The present teachings relate to the field of sensors such as photosensors, chemical sensors, etc., and, more particularly, to sensor structures and fabrication methods.
Detectors and sensors are used in a variety of applications in fields such as defense, security, manufacturing, metrology, energy efficiency and monitoring, environmental monitoring, automation, robotics, health, and many others. For sensing applications, detectors may be provided as a single pixel sensor or as a small format array. For imaging applications, detectors may be incorporated into focal plane arrays (FPAs). One type of FPA includes photosensitive elements that are bonded through indium bumps to a silicon circuitry. The photosensitive elements may produce a photovoltage, which is sensed by a readout integrated circuit (ROIC) formed using a silicon substrate. Typical FPAs based on photonic detectors involve wafer level processing of the photosensitive element followed by dicing of the arrays, particularly for photodetectors sensitive in the infrared and terahertz bands.
To form these photodetectors, a plurality of photodetector dies and a plurality of ROIC dies may be separately manufactured in wafer form using wafer-level fabrication techniques. A photodetector wafer and a ROIC wafer are each formed and diced to form a plurality of individual photodetector dies and a plurality of individual ROIC circuits. Each photodetector is flip-chip bonded to an ROIC to form a complete photosensor chip. Prior to use, the photosensor chip may undergo further processing, such as removal of the substrate, packaging, testing, and operational characterization.
The following presents a simplified summary in order to provide a basic understanding of some aspects of one or more implementations of the present teachings. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its primary purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description presented later.
A sensor according to an implementation of the present teachings includes a transistor having a transistor source, a transistor drain, a transistor channel positioned between the transistor source and the transistor drain, and a transistor gate positioned over the transistor channel. The sensor further includes a sensor element positioned between the transistor gate and the transistor channel. The sensor element is configured to generate an electric current when exposed to a stimulus. The sensor is configured such that a first electric current output by the transistor when the sensor element is exposed to the stimulus is different than a second electric current output by the transistor when the sensor element is not exposed to the stimulus.
The electric current generated by the sensor element results from the exposure to the stimulus. Further, the transistor drain may have a first output when a threshold voltage is applied to the transistor and the sensor element is not being exposed to the stimulus, and the transistor drain may have a second output when the threshold voltage is applied to the transistor and the sensor element is being exposed to the stimulus, wherein the second output is larger than the first output. The sensor element may be a III-V semiconductor, where the senor may be configured to sense photonic radiation. In an implementation, the sensor element may have a thickness of from 10 nanometers to 50 microns, and the transistor gate has a thickness of from 1 nanometer to 10 microns. The transistor gate may be configured for passage of the stimulus therethrough during operation of the transistor.
The sensor element may include at least one of a hydrophilic sensor element or a hydrophobic sensor element, and the sensor may be configured to sense a chemical. The sensor element may be a III-V semiconductor, and the sensor may be configured to sense a hydrophobic chemical reagent or a hydrophilic chemical reagent.
In an implementation, the transistor may be an enhancement mode metal oxide semiconductor or a depletion mode metal oxide semiconductor field effect transistor.
In another implementation, a method for forming a sensor includes forming a transistor comprising a transistor source, a transistor drain, and a transistor channel positioned between the transistor source and the transistor drain, forming a sensor element over the transistor channel, and forming a transistor gate of the transistor such that the sensor element is positioned between the transistor gate and the transistor channel. The sensor element is configured to generate an electric current when exposed to a stimulus and the sensor is configured such that a first electric current output by the transistor when the sensor element is exposed to the stimulus indifferent than a second electric current output by the transistor when the sensor element is not exposed to the stimulus.
The formation of the transistor may further forms a transistor wherein the electric current generated by the sensor element results from the exposure to the stimulus, the transistor drain is configured to have a first output when the transistor channel inverts and the sensor element is not being exposed to the stimulus, and the transistor drain has a second output when the transistor channel inverts and the sensor element is being exposed to the stimulus, wherein the second output is larger than the first output. The forming of the sensor element over the transistor channel may include attaching a photosensitive sensor element comprising a III-V semiconductor to a gate oxide such that the gate oxide is positioned between the photosensitive sensor element and the transistor channel. The forming of the transistor gate may form the transistor gate having a thickness and composition sufficient for passage of the stimulus through the transistor gate during operation of the transistor. The forming of the sensor element over the transistor channel may include attaching a chemically sensitive sensor element having at least one of a hydrophobic element or a hydrophilic element to a gate oxide such that the gate oxide is positioned between the chemically sensitive sensor element and the transistor channel, and the chemically sensitive sensor element is configured to generate a current when exposed to a chemical.
