In at least one aspect, methods for fabricating heterostructure transistors are provided.
Epitaxial heterostructures with lattice mismatch generate defects thereby making epitaxial growth of single crystalline material on a dielectric challenging. Moreover, devices on high thermal conductivity and high electron conductivity substrates are also challenging to fabricate.
Accordingly, there is a need for improved techniques for fabricating low defect epitaxial heterostructures such as high electron conductivity devices, and in particular high power transistors.
In at least one aspect, a method for fabricating low defective non-planar heterostructure transistors is provided. The method includes a step of providing a substrate that is coated with a first dielectric layer when the substrate is not composed of a dielectric material. A layer of a first semiconductor material is formed by template liquid phase (TLP) crystal growth wherein a second dielectric layer is disposed over the first semiconductor material. A trench is patterned into the second dielectric layer. An intermediate heterostructure is formed by epitaxially growing second semiconductor material in the trench to form a fin structure therein. Various power transistor structures can be formed from the intermediate heterostructure.
In another aspect, a method of growing high-quality single-crystalline heterostructures through a sequential growth of non-epitaxial template followed by an epitaxial replacement fin growth technique for device applications is provided.
In another aspect, high-quality single-crystalline heterostructure material on dielectric materials is provided.
In another aspect, a method of growing high-quality single crystalline heterostructure through a sequential growth and patterning of non-epitaxial layer(s) followed by an epitaxial replacement fin growth technique for device applications.
In another aspect, novel structures and methods for bipolar junction and high-mobility electron transistors is provided.
In another aspect, the growth techniques set forth herein enable the monolithic formation of heterogeneous heterojunctions focusing on interfaces that will enable improved performance in power transistors such as bipolar junctions.
In another aspect, heteroepitaxial growth on substrates such as diamond, an active part of the electron and thermal conductivity is provided.
In another aspect, a crystal growth technique includes steps of depositing a layer of a Group III metal onto the first dielectric layer, depositing a second dielectric layer over the layer of a Group III metal, heating or annealing the layer of a Group III metal to form a liquid layer thereof; and exposing the layer of a Group III metal to a gas comprising a Group V atom to form the III-V material.
In another aspect, a crystal growth technique is a template liquid phase (TLP) crystal growth technique.
In another aspect, a high electron mobility transistor includes a substrate and a first dielectric layer disposed over the substrate. A layer of a first semiconductor material is disposed over and directly contacts the first dielectric layer without a separate adhesive layer. The layer of a first semiconductor material has a defect density of 106 defects/cm2 or less. A fin structure is composed of a second semiconductor material. The fin structure is epitaxially growth on the layer of a first semiconductor material. A metal gate layer is disposed on top of the fin structure. Finally, a source is disposed over the fin structure and positioned at a first side of the metal gate layer and a drain disposed over the fin structure and positioned at a second side of the metal gate layer where the first side is an opposite side to the second side. Advantageously, the electron mobility transistor can include an array of fin structures each having a metal contact position on the top thereof.
In another aspect, a bipolar junction transistor is provided. The bipolar junction transistor includes an electrically conductive substrate, a first dielectric layer disposed over the substrate, and a layer of a first semiconductor material disposed over and directly contacting the first dielectric layer without a separate adhesive layer. Characteristically, the layer of a first semiconductor material having a defect density of 106 defects/cm2 or less. A second dielectric layer is disposed over the layer of a first semiconductor material. A trench is defined by the second dielectric layer. A fin structure including a second semiconductor material is disposed in the trench. The fin structure is epitaxially growth on the layer of a first semiconductor material. A fin contact disposed on top of the fin structure. A first contact extends from a top surface of the second dielectric layer to the layer of a first semiconductor material while a second contact extends from a top surface of the second dielectric layer to the electrically conductive substrate. Advantageously, the bipolar junction transistor can includes an array of fin structures each having a metal contact position on the top thereof.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
For a further understanding of the nature, objects, and advantages of the present disclosure, reference should be made to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
Reference will now be made in detail to presently preferred compositions, embodiments and methods of the present invention, which constitute the best modes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.
Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word “about” in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, “parts of,” and ratio values are by weight; the term “polymer” includes “oligomer,” “copolymer,” “terpolymer,” and the like; molecular weights provided for any polymers refers to weight average molecular weight unless otherwise indicated; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.
It must also be noted that, as used in the specification and the appended claims, the singular form “a,” “an,” and “the” comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.
As used herein, the term “about” means that the amount or value in question may be the specific value designated or some other value in its neighborhood. Generally, the term “about” denoting a certain value is intended to denote a range within +/−5% of the value. As one example, the phrase “about 100” denotes a range of 100+/−5, i.e. the range from 95 to 105. Generally, when the term “about” is used, it can be expected that similar results or effects according to the invention can be obtained within a range of +/−5% of the indicated value.
As used herein, the term “and/or” means that either all or only one of the elements of said group may be present. For example, “A and/or B” shall mean “only A. or only B. or both A and B”. In the case of “only A”, the term also covers the possibility that B is absent, i.e. “only A, but not B”.
