The present invention relates to electronic device (e.g., high electron mobility transistor) structures including III-nitride device layers grown on native insulating substrates and methods for making the same.
Gallium nitride and related III-V alloys have exhibited great potential for high power and/or high frequency electronic applications. Particularly desirable applications include high electron mobility transistors (HEMTs), which are electronic devices having three terminals including a gate, a drain, and a source. Electric potential on the gate controls the current flow between the source and the drain. AlGaN/GaN heterostructure-based HEMTs are of interest because a two-dimensional electron gas (2DEG, also referred to as the channel charge) that enhances electron transport capability is spontaneously formed along the heterointerface.
Due to a lack of large-area, high quality native GaN substrates, conventional GaN-based HEMT devices have been grown on non-native (heteroepitaxial) substrates such as sapphire and silicon carbide. Owing to the potentially severe lattice mismatches between substrates and buffers, nucleation layers consisting of AlN, GaN, or AlGaN are routinely used in an attempt to improve the GaN buffers to the substrates. Nucleation layers are typically AlN or AlGaN. The criticality of improving GaN buffer quality to reduce strain renders the engineering of nucleation layers one of the most critical steps in fabrication of GaN-based HEMT devices.
Among various examples of GaN-based HEMT devices, U.S. Pat. No. 5,192,987 to Khan et al. discloses a HEMT structure utilizing a sapphire substrate in which an AlN buffer layer is first deposited on the sapphire substrate, a GaN layer is deposited on the AlN buffer layer, and an AlGaN layer is deposited on the GaN layer. U.S. Pat. No. 6,316,793 to Sheppard et al. discloses HEMTs based on AlGaN/GaN heterostructures grown on silicon carbide substrates.
A multi-layer structure 1 for use in a conventional HEMT is illustrated in
Insulating native III-nitride (e.g., GaN) substrate materials have recently become known. For example, commonly assigned U.S. Patent Publication No. 2005/0009310 (published Jan. 13, 2005) for “Semi-insulating GaN and method of making the same” discloses methods for making large-area single-crystal semi-insulating GaN (“SI GaN”). Applicants have experimented with various methods for using SI GaN as a substrate material for HEMT devices fabricated with epitaxial device layers. Surprisingly, Applicants have found that when homoepitaxial GaN layers are grown on native SI GaN substrates using conventional methods, an unforeseen problem arises: the formation of unintended non-channel charge. While a HEMT desirably has a single conductive channel along an AlGaN/GaN interface (the 2DEG), attempts to construct HEMT devices by homoepitaxial growth of nitride layers on native SI GaN substrates have caused non-channel charge to form well apart from (e.g., below) the 2DEG. It is believed that the non-channel charge may be formed in close proximity to the interface between a GaN epilayer and a SI GaN substrate. While the precise cause of non-channel charge is not fully understood, it is believed that such charge is due at least in part to the presence of impurities such as silicon and oxygen in the interfacial region. The increased impurity concentration possibly arises from differences in growth mode, process conditions, and compensation mechanism differences between the growth of SI GaN and the epitaxial growth of GaN on SI GaN, and/or by the presence of surface preparation residue remaining on the SI GaN. It is also possible that non-channel charge is generated by piezoelectric properties from strain and other structural defects within the initial epitaxial layer and/or along the interface between the epitaxial layer and the substrate.
Non-channel charge is undesirable in HEMT devices, for example, because it provides an alternative current flow path outside of the 2DEG, with the alternative current flow path being difficult to pinch off using conventional gate formulations and operating conditions. Consequently, the presence of non-channel charge renders it difficult to modulate current in any resulting HEMT device, substantially limiting its utility.
In consequence, the art continues to seek improvement in high electron mobility electronic device structures. It would be desirable to fabricate high electron mobility device structures using native substrates, and for the resulting structures to be substantially free of uncontrollable non-channel charge effects.
The present invention relates to electronic device structures including high quality III-nitride layers grown on native insulating III-V substrates and at least one terminal comprising a conductive material, and methods for making these structures. The resulting structures are suitable for use in high electron mobility transistors, electronic/microelectronic devices, and corresponding device precursor structures.
