This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2014-188005, filed Sep. 16, 2014, the entire contents of which are incorporated herein by reference.
Embodiments described herein relate generally to a semiconductor device and a manufacturing method thereof.
In a semiconductor device such as a gallium nitride based HEMT (High Electron Mobility Transistor) or the like, a plurality of gallium nitride containing layers are stacked one over the other on a substrate. A source electrode is formed on the stacked body, and a drain electrode is disposed to the side of the source electrode. A gate electrode is disposed between the source electrode and the drain electrode. In such a semiconductor device, a high breakdown strength is required not only the in the lateral direction but also in the vertical direction.
Here, to lower a manufacturing cost of such a semiconductor device, an inexpensive, as compared to other alternatives, silicon substrate may be used as the substrate of the semiconductor device. Further, in forming a stacked body (film stack) on the silicon substrate, there may be a case where an aluminum nitride layer which configures a buffer layer is formed between the silicon substrate and the stacked nitride body. As a method of increasing a breakdown strength in the vertical direction, there has been known a method where a thickness of the aluminum nitride layer and a thickness of the stacked body are increased as much as possible.
However, when a film thickness of aluminum nitride layer becomes, or exceeds, a predetermined film thickness as a result of increasing the film thickness of the aluminum nitride layer, the stacked body per se does not have an inherent compressive stress at the time of growing thereof. Accordingly, when a temperature of the stacked body returns to a normal temperature from that for the deposition/growth of the nitride semiconductors, there is a possibility of generating defects within the stacked body. When the semiconductor device is manufactured using such a stacked body, the defect remains within the semiconductor device such that a breakdown strength of the semiconductor device is lowered.
An object of an embodiment is to provide a semiconductor device having high breakdown strength (breakdown voltage) and a method of manufacturing the semiconductor device.
In general, according to one embodiment, a semiconductor device includes: a silicon substrate; a multi-layered film formed on the silicon substrate, the multi-layered film including a first aluminum nitride containing layer, a second aluminum nitride containing layer, and a film stack having a super lattice structure in which, between the first aluminum nitride containing layer and the second aluminum nitride containing layer, at least two layers selected from a group of layers including an aluminum nitride containing layer, a gallium nitride containing layer and an aluminum gallium nitride containing layer are alternately disposed between the first aluminum nitride containing layer and the second aluminum nitride containing layer, and a first gallium nitride containing layer formed on the multi-layered film.
In the present disclosure, the same device elements and features as those described previously in the drawings are given the same reference numerals and symbols, and detailed descriptions thereof with respect to later drawings are appropriately omitted.
A semiconductor device (hereinafter, for example, stacked structure 1) according to the first embodiment includes: a silicon substrate 10; a multi-layered film 20 having a plurality of layers; and a first gallium nitride containing layer (hereinafter, for example, gallium nitride containing layer 30) including a plurality of layers. The stacked structure 1 is applicable to a HEMT or the like, for example (described later). Further, the stacked structure 1 illustrated in
In the stacked structure 1, the multi-layered film 20 is formed on the silicon substrate 10. A surface 10u of the silicon substrate 10 on the multi-layered film. 20 forming side is a (111) plane of silicon crystal as an example. The multi-layered film 20 includes: a first aluminum nitride containing layer (hereinafter, for example, an aluminum nitride containing layer 21); a second aluminum nitride containing layer (hereinafter, for example, an aluminum nitride containing layer 22); and a film stack (hereinafter, for example, a super lattice structure (SLs) 23). The super lattice structure 23 is located between the aluminum nitride containing layer 21 and the aluminum nitride containing layer 22. The gallium nitride containing layer 30 is formed on the multi-layered film 20 (AlN layers 21, 22 and superlattice structure 23.
The aluminum nitride containing layer 21 is provided to avoid the gallium nitride containing layer 30 and the silicon substrate 10 being in direct contact with each other. Accordingly, a reaction between gallium (Ga) and silicon (Si) in the stacked structure 1 may be suppressed. The film thickness of the aluminum nitride containing layer 21 falls within a range from 10 nm (nanometer) to 300 nm inclusive, for example. The film thickness of the aluminum nitride containing layer 22 falls within a range from 10 nm to 300 nm inclusive, for example.
