This non-provisional application claims priority under 35 U.S.C. ยง119(a) on Japanese Patent Application No. 2004-279420 filed in Japan on Sep. 27, 2004, the entire contents of which are hereby incorporated by reference.
The present invention generally relates to vapor deposition apparatuses, and more particularly to vapor deposition apparatuses improved for high yield production of nitride semiconductor devices.
Nitride-based group III-V compound semiconductor crystals represented by GaN, InGaN, AlGaN, AlInGaN, etc., have direct-transition-type band gaps and are expected to be applied to semiconductor laser devices. InGaN mixed crystals enable red-to-ultraviolet light emission and thus are attracting special attention as short-wavelength material. These crystals are already in practical use as light emitting diode devices with wavelengths ranging from ultraviolet to green and as bluish purple laser diode devices. Generally, these devices are produced by the metal organic chemical vapor deposition (MOCVD) method by using CVD apparatuses. Specifically, GaN-type, InGaN-type, AlGaN-type, InGaNP-type, InGaNAs-type, and InGaAlN-type nitride semiconductor films are grown over a substrate. CVD apparatuses that grow these semiconductor films with the use of organic metal material are referred to as MOCVD apparatuses.
Production of nitride-based semiconductor lasers made of GaN, AlN, InN, and mixed crystals thereof with the use of conventional MOCVD apparatuses is problematic in that the crystallinity and thickness of the grown film are not uniform throughout the substrate. Also, there are variations between substrates. As a result, the nitride-based semiconductor layers prepared over a substrate are found to suffer crystal distortions and multiple cracks.
Crystal defects including cracks act as the center of non-emitting combination; the defects act as paths for current to cause leakage current, posing the problem of poor yields. Particularly with LD devices, the defects cause an increase in threshold current density, posing the problem of shortened device life. Thus, it is important to reduce crystal defects including cracks.
The present inventors studied the cause of crystal defects including cracks. As a result, it has been found that the concentration distribution and amount of supply of source gas supplied on the substrate vary, which is because the amount of outflow of gas through the space between aperture portion 36 of flow channel 32 and substrate holder 34 is not constant. In MOCVD growth of nitride-based semiconductors, it was found that this effect was important and the uniformity of crystallinity in a crystal film and the uniformity of the thickness in a crystal film plane were not secured.
The present inventors have found the causes of variations in concentration distribution and amount of supply of source gas, which will be described below.
Substrate 33 is carried in as follows. First, heater 35 is kept apart from flow channel 32. Substrate holder 34 with substrate 33 thereon is then mounted on heater 35 (referred to as catching). For positioning, engagement is provided in the part that heater 35 and substrate holder 34 touch. Heater 35 and substrate holder 34 are then moved to flow channel 32, and set such that substrate 33 is placed appropriately relative to flow channel 32.
Because substrate holder 34 expands when heated, or in view of the catching accuracy of substrate holder 34 and heater 35, the engagement need some tolerance. Also some tolerance is necessary to space 21, which is between aperture portion 36 of flow channel 32 and substrate holder 34. At the time of automatic carry-in/out, if revolving axis 39 is off the center of substrate holder 34, this location is referred to as a catching error. In this case, substrate holder 34 is revolved with a varying space relative to aperture portion 36 of flow channel 32. Because of the accuracy of axis processing, revolving axis 39 is generally eccentric to some extent. The axis eccentricity causes variations in space 21, which is between aperture portion 36 of flow channel 32 and substrate holder 34 (the axis eccentricity causing wobbling 22). Under these circumstances the amount of outflow gas 23 varies, which in turn causes biased-flow of source gas, i.e., bias of gas concentration distribution on substrate 33. Also, the gas concentration distribution on substrate 33 is not steady.
The problem of variations in space 21, which is between aperture portion 36 of flow channel 32 and substrate holder 34, also occurs at the time of automatically remounting flow channel 32 and substrate holder 34 after removal thereof for washing. Further, because of the processing accuracy of flow channel 32 and substrate holder 34, it is difficult to repeat the initial positioning, which means space 21 of different size after renewal of flow channel 32 and substrate holder 34.
Since the extent of the above problem varies between apparatuses, growth conditions need to be optimized for each individual apparatus. In nitride-based semiconductor, re-evaporation of the crystal happens because of its high saturated vapor pressure. In accordance with variations in the concentration distribution and amount of supply of source gas, the ratio of III source gas and V source gas also varies. Consequently, crystallinity does not become uniform in a crystal film plane and the thickness does not become uniform in a crystal film plane. Thus, variations in the amount of outflow gas seriously affect crystal growth.