In one aspect, the invention relates to an electronic device structure having a substrate layer including a semi-insulating AlxGayInzN material, wherein 0≦x≦1, 0≦y≦1, 0≦z≦1, and x+y+z=1; a first layer including an AlxGayInzN material; a second layer including an Alx′Gay′Inz′N material, wherein 0≦x′≦1, 0≦y′≦1, 0≦z′≦1, and x′+y′+z′=1; and at least one terminal including a conductive material. The first layer is disposed between the second layer and the substrate, with the materials of the first and second layers being adapted to form a two-dimensional electron gas along the heterointerface. Lattice matching between the first layer and the substrate may be achieved without the use of an intermediate nucleation layer. The first layer thickness is preferably less than about 1000 nanometers, more preferably less than about 500 nanometers, and still more preferably less than about 200 nanometers.
In another aspect, the invention relates to an electronic device structure having a semi-insulating substrate layer, first and second layers adapted to form a two-dimensional electron gas, and at least one terminal including a conductive material. The substrate includes a first III-nitride material and a dopant, the first layer includes the first III-nitride material, and the second layer includes a second III-nitride material.
In another aspect, the invention relates to an electronic device structure having substrate layer including a semi-insulating first III-nitride material, an epitaxially grown first layer including the first III-nitride material that is lattice-matched to the substrate layer, an epitaxially grown second layer including a second III-nitride material, and at least one terminal including a conductive material. The first layer and the second layer define a heterojunction adapted to form a two dimensional electron gas.
In another aspect, the invention relates to a method of fabricating an electronic device structure including several method steps. A first method step includes providing a semi-insulating substrate including an AlxGayInzN material (wherein 0≦x≦1, 0≦Y≦1, 0≦z≦1, and x+y+z=1). A second method step includes epitaxially growing a first layer including the AlxGayInzN material on or adjacent to the substrate. A third method step includes epitaxially growing a second layer including an Alx′Gay′Inz′N, material (wherein 0≦x′≦1, 0≦y′≦1, 0≦z′≦1, and x′+y′+z′=1) on or adjacent to the first layer, with the first layer and second layer being adapted to form a two dimensional electron gas. A fourth method step includes depositing at least one terminal in electrical contact with the two dimensional electron gas.
Other aspects, features and embodiments of the invention will be more fully apparent from the ensuing disclosure and appended claims.
In the drawings, like numbers are intended to refer to like elements or structures. None of the drawings are drawn to scale unless indicated otherwise.
The disclosures of the following patents and patent applications are hereby incorporated herein by reference, in their respective entireties:
U.S. patent application Publication No. 2005/0009310 published Jan. 12, 2005 for “Semi-insulating GaN and Method of Making the Same;”
U.S. Pat. No. 5,679,152 issued Oct. 21, 1997 for “Method of Making a Single Crystal Ga*N Article;”
U.S. Pat. No. 6,156,581 issued Dec. 5, 2000 for “GaN-Based Devices Using (Ga, Al, In)N Base Layers;”
U.S. Pat. No. 6,440,823 issued Aug. 27, 2002 for “Low Defect Density (Ga, Al, In)N and HVPE Process for Making Same;”
U.S. Pat. No. 6,447,604 issued Sep. 10, 2002 for “Method for Achieving Improved Epitaxy Quality (Surface Texture and Defect Density) on Free-Standing (Aluminum, Indium, Gallium) Nitride ((Al, In, Ga)N) Substrates for Opto-Electronic and Electronic Devices;”
U.S. Pat. No. 6,488,767 issued Dec. 3, 2002 for “High Surface Quality GaN Wafer and Method of Fabricating Same;”
U.S. Pat. No. 6,533,874 issued Mar. 18, 2003 for “GaN-Based Devices Using Thick (Ga, Al, In)N Base Layers;”
U.S. Pat. No. 6,596,079 issued Jul. 22, 2003 for “III-nitride Substrate Boule and Method of Making and Using the Same;”
U.S. Pat. No. 6,765,240 issued Jul. 20, 2004 for “Bulk Single Crystal Gallium Nitride and Method of Making Same;”
U.S. patent application Publication No. 2001/0008656 published Jul. 19, 2001 for “Bulk Single Crystal Gallium Nitride and Method of Making Same;”
U.S. patent application Publication No. 2002/0028314 published Mar. 7, 2002 for “Bulk Single Crystal Gallium Nitride and Method of Making Same;” and
U.S. patent application Publication No. 2002/0068201 published Jun. 6, 2002 for “Free-Standing (Al, In, Ga)N and Parting Method for Forming Same.”
