SEMICONDUCTOR LAYER, OSCILLATION ELEMENT, AND SEMICONDUCTOR LAYER MANUFACTURING METHOD
20200135494 ยท 2020-04-30
Inventors
Cpc classification
H01L21/02565
ELECTRICITY
H01L29/66969
ELECTRICITY
H01L21/479
ELECTRICITY
H01L29/24
ELECTRICITY
International classification
H01L21/479
ELECTRICITY
H01L29/66
ELECTRICITY
H01L29/24
ELECTRICITY
H01L21/477
ELECTRICITY
Abstract
A semiconductor layer of the present invention is a semiconductor layer including: a pn junction at which an n-type semiconductor (Al.sub.2O.sub.3 (n-type)) and a p-type semiconductor (Al.sub.2O.sub.3 (p-type)) are joined, the n-type semiconductor (Al.sub.2O.sub.3 (n-type)) having a donor level that is formed by causing an aluminum oxide film (Al.sub.2O.sub.3) to excessively contain aluminum (Al), the p-type semiconductor (Al.sub.2O.sub.3 (p-type)) having an acceptor level that is formed by causing an aluminum oxide film (Al.sub.2O.sub.3) to excessively contain oxygen (O).
Claims
1. A semiconductor layer comprising: a pn junction at which an n-type semiconductor layer and a p-type semiconductor layer are joined, the n-type semiconductor layer having a donor level that is formed by causing an aluminum oxide film to excessively contain aluminum, the p-type semiconductor layer having an acceptor level that is formed by causing an aluminum oxide film to excessively contain oxygen.
2. A semiconductor layer comprising a p-type semiconductor layer having an acceptor level that is formed by causing an aluminum oxide film to excessively contain oxygen.
3. A method for manufacturing a semiconductor layer, comprising the steps of: bringing metallic aluminum and a probe into contact with a first surface and a second surface, respectively, of an aluminum oxide film so as to melt the aluminum oxide film in atmosphere, oxygen-containing gas, or oxygen gas by applying, between the metallic aluminum serving as an anode and the probe serving as a cathode, a voltage at which a dielectric breakdown occurs in the aluminum oxide film; and by causing, in the aluminum oxide film which is being melted, a molten salt electrolysis reaction so as to cool the aluminum oxide film, forming an n-type semiconductor layer and a p-type semiconductor layer on the metallic aluminum side and the probe side, respectively, of the aluminum oxide film, and joining the n-type semiconductor layer and the p-type semiconductor layer.
4. A method for manufacturing a semiconductor layer, comprising the steps of: bringing metallic aluminum and a probe into contact with a first surface and a second surface, respectively, of an aluminum oxide film so as to melt the aluminum oxide film in atmosphere, gas, or a vacuum by applying, between the metallic aluminum serving as a cathode and the probe serving as an anode, a voltage at which a dielectric breakdown occurs in the aluminum oxide film; and by causing, in the aluminum oxide film which is being melted, a molten salt electrolysis reaction so as to cool the aluminum oxide film, forming a p-type semiconductor layer and an n-type semiconductor layer on the metallic aluminum side and the probe side, respectively, of the aluminum oxide film, and joining the n-type semiconductor layer and the p-type semiconductor layer.
5. The method as set forth in claim 3, wherein the molten salt electrolysis reaction is caused in the aluminum oxide film by making a donor concentration of the n-type semiconductor layer and an acceptor concentration of the p-type semiconductor layer controllable by adjusting coulomb amount that causes the molten salt electrolysis reaction.
6. The method as set forth in claim 3, wherein the molten salt electrolysis reaction is caused in the aluminum oxide film by moving the probe while bringing the probe into contact with the aluminum oxide film.
7. The method as set forth in claim 3, wherein the probe which is being brought into contact with the aluminum oxide film is moved by (1) continuously changing the applied voltage, (2) discontinuously changing the applied voltage, (3) unidirectionally or bidirectionally changing a polarity of the applied voltage, or changing the applied voltage by combining (1) through (3).
8. An oscillation element comprising: a pn junction at which an n-type semiconductor layer and a p-type semiconductor layer are joined, the n-type semiconductor layer having a donor level that is formed by causing an aluminum oxide film to excessively contain aluminum, the p-type semiconductor layer having an acceptor level that is formed by causing an aluminum oxide film to excessively contain oxygen.
