Method of making a dual-gate HEMT
10734498 ยท 2020-08-04
Assignee
Inventors
Cpc classification
H01L29/66462
ELECTRICITY
H01L29/778
ELECTRICITY
H01L21/28587
ELECTRICITY
International classification
H01L29/66
ELECTRICITY
H01L29/08
ELECTRICITY
H01L29/778
ELECTRICITY
H01L29/423
ELECTRICITY
Abstract
A four-terminal GaN transistor and methods of manufacture, the transistor having source and drain regions and preferably two T-shaped gate electrodes, wherein a stem of one of the two T-shaped gate electrodes is more closely located to the source region than it is to a stem of the other one of the two T-shaped gate electrodes and wherein the stem of the other one of the two T-shaped gate electrodes is more closely located to the drain region than it is to the stem of said one of the two T-shaped gate electrodes. The the gate closer to the source region is a T-gate, and the proximity of the two gates is less than 500 nm from each other. The spacing between the stem of the RF gate and source region and the stem of the DC gate and drain region are preferably defined by self-aligned fabrication techniques. The four-terminal GaN transistor is capable of operation in the W-band (75 to 100 GHz).
Claims
1. A dual gate transistor, having source and drain regions and two gate electrodes, the lateral dimension between stems of the two gate electrodes and between the stems of each gate electrode and an associated one of said source and drain regions being established by lithographically set lateral dimensions and a thickness of a sacrificial layer thereby defining locations of the source and drain regions and stems of the two gate electrodes that are self-aligned with respect to each other.
2. A method of making dual gate transistor comprising: forming a substrate comprising one or more semiconductor layers; forming two sacrificial structures concurrently on said substrate; covering portions of the two sacrificial structures and a portion of the substrate with a resist material; forming source and drain regions in said substrate where the substrate is not covered by said resist material; removing the resist material; covering the two sacrificial structures and at least portion of the substrate with a first material; removing portions of the two sacrificial structures and portions of said first material which have a height exceeding some predetermined height above said substrate; removing remaining portions of the two sacrificial structures thereby defining two openings in said material, said openings having sidewalls formed of said first material; forming a second material on said sidewalls so that resulting openings occur where each sacrificial structure had been, which resulting openings being reduced in width compared to the first mentioned openings having sidewalls formed of said first material, the second material having a predetermined thickness; depositing a first metal in said resulting openings, the first metal at least partially filling said resulting openings, a sidewall portion of the first metal being spaced from a respective one of said source and drain regions by a distance substantially equal to said predetermined thickness; depositing a second metal over said first metal and filing said resulting openings if not previously filled by said first metal; removing potions of the second metal to thereby defines lengths and heights of a RF gate of said dual gate transistor and a DC gate said of dual gate transistor.
3. A method of making a dual gate transistor, said method including forming source and drain regions and two gate electrodes, a lateral dimension between centerlines of each gate electrode and an associated one of said source and drain regions being established by lithographically set lateral dimensions or lengths (W.sub.s) of first and second instances of a first sacrificial material and a thickness (S) of a second sacrificial material, the first sacrificial material being removed prior to a completion of a formation of the two gate electrodes and second sacrificial materials being at least partially removed prior to a completion of a formation of the two gate electrodes.
4. The method of claim 3 wherein a lateral dimension between the two gate electrodes where they contact a substrate material is established by the lithographically set lateral spacing (SG) between the first and second instances of the first sacrificial material plus twice the thickness (S) of the second sacrificial material.
5. A four-terminal GaN transistor, having source and drain regions and two T-shaped gate electrodes, wherein a stem of one of the two T-shaped gate electrodes is more closely located to the source region than it is to a stem of the other one of the two T-shaped gate electrodes and wherein the stem of the other one of the two T-shaped gate electrodes is more closely located to the drain region than it is to the stem of said one of the two T-shaped gate electrodes and wherein a spacing between the two gates where they contact a substrate material is established by a lithographically set distance GS plus twice a thickness S of a sacrificial layer of material.
6. The four terminal GaN transistor of claim 5 wherein the stem of said one of the two T-shaped gate electrodes is spaced from said source region by a distance S equal to the thickness S of the sacrificial layer of material and wherein the stem of said other one of the two T-shaped gate electrodes is spaced from said drain region also by said distance S.
7. The four terminal GaN transistor of claim 6 wherein said distance S is established by a thickness of a layer of a sacrificial material which is removed during the manufacture of said four terminal GaN transistor.