The term “semi-insulating” as used herein and applied to a material refers to the property of having a sufficiently high resistivity to render it suitable for use as a substrate in an electronic device structure. A semi-insulating material should have a resistivity (at device-operation temperature) of preferably at least about 1×103 ohm-cm, more preferably at least about 1×104 ohm-cm, and more preferably still at least about 1×105 ohm-cm. For substrates of III-nitride materials, if insufficiently pure and high crystalline quality cannot be produced, deep acceptor dopant species such as Mn, Fe, Co, Ni, Cu, or the like are preferably included to compensate unintended donor species in the AlxGayInzN and impart at least semi-insulating character to the substrate.
In accordance with the present invention, the performance of microelectronic device structures including dissimilar III-nitride device layers are improved by the use of native substrates, while formation of non-channel charges is avoided and their impact minimized through epilayer design.
In structures including a substrate, a first layer, and a second layer, with the first layer and second layer comprising different III-nitrides, the growth of a thin first layer lattice-matched to an adjacent semi-insulating native substrate has been discovered to achieve high quality III-nitride layer structures with improved performance characteristics while avoiding the above-mentioned difficulties with controlling non-channel charges. The thickness of the first III-nitride (e.g., GaN) layer grown adjacent to the substrate (e.g., SI GaN) is preferably less than about 1000 nm, more preferably less than about 500 nm, and still more preferably less than about 200 nm.
In contrast, GaN layers in conventional HEMT devices utilizing foreign substrates are relatively thick—typical thicknesses are in the range of 2 to 3 microns. One reason for the use of such thick GaN layers is to reduce dislocation density or increase material quality to improve device performance. As noted previously, nucleation layers are commonly used in GaN-based HEMT devices to mitigate lattice mismatch between GaN layers and non-native substrates; however, nucleation layers fail to eliminate lattice mismatch problems entirely. Through various dislocation elimination mechanisms, epitaxial growth of GaN layers can significantly reduce dislocation density, with the dislocation density decreasing as the epilayer thickness increases. The rate of reduction diminishes once a certain epilayer thickness is achieved. For example, Applicants have experience with fabricating GaN-based HEMT structures on silicon carbide using nucleation layers. In Applicants' experience, the use of 3 micron thickness GaN layers is sufficient to reduce dislocation densities of approximately 1×1010 dislocations per square centimeter along the nucleation layer surface to about 5×108 dislocations per square centimeter along the distal surface of a GaN layer deposited thereon.
In one of Applicants' early attempts to produce GaN-based HEMT structures using native substrates, an undoped GaN layer having a thickness of 3 microns was homoepitaxially deposited on a semi-insulating GaN substrate (containing a compensating dopant) without the use of an intermediate nucleation layer. A layer of approximately 23 nanometers of AlGaN was epitaxially grown on the GaN layer, and source, drain, and gate terminals of conductive materials were added to the structure. The gate terminal was separated from the semi-insulating substrate layer by the 3 micron thickness of the undoped GaN layer. To Applicants' surprise, the resulting device exhibited non-channel charge effects, and the device performed poorly. It is believed that the non-channel charge permitted a secondary conductive channel to form between the undoped GaN layer and the semi-insulating GaN substrate, with the secondary channel not subject to being pinched off by signals from the gate terminal due to the thick (3 micron) undoped GaN layer.
