1. Field of the Invention
The invention relates to a substrate and a fabricating method thereof More particularly, the invention relates to a semiconductor substrate and a fabricating method thereof
2. Description of Related Art
A group III-V nitride material is a semiconductor having a wide band gap. For example, gallium nitride materials have been adopted for fabricating short wavelength light emitting diodes (LEDs), laser diodes, high power electronic devices, and so on for the last couple of years. Having a wide optical penetration band, sapphires have superior light transmittance from near ultraviolet (190 nm) to middle infrared, and include characteristics such as high sound velocity, high temperature tolerance, corrosion resistance, high hardness, high melting point, and low electric conductivity. Accordingly, sapphires are usually applied as substrate bases for growing gallium nitride (GaN) blocks used to fabricate electronic devices.
However, sapphires and semiconductor materials such as GaN have mismatched lattice constants and a large difference between thermal expansion coefficients, so that more lattice defects, for example, dislocation, stacking fault, and the like are generated during the process of growing GaN blocks on the surfaces of sapphire substrate base. Accordingly, the GaN blocks may easily break due to the stress difference generated from the high temperature environment required by the process, thereby affect the optical property thereof.
In addition, since sapphires have high hardness, the hardness of sapphires after epitaxial growth is only next to that of natural diamonds. Moreover, the crystal grains have a small gap therebetween (about 2 mil, 1 mil= 1/1000 inch) and need to be cut with a diamond knife to separate the crystal grains through grinding. Since the crystal grains are fragile, the crystal grains may easily collapse or crack during the cutting process.
One conventional solution is to form a buffer layer between the sapphire substrate base and the GaN block to reduce the stress difference between the sapphire substrate base and the GaN block, thereby decreasing the defect density of the GaN block. Generally, the buffer layer can be constituted by an amorphous GaN structure. The buffer layer indeed improves the cracking caused by the stress generated from high temperature; however, since the amorphous GaN structure has defects on the surface thereof when grown on the sapphire substrate base as the buffer layer, the defect density of the GaN block cannot be decreased effectively. In other words, when grown on a bufferlayer with defects, the GaN block breaks easily due to the defects. Further, since the amorphous GaN structure is grown above the sapphire substrate base in a planar manner, the amorphous GaN structure may break or collapse in the wafer-dicing process due to the stress difference between the sapphire and the GaN.
Therefore, researches now focus on how to prevent the semiconductor layer formed from having lattice defects caused by mismatched lattice constants between the substrate base and the semiconductor layer.
The invention is directed to a fabricating method of a semiconductor substrate for decreasing the defect density of the semiconductor substrate and the stress difference between the semiconductor substrate and a substrate base.
The invention is further directed to a semiconductor substrate having low defect density.
The invention is directed to a fabricating method of a semiconductor substrate. A patterned mask layer is formed on a substrate base. The patterned mask layer includes a plurality of apertures each exposing a portion of the substrate base. A plurality of nano-pillars is formed on the substrate base. Each of the nano-pillars is grown on the portion of the substrate base exposed by each of the apertures. An insulation layer is formed on a sidewall of each of the nano-pillars. An epitaxial lateral overgrowth process is performed on a top portion of each of the nano-pillars to form a semiconductor layer on the nano-pillars. The semiconductor layer is exposed by a plurality of gaps disposed between the nano-pillars.
The invention is directed to a semiconductor substrate including a substrate base, a patterned mask layer, a plurality of nano-pillars, an insulation layer, and a semiconductor layer. The patterned mask layer is disposed on the substrate base and includes a plurality of apertures each exposing a portion of the substrate base. Each nano-pillar is located on the portion of the substrate base exposed by each of the apertures, where each of the nano-pillars has a top portion and a sidewall. The insulation layer covers the sidewall of each of the nano-pillars. The semiconductor layer is disposed on the top portions of the nano-pillars. The semiconductor layer is exposed by a plurality of gaps disposed between the nano-pillars.
According to an embodiment of the invention, each of the apertures has a size ranging from 20 nanometer (nm) to 2000 nm.
According to an embodiment of the invention, each of the gaps has a size ranging from 20 nm to 2000 nm.
