The invention relates to the field of imager devices, for example that of Terahertz (THz) imager devices. The invention is in particular applicable to making such imager devices in MOS technology.
The THz radiation is non-ionizing and is thus considered non-hazardous. This radiation is also penetrating and can thus be used in the field of medical imaging or even in the field of safety imaging (for example for the purpose of detecting objects hidden behind clothes).
THz imaging is a passive imaging which consists in detecting waves directly emitted by the observed elements. An observed element emits waves different according to the temperature of the element which behaves, regarding a THz imager device, as a black body. Thus, with a THz imager device, it is not necessary to illuminate or irradiate what it is desired to be observe or detect.
A technique of making a THz imager device consists in making different elements of the imager device in CMOS technology on a semiconductor substrate, and then implementing so-called post-processing steps, in order to thermally insulate the detectors, or sensors, from the pixels of the imager device.
Each pixel of the imager device includes for example a heat antenna, that is an antenna which collects an electromagnetic radiation and which converts it into heat. This variation in temperature is then detected by the pixel sensor, which sensor can for example be a bolometer, a diode or a MOS transistor (operating for example in sub-threshold regime), as described for example in document WO 2011/151756 A2. The sensor is in this case a heat sensor able to convert a temperature variation emitted by the antenna into an electrical variation of a signal.
Alternatively, it is possible that the antenna of a pixel of the imager device be capacitively coupled to a resistive element which emits heat the intensity of which is a function of the electromagnetic radiation detected by the antenna. This variation in temperature is then detected by the pixel sensor, as described in document WO 2011/048170 A1.
Document WO 2010/076783 A1 further describes the implementation of post-processing steps from unit chips for making THz imager devices.
In order to increase the efficiency of the receiving antenna, document WO 2011/151756 A2 suggests to add, under the antenna of each pixel of the imager device, an electromagnetic wave reflector provided at a distance equal to λ/4 with respect to the antenna, with λ corresponding to the incident wavelength intended to be detected by the antenna. Makin such a reflector is however complex and expensive to implement.
Thus there is a need to provide a method for making an imager device including electromagnetic wave reflectors coupled to the pixels of the imager device, which is less complex and expensive to implement than methods of prior art.
For this, one embodiment provides a method for making an imager device including at least the implementation of the steps of:
This method according to the invention thus proposes to resort to a substrate including a buried reflective layer readily accessible via etching a layer of sacrificial material provided under the one or more pixels of the imager device. The reflective layer can then form the reflector(s) optically coupled to the one or more pixels of the imager device.
The reflective layer and the layer of electric insulating material may be spaced out by a distance equal to about λ/4n, with n corresponding to the refractive index of a medium in the optical cavity, and λ corresponding to the wavelength of the electromagnetic wave. This method thus enables the distance between the reflective layer and the one or more pixels to be readily controlled because this distance λ/4n can be defined by controlling the thickness of the layer of sacrificial material. Such a distance allows to have an optical cavity in which constructive interferences are produced at the antenna of the one or more pixels. This distance may be obtained by making the layer of sacrificial material such that its thickness is equal to about λ/4n.
The antenna of the one or of each pixel may be coupled to at least one electronic sensor of said pixel.
The electronic sensor of the one or of each pixel may include at least one bolometer, or a diode or a transistor, for example of the MOS type.
The method may further include, prior to making the aperture through the layer of electric insulating material, making the one or more pixels in CMOS technology.
The layer of electric insulating material may include a stack of several interlayer insulating layers (ILD). These ILD layers may cover the different semiconductor and metal elements of the one or more pixels made in MOS technology.
The method may further include, between making the one or more pixels and making the aperture through the layer of electric insulating material, making several levels of electric conducting material, for example metal levels, between the interlayer insulating layers such that portions of at least one of the levels of electric conducting material form masks protecting the one or more pixels upon making the aperture through the layer of electric insulating material. Thus, the step allowing the access to the layer of sacrificial material further enables the one of more pixels of the imager device to be geometrically defined.
The one or more pixels may be made on a substrate comprising the sacrificial material, and the method may further include, between making the one or more pixels and making the aperture through the layer of electric insulating material, the implementation of the steps of:
According to an alternative, the one or more pixels may be made on a substrate, and the method may further include, between making the one or more pixels and making the aperture through the layer of electrically insulating material, the implementation of the steps of:
The layer of electric insulating material may comprise semiconductor oxide, for example SiO2, and the layer of sacrificial material may be secured to the layer of electric insulating material through a second layer of electric insulating material comprising semiconductor oxide formed beforehand against the layer of sacrificial material.