The forming of the sensor element over the transistor channel may further include attaching a III-V semiconductor to the gate oxide, and the sensor may be configured to sense a hydrophobic chemical reagent or a hydrophilic chemical reagent.
In an implementation, a method for operating a sensor having a transistor includes exposing a sensor element of the transistor to a stimulus, wherein the sensor element is electrically coupled to a transistor gate and positioned between the transistor gate and a transistor channel. While not exposing the sensor element to the stimulus, the method further includes inverting the transistor and reading a first output of a transistor drain of the transistor, exposing the sensor element to the stimulus and, while exposing the sensor element to the stimulus, inverting the transistor and readings second output of the transistor drain, wherein the second output is higher than the first output.
The exposing the sensor element to the stimulus may include exposing the sensor element to a first intensity or concentration of the stimulus, and the method further may further include exposing the sensor element to a second intensity or concentration of the stimulus, wherein the second intensity or concentration of the stimulus is higher than the first intensity or concentration of the stimulus and, while exposing the sensor element to the second intensity or concentration of the stimulus, inverting the transistor and reading a third output of the transistor drain, wherein the third output is higher than the second output. Each inversion of the transistor may include applying a threshold voltage to the transistor to invert the channel of the transistor. The exposing of the sensor element to the stimulus may expose the sensor element to photonic radiation.
The accompanying drawings, which are incorporated in, and constitute a part of this specification, illustrate implementations of the present teachings and, together with the description, serve to explain the principles of the disclosure. In the figures:
It should be noted that some details of the figures have been simplified and are drawn to facilitate understanding of the present teachings rather than to maintain strict structural accuracy, detail, and scale.
Reference will now be made in detail to exemplary implementations of the present teachings, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
As discussed above, the formation of detectors and sensors may include wafer-level fabrication of a plurality of photodetector dies and a plurality of readout integrated circuit (ROIC) dies on separate semiconductor wafers. Subsequently, the wafers are diced and each photodetector die may be flip-chip mounted to a ROIC die. This die-level hybridization is a low-yield, costly, and complex process. Decreasing manufacturing costs and complexity is a goal of designers and manufacturers.
The present teachings include a sensor manufacturing process, and a resulting sensor device, that may simplify the fabrication of detectors and sensors such as photosensors, chemical-sensors, and other types of sensors compared to conventional designs and manufacturing techniques. Further, the sensor manufacturing process may provides less costly detector and/or sensor. While the present teachings are generally discussed herein relative to photosensors, it will be appreciated that that the concepts and manufacturing techniques described herein may be useful for chemical sensors and other types of sensors, depending on the composition of the sensor element and the stimulus to which the sensor element is sensitive. A “sensor element” may also be referred to herein as a nanomembrane, a sensor material, a photosensitive sensor element, or a chemically sensitive sensor element.
An implementation of a structure of the proposed device of the present teachings is depicted in
The GAME detector 100 of
The sensor element 116 may be or include, for example, a III-V semiconductor or another material that generates a current or voltage when exposed to photonic radiation, and is capacitively coupled to the transistor gate 118. As depicted, the source contact 106 may be electrically coupled to ground, thereby grounding the source 104, and the gate 118 may be electrically coupled to a first voltage (e.g., VGS or “gate-to-source voltage”). Additionally, the drain contact 110, and thus the drain 108, may be electrically coupled to a second voltage (e.g., VDS or “drain-to-source voltage”).
As incident photonic radiation generates a current and/or voltage in the photosensitive sensor element 116, the VGS varies an leads to a change in the drain current VDS. The magnitude of the change depends on whether the transistor is biased in the sub-threshold regime, non-saturation or linear regime or the saturation regime. During operation, the photovoltage may be capacitively coupled to the gate of the transistor. In an enhancement mode (i.e., normally off) device implementation, the GAME detector 100 requires a minimum VGS or threshold voltage “VT” to electrically conduct across the channel 112 (i.e., turn on, invert, or trip the transistor). As known in the art, during inversion of the transistor channel 112, a sheet of positive or negative charge carriers are created that leads to electrical conduction through the channel 112 between the source 104 and the drain 108. In the absence of photonic radiation reaching, and electrically influencing the sensor element 116, the resulting drain current VDS has a first value that may be measured by a readout circuit. In the presence of photonic radiation, the sensor element 116 becomes electrically active and generates a current. When the VT is applied to the cell, the current generated by the sensor element increases the resulting VDS compared to the VDS when the stimulus is absent from the sensor element. Thus by applying the threshold voltage to the transistor and measuring the resulting VDS, it may be determined whether the stimulus is present or absent on the sensor element 116.
