This application claims the priority benefit of Italian Application for Patent No. 102021000017060, filed on Jun. 29, 2021, the content of which is hereby incorporated by reference in its entirety to the maximum extent allowable by law.
Embodiments herein concern a process for manufacturing a vertical conduction silicon carbide electronic device and a vertical conduction silicon carbide electronic device.
As known, silicon carbide (SiC) electronic devices such as Junction Barrier Schottky (JBS) diodes, Merged PiN Schottky (MIPS) diodes and MOSFET transistors, have better performances than silicon electronic devices, in particular for power applications, wherein high operating voltages or other specific operating conditions, such as high temperature, are employed.
A silicon carbide electronic device for power applications, hereinafter referred to as power device, comprises a silicon carbide body, a front metal region and a back metal region. In use, a current may flow through the silicon carbide body between the front metal region and the back metal region.
It is known to obtain the power device from a silicon carbide wafer having a front surface and a back surface, in one of its polytypes, such as 3C-SiC, 4H-SiC and 6H-SiC.
During initial manufacturing steps, devices like transistors, diodes, resistors, etc., are generally formed in the silicon carbide body from the front surface. Then, the front metal region is formed on the front surface to mutually interconnect the integrated devices as well as to allow connection of the power device with external circuit components and/or stages.
In addition, the back surface of the wafer is processed, so as to form the back metal region. To this end, a metal layer (e.g., nickel or titanium) is deposited on the back surface. Then, a laser beam is used to heat the metal layer and cause the metal layer to fully react with the silicon carbide atoms of the wafer, thereby forming a silicide layer (e.g., titanium or nickel silicide).
In detail, the used laser beam has a spot having an area that is much smaller than the area of the back surface of the wafer. Therefore, in order to entirely expose the back surface, a step-and-repeat approach is used, wherein a first laser shot exposes a first portion of the back surface, the laser beam (or the wafer) is moved, and a second laser shot exposes a second portion of the back surface.
In order to maximize the throughput of the manufacturing process, it is known to move the laser beam so that the spots of adjacent laser shots have possibly no overlap on the back surface. In practice, the laser beam is moved, between two consecutive shots, by a quantity that is approximately equal to the size of the spot. Subsequently, a metallization layer is deposited on the silicide layer. After final manufacturing steps including dicing, the power device is obtained.
The inventors have verified that, in some cases, the silicide layer of such known power devices has a low mechanical stability. In fact, during some reliability tests, it has been observed that the silicide layer has a high probability of delamination from the silicon carbide body or mechanical fracture, thereby causing failure of the power device.
There is a need to overcome the disadvantages of the prior art.
In an embodiment, a process for manufacturing a vertical conduction silicon carbide electronic device comprises: depositing, on a wafer comprising silicon carbide, a metal layer, the metal layer forming a contact face; and laser annealing the contact face with a laser beam, the laser beam having a footprint having a size, thereby causing the metal layer to react with the wafer, forming a silicide layer. The laser annealing of the contact face comprises: irradiating a first portion of the contact face, moving the footprint of the laser beam by a step smaller than the size of the footprint and irradiating a second portion of the contact face, thereby causing the first portion and the second portion of the contact face to overlap.
In an embodiment, a vertical conduction silicon carbide electronic device comprises: a body of silicon carbide; and a contact region of silicide extending on the body and forming a connection surface. The contact region comprises a first rough portion and a second rough portion, the first rough portion extending at a distance from the second rough portion, the first rough portion and the second rough portion including a plurality of irregularly arranged protrusions of silicide.
For a better understanding of the present invention, a non-limiting embodiment is now described, with reference to the attached drawings, wherein:
The work body 1 has already been subject to first manufacturing steps.
The work body 1 is formed by a wafer 5 of silicon carbide (SiC) in one of its polytypes, such as 3C-SiC, 4H-SiC and 6H-SiC, having a first surface 5A and a second surface 5B, and by a connection structure layer 8 extending on the first surface 5A of the wafer 5.
The wafer 5 comprises a work substrate 12, which forms the second surface 5B of the wafer 5, and a device layer 15, which forms the first surface 5A of the wafer 5 and extends directly on the work substrate 12.
The device layer 15 may be a portion of the work substrate 12 or may be an epitaxial layer grown on the work substrate 12.
The device layer 15 comprises current conduction zones, here not shown, whose structure, number and configuration depend on the specific application.