9. A method for manufacturing an oscillation element, comprising the steps of: bringing metallic aluminum and a probe into contact with a first surface and a second surface, respectively, of an aluminum oxide film so as to melt the aluminum oxide film in atmosphere, oxygen-containing gas, or oxygen gas by applying, between the metallic aluminum serving as an anode and the probe serving as a cathode, a voltage at which a dielectric breakdown occurs in the aluminum oxide film; and by causing, in the aluminum oxide film which is being melted, a molten salt electrolysis reaction so as to cool the aluminum oxide film, forming an n-type semiconductor layer and a p-type semiconductor layer on the metallic aluminum side and the probe side, respectively, of the aluminum oxide film, and joining the n-type semiconductor layer and the p-type semiconductor layer, a depletion layer, formed by joining the n-type semiconductor layer and the p-type semiconductor layer, having a thickness of not more than 1 nm.
10. A method for manufacturing an oscillation element, comprising the steps of: bringing metallic aluminum and a probe into contact with a first surface and a second surface, respectively, of an aluminum oxide film so as to melt the aluminum oxide film in atmosphere, gas, or a vacuum by applying, between the metallic aluminum serving as a cathode and the probe serving as an anode, a voltage at which a dielectric breakdown occurs in the aluminum oxide film; and by causing, in the aluminum oxide film which is being melted, a molten salt electrolysis reaction so as to cool the aluminum oxide film, forming a p-type semiconductor layer and an n-type semiconductor layer on the metallic aluminum side and the probe side, respectively, of the aluminum oxide film, and joining the n-type semiconductor layer and the p-type semiconductor layer, a depletion layer, formed by joining the n-type semiconductor layer and the p-type semiconductor layer, having a thickness of not more than 1 nm.
11. The method as set forth in claim 9, wherein the molten salt electrolysis reaction is caused in the aluminum oxide film by moving the probe while bringing the probe into contact with the aluminum oxide film.
12. A method for manufacturing a semiconductor layer, comprising the steps of: bringing metallic aluminum and a probe into contact with a first surface and a second surface, respectively, of an aluminum oxide film so as to melt the aluminum oxide film in atmosphere, oxygen-containing gas, or oxygen gas by applying, between the metallic aluminum serving as an anode and the probe serving as a cathode, a voltage at which a dielectric breakdown occurs in the aluminum oxide film; and by causing, in the aluminum oxide film which is being melted, a molten salt electrolysis reaction so as to cool the aluminum oxide film, (1) forming an n-type semiconductor layer on the metallic aluminum side of the aluminum oxide film or (2) forming a p-type semiconductor layer on the probe side of the aluminum oxide film.
13. A method for manufacturing a semiconductor layer, comprising the steps of: bringing metallic aluminum and a probe into contact with a first surface and a second surface, respectively, of an aluminum oxide film so as to melt the aluminum oxide film in atmosphere, gas, or a vacuum by applying, between the metallic aluminum serving as a cathode and the probe serving as an anode, a voltage at which a dielectric breakdown occurs in the aluminum oxide film; and by causing, in the aluminum oxide film which is being melted, a molten salt electrolysis reaction so as to cool the aluminum oxide film, (1) forming an n-type semiconductor layer on the metallic aluminum side of the aluminum oxide film or (2) forming a p-type semiconductor layer on the probe side of the aluminum oxide film.
Description
BRIEF DESCRIPTION OF DRAWINGS
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[0048] (a) and (b) of
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DESCRIPTION OF EMBODIMENTS
[0054] [Material]
[0055] A film for forming a semiconductor layer by a spark method can be made of any material provided that the material is (i) a metallic compound that is more powerful in ionic bonding property than in covalent bonding property and (ii) an insulator or a substance whose electric conductivity is extremely low. The material can be, for example, a metal oxide such as an aluminum oxide or a titanium oxide, a metal hydroxide such as an aluminum hydroxide, or a metal nitride such as an aluminum nitride. The material can alternatively be a compound (e.g., boehmite) in which an aluminum oxide contains a water molecule.