The conversion of photovoltage into the current occurs in the MOSFET within the GAME detector. The operation region of the MOSFET can be controlled by the voltage of the gate terminal, VGS, and the drain-source voltage, VDS.
For example, if the MOSFET operates in saturation region, the output current of the GAME detector will be determined by the transconductance of the MOSFET, gm, at its operating point as shown below:
I
DS
=g
m
V
gs
=g
m
V
ph and gm=K′n(W/L)(Vgs=VT)
where K′n is the process transconductance parameter, W is the width, L is the channel length, VGS is the gate bias voltage and VT is the threshold voltage. The MOSFET transconductance depends on the device physical parameters, and is typically around ˜1 milliamp per volt (mA/V). If the photovoltage change is about 70 millivolts (mV), the output drain current change will be about 70 microamps (μA), which can be easily detected by a readout circuit.
On the other hand, the MOSFET can be in subthreshold region to enhance the detector responsivity. In this case, the GAME detector output current will be exponentially dependent on the gate photovoltage, VGS, as shown in the graph of
where I0 is the current coefficient, VGS, is the gate voltage, VDS, is the drain current, n is a scaling coefficient, and KT/q is the thermal potential. The relationship between output current and the photovoltage can also be calculated using the equation for subthreshold swing:
where S is the subthreshold swing. For example, the subthreshold swing of a typical MOSFET is around ˜70 mV/decade at room temperature, which means that if the photovoltage change is about 70 mV, the output drain current will change 10 times. This provides a superior sensitivity that is needed in variety of applications. At lower temperatures the subthreshold swing is smaller, which results in even greater sensitivity of the proposed GAME detector 100.
The electrical operation of the GAME detector 100 will be understood by one of ordinary skill in the art from the description herein.
A method for forming a GAME detector, and various in-process structures according to an implementation of the present teachings, are depicted in
As depicted in
Subsequently, the exposed field oxide 302 is removed to expose the substrate 300. The exposed field oxide 302 may be removed, for example, with a vertical anisotropic etch using an etchant that removes the field oxide 302 selective to the substrate 300 and the mask 304 (i.e., the etchant removes the field oxide 302 at a faster rate than it removes the substrate 300 and the mask 304) to result in a structure similar to that depicted in
Next, a blanket implant process of, for example, phosphorus may be performed to form the N-type transistor source 500 and the transistor drain 502 as depicted in
Next, as depicted in
Next, a sensor element 800 is provided over a transistor channel region 802 as depicted in
In an implementation, the sensor element 800 may have a thickness of from about 1 nanometer (nm) to about 50 microns. The thickness may depend, for example, on an absorption coefficient Of the material used to form the sensor element 800.
In an implementation, the sensor layer 800 may be a photosensitive layer that is or includes a III-V semiconductor material that generates a photovoltage (i.e., an electric voltage produced by the sensor layer when exposed to, and induced by the action of, photonic radiation). In another implementation, the sensor layer 800 may be or include a material that generates a current or voltage when exposed to a stimulus or stimuli different from photonic radiation, such as a chemical sensor that generates a current or voltage when exposed to one or more chemicals. In one implementation, the sensor layer 800 may be a chemical sensor such as a III-V semiconductor material that is, or has been treated to be, hydrophilic or hydrophobic to generate a voltage when exposed to a chemical such as a chemical reagent, for example, a bio-chemical hydrophilic reagent or a bio-chemical hydrophobic reagent. Other suitable chemical sensor materials that generate a voltage in the presence of one or more chemicals, and the chemicals sensed by the other chemical sensor materials, are known in the art and contemplated for use with the present implementations.
In one method for providing the patterned sensor element 800, patterned sensor element 800, such as a III-V semiconductor material, may be grown, for example as an epitaxial layer, on a separate growth substrate, such as a semiconductor wafer, and then transferred from the growth substrate to substrate 300. In an implementation, a plurality of patterned sensor elements 800 are grown on the growth substrate and then simultaneously transferred to the wafer substrate 300 where the plurality of GAME detectors 100 are being formed. In one implementation, the one or more sensor elements 800 may be transferred using a transfer layer such as a polydimethylsiloxane (PDMS) transfer layer or another transfer layer. In another process, a blanket layer of sensor element material may be formed on a transfer layer and then segmented using an etch or a dicing process to form a plurality of sensor elements 800. The sensor elements 800 may then be transferred to the gate oxide 700.