8. A four-terminal GaN transistor, comprising source and drain regions and two gate electrodes wherein a one of the two gate electrodes closer to the source region is a T-shaped gate and a spacing between the two gates where they contact a substrate material is less than 500 nm to each other which is established by a lithographically set distance GS plus twice the thickness S of a sacrificial layer of material.
9. A four-terminal GaN transistor, having source and drain regions and at least one T-shaped RF gate electrode and at least one DC gate electrode, wherein a stem of the T-shaped gate RF electrode is more closely located to the source region than it is to the DC gate electrode and wherein the DC gate electrode is spaced from said drain region by essentially the same distance that the stem of the T-shaped gate RF electrode is spaced from the source region.
10. The four-terminal GaN transistor of claim 9 capable of operation in the W-band (75 to 100 GHz).
11. The four-terminal GaN transistor of claim 8 capable of operation in the W-band (75 to 100 GHz).
12. The four-terminal GaN transistor of claim 5 capable of operation in the W-band (75 to 100 GHz).
13. The four-terminal GaN transistor of claim 12 wherein a spacing between the two gates where they contact a substrate material is established by a lithographically set distance GS plus twice the thickness S of a sacrificial layer of material.
14. The four terminal GaN transistor of claim 5 wherein the stem of said one of the two T-shaped gate electrodes is spaced from said source region by a distance S and wherein the stem of said other one of the two T-shaped gate electrodes is spaced from said drain region also by said distance S, the distance S being set by said thickness S of the sacrificial layer of material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(9) The following description is presented to enable one of ordinary skill in the art to make and use the invention and to incorporate it in the context of particular applications. Various modifications, as well as a variety of uses in different applications will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to a wide range of embodiments. Thus, the present invention is not intended to be limited to the embodiments presented, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
(10) In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without necessarily being limited to these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present invention.
(11) The reader's attention is directed to all papers and documents which are filed concurrently with this specification and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All the features disclosed in this specification, (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
(12) A dual gate device is a transistor with two gate structures placed between a set of source and drain contacts. The device operates like a cascode (a common-source followed by a common-gate transistor), except within a single device rather than two separate devices. The RF gate is placed closer to the source contact, and functions in the same way that a gate does within a standard common-source amplifier cell in that it receives the RF input signal. The DC gate is placed closer to the drain, and receives a constant DC voltage to enable operation as a common-gate device. This configuration is advantageous in that it increases output resistance and greatly reduces the Miller effect (amplification of the feedback capacitance caused by transistor voltage gain).
(13) Traditionally dual-gate devices within GaN are designed using field-plate gates, and are intended to operate at microwave frequencies below 10 GHz. Achieving high-performance at mm-wave frequencies within a dual-gate device will require fabricating highly-scaled RF T-gates and it will require an unprecedented degree of lateral scaling between the RF and DC gates, both of which present significant fabrication challenges. In particular, if the prior art is followed, it will be difficult to form both the RF and DC gates at the same time because resist undercut needed by standard bi-layer or tri-layer e-beam process will make it impractical to resolve the features in proximity that is closer than 1 to 2 m.
(14) The following description begins with the disclosure of a non-self-aligned device (and a method of making same) and then follows with a self-aligned device (and a method of making same). As will be seen, the lateral dimensions of the self-aligned device are considerably better than those of the non-self-aligned device in that the drain to source spacing is much less than 1 m (and as tight as about 250 nm in the disclosed embodiment). The drain to source spacing of the non-self-aligned device is better than that generally found in the prior art in that that spacing is somewhat less than 1 m. However the self-aligned device is expected to operate at higher frequencies than the non-self-aligned device would be capable of given the even closer source-drain spacing which can be obtained.