[0056] Note that a metal ion contained in the film for forming a semiconductor layer by a spark method and a metal of which a substrate of the film is made can be different in kind. The film for forming a semiconductor layer by a spark method can be, for example, a film obtained by forming a zirconium oxide on metallic aluminum by sputtering, or a film formed on a surface of metallic aluminum by chemical treatment.
[0057] In a case where the substrate is made of metallic aluminum, the metallic aluminum can be an aluminum alloy. Specifically, examples of the metallic aluminum include not only high-purity aluminum of not less than 4 N and pure aluminum (1000 series) but also an Al-Mn-based alloy (3000 series), an Al-Si-based alloy (4000 series), an Al-Mg-based alloy (5000 series), an Al-Cu-Mg-based alloy (2000 series), an Al-Mg-Si-based alloy (6000 series), and an Al-Zn-Mg-based alloy (7000 series).
[0058] In a case where the film is made of a metal oxide, the metal oxide is a transparent oxide in many cases. In a case where such a metal oxide is made into a semiconductor by a spark method but the semiconductor has a wide band gap, the semiconductor absorbs no energy in a visible light region. This causes the semiconductor to be a transparent oxide semiconductor.
[0059] A probe material for sparking such a film material (described earlier) by bringing the probe material into contact with the film material can be a highly electrically conductive substance such as platinum, stainless steel, copper, or carbon. The probe material, which reaches a high temperature due to a spark, is preferably a material that is highly resistant to heat. Platinum is an excellent material but is high in cost. The probe material can be, for example, a material obtained by plating an outermost surface of a core of Si with platinum.
Embodiment 1
[0060] Embodiment 1 of the present invention is described below with reference to
[0061] <Semiconductor Layer>
[0062] The following description discusses a semiconductor layer in accordance with Embodiment 1. The semiconductor layer in accordance with Embodiment 1 is formed by a method of sparking an aluminum oxide film. An example of how the semiconductor layer in accordance with Embodiment 1 is formed by that method is shown below.
[0063] (Sample and Apparatus)
[0064] As illustrated in
[0065] Next, a manual prober 20 was prepared and the probe 101 that had a configuration illustrated in
[0066] An apparatus 10 illustrated in
[0067] A 1085 material (12 mm30 mm, 20 m in thickness) was used as the metallic aluminum to carry out a boehmite treatment with respect to a surface of the sample. The boehmite treatment was carried out by dipping the sample in pure water at 95 C. for 30 s, washing the sample in water, and drying the sample. A boehmite-treated film, which is insulative, was removed by partially filing the sample away, so that the sample could be electrically conducted. The probe illustrated in
[0068] (Electric Conduction)
[0069] In
[0070] The switch was closed at 0.28 s, but a trigger occurred under a condition that an electric current value actually exceeded 0.05 A. Thus, a point in time at which the trigger occurred was set to 0 s. Since a widely-used direct-current power supply was used, the power supply was in a standby state during a period from 0.28 s to 0 s. Thus, during this period, an output of the power supply did not reach 36 V, which was set as an output of the widely-used direct-current power supply, and a voltage of approximately 20 V was outputted. At a voltage of 20 V, no spark occurred, and little electric current flowed to the sample.
[0071] A voltage of 36 V was momentarily applied to the sample at 0 s, but the voltage decreased to approximately 10 V as soon as an electric current caused by a spark flowed to the sample. An electric current value was approximately 0.1 A. This state continued for 0.3 s. It is considered that a spark continued during this period, and the film reached a high temperature, reached a molten state, and was made thick. Furthermore, there is a great fluctuation in voltage during this period. Note, however, that it is unclear whether the great fluctuation is due to a transient phenomenon that was caused by reactance such as inductance of the device when the switch was closed or due to a material inherent characteristic. After 0.3 s had passed, the voltage decreased to approximately 0 V, and the electric current increased to 0.17 A.