Next, the source contact 900, the drain contact 902, and the transistor gate 904 may be formed, for example, as depicted in
As discussed above, the voltage generated within the sensor element 800 in the presence of the stimulus alters the resulting drain current which is measured by a ROIC through the drain contact 110. The VDS that results from the application of VT to the transistor provides an indication of whether the stimulus is being applied to the sensor element 800. Additionally, an intensity of a stimulus may result in different current levels being generated by the sensor element 800 which, in turn, results in different VDS values. Through experimentation or modeling, the amplitude of the measured VDS may provide an indication of the intensity or concentration of the stimulus to which the sensor element 800 is being subjected, with lower values indicated that little or no stimulus is reaching the sensor element and high values indicating a large amount of stimulus is reaching the sensor element.
Subsequently, after forming a structure similar to that depicted in
It will be appreciated that while the process above and depicted in
The completed structure described herein is in the form of an enhancement mode MOSFET, but it will be appreciated that the GAME detector may be or include one or more other types of devices such as other types of transistor devices. These one or more devices may be or include N-channel or P-channel metal oxide semiconductor (MOS) devices, complementary MOS devices, bipolar junction transistor (BJT) devices including NPN, PNP, etc., high-electron-mobility transistors (HEMTs), heterojunction bipolar transistors (HBTs), other field effect transistors (FETs), etc. The devices may be formed to include, semiconductor materials such as silicon (e.g., monocrystalline or polycrystalline silicon), gallium (e.g., gallium arsenide GaAs, gallium antimonide GaSb), and/or indium (e.g., indium arsenide InAs, indium phosphide InP, indium antimonide InSb). The devices may further include materials such as graphene, molybdenum disulfide (MoS2), molybdenum diselenide (MoSe2), gallium nitride (GaN), aluminum gallium nitride (AlGaN), ultra-wide bandgap semiconductors, etc.
Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present teachings are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein. For example, a range of “less than 10” can include any and all sub-ranges between (and including) the minimum value of zero and the maximum value of 10, that is, any and all sub-ranges having a minimum value of equal to or greater than zero and a maximum value of equal to or less than 10, e.g., 1 to 5. In certain cases, the numerical values as stated for the parameter can take on negative values. In this case, the example value of range stated as “less than 10” can assume negative values, e.g., −1, −2, 3, −10; −20, −30, etc.
While the present teachings have been illustrated with respect to one or more implementations, alterations and/or modifications can be made to the illustrated examples without departing from the spirit and scope of the appended claims. For example, it will be appreciated that while the process is described as a series of acts or events, the present teachings are not limited by the ordering of such acts or events. Some acts may occur in different orders and/or concurrently with other acts or events apart from those described herein. Also, not all process stages may be required to implement a methodology in accordance with one or more aspects or implementations of the present teachings. It will be appreciated that structural components and/or processing stages can be added or existing structural components and/or processing stages can be removed or modified. Further, one or more of the acts depicted herein may be carried out in one or more separate acts, and/or phases. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” The term “at least one of” is used to mean one or more of the listed items can be selected. As used herein, the term “one or more of” with respect to a listing of items such as, for example, A and B, means A alone, B alone, or A and B. The term “at least one of” is used to mean one or more of the listed items can be selected. Further, in the discussion and claims herein, the term “on” used with respect to two materials, one “on” the other, means at least some contact between the materials, while “over” means the materials are in proximity, but possibly with one or more additional intervening materials such that contact is possible but not required. Neither “on” nor “over” implies any directionality as used herein. The term “conformal” describes a coating material in which angles of the underlying material are preserved by the conformal material. The term “about” indicates that the value listed may be somewhat altered, as long as the alteration does not result in nonconformance of the process or structure to the illustrated implementation. Finally, “exemplary” indicates the description is used as an example, rather than implying that it is an ideal. Other implementations of the present teachings will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the present teachings being indicated by the following claims.
Terms of relative position as used in this application are defined based on a plane parallel to the conventional plane or working surface of a workpiece, regardless of the orientation of the workpiece. The term “horizontal” or “lateral” as used in this application is defined as a plane parallel to the conventional plane or working surface of a workpiece, regardless of the orientation of the workpiece. The term “vertical” refers to a direction perpendicular to the horizontal. Terms such as “on,” “side” (as in “sidewall”), “higher,” “lower,” “over,” “top,” and “under” are defined with respect to the conventional plane or working surface being on the top surface of the workpiece, regardless of the orientation of the workpiece.
This application claims the benefit of U.S. Provisional Application No. 62/329,668, filed Apr. 29, 2016, which is incorporated herein by reference as if set forth in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2017/023424 | 3/21/2017 | WO | 00 |
Number | Date | Country | |
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62329668 | Apr 2016 | US |