In GaN-based HEMT structures utilizing semi-insulating GaN substrates, the growth of thinner GaN layers on such substrates according to the present invention substantially eliminates the problem of controlling conduction effects arising from non-channel charge. The thickness of the GaN layer is preferably less than about 1000 nm, more preferably less than about 500 nm, and still more preferably less than about 200 nm. It is believed that secondary conductive channels remain present in such devices, but that the reduction in the thickness of the GaN layer permits signals from a less-distant gate terminal to pinch off the secondary channels. Preferably, the non-channel charge is reduced as much as possible through techniques known to one skilled in the art. Such techniques include, for example, properly finishing and cleaning the surface, optimizing the choice of conditions associated with ramping to growth, carefully choosing and controlling growth conditions, and/or utilizing compensating impurities. The non-channel charge, which may be present in any of the substrate and the first layer outside the two-dimensional electron gas, is preferably less than about 1×1013 cm−2; more preferably less than about 1×1012 cm−2, and still more preferably less than about 1×1011 cm−2.
A thin GaN layer in a HEMT device provides further advantages in addition to facilitating control of secondary conductive channels. Reducing the thickness of a GaN layer increases sheet resistance and permits it to more closely conform to the surface of the underlying GaN substrate. Preferably, the substrate is treated with a chemical mechanical polishing (CMP) process (such as disclosed in U.S. Pat. No. 6,488,767) and then cleaned prior to the growth of the first GaN layer. When a CMP process is used on a GaN substrate and a thin GaN layer is grown thereon, the smooth layers and sharp heterojunction interface leads to improved electron mobility and sheet charge confinement of the resulting 2DEG, thus enhancing frequency response and general electrical characteristics of the resulting device.
GaN is a polar crystal, and the c-plane has two different surfaces. One surface is terminated with gallium and other surface is terminated with nitrogen for the c-plane substrates. The direction of the wafer surface can be exactly parallel to the c-axis, or can be tilted at a small angle (e.g., ≦10 degrees) with respect to the crystalline c-plane. Such plane is called a vicinal plane. Epitaxial device layers suitable for use in a HEMT are preferably grown on the gallium side of the c-plane substrates or on the vicinal plane substrates. Other materials and other orientations, however, might be employed. Assuming a wafer comprising AlxGayInzN, wherein 0≦x≦1, 0≦y≦1, 0≦z≦1, and x+y+z=1, the wafer surface may be selected from the group consisting of: AlxGayInz-terminated surfaces of AlxGayInzN in an (0001) orientation, offcuts of AlxGayInz-terminated surfaces of AlxGayInzN in an (0001) orientation, offcuts of N-terminated surfaces of AlxGayInzN in an (0001) orientation, A-plane surfaces, M-plane surfaces, R-plane surfaces, offcuts of A-plane surfaces, offcuts of M-plane surfaces and offcuts of R-plane surfaces.
Although discussion herein is directed primarily to AlGaN and GaN as illustrative III-nitride species for application of the present invention, it will be recognized that the invention is broadly applicable to III-nitride compounds, including binary compounds and alloys. As used herein, the term “III-nitride” refers to semiconductor material including nitrogen and at least one of Al, In and Ga. Such III-nitride material may be denoted symbolically as AlxGayInzN wherein 0≦x≦1, 0≦y≦1, 0≦z≦1, and x+y+z=1. The term AlxGayInzN includes all permutations of nitrides including one or more of Al, In and Ga, and thus encompasses as alternative materials AlN, InN, GaN, AlInN, AlGaN, InGaN and AlInGaN, wherein the stoichiometric coefficients of Al, In, and Ga in compounds containing two, or all three, of such metals may have any appropriate values between 0 and 1 with the proviso that the sum of all such stoichiometric coefficients is 1. In this respect, impurities such as hydrogen or carbon, dopants, or strain-altering materials such as boron can also be incorporated in the AlxGayInzN material, but the sum of all stoichiometric coefficients is 1 within a variation of ±0.1%. Examples of such compounds include AlxGa1-xN wherein 0≦x≦1, and AlxInyGa1-x-yN wherein 0≦x≦1 and 0≦y≦1. Thus, although the ensuing discussion is directed to GaN and AlGaN as illustrative materials, other III-nitride materials may likewise be employed in microelectronic device structures according to the invention.