[0072] (Result of I-V Measurement)
[0073] The semiconductor layer thus obtained was subjected to I-V measurement. A result of this is shown in
[0074] A substantially linear relationship was obtained in a voltage range of 0.55 V to +0.2 V. It is considered that a tunnel current or an electric current caused by a metallized electron state of the film flowed between the metallic aluminum and the probe in this voltage range. At a voltage of not more than 0.55 V and in a voltage range of +0.2 V to +0.55 V, a current-voltage relationship deviated from the linear relationship, so that a large electric current flowed. In a voltage range of +0.55 V to +1.0 V, little electric current flowed. It is currently unclear why the current-voltage relationship deviates from the linear relationship in such a wide voltage range. However, it is considered that a carrier behavior of the semiconductor layer is in an unstable state. In a case where a short circuit occurs between the metallic aluminum and the probe, the linear relationship should be obtained in an entire voltage region of the I-V characteristic. As long as the linear relationship is not obtained in the entire voltage region, the linear relationship obtained in the voltage range of 0.55 V to +0.2 V can be said to be a characteristic unique to the semiconductor layer formed.
[0075] Next, the electric current limiting resistor 15 illustrated in
[0076] Note that a molten salt was herein used in such a broad sense as below. Specifically, a movement (electrophoresis) caused by electrolysis of aluminum ions and oxygen ions can be achieved in not only a completely molten salt but also a solid-liquid mixture in which solid states are mixed. Under the circumstances, a salt in a solid-liquid mixed state was also expressed as a molten salt.
[0077] It is found from the results of the above two examples (i) that a large quantity of electric conduction during molten salt electrolysis caused by a spark causes a semiconductor layer to have a high carrier concentration, and causes a depletion layer formed in a pn junction to have a small thickness, so that a tunnel current or an electric current caused by a metallized electron state of the film flows to the semiconductor layer and (ii) that a small quantity of electric conduction during molten salt electrolysis caused by a spark causes the semiconductor layer to have a low carrier concentration, and causes the depletion layer formed in the pn junction to have a large thickness.
[0078] According to the above description, a semiconductor layer is formed by sparking an aluminum oxide film under a condition that a metallic aluminum side is an anode (positive side) and a probe side is a cathode (negative side), and, consequently, the aluminum oxide film has an n-type semiconductor on the metallic aluminum side and has a p-type semiconductor layer on the probe side.
[0079] The semiconductor layer can alternatively be formed by sparking the aluminum oxide film under a condition that the metallic aluminum side is the cathode (negative side) and the probe side is the anode (positive side). In this case, the aluminum oxide film has a p-type semiconductor on the metallic aluminum side and has an n-type semiconductor layer on the probe side.
[0080] (Estimation of Semiconductor Configuration by the Present Method)
[0081] (Element Constituting Semiconductor Layer)
[0082] As described earlier, a semiconductor layer in accordance with an embodiment of the present invention is formed by subjecting an aluminum oxide film to dielectric breakdown by a spark. A configuration of a semiconductor layer formed by a spark was determined by capturing an image of a cross section of the semiconductor layer with use of a transmission electron microscope (TEM) and carrying out EDS analysis (elementary analysis). In capturing the image with use of the TEM, a sample was prepared by using a focused ion beam (FIB) to cause the cross section of the semiconductor layer to be a thin film.
[0083]
[0084]
[0085] A close look at distribution of Al and O in the semiconductor layer shows that Al has a high concentration on a lower side, which is the metallic aluminum side, and O has a high concentration on an upper side, which is the filler side (atmosphere side before the semiconductor layer is used as an analysis sample). In a case where distribution of Al is observed in comparison with the BF image, it seems that a part in which Al is dense has a thickness of approximately 15 nm and extends along an Al metal surface so as to be belt-shaped. This part is considered to be a part in which O.sup.2 of Al.sub.2O.sub.3 is nonstoichiometrically depleted and Al.sup.3+ is excessively present (N.sup.++). In contrast, in a case where distribution of O is observed, a part in which O is dense has a thickness of approximately 15 nm and extends along a semiconductor layer film surface a so as to be belt-shaped. This part is considered to be a part in which Al.sup.3+ of Al.sub.2O.sub.3 is nonstoichiometrically depleted and O.sup.2 is excessively present (P.sup.++).
[0086] The drawing on the left in
[0087] A result of the above elementary analysis shows (i) that the semiconductor layer formed by a spark method is an aluminum oxide film but has a highly specific structure in which Al and O are segregated to the metallic aluminum side and the semiconductor layer surface, respectively, and (ii) that the pn junction is present in an extremely limited part.