(15) A Non-Self-Aligned Device and Method
(16) A proposed process flow for fabrication of a non-self signed embodiment of a dual-gate devices begins with
(17) Then as shown in
(18) The e-beam resist (not shown) utilized to define the opening 22 in layer 20 for the DC gate region is then removed. A layer of DC gate metal is formed on the layer 20 of SiN and over opening 22 and then a second bi-layer e-beam process is used to first evaporate and the lift-off excess DC gate metal thereby defining a DC gate 24 covering opening 22 in the DC gate region. In past work, HRL has found that depositing a layer of passivation on a planar surface (before gate lift-off) significantly reduces DC-RF dispersion in the final device. The DC gate 24 is preferably fabricated first using two e-beam lithography based steps:
(19) (1) A positive tone e-beam resist (using resists such as ZEP520A or PMMA, not shown) is laid down followed by an appropriate etch (such as a CF4-based dry etch) to thereby define an opening 22 (see
(20) (2) Next a second a bi-layer e-beam lithography process is followed by a metal evaporation (Pt/Au or Ni/Au, for example) and a lift-off step to thereby form the DC gate 24 (see
(21) Within a dual-gate structure, gate resistance of the DC gate 24 is less critical to device performance than it is for the RF gate 30 (see
(22) The RF T-gate 30 is fabricated preferably using a ZEP/PMGI/ZEP tri-layer e-beam resist (see numerals 25-1, 25-2 and 25-3) process, which is a standard process used by HRL Laboratories in the fabrication of 40 nm GaN T3 devices, although other resist stacks are possible (including PMMA/MMA/PMMA for example). It is known that the surface topology can locally influence e-beam resist thickness during a spin coating procedure, which could alter this process. Our expectation is that the presence of the DC gate 24 will not alter the T-gate 30 formation process significantly because the DC gate metal 24 will be relatively thin and the resist behavior is more likely to be dominated by the presence of source and drain ohmic metal 28, 26. After the resist is developed, the SiN is dry-etched from the gate foot to form the RF gate foot, and the Pt/Au RF gate metal is evaporated, the metal is lifted off and a final layer 34 of SiN passivation is deposited (see
(23) Those skilled in the art will appreciate the fact device of
(24) A Self-Aligned Device and Method
(25) The non-self-aligned embodiment of
(26) The dual gate formation begins with the simultaneous forming of two sacrificial dummy gate structures 102 and 104 which are defined with a height preferably in a range of about 300 to 500 nm and a width (W.sub.S) of about 50 to 150 nm directly on a device substrate 100 by e-beam lithography. The device substrate 100 may include a Scaled Graded Composite Channel as taught by U.S. Provisional Patent Application Ser. No. 62/630,688 filed on 14 Feb. 2018, referenced above. See
(27) The sacrificial dummy gate structures 102 and 104 are formed of a resist preferably capable of a fine feature resolution preferably less than 10 nm. So Hydrogen Silsesquioxane (HSQ) is preferably used as the resist for sacrificial dummy gate structures 102 and 104. Since sacrificial dummy gate structures 102 and 104 are formed at the same time with a resist such as HSQ exhibiting fine feature control, the distance GS between the two sacrificial dummy gate structures 102 and 104 can be tightly controlled. As will be seen, the resulting distance W.sub.GS between the stems 127 of the gates and the distance S between the stems 127 of the each of the gates and the source and drain regions 114, 116 will be self-aligned and are based on the distances selected for W.sub.S and GS as well as the thickness S selected for layer 122.
(28) Substrate 100 may be a GaN substrate suitable for use in making HEMT devices and thus may comprise a number of epitaxially formed layers known to those skilled in the art of making HEMT devices.
(29) A dielectric mask 106 (such as SiN) is next deposited to a thickness (height) preferably in a range of about 100-200 nm on the exposed surface, which includes the sidewalls of the sacrificial dummy gate structures 102 and 104 (see
(30) Next, as is shown by
(31) Turning to
(32) The sacrificial dummy gate structures 102 and 104 are then selectively removed (see
(33) To metallize the gates (see
(34) For the final steps, the residual (exposed) metallic membrane 126 is removed using, for example, an ion mill step (which will also likely remove a small amount of the gate heads 128, but the gate heads 128 are significantly thicker than the residual metallic membrane 126 so that the ion milling removes all of the exposed metallic membrane 126 and only a small percentage of height of the Au gate heads 128. The remaining SiN 118 is then preferably removed (see
(35) This self-aligned embodiment (according to
(36) The DC gate 132 in this self-aligned embodiment may be made without a stem, for example, by increasing the length of opening 120.sub.Dc depicted in
(37) The self-aligned embodiment of
(38) Having now described the invention in accordance with the requirements of the patent statutes, those skilled in this art will understand how to make changes and modifications to the present invention to meet their specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention as disclosed herein.
(39) The foregoing Detailed Description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable.
(40) Reference to a claim element in the singular is not intended to mean one and only one unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the Claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Section 112, as it exists on the date of filing hereof, unless the element is expressly recited using the phrase means for . . . and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase comprising the step(s) of . . . .
(41) Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the invention. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components. The methods may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order. As used in this document, each refers to each member of a set or each member of a subset of a set.