For example, the device layer 15 may comprise a drift layer and one or more implanted regions which may form, for example, source regions and body regions, depending on the specific application, examples whereof are shown for illustrative purposes in
In an embodiment, the device layer 15 may also comprise gate structures. In another embodiment, the device layer 15 may be a multilayer, with different device structures integrated in the various layers.
The connection structure layer 8 comprises one or more metal layers that form an electrical interconnect structure for the device layer 15.
According to an embodiment, the connection structure layer 8 may also comprise one or more layers of insulating materials, forming passivation structures.
The device layer 15 and the connection structure layer 8 form at least one die portion, here a plurality of die portions 18.
Each die portion 18 is intended to form a respective electronic device, after dicing the work body 1.
Each die portion 18 has a die area, which occupies a respective portion of the area of the first surface 5A of the wafer 5.
In
In detail, in this embodiment, each die portion 18 has a rectangular shape in top plan view. By way of example only, the die area may be approximately of few millimeters squared, for example approximately 4 mm by 5 mm.
Subsequently,
The contact layer 20 is a metal material such as nickel, titanium or an alloy of nickel and silicon, and has a thickness, measured parallel to the third axis Z, comprised for example between 20 nm and 150 nm, in particular of about 100 nm.
Then, as shown in
In detail, a laser source 30 is used to generate a light beam 33 and focus the light beam 33 on the contact surface 22.
The light beam 33 has an energy density higher than 3 J/cm2, for example comprised between 3.4 J/cm2 and 4.8 J/cm2, in particular of 4.0 J/cm2.
The light beam 33 has a wavelength comprised, for example, between 290 nm and 370 nm, in particular of 310 nm.
The light beam 33 may be a pulsed light beam having a duration comprised, for example, between 100 ns and 300 ns, in particular of 160 ns.
The light beam 33 has a beam footprint 35 on the contact surface 22.
In detail (
In particular, the beam energy may decrease linearly in the first sloped regions 37, from the first energy Emax,X to zero.
Moreover, in this embodiment, the first energy Emax,X is constant.
The first width WX may be comprised, for example, between 8 mm and 36 mm, in particular may be about 10 mm.
In this embodiment, the first slope length Ls,X is much smaller than the first plateau length Lp,X. For example, the first slope length Ls,X is comprised between 0.5% and 5% of the first plateau length Lp,X, in particular about 3% of the first plateau length Lp,X.
For example, the first slope length Ls,X may be comprised between 50 μm and 500 μm, in particular may be 300 μm.
Accordingly, in a first approximation, the first plateau length Lp,X is about the same as the first width WX of the beam footprint 35.
In addition (
In particular, here, the beam energy may decrease linearly in the second sloped regions 39, from the second energy Emax,Y to zero.
Moreover, in this embodiment, the second energy Emax,Y is constant and equal to the first energy Emax,X.
The second width WY may be comprised, for example, between 8 mm and 36 mm, in particular may be about 10 mm.
In this embodiment, also the second slope length Ls,Y is much smaller than the second plateau length Lp,Y. For example, the second slope length Ls,Y is comprised between 0.5% and 5% of the second plateau length Lp,Y, in particular about 3% of the second plateau length Lp,Y.
For example, the second slope length Ls,Y may be comprised between 50 μm and 500 μm, in particular may be 300 μm.
Accordingly, in a first approximation, the second plateau length Lp,Y is about the same as the second width WY of the beam footprint 35.
In this embodiment, the beam footprint 35 has the same energy profile as the ones shown in
Moreover, in this embodiment, the energy profile of the beam footprint 35 along any direction parallel to the first axis X is equal to the energy profile along any direction parallel to the second axis Y. Therefore, a 3-dimesional representation of the energy profile of the beam footprint 35 is a truncated pyramid, as shown in the perspective view of
The footprint 35 may be obtained for example using the laser LT-3100 manufactured by SCREEN Semiconductor Solutions Co., Ltd.
The beam footprint 35 forms a polygonal shape on the contact surface 22, in particular a squared shape, as shown in
In practice, for each portion of the contact surface 22 that is exposed by the laser beam 33, the beam footprint 35 forms a central region 42, which is irradiated with a constant energy and corresponds to the first plateau region 36 and the second plateau region 38, and a gradient region 44, which is irradiated with a non-constant energy and corresponds to the first sloped regions 37 and the second sloped regions 39, wherein the gradient region 44 surrounds the central region 42.
In
During the annealing step of
The laser beam 33 is absorbed by the contact layer 20 and by part of the work substrate 12. The absorbed light generates heat locally (i.e., immediately under the first portion 47 of the contact surface 22), for example to a depth of few microns from the contact surface 22.
