Method for fabricating a semiconductor device
11011377 · 2021-05-18
Assignee
Inventors
- Svenja Mauthe (Zurich, CH)
- Marilyne Sousa (Adliswil, CH)
- Fabian Konemann (Zurich, CH)
- Kirsten Emilie Moselund (Rueschlikon, CH)
Cpc classification
C30B29/40
CHEMISTRY; METALLURGY
International classification
H01L21/02
ELECTRICITY
H01L21/20
ELECTRICITY
Abstract
A cavity structure comprises one or more seed surfaces, a first growth path for the growth of a first semiconductor structure from one of the one or more seed surfaces and a second growth path for the growth of a second semiconductor structure from one of the one or more seed surfaces. The cavity structure further comprises at least one opening for supplying precursor materials to the cavity structure. A method can include selectively growing the first semiconductor structure along the first growth path and selectively growing the second semiconductor structure along the second growth path. The first semiconductor structure has a first growth front and the second semiconductor structure has a second growth front. The method can further include merging the first and the second growth front at a border area of the first and the second semiconductor structure.
Claims
1. A method for fabricating a semiconductor device on a substrate, the method comprising: providing a substrate; providing a cavity structure on the substrate, the cavity structure comprising one or more seed surfaces; a first growth path for the growth of a first semiconductor structure from one of the one or more seed surfaces; a second growth path for the growth of a second semiconductor structure from one of the one or more seed surfaces; and at least one opening for supplying precursor materials to the cavity structure; selectively growing the first semiconductor structure along the first growth path, the first semiconductor structure having a first growth front; selectively growing the second semiconductor structure along the second growth path, the second semiconductor structure having a second growth front; and merging the first and the second growth front at a border area of the first and the second semiconductor structure, thereby growing a defined dislocation region at the border area; wherein the cavity structure further comprises: a first tapered edge portion adapted to extend the first growth path to the border area; and a second tapered edge portion adapted to extend the second growth path to the border area; wherein the first tapered edge portion and the second tapered edge portion converge at the dislocation region.
2. A method as claimed in claim 1, wherein the one or more seed surfaces comprise a first seed surface and a second seed surface, the second seed surface being spaced apart from the first seed surface, the method comprising selectively growing from the first seed surface the first semiconductor structure; and selectively growing from the second seed surface the second semiconductor structure.
3. A method as claimed in claim 1, wherein the one or more seed surfaces comprise a common seed surface for the first semiconductor structure and the second semiconductor structure; the cavity structure comprises a separation structure arranged in a separation area between the first growth path and the second growth path; and the cavity structure comprises a merging area for merging the growth fronts of the first and the second semiconductor structure; the method comprising selectively growing from the common seed surface a common semiconductor structure; selectively growing the first semiconductor structure and the second semiconductor structure along the separation structure, thereby separating the common semiconductor structure by the separation structure; and merging the first and the second growth front in the merging area of the cavity structure.
4. A method as claimed in claim 1, wherein the defined dislocation region establishes a dislocation plane.
5. A method as claimed in claim 1, wherein the dislocation region comprises grain boundaries.
6. A method as claimed in claim 1, wherein the one or more seed surfaces are arranged with a predefined angle towards each other.
7. A method as claimed in claim 1, wherein the cavity structure comprises a third growth path for the growth of a third semiconductor structure from one of the one or more seed surfaces; and the method further comprises selectively growing the third semiconductor structure along the third growth path, the third semiconductor structure having a third growth front; and merging the second and the third growth front at a border area of the second and the third semiconductor structure, thereby growing a defined dislocation region at the border area of the second and the third semiconductor structure.
8. A method as claimed in claim 1, wherein the selective growing of the first semiconductor structure and the second semiconductor structure is performed by selective epitaxial growth.
9. A method as claimed in claim 8, wherein the selective growing of the first semiconductor structure and the second semiconductor structure is performed by one of: metal organic chemical vapor deposition (MOCVD); atmospheric pressure CVD; low or reduced pressure CVD; ultra-high vacuum CVD; molecular beam epitaxy (MBE); atomic layer deposition (ALD) and hydride vapor phase epitaxy.
10. A method as claimed in claim 1, wherein the first semiconductor structure and the second semiconductor structures comprise a compound semiconductor material.
11. A method as claimed in claim 10, wherein the first semiconductor structure and the second semiconductor structure comprise a group III-V compound material or a group II-VI compound material.
12. A method as claimed in claim 1, wherein the one or more seed surfaces have an area of order 10.sup.4 nm.sup.2 or less.