[0088] In a case where a semiconductor layer is formed by a spark method of an aspect of the present invention, the ab cross section has a small area, but the semiconductor layer is always present in a part in which P.sup.++ and N.sup.++ cross each other. Thus, the spark method is a production method that is highly reproducible.
[0089] A semiconductor layer obtained by an embodiment of the present invention is considered to have an amorphous structure. This is because, since a time for which an aluminum oxide layer is melted by a spark and then cooled and solidified is extremely short, the aluminum oxide layer is less likely to be crystallized. According to a covalent bonding semiconductor such as an Si semiconductor, a size of a bond has direction dependency. Thus, in a case where the covalent bonding semiconductor is not crystalline, it is impossible to obtain a carrier conducting pathway. In contrast, according to a semiconductor that has a powerful ionic bonding property, such as aluminum oxide, a size of a bond has no direction dependency. Thus, even in a case where the semiconductor is amorphous, it is possible to achieve a carrier conducting pathway. With this, also in a case where a semiconductor layer has an amorphous structure, it is possible to obtain a semiconductor characteristic.
[0090] (Estimation of Process for Forming Semiconductor Layer)
[0091] (In Case of Spark Carried Out Under Condition that Metallic Aluminum is Positive and Probe is Negative)
[0092] The reason why a semiconductor layer that has such a highly specific elemental structure is obtained was estimated.
[0093] First, the following description discusses a case where a spark is carried out under a condition that metallic aluminum is positive and a probe is negative.
[0094]
Anode reaction (Al metal side) Al.fwdarw.Al.sup.3++3e (1)
Cathode reaction (probe side) O.sub.2+4e.fwdarw.2O.sup.2(2)
Overall reaction 4Al+3O.sub.2.fwdarw.4Al.sup.3++6O.sup.2(3)
[0095] In a case where the spark is finished, the temperature decreases. Note, however, that a rate of decrease in temperature is not perfectly uniform in the semiconductor layer. A solid and a liquid are mixed and partially solidified, so that Al.sub.2O.sub.3 is formed. For (i) the reason that a part that remains molten is still ionized or (ii) the reason that Al.sub.2O.sub.3, which is a solid, is an insulator at a room temperature but has electronic conductivity at a high temperature close to a melting point, or for both the reasons (i) and (ii), the above anode reaction and the above cathode reaction continue to occur as illustrated in
[0096] In a case where the temperature further decreases to the room temperature, a semiconductor layer that has a configuration illustrated in
[0097]
[0098] It is estimated that a pn junction diode is formed by the above mechanism. Note, however, that a part in which a pn junction is actually formed by a spark method is considered to have a small area.
[0099] (In Case of Spark Carried Out Under Condition that Metallic Aluminum is Negative and Probe is Positive)
[0100] Next, the following description discusses a case where a spark is carried out under a condition that metallic aluminum is negative and a probe is positive.
[0101]
Cathode reaction (metallic aluminum side) Al.sup.3++3e.fwdarw.Al (4)
Anode reaction (probe side) 2O.sup.2.fwdarw.O.sub.2+4e (5)
Overall reaction 4Al.sup.3++6O.sup.2.fwdarw.4Al+3O.sub.2 (6)
[0102] In a case where the spark is finished, the temperature decreases. Note, however, that a rate of decrease in temperature is not perfectly uniform in the semiconductor layer. A solid and a liquid are mixed and partially solidified, so that Al.sub.2O.sub.3 is formed. For (i) the reason that a part that remains molten is still ionized or (ii) the reason that Al.sub.2O.sub.3, which is a solid, is an insulator at a room temperature but has electronic conductivity at a high temperature close to a melting point, or for both the reasons (i) and (ii), the above cathode reaction and the above anode reaction continue to occur as illustrated in
[0103] In contrast, on the probe side of the semiconductor layer, Al.sup.3+ ions are in excess, but a new donor level is formed in the semiconductor layer so that electroneutrality is maintained.
