Embodiments of the disclosed subject matter generally relate to semiconductor devices having a group-III oxide active layer comprising at least two group-III materials and methods for forming such devices so that the content of the group-III materials of the active layer can be selected to achieve a desired content of the group-III materials.
Group-III oxides are particularly useful materials for use as an active layer in a number of different types of semiconductor devices, including power transistors and photodetectors. Different group-III materials exhibit different effects on the active layer. For example, it is common to form power transistors, such as power metal-insulator-semiconductor field-effect transistors (MISFETs) having an active layer comprising gallium oxide (Ga2O3). One study demonstrated that a photodetector with a gallium oxide active layer can produce higher photocurrent and exhibit an improved response by adding aluminum so that the active layer comprises aluminum gallium oxide ((AlxGa1-x)2O3).
One conventional way of forming an aluminum gallium oxide active layer on a substrate is using pulsed laser deposition (PLD) in which a target having a particular composition of aluminum, gallium, and oxygen is subjected to a pulsed laser, which causes the materials of the target to rise and be deposited on a substrate. The amount of each of aluminum, gallium, and oxygen in the target is predetermined and corresponds to the desired amount of each of these materials in the active layer formed by pulsed laser deposition. Thus, any error in the composition of aluminum and gallium in the target will result in the active layer formed using pulsed laser deposition not having the corresponding desired amount of aluminum and gallium, and thus the resulting semiconductor device may not operate as intended, e.g., it may be less efficient and/or less responsive. Further, the conventional technique limits customizability of the composition of the active layer because each different composition requires creating targets having corresponding different compositions. Moreover, the conventional pulsed laser deposition technique can result in an active layer having crystal defects, which can reduce the efficiency and responsiveness of the active layer.
Thus, there is a need for a method for forming a semiconductor device having a group-III oxide active layer comprising at least two group-III materials that provides greater control over the amount of one of the at least two group-III materials in the active layer in a simpler manner than conventional pulsed laser deposition techniques and forms group-III oxide active layer comprising at least two group-III materials with improved crystal quality compared to active layers formed with conventional pulsed laser deposition techniques.
According to an embodiment, there is a method for forming a semiconductor device with a group-III oxide active layer comprising at least two group-III materials. A group-III oxide substrate is provided and a group-III oxide active layer comprising at least one group-III material is formed on the group-III oxide substrate. A group-III material in the group-III oxide substrate is different from the at least one group-III material in the group-III oxide active layer. The group-III oxide active layer comprising at least one group-III material and the group-III oxide substrate are annealed at a temperature greater than or equal to 1,000° C. so that the group-III material in the group-III oxide substrate diffuses into the group-III oxide active layer to form the group-III oxide active layer comprising the at least two group-III materials.
According to another embodiment, there is a semiconductor device with a group-III oxide active layer comprising at least two group-III materials. The semiconductor device comprises a group-III oxide substrate, a group-III oxide active layer comprising the at least two group-III materials and arranged on the group-III oxide substrate. One of the at least two group-III materials of the group-III oxide active layer is a same group-III material as in the group-III oxide substrate. An inter-diffusion region is arranged between the group-III oxide substrate and the group-III oxide active layer.
According to a further embodiment, there is a method for forming a semiconductor device with a group-III oxide active layer comprising at least two group-III materials. An amount of one of the two group-III materials for the group-III oxide active layer comprising the at least two group-III materials is determined. An annealing temperature is determined based on the determined amount of the one of the at least two group-III materials. A group-III oxide active layer comprising at least one group-III material is formed on a group-III oxide substrate. The group-III oxide substrate includes the one of the at least two group-III materials. The group-III oxide active layer comprising at least one group-III material and the group-III oxide substrate are annealed at the determined annealing temperature so that the one of the at least two group-III materials in the group-III oxide substrate diffuses into the group-III oxide active layer comprising at least one group-III material to form the group-III oxide active layer comprising the at least two group-III materials. The determined annealing temperature is greater than or equal to 1,000° C.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:
The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of semiconductor devices having a group-III oxide active layer comprising at least two group-II II materials.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
A method for forming a semiconductor device having a group-III oxide active layer comprising at least two group-III materials according to embodiments will now be described in connection with
The group-III oxide active layer comprising at least one group-III material 210 can be alpha-, beta-, or epsilon-phase. Similarly, group-III oxide active layer comprising at least two group-III materials 215 can be alpha-, beta-, or epsilon-phase. However, in practice, the high-temperature annealing will, in many cases, result in a beta-phase because this is the most stable phase.