The super lattice structure 23 includes multiple layers 25 and multiple layers 26. In the super lattice structure 23, the layer 25 and the layer 26 are disposed alternately in the direction toward the gallium nitride containing layer 30 from the silicon substrate 10 (for example, in the Z direction in
The gallium nitride containing layer 30 includes: a fifth aluminum gallium nitride containing layer (hereinafter, for example, an aluminum gallium nitride containing layer 31); a fourth gallium nitride containing layer (hereinafter, for example, a gallium nitride containing layer 32); and a fifth aluminum gallium nitride containing layer (hereinafter, for example, an aluminum gallium nitride containing layer 33).
The aluminum gallium nitride containing layer 31 is formed on the multi-layered film 20. The aluminum gallium nitride containing layer 31 may be omitted. The gallium nitride containing layer 32 is formed on the aluminum gallium nitride containing layer 31. The aluminum gallium nitride containing layer 33 is formed on the gallium nitride containing layer 32. The film thickness of the gallium nitride containing layer 30 falls within a range from 1 μm to 10 μm inclusive, for example.
The combination of the layers 25 and the layers 26 included in the super lattice structure 23 may be a super lattice structure 23A illustrated in
In the super lattice structure 23A illustrated in
In the super lattice structure 23B illustrated in
In the super lattice structure 23C illustrated in
Before explaining manufacturing steps of the stacked structure 1 according to the first embodiment, manufacturing steps of a stacked structure according to a reference example are explained.
In the manufacturing steps according to the reference example, the manufacturing steps proceed without forming the super lattice structure 23 and the aluminum nitride containing layer 22 according to the first embodiment. A growth temperature during epitaxial growth of the nitride layers 25, 26 ranges from 900° C. to 1,100° C., for example.
For example, as illustrated in
The lattice constant of an aluminum nitride crystal is smaller than the lattice constant of the silicon crystal (111). Accordingly, as illustrated in
However, as illustrated in
Next, as illustrated in
The lattice constant of a gallium nitride crystal is larger than the lattice constant of an aluminum nitride crystal. Accordingly, as illustrated in
Next, the epitaxial growth of the gallium nitride containing layer 30 is finished, and the temperature of the whole wafer is lowered to a normal temperature from a temperature at the time of epitaxially growth of the gallium nitride containing layer 30. Here, a thermal expansion coefficient of gallium nitride crystal is larger than a thermal expansion coefficient of silicon crystal.
Accordingly, as illustrated in
On the other hand,
For example, as shown in
In the first embodiment, the growth of the aluminum nitride containing layer 21 is stopped before a film thickness of the aluminum nitride containing layer 21 reaches a critical film thickness.
Next, as illustrated in
Next, as illustrated in
Here, both of the aluminum nitride containing layers 21, 22 have a tensile stress therein, i.e., they are in tension. Further, a sub-critical thickness single-layered aluminum nitride containing layer 22 is formed on the super lattice structure 23.
Next, as illustrated in
Here, a lattice constant of gallium nitride crystal is larger than a lattice constant of aluminum nitride crystal. Accordingly, as illustrated in
Next, epitaxial growth of the gallium nitride containing layer 30 is stopped, and a temperature of the whole wafer is lowered to a normal temperature from a temperature during the epitaxial growth of the gallium nitride containing layer 30. Here, a tensile stress remains within the aluminum nitride containing layers 21, 22 which underlie the gallium nitride containing layer 30 during the epitaxial growth. Further, a lattice constant of a surface layer of the aluminum nitride containing layer 22 takes an approximately fixed value. That is, the gallium nitride containing layer 30 maintains a sufficient compressive stress during the growth of the gallium nitride containing layer 30.
Accordingly, even when the gallium nitride containing layer 30 shrinks, the wafer maintains an upwardly protruding (concavity extends upwardly) state. Such a state is illustrated in
That is, in the first embodiment, the wafer does not warp in a downwardly protruding manner and hence, the gallium nitride containing layer 30 is not brought into a state where a tensile stress is applied to the inside of the gallium nitride containing layer 30 at a normal temperature, whereby the defects 30cr minimally occur in the gallium nitride containing layer 30. Accordingly, it is possible to acquire the high-quality gallium nitride containing layer 30.