According to an embodiment of the invention, a material of the nano-pillars is the same as a material of the semiconductor layer.
According to an embodiment of the invention, a material of the semiconductor layer includes a group-III metal nitride.
According to an embodiment of the invention, a material of the semiconductor layer includes gallium nitride (GaN), aluminum gallium nitride (AlGaN), aluminum nitride (AlN), indium gallium nitride (InGaN), or a combination thereof.
According to an embodiment of the invention, a method of forming the insulation layer on the sidewall of each of the nano-pillars includes the following. An insulation material layer is formed on each of the nano-pillars. The insulation material layer covers the sidewall and the top portion of each of the nano-pillars. The insulation material layer on the top portion of each of the nano-pillars is removed so as to expose the top portion of each nano-pillar.
According to an embodiment of the invention, a method of forming the insulation material layer includes a plasma-enhanced chemical vapor deposition (PECVD), an inductively coupled plasma chemical vapor deposition (ICP-CVD), or other deposition methods.
According to an embodiment of the invention, a method of removing the insulation material layer on the top portion of each of the nano-pillars includes a dry etching process.
According to an embodiment of the invention, a material of the insulation layer includes silicon nitride or silicon dioxide.
According to an embodiment of the invention, a method of forming the semiconductor layer includes the following. A crystal is formed on the top portion of each of the nano-pillars through the epitaxial lateral overgrowth process. The epitaxial lateral overgrowth process is then continued for the crystals on the top portions of the nano-pillars to coalesce one another laterally.
According to an embodiment of the invention, a thermal annealing process is further performed to the semiconductor layer.
According to an embodiment of the invention, a separation process is further performed to separate the semiconductor layer and the substrate base after the semiconductor layer is formed.
According to an embodiment of the invention, the separation process includes truncating the nano-pillars.
In light of the foregoing, a plurality of nano-pillars each having the sidewall covered with the insulation layer is formed on the substrate base in the invention. The semiconductor is then formed on the nano-pillars through the epitaxial lateral overgrowth process. Since the semiconductor layer is formed on the nano-pillars by a coalescence through the epitaxial lateral overgrowth process, the stress generated in the semiconductor layer during the epitaxial lateral overgrowth process can be reduced as being released through the gaps between the nano-pillars. The semiconductor layer thus has a surface with low defect density. Accordingly, the light emitting efficiency of the light emitting device can be enhanced when applying the semiconductor layer in the light emitting device.
In order to make the aforementioned and other features and advantages of the invention more comprehensible, several embodiments accompanied with figures are described in detail below.
The accompanying drawings are included to provide further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and, together with the description, serve to explain the principles of the invention.
Thereafter, the patterned mask layer 104 is formed on the substrate base 102. The patterned mask layer 104 includes the apertures 104a each exposing a portion of the substrate base 102. The apertures 104a are arranged in an array, for example, and the apertures 104a have a certain gap therebetween. In the present embodiment, the apertures 104a have a hexagonal shape, triangular shape, square shape, rectangular shape, elliptical shape, or circular shape, for instance. The apertures 104a have a size dl ranging from 20 nanometer (nm) to 2000 nm, for instance. The apertures 104a have a gap ranging from 20 nm to 2000 nm, for instance. A material of the patterned mask layer 104 includes, for instance, a dielectric material such as silicon nitride, silicon dioxide, silicon oxynitride, fluorinated silicon oxide, silicon oxycarbide, hafnia, hafnium silicate, hafnium silicon oxynitride, zirconium oxide, aluminum oxide, and so on. The patterned mask layer 104 has a thickness ranging from 10 Å to 5000 Å, for example.
Referring to
In details, the substrate base 102 shown in
It should be noted that since the nano-pillars 110 are grown on the portion of the substrate base 102 exposed by the apertures 104a of the patterned mask layer 104, the patterned mask layer 104 can be adopted as a source of lateral support for the nano-pillars 110 in the growing process of the nano-pillars 110 so as to enhance the stability of the nano-pillars 110.