[0104] In a case where the temperature further decreases to the room temperature, a semiconductor layer that has a configuration illustrated in
[0105]
Embodiment 2
[0106] (Scale-Up of Semiconductor Layer by Scanning Method)
[0107] Embodiment 2 of the present invention is described below with reference to
[0108] (Object of Scanning)
[0109] In a case where a spark electric current is caused to flow between metallic aluminum and a probe, whose position is fixed, so that an aluminum oxide film that is formed on the metallic aluminum is brought into contact with the probe, a semiconductor layer to be formed or the aluminum oxide film to be decomposed has a diameter of approximately 1 m to 2 m, and it is difficult to make the semiconductor layer or the aluminum oxide film larger. In order to scale up a semiconductor layer, the inventor of the present invention considered that the semiconductor layer can have a larger area and a greater volume in a case where a probe that is brought into contact with an aluminum oxide film is moved while a spark electric current is caused to flow to the aluminum oxide film. The present method is hereinafter referred to as a scanning method. The following description discusses (i) a relationship between (a) a semiconductor layer to be formed or an aluminum oxide film to be decomposed and (b) a quantity of spark electricity, which quantity is an accumulated value of the spark electric current having flowed to the aluminum oxide film, and (ii) specifically how to carry out the scanning method.
[0110] (Principle of Scanning Method)
[0111] (Electrochemical Reaction Occurring During Spark)
[0112] In a case where a probe is brought into contact with an aluminum oxide film that is formed on metallic aluminum and a spark electric current is caused to flow between the metallic aluminum and the probe, the aluminum oxide film is melted for an extremely short time of not longer than 1 s. It is considered that a molten salt reaction represented by a formula (7) occurs in a case where a metallic aluminum side is an anode (positive), and a molten salt reaction represented by a formula (8) occurs in a case where the metallic aluminum side is a cathode (negative).
[0113] In a case where the metallic aluminum side is an anode,
4Al+3O.sub.2.fwdarw.4Al.sup.3++6O.sup.2(7)
In a case where the metallic aluminum side is a cathode,
4Al.sup.3++6O.sup.2.fwdarw.4Al+3O.sub.2 (8)
[0114] According to this reaction, electricity in a quantity of 6 Faraday (F) is consumed in forming 1 mol of Al.sub.2O.sub.3 (actually, 2Al.sup.3++3O.sup.2) (the formula (7)) or decomposing 1 mol of Al.sub.2O.sub.3 (the formula (8)). Al.sub.2O.sub.3 that has a molecular weight M (101.96 g/mol) and a density (4.010.sup.6 g/m.sup.3) has a volume per mol of M/ (m.sup.3/mol). A volume of Al.sub.2O.sub.3 that is formed or decomposed by consumption of electricity in a quantity of 1 F is M/6 (m.sup.3/F). A volume of Al.sub.2O.sub.3 that is formed or decomposed by consumption of electricity in a quantity of 1 C is calculated by substituting M and p into the following equation: M/(6 F.sub.c)/=4.410.sup.11 (m.sup.3/C). Note, however, that F.sub.c is a Faraday constant (1 F=96500 C).
[0115] Thus, V.sub.m (m.sup.3), which is (i) a volume of a semiconductor layer that is formed by electricity in a quantity of Q (C) or (ii) a volume of Al.sub.2O.sub.3 that is decomposed, is expressed by the following equation: V.sub.m=MQ/(6 F.sub.c)=4.410.sup.11.Math.Q (9).
[0116] Next, a density N.sub.AO (/m.sup.3) of Al.sub.2O.sub.3 is expressed by the following equation, N.sub.AO=A.sub.v/M (10), where A.sub.v is Avogadro's number (6.02210.sup.23/mol). Q (C), which is coulomb amount involved in formation of a semiconductor is expressed by the following equation, Q=it (11), where i is an electric current (A) and t is a time (s) of electric conduction. In a case where Q.sub.n is a quantity (C) of electricity used to form n mol of Al.sub.2O.sub.3 and F.sub.c is a Faraday constant (c/mol), the following equation, n=Q.sub.n/(6 F.sub.c) (12), holds true based on Q.sub.n=6 F.sub.cn. Based on the equation (11), the following equation, n=it/(6 F.sub.c) (13), holds true. Furthermore, N.sub.AO, which is the number of n mol of Al.sub.2O.sub.3 formed or the number of n mol of Al.sub.2O.sub.3 decomposed is represented by the following equation: N.sub.AO=A.sub.vn/V.sub.m (14). N.sub.AO is expressed by the following equation, N.sub.AO=A.sub.vit/(6 F.sub.cV.sub.m) (15), based on the equation (13). Since 2 mol of Al.sup.3+ is generated with respect to 1 mol of Al.sub.2O.sub.3, N.sub.A1, which is the number of n mol of Al formed or the number of n mol of Al decomposed, is represented by the following equation: N.sub.A1=A.sub.vit/(3 F.sub.cV.sub.m) (16). Since 3 mol of O.sup.2 is generated with respect to 1 mol of Al.sub.2O.sub.3, N.sub.O, which is the number of n mol of O formed or the number of n mol of O decomposed, is represented by the following equation: N.sub.O=A.sub.vit/(2 F.sub.cV.sub.m) (17).