In view of the foregoing and other problems, it is an object of the present invention to provide a vapor deposition apparatus improved for stable gas distribution throughout the substrate.
It is another object of the present invention to provide a vapor deposition apparatus improved for a stable amount of outflow gas.
It is another object of the present invention to provide a vapor deposition apparatus improved to prevent crystallinity in a crystal film plane and the thickness in a crystal film plane from varying.
It is another object of the present invention to provide a vapor deposition apparatus that eliminates the need for optimization of growth conditions for each individual apparatus.
It is another object of the present invention to provide a vapor deposition apparatus that realizes high-yield production of light emitting devices of nitride semiconductor with a long life and high light-emission efficiency.
It is another object of the present invention to provide an MOCVD apparatus that realizes high light-emission efficiency and high-yield production of long-lived light emitting devices of nitride semiconductor.
In order to accomplish the above and other objects, the vapor deposition apparatus according to the present invention is a vapor deposition apparatus comprising: a substrate holder comprising a substrate holding surface for holding a substrate thereon; a flow channel for supplying a source gas onto the substrate, the flow channel comprising an upper wall and a lower wall; and an aperture portion provided in the lower wall of the flow channel. The substrate holding surface of the substrate holder fits in the aperture portion while forming a space between the substrate holding surface and the aperture portion. The apparatus also comprises a means for reducing leakage of gas through the space between the aperture portion and the substrate holder.
According to the invention, since a means for reducing leakage of gas through the space is provided between the aperture portion and the substrate holder, variations in the amount of outflow gas can be decreased.
The means for reducing leakage of gas is preferably formed by bending the space from the inside of the flow channel to the outside thereof.
The means for reducing leakage of gas preferably comprises: an upward dent portion dented in an upward direction, the upward dent portion being provided along a periphery of the aperture portion and in a thickness portion of the lower wall of the flow channel; and a brim projecting from a side wall of the substrate holder in a lateral direction, the brim fitting in the upward dent portion while forming a space between the brim and the upward dent portion, when the substrate holding surface of the substrate holder is in a state of fitting in the aperture portion.
With this structure, the space formed between the aperture portion of the flow channel and the substrate holder has a bent passage. The bent passage is composed of a first passage extending downward from the inside of the flow channel, a second passage extending in a lateral direction from the end of the first passage, and a third passage extending from the end of the second passage down to the outside of the flow channel.
Since the space is formed of a bent passage, the conductance with respect to outflow gas decreases, thus significantly reducing the amount of outflow gas through the space.
Another embodiment of the means for reducing leakage of gas comprises a brim projecting from a side wall of the substrate holder in a lateral direction, while forming a space between the brim and the lower wall of the flow channel, when the substrate holding surface of the substrate holder is in a state of fitting in the aperture portion.
With this structure, the space formed between the aperture portion of the flow channel and the substrate holder has a bent passage composed of a first passage extending downward from the inside of the flow channel and a second passage extending in a lateral direction from the end of the first passage to the outside of the flow channel.
When the space has a passage bent in this manner, the conductance with respect to outflow gas also decreases, thus reducing the amount of outflow gas through the space.
The vapor deposition apparatus may have a mechanism for revolving the substrate holder. With this structure, even if the substrate holder is rotated, variations in the amount of outflow gas can be decreased.
The vapor deposition apparatus preferably comprises: a heater for heating the substrate, the substrate holder holding the substrate being mounted on the heater, the heater being vertically movable and provided below the aperture portion of the flow channel; a mounting mechanism for mounting the substrate holder on the heater; and a moving mechanism for moving the heater with the substrate holder mounted thereon while fitting the substrate holding surface of the substrate holder in the aperture portion of the flow channel. According to this structure, variations in the amount of outflow gas are reduced at the time of automatically carrying in/out the substrate.
The substrate holder preferably comprises a disk comprising a brim provided along its side wall.
The vapor deposition apparatus is preferably used as an MOCVD apparatus for vapor deposition of a nitride semiconductor.
In the vapor deposition apparatus of the present invention, a means for reducing leakage of source gas through the space between the aperture portion of the flow channel and the substrate holder is provided. Source gas flowing from upstream in the flow channel is therefore not leaked through the space between the aperture portion of the flow channel and the substrate holder, or the amount of the gas leakage is significantly reduced. This reduces variations in outflow gas and thus assures uniformity of crystallinity and layer thickness of thin films throughout the substrate plane.