The group-III material in the group-III oxide substrate 205 can be any group-III material, including aluminum, gallium, indium, or boron. For example, the group-III oxide substrate 205 can be comprised of aluminum oxide (Al2O3), i.e., sapphire, or gallium oxide (Ga2O3). The high temperature annealing causes the group-III material and oxide of the group-III oxide substrate 205 to diffuse into the group-III oxide active layer comprising at least one group-III material 210 to form a group-III oxide active layer comprising at least two group-III materials 215. It has been recognized that there is a dependence between the annealing temperature and the amount of the group-III material that diffuses from the group-III oxide substrate 205 into the group-III oxide layer active layer comprising at least one group-III material 210, the details of which will be addressed below. In general, the annealing temperature can be greater than or equal to 1,000° C. and less than or equal to 1,500° C. The annealing also improves the crystal quality of the group-III oxide layer active layer comprising at least two group-III materials 215. Based on experiments, it was found that the crystal quality of a beta-phase aluminum group-III oxide layer active layer 215 did not improve much past three hours of annealing, and thus the annealing can be performed for three hours.
The annealing can be performed with ambient air and the group-III oxide active layer comprising at least one group-III material 210 can be formed using pulsed laser deposition (PLD). The method is applicable to a variety of different compositions of group-III materials and the composition can be, for example, a binary composition including a single group-III material or can be a ternary composition including two group-III materials. The group-III material of the group-III oxide active layer comprising at least one group-III material 210 can be aluminum, gallium, indium, or boron. It should be recognized that at least one of the group-III materials of the group-III oxide substrate 205 is a different group-III material than at least one of the group-III materials of the group-III oxide active layer comprising at least one group-IIII material 210. For example, the group-III oxide substrate 205 can comprise aluminum oxide (Al2O3), gallium oxide (Ga2O3), indium oxide (In2O3), or boron oxide (B2O3), and the group-III oxide active layer comprising at least one group-II II material 210 can be the other one of Al2O3, Ga2O3, In2O3, and B2O3. Thus, after annealing, the group-III oxide layer active layer 215 can be an aluminum gallium oxide ((AlGa)2O3) active layer, an aluminum indium oxide ((AlIn)2O3) active layer, an aluminum boron oxide ((AlB)2O3) active layer, an aluminum gallium indium oxide ((AlGaIn)2O3) active layer, an aluminum gallium boron oxide ((AlGaB)2O3) active layer, an aluminum indium boron ((AlInB)2O3) active layer, a gallium indium oxide ((GaIn)2O3) active layer, a gallium boron oxide ((GaB)2O3) active layer, a boron indium oxide ((BIn)2O3) active layer, a gallium indium boron oxide ((GaInB)2O3) active layer, etc.
The diffusion occurring during the annealing forms an inter-diffusion region between the group-III oxide substrate 205 and the group-III oxide active layer comprising at least two group-III materials 215. A non-limiting example will now be presented in connection with
It should be recognized that in
The semiconductor device comprising the group-III oxide substrate 205 and the group-III oxide active layer comprising at least two group-III materials 215 can be used to form, for example, a photodetector or power transistor, such as a metal-insulator-semiconductor field effect transistor (MISFET). Returning to the non-limiting example of a beta-phase aluminum gallium oxide active layer 215 formed on a sapphire substrate, by adjusting the amount of aluminum incorporated into a group-III oxide active layer to form a ternary alloy, e.g., β-(AlGa)2O3, the cut-off wavelength of a deep-ultra-violet (UV) photodetector can be adjusted. It will be recognized that the scaling of a power transistor, such as a MISFET, is benefited by a higher breakdown voltage of the active layer with wider energy bandgap engineering, which can be achieved using the aluminum group-III oxide active layer. This non-limiting example applies equally to other substrates 205 and group-III oxide active layers 215 having different constituent materials, the combinations of which are described above
As mentioned above, it has been recognized that there is a correlation between the annealing temperature and the amount of the group-III material that diffuses from the group-III oxide substrate 205. A method for forming a semiconductor device with a group-III oxide active layer comprising at least two group-III materials 215 using this correlation is illustrated in
A graph formed using the data from this table is illustrated in
Table 1 also includes data collected from testing identifying the (−201) β-Ga2O3 peak, the (0006) sapphire peak and the difference in the β-Ga2O3 peak between the deposited but not annealed gallium oxide active layer versus the annealed gallium oxide active layer that includes aluminum as the result of the annealing. These additional columns demonstrate that the annealing had little effect on the sapphire substrate but the β-Ga2O3 peak increased as the result of annealing due to the diffusion of aluminum into the active layer. These additional columns are included in Table 1 merely to demonstrate that aluminum from the sapphire substrate diffused into the active layer and these additional columns need not be part of a look-up table used to determine the annealing temperature to obtain a particular aluminum content in the active layer.