The generated heat causes the contact layer 20 and the work substrate 12 to react locally, at a respective portion of the second surface 5B of the wafer 5, forming a silicide, for example nickel silicide or titanium silicide.
In order to cause the reaction of the entire contact layer 20 with the work substrate 12, the contact surface 22 is scanned using a step-and-repeat approach.
In detail, the work body 1 is moved with respect to the laser beam 33 so that the laser beam 33 is focused on a second portion 48 of the contact surface 22 (
For clarity, in
The second portion 48 of the contact surface 22 partially overlaps the first portion 47 of the contact surface 22 and partially extends next to the first portion 47 of the contact surface 22 along a first scanning line A parallel to the first axis X.
In detail, the relative movement of the work body 1 with respect to the laser source 30 causes the beam footprint 35 to move by a first shift step DX along the first scanning line A. Therefore, also the second portion 48 of the contact surface 22 is shifted with respect to the first portion 47 of the contact surface 22 along the first scanning line A, on the right in
The first shift step DX is smaller than the first width WX of the beam footprint 35.
In detail, the first shift step DX is a fraction of the first width WX, for example comprised between one tenth and one half of the first width WX, in particular about one fourth of the first width WX.
For example, in one embodiment, the first width WX may be 10 mm and the first shift step DX may be smaller than 2.5 mm.
Subsequently, the laser source 30 focuses the laser beam 33 on subsequent portions of the contact surface 22 along the first scanning line A throughout the entire length of the contact surface 22 along the first scanning line A.
Subsequently, the laser beam 33 scans the contact surface 22 along a second scanning line, here not shown, parallel to the first scanning line A and shifted along the second axis Y to expose a third portion 49 of the contact surface 22, as shown for example in
The third portion 49 of the contact surface 22 partially overlaps the first portion 47 of the contact surface 22 and partially extends next to the first portion 47 of the contact surface 22 along a direction parallel to the second axis Y.
In detail, the relative movement of the work body 1 with respect to the laser source 30 causes the beam footprint to move by a second shift step DY in a direction parallel to the second axis Y with respect to the position of the first portion 47 (
The second shift step DY is smaller than the second width WY. In detail, the second shift step DY is a fraction of the second width WY, for example comprised between one tenth and one half of the second width WY, in particular about one fourth of the second width WY.
For example, in one embodiment, the second width WY may be 10 mm and the second shift step DY may be smaller than 2.5 mm.
By repeating the steps discussed above, the entire contact surface 22 is scanned by the laser beam 33.
In general, adjacent irradiated portions of the contact surface 22 may be shifted by steps different from the first shift step DX and the second shift step DY.
For example, the first shift step DX may be different from the second shift step DY. In addition, the first shift step DX or the second shift step DY may be varied along a same scan line or among different scan lines. This may allow to tune the distance between adjacent gradient regions 44, for example to increase (or decrease) the density of gradient regions 44 in specific portions of the contact surface 22.
The ohmic layer 50 is of silicide and extends between a first surface 50A, which corresponds to the second surface 5B of the wafer 5, and a second surface 50B, which corresponds to the contact surface 22.
Generally, the ohmic layer 50 is thicker than the contact layer 20, since also part of the work substrate 12 has reacted to form the ohmic layer 50.
The smooth regions 57 correspond to the portions of the contact surface 22 that have been exposed only to the first plateau region 36 and the second plateau region 38 of the beam footprint 35 (i.e., that have received a spatially uniform energy).
The rough region 55 corresponds to the gradient portions 44 of the contact surface 22 (i.e., to the portions of the contact surface 22 that have received a spatially non-uniform energy).
The gradient of energy of the gradient regions 44 generates in fact also a thermal gradient during the laser annealing step of
Again, with reference to
Each horizontal stripe 58 has a width Lx, parallel to the first axis X, which approximately corresponds to the first slope length Ls,X of the beam footprint 35 and extends at a distance from an adjacent horizontal stripe 58 that is approximately equal to the first shift step DX.
Each vertical stripe 59 has a width LY, parallel to the second axis Y, which approximately corresponds to the second slope length Ls,Y of the beam footprint 35 and extends at a distance from an adjacent vertical stripe 59 that is approximately equal to the second shift step DY.
By changing the first shift step DX and the second shift step DY, the number of horizontal stripes 58 and vertical stripes 59 may be changed.
In this embodiment, as visible in
In
The metallization layer 60 is useful for subsequent manufacturing steps, for example assembling processes such as sintering and diffusion soldering.