In the structure 1 according to the first embodiment, the multi-layered film 20 having a large film thickness compared to the aluminum nitride containing layer 21 is formed on the silicon substrate 10. Accordingly, a breakdown strength of the stacked structure 1 in the Z direction is increased.
A semiconductor device 100 according to the second embodiment includes: the above-mentioned stacked structure 1; a first electrode (hereinafter, for example, a source electrode 51) which is formed on the stacked structure 1; a second electrode (hereinafter, for example, a drain electrode 52) which is disposed parallel to the source electrode 51; and a third electrode (hereinafter, for example, a gate electrode 50) which is disposed between the source electrode 51 and the drain electrode 52. A gate insulation film 53 is disposed between the gate electrode 50 and the stacked structure 1. The semiconductor device 100 is an HEMT.
The source electrode 51 and the drain electrode 52 are in ohmic contact with the aluminum gallium nitride containing layer 33. The gate insulation film 53 includes one of silicon nitride (Si3N4), silicon oxide (SiO2) and aluminum oxide (Al2O3).
The multi-layered film 20 and the aluminum gallium nitride containing layer 31 function as a buffer layer of the HEMT respectively. The gallium nitride containing layer 32 functions as a carrier layer of the HEMT. The aluminum gallium nitride containing layer 33 functions as a barrier layer of the HEMT. The aluminum gallium nitride containing layer 33 is a non-doped layer or an n-type AlxGa1-xN(0<X≦1) layer. Two-dimensional electron gas is generated in the gallium nitride containing layer 32 in the vicinity of a boundary between the gallium nitride containing layer 32 and the aluminum gallium nitride containing layer 33.
The semiconductor device 100 includes the multi-layered film 20 having a large film thickness between the silicon substrate 10 and the gallium nitride containing layer 30. Accordingly, a breakdown strength of the semiconductor device 100 in the Z direction is increased.
In this disclosure, “nitride semiconductor” comprehensively includes all semiconductors having the composition where composition ratios x, y and z are changed within respective ranges in a chemical formula BxInyAlzGa1-x-y-zN (0≦x≦1, 0≦z≦1, x+y+z≦1). Further, “nitride semiconductor” may further include semiconductors having the composition where a group V element other than N (nitrogen) is further added to the above-mentioned chemical formula, semiconductors having the composition where various elements added for controlling various physical properties such as a conductive type are further added to the above-mentioned chemical formula, and semiconductors having the composition where various elements which are contained unintentionally are added.
In the embodiment described above, “on” in an expression that “a portion A is provided on a portion B” is used to mean a case where the portion A does not come into contact with the portion B and the portion A is provided above the portion B in addition to a case where the portion A comes into contact with the portion B and the portion A is provided on the portion B. Furthermore, “the portion A is provided on the portion B” may be applied to a case where the portion A and the portion B are reversed and the portion A is positioned below the portion B, or a case where the portion A and the portion B are horizontally provided in the same line with each other. This is because the structure of the semiconductor device is not changed between before and after the rotation even if the semiconductor device according to the embodiment is rotated.
Hitherto, the embodiments are described with reference to the specific examples. However, the embodiments are not limited to the specific examples. That is, one in which those skilled in the art apply appropriate design changes to those specific examples is included in the range of the embodiments as long as it includes the characteristics of the embodiments. Each element included in the specific examples and, a disposition, a material, a condition, a shape, a size thereof, and the like are not limited to those which are illustrated above and can be appropriately changed.
Furthermore, each of the elements included in each embodiment can be combined as long as it is technically possible and the combination is included in the range of the embodiments as long as each of the elements includes the characteristics of the embodiments. In addition, in a category of the spirit of the embodiments, those skilled in the art can derive various modified examples and corrected examples, and the modified examples and the corrected examples are understood to be also included in the range of the embodiments.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
Number | Date | Country | Kind |
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2014-188005 | Sep 2014 | JP | national |