Returning to
Similar to the method discussed above in connection with
The beta-phase gallium oxide active layers that were used to determine the aluminum content of the annealed active layer were also evaluated to determine the crystallinity of the annealed active layer, the results of which are reproduced in Table 2 below.
As reflected in Table 2, as the annealing temperature increased the crystallinity of the active layer improved. The FWHM of the rocking curve reduces with increased annealing temperatures and the crystalline domain size also increases, which results in a better crystal quality. The AFM RMS value, which corresponds to the surface roughness of the aluminum group-III oxide active layer maintains a relatively stable value (<1.85 nm, below 1400° C.) until the annealing temperature reaches 1500° C. By selecting an appropriate annealing temperature and time, one can obtain either significantly improved crystal quality of the active layer or a relatively smooth surface on the top of the active layer. The improved crystallinity results in a more efficient and responsive active layer, and thus an improved semiconductor device.
A 50 nm thick gallium oxide active layer on a sapphire substrate was also evaluated using secondary ion mass spectrometry (SIM) to determine the depth profile of oxygen, gallium oxide, gallium, and aluminum. This evaluation included a 50 nm thick gallium oxide active layer on a sapphire substrate without any annealing (i.e., the layer directly after the pulsed laser deposition), annealing at 1000° C. for three hours in air, annealing at 1200° C. for three hours in air, and annealing at 1400° C. for three hours in air. The results of this evaluation demonstrated that under all annealing scenarios, aluminum was present throughout the active layer. It should be recognized that the diffusion caused by the annealing process reduces the thickness of the sapphire substrate and increases the thickness of the resulting aluminum gallium oxide active layer. Specifically, annealing at 1000° C. caused the 50 mn gallium oxide active layer to increase in thickness to 110 nm as the aluminum gallium oxide active layer, annealing at 1200° C. caused the 50 mn gallium oxide active layer to increase in thickness to 190 nm as the aluminum gallium oxide active layer, and annealing at 1400° C. caused the 50 mn gallium oxide active layer to increase in thickness to 250 nm as the aluminum gallium oxide active layer. It should be recognized that the sapphire substrate is of sufficient thickness (i.e., a thickness that is at least two times as thick as the original gallium oxide active layer) that the reduced thickness caused by diffusion during the annealing does not affect the electrical or physical characteristics of the sapphire substrate in a way that would be problematic to the intended purpose of the sapphire substrate in the resulting semiconductor device.
As will be appreciated from the discussion above, a correlation between annealing temperature and the amount of group-III material that diffuses from the group-III oxide substrate 205 into the group-III oxide active layer 210 has been discovered. This correlation is particularly advantageous because the group-III material content (and in turn the bandgap) can be controlled based upon annealing temperature and not based upon the composition of the target used for pulsed laser deposition. Further, this provides additional manufacturing flexibility because a device having a group-III oxide active layer comprising at least two group-III materials on a group-III oxide substrate can be produced in volume and then semiconductor devices with varying group-III material compositions in the active layer can be produced by varying the annealing temperature.
The disclosed embodiments provide semiconductor devices having a group-III oxide active layer comprising at least two group-III materials and methods for forming such devices. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
This application claims priority to U.S. Provisional Patent Application No. 62/799,140, filed on Jan. 31, 2019, entitled “METHOD TO TRANSFORM BINARY OXIDE MATERIAL INTO TERNARY AND QUATERNARY OXIDE MATERIALS WITH GROUP-III MATERIAL BY HIGH TEMPERATURE ANNEALING,” the disclosure of which is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2020/050268 | 1/14/2020 | WO | 00 |
Number | Date | Country | |
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62799140 | Jan 2019 | US |