The method may further include, prior to making the aperture through the layer of electric insulating material, making an etching mask onto the layer of electric insulating material such that portions of the etching mask cover bonding pads electrically connected to the one or more pixels.
The method may further include, after removing at least one part of the layer of sacrificial material through the aperture, filling the optical cavity with at least one gas or material having a refractive index equal to n, forming a medium of the optical cavity.
The sacrificial material may be silicon and/or germanium and/or wherein the layer of electrically insulating material may comprise semiconductor oxide.
The reflective layer may include a stack of at least one etch stop layer comprising a material able to resist to an etching agent used upon removing at least one part of the layer of sacrificial material and at least one reflective layer, the etch stop layer being provided between the reflective layer and the layer of sacrificial material.
The reflective layer is advantageously metallic, but may also be silicon-based.
The etch stop layer may comprise semiconductor oxide and/or the reflective layer may be aluminium-based.
The electromagnetic wave may include a wavelength λ between about 0.5 THz and 10 THz, or advantageously between about 0.5 THz and 1.5 THz.
The present invention will be better understood upon reading the description of exemplary embodiments given for indicative purpose only and in no way limiting while referring to the appended drawings wherein:
Identical, similar or equivalent parts of the different figures described hereinafter bear the same reference numerals so as to facilitate switching from one figure to another.
The different parts shown in the figures are not necessarily drawn at a uniform scale, to make the figures more legible.
The different possibilities (alternatives and embodiments) should be understood as being non-mutually exclusive and can be combined together.
We will refer to
The imager device 100 includes a substrate 102 or wafer, semiconductor-based, for example silicon-based. A reflective layer 104, intended to form electromagnetic wave reflectors under an array of pixels of the imager device 100, is provided on the substrate 102. In this first embodiment, the reflective layer 104 corresponds to an oxide/metal bilayer, made for example of an aluminium layer covered by a SiO2 layer, and the reflective layer of which, herein metallic, is in contact with the substrate 102. Alternatively, the reflective layer 104 can correspond to alternating etched metal layers (for example of aluminium) and dielectric layers (for example oxide such as SiO2), increasing the range of electromagnetic wavelengths that can be reflected by this reflective layer 104. It is also possible that the reflective layer 104 be formed by a single layer of material able to perform both a function of reflecting electromagnetic waves and a function of etch stop (upon etching a layer of sacrificial material 106 provided on the reflective layer 104, as described later), for example comprising aluminium, a XeF2 type etching that can be used for etching silicon of which the layer of sacrificial material 106 is made without attacking the aluminium.
The layer of sacrificial material 106, for example semiconductor-based such as silicon or germanium, is deposited onto the reflective layer 104. Generally, the material of the sacrificial layer 106 is selected such that it can be selectively etched with respect to the material of the reflective layer 104 in contact with the sacrificial material (for example with respect to the oxide when the reflective layer 104 is formed by an oxide/metal bilayer) and possible other materials in contact with parts of the layer of sacrificial material 106 which are intended to be etched subsequently.
The layer of sacrificial material 106 is covered with a layer of electric insulating material 108 such as a dielectric layer, for example comprising SiO2, within which is made in particular the array of pixels of the imager device 100. In
Thus, each pixel of the imager device 100 comprises an antenna able to transform an electromagnetic wave received into heat or electric current. The variation in heat or electric current it then detected by the sensor which is coupled to the antenna.
Second and third levels of electric conducting material, herein metal levels (called METAL 2, or M2, and METAL 3, or M3), referenced 118 and 120 respectively, are also formed in the dielectric layer 108, above the first metal level 116. Each of the metal levels 118 and 120 is for example made from an aluminium-based etched metal layer. Each one of the metal portions of the metal levels 116, 118 and 120 has for example a thickness between about 200 nm and 500 nm.
Finally, bonding pads 122 are also made in the dielectric layer 108, at the periphery of the pixels 110a, 110b so as not to interfere in the electromagnetic waves receipt by the pixels 110a, 110b. These pads 122 are for example obtained from a metal layer having a thickness equal to a few microns (for example 4 μm) and aluminium-based. The bonding pads 122 are in particular electrically connected to the outputs of the sensors 111a, 111b of the pixels 110a, 110b via portions of the different metal levels 116, 118 and 120. Electric links between the different metal levels 116, 118, 120 and with the sensors 111a, 111b and the bonding pads 122 are made with electric conducting vias made in the dielectric layer 108.