13. A method as claimed in claim 1, wherein the one or more seed surfaces have a monocrystalline semiconductor surface.
14. A method as claimed in claim 1, wherein the substrate is used as one of the one or more seed surfaces.
15. A method as claimed in claim 1, comprising, after growing the first and the second semiconductor structure, removing the cavity structure.
16. A method as claimed in claim 1, wherein the first growth path and the second growth path extend laterally over the substrate.
17. A method as claimed in claim 1, wherein the first growth path and the second growth path extend vertically to the substrate.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(10) At first, some general aspects and terms of embodiments of the invention are described.
(11) The term cavity structure may be defined as a hollow, partly filled or filled structure that is formed by a solid surrounding, e.g. surroundings walls. According to embodiments of the invention the cavity structure has one or more openings through which precursor materials can be supplied to the cavity structure. The cavity structure may be in particular adapted to confine and guide materials of a vapor phase epitaxial process from the one or more openings to one or more seed surfaces to initiate crystal growth.
(12) The first and the second growth path may extend according to embodiments in a lateral direction extending laterally over a substrate. The term “laterally” is used in this context to indicate orientation generally parallel to the plane of the substrate, as opposed to generally vertically, or outwardly, from the substrate surface. According to other embodiments the first and the second growth path may extend in a direction that is vertically to the surface of the substrate.
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(15) The cavity structure 110 comprises a first growth channel 111 for the first growth path 131. According to this embodiment, the first growth channel 111 comprises a first part with a fixed width w11, a second part with an increasing width w12 and a third part with a fixed width w13.
(16) The cavity structure 110 comprises a second growth channel 112 for the second growth path 132. According to this embodiment, the second growth channel 112 comprises a first part with a fixed width w21, a second part with an increasing width w22 and a third part with a fixed width w23.
(17) The cavity structure 110 comprises a first tapered edge portion 110a adapted to extend the first growth path 131 to a border area 101 and a second tapered edge portion 110b adapted to extend the second growth path 132 to the border area 101. The border area 110 is an area at which the first growth channel 111 and the second growth channel 112 adjoin. The first tapered edge portion 110a and the second tapered edge portion 110b converge at the border area 101. The border area 101 is illustrated by a dash-dot line.
(18) The cavity structure 110 furthermore comprises a third tapered edge portion 110c adapted to extend the first growth path 131 and a fourth tapered edge portion 110d adapted to extend the second growth path 132. The third tapered edge portion 110c is arranged symmetrical to the first tapered edge portion 110a with respect to the first growth path 131 and the fourth tapered edge portion 110d is arranged symmetrical to the second tapered edge portion 110b with respect to the second growth path 132.
(19) The first seed 121 provides a seed for growing a first semiconductor structure 141 selectively from the first seed surface 121a and the second seed 122 provides a seed for selectively growing from the second seed surface 122a a second semiconductor structure 142 (see
(20) The cavity structure 110 comprises schematically illustrated openings 115 for supplying precursor materials to the cavity structure 110.
(21) The first seed surface 121a and the second seed surface 122a are substantially perpendicular to the first growth path 131 and the second growth path 132 respectively.
(22) The selective growing of the first semiconductor structure 141 and the second semiconductor structure 142 may be performed in particular by selective epitaxial growth. Methods that are in particular suitable according to embodiments are metal organic chemical vapor deposition (MOCVD), atmospheric pressure CVD, low or reduced pressure CVD, ultra-high vacuum CVD, molecular beam epitaxy (MBE), atomic layer deposition (ALD) and hydride vapor phase epitaxy.
(23) The first seed surface 121a and the second seed surface 122a may have in particular an area of order 10.sup.4 nm.sup.2 or less, to ensure a single point of nucleation. The first seed surface 121a and the second seed surface 122a may be embodied as monocrystalline semiconductor surfaces, in particular of silicon.
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(28) In general, the first and the second semiconductor structures may comprise any desired semiconductor materials. In preferred embodiments the first semiconductor structure and the second semiconductor structure comprise a compound semiconductor material. A compound semiconductor material includes a III-V compound semiconductor material, a II-VI compound semiconductor material and/or a IV-IV compound semiconductor material. In particular, indium gallium arsenide, indium arsenide and/or gallium arsenide may be used in view of a higher carrier mobility than silicon, thereby allowing high-frequency semiconductor devices.
(29) According to embodiments, material composition and/or dopant levels may be varied during the growth processes if desired.
(30) Referring now to
(31) Then, in another fabrication step, the result of which is illustrated in
(32) The semiconductor device shown in
(33) According to embodiments the semiconductor device shown in
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(35) Hence methods according to embodiments of the invention may facilitate the fabrication of semiconductor devices having dislocations at predefined areas of the semiconductor device in a predefined and desired way.