Preferred embodiments of the present invention will be described referring to drawings. It will be appreciated that the present invention is not limited to these embodiments.
A feature of the present invention is provision of a means for reducing leakage of gas through the space between the aperture portion and the substrate holder in order to reduce variations in the amount of outflow gas. This will be described in detail in embodiments 1 and 2 below.
This vapor deposition apparatus is designed to reduce leakage of gas through space 21, which is between aperture portion 16 of flow channel 12 and substrate holder 14. A means for the reduction of gas leakage is composed of a combination of upward dent portion 12c and brim 14b. Upward dent portion 12c is dented in an upward direction, and is provided along the periphery of aperture portion 16 and in a thickness portion of lower wall 12b of flow channel 12. Brim 14b projects from the side wall of substrate holder 14 in a lateral direction. This will be described in greater detail later.
As shown in
The substrate is carried in as follows. As shown in
Generally, the amount of source gas that outflows through the space between aperture portion 16 of flow channel 12 and substrate holder 14 is proportionate to the difference between the cross-sectional area of flow channel 12 and the area of the space. Practice shows that the amount of leakage of gas through the space is especially larger at the upstream side of the substrate. Further, as described above, variations in the space cause variations in the amount of supply of source gas onto the substrate.
The operation of reducing leakage of gas through the space between the aperture portion of the flow channel and the substrate holder, realized in this embodiment, will be described below.
That is, space 21 formed between aperture portion 16 of flow channel 12 and substrate holder 14 is a bent passage composed of first passage 101 extending downward from the inside of flow channel 12, second passage 102 extending in a lateral direction from the end of first passage 101, and third passage 103 extending from the end of second passage 102 down to the outside of flow channel 12. More specifically, the means for reducing leakage of gas is composed of upward dent portion 12c and brim 14b. Upward dent portion 12c is dented in an upward direction, and is provided along the periphery of aperture portion 16 and in a thickness portion of lower wall 12b of flow channel 12. Brim 14b projects from the side wall of substrate holder 14 in a lateral direction. When substrate holding surface 14a of substrate holder 14 is in a state of fitting in aperture portion 16, brim 14b fits in upward dent portion 12c while forming a space between brim 14b and upward dent portion 12c.
This structure decreases the conductance with respect to outflow of source gas even when the area of space 21 between aperture portion 16 of flow channel 12 and substrate holder 14 is the same as ever. This significantly reduces outflow of source gas through space 21, which is between aperture portion 16 of flow channel 12 and substrate holder 14, or stops the outflow. Since variations in the amount of outflow of gas are reduced, the flow of source gas becomes stable and the uniformity of crystallinity and layer thickness of thin films is secured throughout the substrate plane.
Also, an AlGaN layer was grown on a substrate by using the MOCVD apparatus according to this embodiment. The Al composition and layer thickness were uniform throughout the substrate plane. Thus, crystal distortions were inhibited which would otherwise have been caused by non-uniform composition and layer thickness of the thin film on the substrate, and accordingly no cracks were found.
In this embodiment, as shown in
In this embodiment, as in embodiment 1, a revolving mechanism and a substrate automatic carry-in/out equipment may be provided, though not shown. While in this embodiment the three-dimensional shape of the flow channel is basically the same as that in embodiment 1, the aperture portion may be shaped similarly to the aperture portions of flow channels of conventional vapor deposition apparatuses.
This structure, as in embodiment 1, decreases the conductance with respect to outflow of source gas even when the area of space 21 between aperture portion 16 of flow channel 12 and substrate holder 14 is the same as ever.
With this structure, as in embodiment 1, since variations in the amount of outflow of gas were reduced, the flow of source gas became stable and the uniformity of crystallinity and layer thickness of thin films throughout the substrate plane were secured.
While in embodiments 1 and 2 specific examples of the orifice structure have been shown, the present invention is not limited to the examples; any orifice structure that does not allow gas to flow therethrough can be applied to the present invention. For example, as shown in
The Embodiments herein described are to be considered in all respects as illustrative and not restrictive. The scope of the invention should be determined not by the Embodiments illustrated, but by the appended claims, and all changes which come within the meaning and range of equivalency of the appended claims are therefore intended to be embraced therein.
Number | Date | Country | Kind |
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2004-279420 | Sep 2004 | JP | national |