The present disclosure relates to a power semiconductor device comprising a silicon carbide semiconductor structure with at least one ohmic contact and at least one Schottky barrier contact, such as a Schottky barrier diode or a vertical FET, and methods for their manufacture.
Silicon carbide (SiC) semiconductor Schottky barrier diodes (SBD) generally have a low leakage current, forward voltage drop and reverse recovery time, and are therefore suitable for many application areas, such as automotive applications, including charging of electric vehicles, renewable energy generation and distribution, and others.
A SiC SBD may be formed by metallization of a SiC semiconductor structure in a two-step process. First, a low contact resistance, ohmic contact is deposited on a SiC substrate and then sintered at a relatively high temperature of 900 to 1000° C. In a subsequent, second step, a Nickel (Ni) layer is deposited on an epilayer of the SiC semiconductor structure in order to obtain a Schottky barrier contact on an opposite side.
US 2006/178016 A1 discloses that a silicon carbide-based device contact and contact fabrication method employ a layer of poly-silicon on a SiC substrate, with the contact's metal layer deposited on top of the poly-silicon. Both Schottky and ohmic contacts can be formed. The poly-silicon layer can be continuous or patterned, and can be undoped or doped to be n− type or p− type.
CN 109 686 797 A discloses a silicon carbide Schottky diode and a manufacturing method thereof. The silicon carbide Schottky diode comprises a composite Schottky contact structure, wherein the composite Schottky contact structure comprises a silicon carbide epitaxial layer, a Schottky metal layer and a graphene layer arranged between the silicon carbide epitaxial layer and the Schottky metal layer, the graphene layer is used for blocking the interpenetration between silicon carbide atoms of the silicon carbide epitaxial layer and metal atoms of the Schottky metal layer, thereby reducing the leakage current of the composite Schottky contact structure.
INABA MASAFUMI ET AL: “Very low Schottky barrier height at carbon nanotube and silicon carbide interface”, APPLIED PHYSICS LETTERS, AMERICAN INSTITUTE OF PHYSICS, 2 HUNTINGTON QUADRANGLE, MELVILLE, NY 11747, vol. 106, no. 12, 23 Mar. 2015, ISSN: 0003-6951, DOI: 10.1063/1.4916248, discloses that electrical contacts to silicon carbide with low contact resistivity and high current durability are crucial for future SiC power devices, especially miniaturized vertical-type devices. A carbon nanotube (CNT) forest formed by silicon carbide (SiC) decomposition is a densely packed forest, and is ideal for use as a heat-dissipative ohmic contact in SiC power transistors.
U.S. Pat. No. 6,139,624 discloses a method for producing an electrical contact on a SiC surface. A carbon coating, preferably a graphite coating, is first created on the silicon carbide surface. Said carbon coating is then converted, with a carbide-forming metal, into a metal carbide coating.
US 2019/296156 A1 discloses that a semiconductor device includes a first electrode; a second electrode; a silicon carbide layer disposed between the first electrode and the second electrode; a first n− type silicon carbide region disposed in the silicon carbide layer; and a first nitrogen region disposed in the silicon carbide layer, the first nitrogen region disposed between the first n− type silicon carbide region and the first electrode, and the first nitrogen region having a first nitrogen concentration higher than a first n− type impurity concentration of the first n− type silicon carbide region.
US 2018/166540 A1 discloses that a semiconductor device may include an n− type layer disposed at a first surface of an n+ type silicon carbide substrate; a trench disposed at the n− type layer; a p type region, an n+ type region, and a p+ type region disposed at an upper portion in the n− type layer; a gate insulating layer disposed on the n− type layer, the n+ type region, and the p type region; a gate electrode disposed on the gate insulating layer; an insulating layer disposed on the gate electrode; a source electrode disposed on the insulating layer and in the trench; and a drain electrode disposed at a second surface of the n+ type silicon carbide substrate, wherein the source electrode includes an ohmic junction region and a Schottky junction region.
It is an aim of the present disclosure to show alternative, preferably more efficient manufacturing methods for forming power semiconductor device comprising a SiC structure and corresponding power semiconductor devices. In particular, it would be desirable to describe power semiconductor devices that are less susceptible to adverse conditions during their manufacture, thus enabling an improved manufacturing process.
Embodiments of the disclosure relate to a power semiconductor device comprising a SiC structure, a Schottky barrier diode, a vertical field effect transistor, and a method for manufacturing a power semiconductor device according to the independent claims.
According to a first aspect of the disclosure, a power semiconductor device is disclosed. The device comprises a silicon carbide semiconductor (SiC) structure, comprising a SiC layer, at least one ohmic contact formed on a first main surface of the SiC structure, and at least one Schottky barrier contact formed on a second main surface of the SiC structure. The at least one Schottky barrier contact comprises a metal layer and a carbon group interlayer arranged between the metal layer and the second main surface of the SiC structure.