(36) An exemplary fabrication method of the cavity structure will now be described in more detail with reference to
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(38) In a first step of the method the Si layer 201 is patterned to form a silicon structure 204 as shown in
(39) The resulting structure 204 of a seed material for the one or more seeds first thus projects from dielectric layer 202.
(40) In this example, the structure 204 has a U-shaped form corresponding to e.g. the U-shaped form of the cavity structure 110 as illustrated in
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(42) Each of dimensions y, z in this example may be according to embodiments between 200 nm and 10 nm. However, generally any other shapes and dimensions may be used as desired.
(43) In a second step of the fabrication process of the cavity structure, a second dielectric layer 205, e.g. of silicon oxide, is deposited over, and in contact with, the structure 204 and the first dielectric layer 202. The result of this step is illustrated in
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(45) Next, as illustrated in
(46) The first and second dielectric layers 202, 205 together form a cavity structure with a first growth path and a second growth path corresponding to the cavity structure 110 of
(47) In other methods embodying the invention, the cavity structure can be formed by any convenient processing techniques on a substrate. As an example, the substrate 203 may be used as seed surface for growing the first semiconductor structure and the second semiconductor structure. Such an example is illustrated in
(48) Prior to the selective growth step, the Si seed surface is preferably cleaned, by flushing with an HF dip, to remove any surface oxidation, or by another surface cleaning method such as thermal desorption.
(49) According to embodiments, the substrate may be any suitable substrate and may be embodied e.g. as a Si-substrate, a SIM wafer, a GaAs-substrate, an InP-substrate, a SiC-substrate or a GaN-substrate.
(50) While the seed surfaces may be a monocrystalline semiconductor surfaces, this is not essential. In particular for embodiments where the area of the seed surface is constrained, the seed surface may be provided by a surface of an amorphous or polycrystalline semiconductor or a metal or a metal-semiconductor alloy such as a metal silicide.
(51) After formation of the first and the second semiconductor structure, the cavity structure may be removed as desired, e.g. by etching. The structure may then be further optimized, e.g. to refine shape, and subsequent device processing steps may be performed as appropriate to build a required device structure around the first and the second semiconductor structure.
(52) The basic fabrication steps described above can be performed using well-known material processing techniques.
(53) By way of illustration, details of an exemplary process for fabricating the structure as shown in
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(70) It should be noted that the above described cavity structures are only exemplary examples and that by appropriate shaping of the cavity structure semiconductor structures may be fabricated with dislocation regions of a plurality of desired shapes.
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(72) At a step 801, a cavity structure is provided, e.g. the cavity structure 110 of
(73) At a step 802, a first semiconductor structure is selectively grown from the first seed surface along the first growth path.
(74) Concurrently, at a step 803, a second semiconductor structure is grown from the second seed surface along the second growth path.
(75) At a step 804, the growth fronts of the first and the second semiconductor structures are merged at a border area between the first and the second semiconductor structure. Thereby, a defined dislocation region is grown at the border area.
(76) At a step 805, the cavity structure is removed as desired, e.g. by etching.
(77) At a step 806, a device structure is patterned as desired, e.g. by etching away undesired semiconductor or materials.
(78) Finally, in a further step electrical contacts or a gate may be provided as desired.
(79) A method for fabricating a semiconductor device on a substrate may be provided. The method can comprise steps of providing a substrate and providing a cavity structure on the substrate. The cavity structure can comprise one or more seed surfaces, a first growth path for the growth of a first semiconductor structure from one of the one or more seed surfaces and a second growth path for the growth of a second semiconductor structure from one of the one or more seed surfaces. The cavity structure can further comprise at least one opening for supplying precursor materials to the cavity structure. The method can further comprise steps of selectively growing the first semiconductor structure along the first growth path and selectively growing the second semiconductor structure along the second growth path. The first semiconductor structure can have a first growth front and the second semiconductor structure can have a second growth front. The method can comprise a further step of merging the first and the second growth front at a border area of the first and the second semiconductor structure. Thereby, a defined dislocation region can be grown at the border area. Related semiconductor devices obtainable by such a method can be provided.
(80) While particular examples have been described above, numerous alternatives and modifications may be envisaged. E.g., various other compound semiconductors may be used in the above processes, and other dopant and etchant combinations may be used. The resulting semiconductor structures may be further processed if desired, e.g. via additional etching and/or growth stages to produce more complex structures.
(81) The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.