[0117] (Molten Salt Reaction Occurring in Case Where Metallic Aluminum Side is Anode)
[0118] Next, the following description discusses a scanning method as a method for moving a position of a tip of a probe on an aluminum oxide film surface 201.
[0119] A time for which the semiconductor layer is formed by the spark electric current i, i.e., a time t for which a contact surface of the tip of the probe passes through the region of u.sub.1u.sub.2 is expressed by the following equation: t=u.sub.1/v.
[0120] A quantity Q of electricity passed is expressed by the following equation: Q=u.sub.1i/v (18). V.sub.m, which is a volume of the semiconductor layer to be formed for the time t, is expressed by the following equation: V.sub.m=u.sub.1u.sub.2h. Thus, h is expressed by the following equation: h=V.sub.m/(u.sub.1u.sub.2) (19). In a case where the equation (9) and the equation (18) are substituted into the equation (19), h is expressed by the following equation: h=4.410.sup.11.Math.i/(u.sub.2v) (20). By this, i is expressed by the following equation: i=2.310.sup.10.Math.u.sub.2vh (21).
[0121] Assuming here that a width (u.sub.2) of the contact surface of the tip of the probe, the width extending in a direction perpendicular to a direction in which scanning is carried out, is 10 m, a scanning velocity (v) is 14.6 m, and the thickness (h) of the semiconductor layer to be formed is 50 nm, a necessary spark electric current value (i) is calculated. In a case where u.sub.2=1.010.sup.5 (m), v=14.610.sup.6 (m/s), and h=5.010.sup.8 (m) are substituted into the equation (21), i1.710.sup.7 (A), so that a spark electric current value of 0.17 A is necessary.
[0122] (Molten Salt Reaction Occurring in Case Where Metallic Aluminum Side is Cathode)
[0123]
[0124] (Method for Scanning)
[0125]
[0126] First scanning is an operation to (i) move the probe to a starting point of
[0127] Second scanning is an operation to (i) bring the tip of the probe into contact with the sample again at the left end of the second line and (ii) turn on i by application of a voltage V so as to immediately move the probe from the left to the right along the second line m.sub.2. i is turned off by making V zero at the right end so as to separate the probe from the sample. Then, the probe is moved to a lower line by a return r.sub.2 so as to be moved to the left end of the third line.
[0128] Such a back-and-forth movement is repeated, and scanning is finished when the tip of the probe reaches the right end of the last line. In this case, assuming that a resolution of a vertical axis is p, a pitch of the vertical axis is b/p (m).
[0129] Note here that, in a case where u.sub.2 and b/p are in a relationship of u.sub.2=b/p, according to calculation, in the entire scanned region of ab, the semiconductor layer is formed so as to have a uniform thickness, or the aluminum oxide film is decomposed so as to have a uniform thickness. In a case where u.sub.2 and b/p are in a relationship of u.sub.2<b/p, a part in which no semiconductor layer is formed or no aluminum oxide film is decomposed is linearly generated. In a case where u.sub.2 and b/p are in a relationship of u.sub.2>b/p, a part in which the semiconductor layer is excessively formed or the aluminum oxide film is excessively decomposed is linearly generated. A result that is actually obtained may be not in accordance with calculation. Thus, by repeating trial production and a change in condition, it is possible to form a semiconductor layer that has been scaled up.