In
The different elements of the array of pixels which are described above are for example made by implementing the steps of deposit, photolithography and etching of different layers of materials, corresponding to a MOS type making method.
In addition to the electric interconnecting function provided by some portions of the metal levels 116, 118 and 120, the second metal level 118 is made such that the remaining portions 124 of this second metal layer 118 each form an etching mask, protecting the sensor 111a, 111b and the antenna 117a, 117b of each pixel 110a, 110b during an etching which will be subsequently implemented to etch part of the dielectric layer 108. Likewise, the third metal level 120 is made such that the remaining portions 126 form an etching mask protecting in particular portions of the dielectric layer 108, of the second metal level 118 and the first metal level 116 (and possibly other materials that were used for making the sensors) intended to form, in each pixel 110a, 110b, a frame ensuring mechanical support for the antenna 117a, 117b and the sensor 111a, 111b of the pixel 110a, 110b. Portions of the first metal level 116 can also be used as an etching mask for portions of materials (silicon, polysilicon, dielectric, etc.) located under the same. In the example of
Although not shown in
As shown in
Then, the etching of the dielectric layer 108 is made, for example via a C4F8 type etching (
The portions of resin 128 as well as the metal portions developed by etching, that is the metal portions that were used as etching masks, are then withdrawn, for example via the implementation of another etching suitable for the materials to be withdrawn.
As shown in
The etching of the layer of sacrificial material 106 forms, between the reflective layer 104 and the pixels 110a, 110b of the imager device 100, an optical cavity 136. The thickness, or height, of the optical cavity 136, corresponding to the dimension of the optical cavity 136 along the Z axis shown in
In the example described in connection with
The layer of sacrificial material 106 is made with a thickness such that the distance between the reflective layer 104 and the antennas 117a, 117b is equal to about λ/4n, with n corresponding to the index of the medium (material and/or gas) being in the optical cavity 136 (that is n equal to about 1 when the cavity 136 is not filled with a material after the layer of sacrificial material 106 is etched, and thus when air is present in the optical cavity 136, as is the case in
This distance between the antennas and the reflective layer can be approximated by making the reflective layer 104 and the dielectric layer 108 such that they are spaced out by the distance equal to about λ/4n, by making for this the layer of sacrificial material 106 such that its thickness is equal to about λ/4n. Indeed, because the height of the optical cavity 136 (dimension along the Z axis), corresponding to the thickness of the layer of sacrificial material 106 and for example equal to about 75 μm, is much higher (for example by a factor of at least 10) than the thickness of the dielectric material, for example of about 1 μm, located between the antennas 117a, 117b and the layer of sacrificial material 106, the phase shift induced by this thickness of dielectric material onto the incident electromagnetic wave is negligible relative to the phase shift of the optical cavity 136.
In this first embodiment, the previously described steps in connection with
As shown in
A mechanical handle 204, corresponding for example to another substrate, or wafer, of semiconductor or even glass, is secured to an upper face 206 of the dielectric layer 108 (
As shown in
Finally, another substrate, or wafer, bulk 212, on which a reflective layer 210, for example of metal and that can be similar to the previously described reflective layer 104 is made, is secured to the layer of sacrificial material 208 such that the reflective layer 210 is provided against the layer of sacrificial material 208 (Fig. D).
The mechanical handle 204 is then removed and the making of the imager device 200 is completed by implementing steps similar to those previously described in connection with the
As shown in
As in the second embodiment, a mechanical handle 204, corresponding for example to a second substrate, or wafer, of semiconductor or even glass, is secured to an upper face 206 of the dielectric layer 108 (
As shown in
Another wafer including in particular a layer of sacrificial material 307, for example which nature and dimensions are similar to the layers of sacrificial material 106 and 208 previously described, is secured against the back face 302 of the dielectric layer 108 via for example an oxide-oxide bonding (an oxide layer is therefore formed, prior to bonding, onto the layer of sacrificial material 304). This other wafer further includes a reflective layer 306, for example of metal and that can be similar to the reflective layers 104 and 210 previously described, provided against the layer of sacrificial material 304, as well as a substrate, or thick layer, 308 for example silicon-based and secured to the reflective layer 306, providing for mechanical support of the assembly (
The mechanical handle 204 is then removed and the making of the imager device 300 is completed by implementing steps similar to those previously described in connection with
The previously described methods are particularly suitable for making THz imager devices operating for example in the range of wavelengths between about 0.5 THz and 10 THz, and advantageously between about 0.5 THz and 1.5 THz.
Number | Date | Country | Kind |
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13 51357 | Feb 2013 | FR | national |