The carbon group interlayer may have a thickness in the range between 10 to 100 nm and may be formed by depositing chemical elements from the carbon group on the second main surface of the SiC structure. Such a thickness is sufficient to achieve an improved thermal stability of the Schottky barrier contact and, at the same time, maintain the desired Schottky barrier formation.
Among others, the inventors have found that a Schottky barrier contact comprising a stack including a carbon group interlayer and a metal layer does not degrade at higher temperatures, for example, at an annealing temperature of about 1000° C. Accordingly, the resistance of the Schottky barrier contact to adverse conditions during semiconductor device manufacturing is reduced, allowing, amongst other advantages, the simultaneous formation of the at least one ohmic contact and the at least one Schottky barrier contact.
According to at least one embodiment, the SiC layer is a semi-conductive SiC layer having a dopant concentration below 1017 cm−3, in particular in the range of 1013 cm−3 to 1017 cm−3. For example, an epitaxially grown SiC layer may be doped with 3·1014 cm−3 to 5·1014 cm−3 nitrogen atoms. Alternatively, the SiC layer may be a high purity semi-insulating SiC layer having an electrical resistivity of 107 to 109 Ohm cm. Among other advantages, the inventors have found that a SiC layer having a relatively low dopant concentration is a suitable foundation for the above stack in that such a low dopant concentration SiC layer does not react with the materials of the Schottky barrier contact during annealing and similar high temperature processing steps.
According to a second aspect of the disclosure, a Schottky barrier diode is provided. The Schottky barrier diode comprises the power semiconductor device according to the first aspect, an anode terminal connected to the at least one Schottky barrier contact, and a cathode terminal connected to the at least one ohmic contact.
Such a Schottky barrier diode is easy to manufacture, has a relatively low leakage current, low forward voltage drop and a low reverse recovery time.
According to a third aspect of the disclosure, a vertical field effect transistor (FET), in particular a power MOSFET, is provided. The vertical FET comprises a power semiconductor device according to the first aspect, a source terminal connected to the at least one Schottky barrier contact, a drain terminal connected to the at least one ohmic contact, and a gate terminal connected to an insulated gate electrode arranged on the second main surface of the SiC structure.
In such a vertical FET with a built-in body diode, no additional device is required to serve as a freewheeling diode. Integration of the Schottky diode into the vertical FET is enabled by the increased thermal budget of the above Schottky contact. Moreover, integrating a Schottky diode into a MOSFET or a similar power semiconductor structure is one option to reduce a turn-on voltage of the body diode from more than 2.5 V to below 1 V.
According to a fourth aspect of the disclosure, a method for manufacturing a power semiconductor device is provided. The method comprises the steps of:
The above method steps enable the formation of ohmic and Schottky barrier contacts in the same process step and at the same temperature. The disclosed method increases a thermal budget of the formed Schottky barrier contact and reduces the integration effort significantly. It also allows other high temperature steps to be performed after formation of the Schottky barrier contact.
The above power semiconductor device and method for forming the same are particularly suitable for the manufacturing of Schottky barrier diodes, vertical FETs and other semiconductor devices comprising at least one Schottky barrier contact structure.
Features and advantages described in connection with the power semiconductor device in general and the Schottky barrier diode or the vertical FET in particular can therefore be used in any of the disclosed devices. Moreover, specific aspects, such as the choice of materials, dimensions or similar parameters disclosed with respect to the various devices are also applicable to the corresponding steps of the manufacturing method and vice versa.
The accompanying figures are included to provide further understanding. In the figures, elements of the same structure and/or functionality may be referenced by the same or corresponding reference signs. It is to be understood that the embodiments shown in the figure are illustrative representations and are not necessarily drawn to scale.
While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the figures and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure defined by the appended claims.
In the depicted embodiment, the power semiconductor device 100 further comprises an ohmic contact 120 formed on the first main surface 114. For example, a first metal layer 122, such as a nickel layer, may be deposited on the lower main surface 114 and may then be sintered and/or annealed to form the ohmic contact 120.
In case the SiC layer 112 extends all the way from the first main surface 114 to the second main surface 116, prior to formation of the at least one ohmic contact 120, an n+ layer or n+ region may be formed at least at a corresponding area of the first main surface 114 by ion implantation or plasma immersion ion implantation (PIII), followed by a high temperature activation at 1600° C.