It is also to be understood that this invention is not limited to the specific embodiments and methods described below, as specific components and/or conditions may, of course, vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present invention and is not intended to be limiting in any way.
The term “comprising” is synonymous with “including,” “having,” “containing,” or “characterized by.” These terms are inclusive and open-ended and do not exclude additional, unrecited elements or method steps.
The phrase “consisting of” excludes any element, step, or ingredient not specified in the claim. When this phrase appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.
The phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.
The phrase “composed of” means “including” or “consisting of.” Typically, this phrase is used to denote that an object is formed from a material.
With respect to the terms “comprising,” “consisting of,” and “consisting essentially of,” where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.
The term “one or more” means “at least one” and the term “at least one” means “one or more.” The terms “one or more” and “at least one” include “plurality” and “multiple” as a subset. In a refinement, “one or more” includes “two or more.”
The term “substantially,” “generally,” or “about” may be used herein to describe disclosed or claimed embodiments. The term “substantially” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” may signify that the value or relative characteristic it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.
It should also be appreciated that integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4 . . . 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1. to 2.1 the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits.
When referring to a numeral quantity, in a refinement, the term “less than” includes a lower non-included limit that is 5 percent of the number indicated after “less than.” For example, “less than 20” includes a lower non-included limit of 1 in a refinement. Therefore, this refinement of “less than 20” includes a range between 1 and 20. In another refinement, the term “less than” includes a lower non-included limit that is, in increasing order of preference, 20 percent, 10 percent, 5 percent, or 1 percent of the number indicated after “less than.”
For all compounds or materials expressed as an empirical chemical formula with a plurality of letters and numeric subscripts (e.g., CH2O), values of the subscripts can be plus or minus 50 percent of the values indicated rounded to or truncated to two significant figures. For example, if CH2O is indicated, a compound of formula C(0.8-1.2)H(1.6-2.4)O(0.8-1.2). In a refinement, values of the subscripts can be plus or minus 30 percent of the values indicated rounded to or truncated to two significant figures. In still another refinement, values of the subscripts can be plus or minus 20 percent of the values indicated rounded to or truncated to two significant figures.
Throughout this application, where publications are referenced, the disclosures of these publications in their entireties are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains.
“HEMT” means high electron mobility transistor formation.
“TLP” means template liquid phase.
“EUV” means extreme ultraviolet radiation.
“LELE” means litho-etch-litho-etch.
“MOCVD” means metal-organic chemical vapor deposition.
“RIE” means reactive-ion etching.
Referring to
Still referring to
In step b), trench 22 is patterned into the second dielectric layer 16. Trench 22 can be formed using e-beam lithography, EUV lithography, or LELE patterning techniques followed by etching (e.g., RIE) to form the trench. In step c), intermediate heterostructure 23 is formed by epitaxially growing second semiconductor material 24 into the trench to form a fin structure 26. In a refinement, fin structure 26 has a height less than about 60 nm and a width less than or equal to 10 nm. Second semiconductor material 24 can be epitaxially grown by MOCVD. Fin structure 26 typically has a defect density of 106 defects/cm2 or less. In a refinement, fin structure 26 has a defect density of 105 defects/cm2 or less. Examples of the second semiconductor material include but are not limited to gallium nitride, aluminum gallium nitride, indium gallium phosphide, indium phosphide, indium nitride, aluminum nitride, and combinations thereof. Fin structure 26 can be coated with a layer of a high K material. Table 1 provides non-limiting examples for intermediate heterostructure 23.
Various power transistor structures can be formed from intermediate heterostructure 23 as follows. For example, a high electron mobility transistor is formed as follows. In step d1, second dielectric layer 16 is removed and a metal gate layer 28 is disposed over fin structure 26 and portions of layer 20. In step e1, source 30 and drain 32 are deposited to form transistor 34. In a refinement, an array of fin structures are formed interposed between the source and drain. In a variation as described below in more detail, a source 30 is deposited onto the layer of a first semiconductor material at a first side of the metal gate layer. Similarly, drain 32 is deposited onto the layer of a first semiconductor material at a second side of the metal gate layer with the first side being an opposite side to the second side. In a refinement, the source and drain are independently composed of a semiconductor. In a refinement, the source and drain extend to the first semiconductor material.
In another example, a transistor (e.g., a bipolar transistor) is formed as follows. In step d2, first contact 40 is formed from surface 42 of second dielectric layer 16 to layer 20 while second contact 44 is formed from surface 42 of second dielectric layer 16 to substrate 10. A fin contact 46 (e.g., a gate layer) is optionally deposited on top of the fin structure.
In step d), silicon dioxide layer 56 is removed and the fin 64 and exposed portion of gallium nitride layer 60 are coated with gate layer 74.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
This application claims the benefit of U.S. provisional application Ser. No. 63/221,638 filed Jul. 14, 2021, the disclosure of which is hereby incorporated in its entirety by reference herein.
Filing Document | Filing Date | Country | Kind |
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PCT/US2022/037174 | 7/14/2022 | WO |
Number | Date | Country | |
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63221638 | Jul 2021 | US |