM NITRIDE AND METAL OXIDE,” attorneys docket number SIXPOI-012US; U.S. Utility patent application Ser. No. 13/781,543, filed on Feb. 28, 2013, by Tadao Hashimoto, Edward Letts, Sierra Hoff entitled “A BISMUTH-DOPED SEMI-INSULATING GROUP III NITRIDE WAFER,” attorneys docket number SIXPOI-013US; U.S. Utility patent application Ser. No. 13/833,443, filed on Mar. 15, 2013, by Tadao Hashimoto, Edward Letts, Sierra Hoff entitled “METHOD OF GROWING GROUP III NITRIDE CRYSTALS,” attorneys docket number SIXPOI-014U51; U.S. Utility patent application Ser. No. 13/834,015, filed on Mar. 15, 2013, by Tadao Hashimoto, Edward Letts, Sierra Hoff entitled “METHOD OF GROWING GROUP III NITRIDE CRYSTALS,” attorneys docket number SIXPOI-014U52; U.S. Utility patent application Ser. No. 13/834,871, filed on Mar. 15, 2013, by Tadao Hashimoto, Edward Letts, Sierra Hoff entitled “GROUP III NITRIDE WAFER AND ITS PRODUCTION METHOD,” attorneys docket number SIXPOI-015U51; U.S. Utility patent application Ser. No. 13/835,636, filed on Mar. 15, 2013, by Tadao Hashimoto, Edward Letts, Sierra Hoff entitled “GROUP III NITRIDE WAFER AND ITS PRODUCTION METHOD,” attorneys docket number SIXPOI-015U52; U.S. Utility patent application Ser. No. 13/798,530, filed on Mar. 13, 2013, by Tadao Hashimoto, entitled “GROUP III NITRIDE WAFERS AND FABRICATION METHOD AND TESTING METHOD,” attorneys docket number SIXPOI-016US; U.S. Utility patent application Ser. No. 14/329,730, filed on Jul. 23, 2014, by Tadao Hashimoto, entitled “ELECTRONIC DEVICE USING GROUP III NITRIDE SEMICONDUCTOR AND ITS FABRICATION METHOD,” attorneys docket number SIXPOI-017US; which applications are incorporated by reference herein in their entirety as if put forth in full below.
Number | Date | Country | |
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63389363 | Jul 2022 | US |