The work body 1 is then subject to known final manufacturing steps, such as dicing, thereby forming an electronic device 100 (
The electronic device 100 comprises a die 103 including a body 105 having a first surface 105A, which corresponds to the first surface 5A of the wafer 5, and a second surface 105B, which corresponds to the first surface 50A of the ohmic layer 50.
The body 105 comprises a substrate 107 (corresponding to the work substrate 12 and forming the second surface 105B) and a device region 109 (corresponding to the device layer 15 and forming the first surface 105A).
The device region 109, as discussed above for the device layer 15, accommodates functional regions of various kind and dimensions, according to the specific type of the electronic device 100 and the specific application.
By way of example, the electronic device 100 may be a JBS or an MPS diode. In this case, as shown in
As an alternative, as also shown as an example in
The die 103 comprises an ohmic connection region 123, corresponding to the ohmic layer 50, extending on the second surface 105B of the body 105 and forming a metallization contact surface, which corresponds to the second surface 50B of the ohmic layer 50 and therefore it is indicated by the same reference number.
The die 103 also comprises a back metallization region 125 corresponding to the metallization layer 60 and extending on the metallization contact surface 50B.
The die 103 further comprises a connection structure region 127 corresponding to the connection structure layer 8, extending on the first surface 105A of the body 105.
In detail, the device region 109 and the connection structure region 127 correspond to a respective die portion 18 (
In use, the electronic device 100 has a current path 128, schematically represented by a dashed arrow in
In use, a current may flow through the current path 128, depending on the specific structure of the device region 109 (i.e., on the type of the electronic device 100).
The ohmic connection region 123 shows a high mechanical stability.
The ohmic connection region 123 comprises a rough region and one or more smooth regions. The rough region and the smooth regions correspond to the portion of the rough region 55 and, respectively, to the smooth regions 57 within the respective die portion 18 of
The shape of the rough region 55 of the ohmic connection region 123 depends on the first and the second shift step DX, DY, and on the first width WX, the second width WY, the first slope length Ls,X and the second slope length Ls,Y of the beam footprint 35. Accordingly, the rough region 55 of the ohmic connection region 123 is formed by portions of the horizontal stripes 58 and portions of the vertical stripes 59.
In detail, in this embodiment, the rough region 55 of the ohmic connection region 123 is formed by portions of two adjacent horizontal stripes 58 and portions of two adjacent vertical stripes 59.
Depending on the first and the second shift step DX, DY, and on the first width WX, the second width WY, the first slope length Ls,X and the second slope length Ls,Y of the beam footprint 35, the percentage of the ohmic connection region 123 that is formed by the smooth regions 57 (and accordingly by the rough region 55) may be varied.
The rough region 55 of the ohmic connection region 123 has a non-uniform thickness along the third axis Z.
The rough region 55 of the ohmic connection region 123 has, at the second surface 105B of the body 105 and at the second surface 50B of the ohmic connection region 123, a higher roughness than the smooth regions 57 of the ohmic connection region 123.
The micrograph of
The inventors have verified that the protrusions 140 increase the mechanical robustness of the ohmic connection region 123. The electronic device 100 is therefore less subject to mechanical defects such as fracture and delamination of the ohmic connection region 123.
In particular, a shear test of the electronic device 100, performed by the inventors after subjecting test devices to one hundred thermal cycles, shows an average increase of the shear strength of the electronic device 100 even up to 156% with respect to a case wherein the electronic device 100 has no overlap portions.
At the same time, the ohmic connection region 123 ensures a good electrical contact, in particular an ohmic contact, with the substrate 107. Therefore, the electronic device 100 also maintains good electrical properties.
It is clear that the present manufacturing method and the corresponding electronic device may be subject to modifications and variations without departing the scope of the present invention, as defined in the attached claims.
For example, the beam footprint 35 may have a different shape such as rectangular, circular or any other shape.
In addition, the energy profile along the first axis may be different from the energy profile along the second axis Y. For example, the spatial trend of the first and the second sloped regions 37, 39 may be different, such as non-linear.
Moreover, a higher number of laser shots or pulses may be used to expose each irradiated portion of the contact surface 22. For example, two to five laser shots or pulses may be used.
In the annealing step of
Moreover, the shape of the rough region 55 of
Alternatively, the rough region 55 may have a shape different from a grid, for example the rough region 55 may form a non-regular pattern such as a plurality of separated portions with increased roughness.
Number | Date | Country | Kind |
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102021000017060 | Jun 2021 | IT | national |