The power semiconductor device 100 further comprises a layer stack 132 comprising an interlayer 134 and a second metal layer 136 formed on top of the interlayer 134. The layer stack 132 forms a Schottky barrier contact 130 on the second main surface 116 of the underlying SiC layer 112. For this purpose, a suitable metal material, for example a nickel (Ni), can be used to form a Schottky barrier with respect to the band structure of the semiconductor material of the SiC layer 112. As shown in
To make the second metal layer 136 more resilient to higher temperatures, for example during annealing of the ohmic contact 120, the interlayer 134 comprises a suitable material, in particular a material from the carbon group (also referred to as IUPAC group 14 or Group IV), comprising elements with four valence electrons. In the described embodiment, carbon (C) is used for the interlayer 134. Alternatively, other carbon group materials having a relatively high melting point, such as silicon (Si), germanium (Ge) or lead (Pb) may be used.
The presence of the interlayer 134 prevents a direct contact between the material of the second metal layer 136 and the layer 112. Accordingly, no chemical reactions take place at the interface between the SiC structure 110 and the Schottky barrier contact 130 formed on its second surface 116 during higher temperatures, for example during annealing of the ohmic contact 120.
In a first step S1, a SiC layer 112 is epitaxially grown on a suitable substrate to form a SiC structure 110. In the described embodiment, the epitaxial SiC layer 112 is doped with a suitable dopant at a relatively low concentration of below 1017 cm−3 or even below 1017 cm−3. For example, the epitaxial SiC layer 112 may be doped with nitrogen (N) at a concentration of 3·1014 cm−3 to 5·1014 cm−3. The thickness of the SiC layer 112 is determined by the desired function, voltage and/or current class of the semiconductor device 100 and may lie in the range of may lie in the range several microns to tenth of microns, for example 5 to 15 μm.
In a further step S2, an interlayer 134 is deposited on the SiC layer 112, forming one of the main surfaces, e.g. the second surface 116 shown in
In a further step S3, which may be performed at any stage of the manufacturing process after step S1 and before an annealing step S5, a conductive layer is deposited on the opposite side of the SiC structure 110. In the described example, a first metal layer 122 is deposited on the backside of the semiconductor device. For example, 100 nm of nickel may be deposited on a SiC substrate carrying the epitaxial SiC layer 112. Alternatively, different methods or materials for forming an ohmic contact may be used. For example, instead of nickel, titanium aluminum or titanium aluminum nickel alloys may be deposited, e.g. by firstly depositing titanium, then aluminum, and, optionally, nickel, and heating the resulting metal stack, for example at a temperature of 1000° C., to form a corresponding alloy. Similarly, silver paste may be employed as ohmic contact on the backside of the substrate.
In a further step S4, which may be performed at any stage of the manufacturing process after step S2 and before the annealing step S5, a metal suitable to form a Schottky barrier contact 130 is deposited on the interlayer 134. For example, 10 to 100 nm of nickel may be deposited in a second metal layer 136 on top of the interlayer 134.
In a further step S5, at least parts of the power semiconductor device 100 are annealed. The annealing step S5 may comprise sintering and/or rapid thermal annealing (RTA) performed at a temperature in excess of 600° C. Attention is drawn to the fact that at this stage, both surfaces of the semiconductor device 100 are covered with a metal layer 122 and 136, respectively. Thus, the first metal layer 122 as well the second metal layer 136 deposited in steps S3 and S4 are subjected to the same thermal treatment. For example, both surfaces may be sintered for 10 minutes in either a vacuum or an ambient atmosphere comprising a protective gas such as argon, by RTA. As a consequence, an ohmic contact 120 is formed on the backside of the semiconductor device 110. However, due to the presence of the interlayer 134, the layer stack 132 comprising the second metal layer 136 maintains its function as a Schottky barrier contact 130.
As shown in
As shown by the dotted curve of
In the investigated power semiconductor device 100, the Schottky barrier height ΦB before annealing was approximately 1.5 eV (obtained by analysis of its C-V characteristics, not shown). In contrast, the power semiconductor device 100 annealed at a temperature of 600° C. had a Schottky barrier height ΦB of 1.45 eV and the power semiconductor device 100 annealed at 1000° C. had a Schottky barrier height ΦB of 1.8 eV. That is to say, by also annealing the layer stack 132 comprising the interlayer 134 and the metal layer 136, the Schottky behaviour of the formed power semiconductor device 100 was improved compared to the non-annealed state.
In the following, processes for the manufacturing of different power semiconductor devices comprising at least one Schottky barrier junction are described. In particular,
Both metal layers 422 and 436 are then annealed using rapid thermal processing (RTP). For example, the SiC structure 410 with all deposited layers may be treated at a temperature at or above 800° C. for 1 to 10 minutes or even longer. As a consequence, on the backside of the substrate 414, an ohmic contact 420 is formed. Opposite, on the n− type SiC epilayer 412, a Schottky contact 430 of the Schottky barrier diode 400 is formed or improved.
The power MOSFET 500 shown in
It also other allows high temperature steps to be performed after the contact formation shown in
The embodiments shown in
Number | Date | Country | Kind |
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21199433.0 | Sep 2021 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2022/076833 | 9/27/2022 | WO |