Referring to
Referring to
In the present embodiment, an additive having a concentration gradient can be added to control the width of the crystals 128 growing on the top portions 114 of the nano-pillars 110, such that the width of the crystals 128 is increased gradually. Accordingly, when the width of the crystals 128 increases to a certain level, the adjacent crystals 128 connect to one another and are coalesced to form a flat and extending semiconductor layer 130 on the top portions 114 of the nano-pillars 110. Particularly, the nano-pillars 110 provide a more stable support to the crystals 128 with gradually increasing width to prevent the nano-pillars 110 from bending or breaking due to the weight. The additive can be trimethylgallium (TMGa), triethylgallium (TEGa), trimethylindium (TMIn), triethylindium (TEIn), trimethylaluminum (TMAl), or other suitable additive. The semiconductor layer 130 has a thickness ranging from 2 μm to 20 μm, for example. In the present embodiment, a material of the semiconductor layer 130 is, for instance, a group III metal nitride including GaN, AlGaN, AlN, InGaN, or a combination thereof. Here, the semiconductor layer 130 is favorably GaN. It should be illustrated that since the crystals with gradually increasing width and the gaps between the nano-wires are conducive to release the stress generated by the substrate base, the semiconductor layer can provide a stable structure when adopted as the substrate base for forming the semiconductor blocks, so as to allow the formation of thicker blocks thereon.
Referring to
The semiconductor substrate formed using the method aforementioned is shown in
After the semiconductor layer 130 is formed, the separation process can then be performed to separate the semiconductor layer 130 and the substrate base 102 as shown in
In summary, in the invention, the nano-pillars are formed on the substrate base, the semiconductor layer is formed on the top portions of the nano-pillars through the epitaxial lateral overgrowth process after the sidewall of each nano-pillar is covered with the insulation layer. Since the semiconductor layer is formed by coalescing the nano-pillars through the epitaxial lateral overgrowth process, the gaps between the nano-pillars can release the stress generated from the cooling process of the semiconductor layer performed during the epitaxial overgrowth. As a consequence, the quality of the semiconductor layer can be enhanced and the probability of the semiconductor layer breakage can be decreased. In other words, the invention utilizes the gaps between the nano-pillars as a buffer to prevent the breakage or the defect formation of the semiconductor layer caused by stress resulted in the fabricating process. Additionally, when the semiconductor layer is applied in the fabrication of light emitting devices, the gaps between adjacent nano-pillars then provide different refraction indexes in the light exiting path. As a result, the total reflection of the incident light can be reduced significantly and the diffraction angle of the incident light can be increased, so as to enhance the light extraction efficiency of the light emitting device.
On the other hand, the sidewalls of the nano-pillars in the invention are covered with the insulation layer, such that the semiconductor epitaxial layer has growth selectivity when growing on the nano-pillars and the epitaxial lateral overgrowth process is performed on the top portions of the nano-pillars. The lateral growth of the sidewalls of the nano-pillars can therefore be prevented to maintain the gaps between the nano-pillars so as to ensure the stress generated from the growing process of the semiconductor layer can be released from the gaps between the nano-pillars. Furthermore, the insulation layers on the sidewalls of the nano-pillars prevent the nano-pillars from being corroded in the growing process. Also, when adopting the substrate base with the nano-pillars as the substrate base for growing the semiconductor layer, the contact area between the semiconductor material and the substrate base is reduced and the stress between the substrate base and the semiconductor layer is decreased, so as to avoid the breakage of the semiconductor crystal. Moreover, since the contact area between the semiconductor layer and the nano-pillars is extremely small, a faster and easier method can be applied for separating the two (i.e. the breaking of the nano-pillars due to the large stress generated when the semiconductor reaches a certain thickness, or the etching of the nano-pillars using the etching solution). As a consequence, the complexity for separating the substrate base and the semiconductor layer with the laser lift-off process can be prevented and the fabrication cost can be reduced. Therefore, the semiconductor layer obtained is not damaged by laser or other processes, and the semiconductor substrate fabricated in the invention has better quality comparing to conventional semiconductor substrates. When applied in the fabrication of light emitting device, this semiconductor substrate also enhances the light emitting efficiency of the light emitting device.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the disclosed embodiments without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
This application claims the priority benefits of U.S. provisional application Ser. No. 61/483,066, filed on May 6, 2011. The entirety of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification.
Number | Date | Country | |
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61483066 | May 2011 | US |