A multi-layer microelectronic device structure 100A according to a first embodiment is illustrated in
Any appropriate growth technique may be used to grown the first and second device layers 120A, 130A. For example, processes such as metal organic vapor phase epitaxy (MOVPE) (also known as metal organic chemical vapor deposition (MOCVD)), hydride vapor phase epitaxy (HVPE), atomic layer epitaxy (ALE), or molecular beam epitaxy may be used. At least one conductive terminal (such as the terminals 141-143 shown in
An embodiment representing a subset of the multi-layer structure of
In another embodiment, a HEMT device that incorporates the structure 100B of
In another embodiment illustrated in
In another embodiment, a cap layer is added to a III-nitride multi-layer device structure having a thin (e.g., ≦1000 nm) first layer and a native substrate. Referring to
In yet another embodiment, a fourth layer may be disposed between the dissimilar III-nitride material layers to serve as an intermediate barrier layer along the 2DEG in a device structure having a thin first layer and a native substrate. A fourth layer may be provided whether or not a third layer (e.g., GaN cap layer 235) as described previously is also present. Referring to
In still another embodiment, a fifth layer may be disposed between the substrate and the first GaN layer to serve as an additional bottom electron barrier. Referring to
Following formation of the fifth layer 415, a first GaN layer 420 is grown on the fifth layer 415, and a second AlGaN layer 430 is then grown on the first layer 420 to form a 2DEG 425 along the heterointerface. Optionally, a third GaN cap layer 435 may be grown on the second layer 430 to increase surface barrier height. Because of the discontinuity of polarization between the first GaN layer 420 and the fifth InGaN electron barrier layer 415, an electric field develops in the fifth layer 415 that reduces the probability that hot electrons may escape from the first layer 420 and become trapped in the sixth layer 414 (if present) and/or substrate layer 410, thus improving performance of the device structure 400.
In yet another embodiment, a III-nitride multi-layer device structure including a thin first layer and a native substrate may include any combination of or all of the enhancements illustrated in and described in connection with
In another embodiment, a seventh layer may be disposed between the dissimilar III-nitride material layers (first and second layers) to serve as a channel defining layer to facilitate improved 2DEG transport. The seventh layer may be provided whether or not a third layer (e.g. a GaN cap layer), a fourth layer (e.g. and AlN interlayer), a fifth layer (electron barrier) and/or a sixth layer (initiation layer) as described previously are also present. Referring to
One skilled in the art could envision altering and/or combining various aspects of these embodiments to produce further innovative structures on insulating III-nitride substrates. For example, a first approach may include fabricating a first layer from a larger bandgap material than GaN (e.g., by increasing defect or impurity ionization energy) to improve electron confinement. A second approach may include doping the first layer (e.g., GaN) or the fifth or sixth layers with a compensating impurity such as Mg, Fe, Zn, or the like to increase the resistance of these layers. A third approach may include fabricating a first layer from an AlInGaN material of appropriate composition to create an electric field to suppress deleterious hot electron effects. A fourth approach may include fabricating a first layer from an AlInGaN lattice matched quaternary alloy. Various other alterations and combinations will be apparent to the skilled artisan upon reviewing the present disclosure.
The advantages and features of the invention are further illustrated with reference to the following examples, which are not to be construed as in any way limiting the scope of the invention but rather as illustrative of various embodiments of the invention in specific applications thereof.
A first III-nitride multi-layer device structure of the type shown schematically in
A second III-nitride multi-layer device structure of the type shown schematically in
A III-nitride multi-layer structure of the type shown schematically in
A III-nitride multi-layer structure of the type shown schematically in
Work relevant to the subject matter hereof was conducted in the performance of DARPA Contract No. N00014-02-C-0321. The United States government may have certain rights in this invention.