[0130] (Setting of Scanning Condition)
[0131] Here, a relationship with a scanning condition is found, the scanning condition being set for a carrier concentration of a semiconductor layer that is desired to be formed with use of a spark electric current. The carrier concentration is classified into (i) a donor density, which is present at a donor level that increases in accordance with a concentration of Al.sup.3+ ions that are excessively injected into the semiconductor layer, and (ii) an acceptor density, which is present at an acceptor level that increases in accordance with a concentration of O.sup.2 ions that are excessively injected into the semiconductor layer. Calculation is carried out by taking the donor density, i.e., the concentration of Al.sup.3+ ions as an example.
[0132] An Al.sup.3+ ion concentration C.sub.A1 (/m.sup.3) is obtained by multiplying, by an efficiency .sub.A1, a concentration N.sub.A1(/m3) of Al that is formed or decomposed by sparking an aluminum oxide film. Thus, the equation (16) is expressed as below.
C.sub.A1=.sub.A1N.sub.A1=.sub.A1A.sub.vit/(3 F.sub.cV.sub.m) (22)
[0133] Note here that V.sub.m=u.sub.1u.sub.2h and t=u.sub.1/v. Thus, in a case where these equations are substituted into the equation (22), the following equation, C.sub.A1=.sub.A1.Math.A.sub.v/(3 F.sub.cu.sub.2h).Math.i/v, holds true.
[0134] Thus, a scanning velocity v (m/s) of a probe during scanning, a flowing electric current i (A), a thickness h (m) of an aluminum oxide film formed or decomposed, a width u.sub.2 (m) of the probe, the width extending in a direction perpendicular to a direction in which scanning is carried out, an efficiency .sub.A1 of carrier generation, and an Al.sup.3+ ion concentration C.sub.A1 (/m.sup.3) are represented by the following equation (23):
C.sub.A1=2.0810.sup.18.Math.i/(u.sub.2hv).Math..sub.A1 (23).
[0135] (Specifications of Scanning Apparatus)
[0136] Specifications of an apparatus obtained by providing a scanning probe microscope (JSPM-5200, manufactured by JEOL Ltd.) with an electrically conductive probe were examined for a possibility of formation of a semiconductor layer with use of the apparatus. As a result of this, specifications of an apparatus used to form a semiconductor layer by a scanning method are as shown in Table 1.
TABLE-US-00001 TABLE 1 Specifications of JSPM-5200 used in scanning method Item Specifications Maximum applied voltage 60 V Maximum electric current 1 A, 100 nA, 10 nA Maximum range of scanning 25 m 25 m Resolving power 512 512, 1024 1024 Scanning velocity 488 nm/s-732 m/s
[0137] According to the present apparatus, it is possible to carry out scanning while applying a constant voltage between the probe and a sample, but it is impossible to carry out constant electric current scanning. Note, however, that it is possible to set a maximum electric current by setting a range of a measured electric current.
[0138] (Calculation Carried Out with Respect to Formation by Scanning Method)
[0139] (Formation of High Carrier Concentration Semiconductor Layer)
[0140] Calculation was carried out with use of JSPM-5200 with respect to formation of a semiconductor layer by a scanning method. For example, an electric current value i obtained in a case where an electric current flows in a direction that is in accordance with the formula (7), an aluminum oxide film serving as a base is a naturally oxidized film, and C.sub.A1 is a high concentration of 11028 (/m.sup.3) was calculated based on the equation (23). In a case where the width U.sub.2 of the tip of the probe is 110.sup.6 m (1.0 m), the height h of the semiconductor layer formed is 210.sup.8 m (20 nm), the scanning velocity v is 1.4610.sup.5 m/s (14.6 m/s), and the efficiency .sub.A1 of carrier generation is 0.1, i=1.410.sup.8 (A), i.e., 14 nA. Use of a range of a maximum electric current of 10 nA causes C.sub.A1 to be slightly lower but makes it possible to form the semiconductor layer.
[0141] (Formation of Low Carrier Concentration Semiconductor Layer)
[0142] A case where an electric current flows in a direction that is in accordance with the formula (7) and C.sub.A1 is a low concentration of 110.sup.25 (/m.sup.3) was discussed. In this case, the concentration is three-digit lower than in the case of the high concentration. This makes it necessary to three-digit lower the electric current value, three-digit increase the velocity, or change setting of both the electric current value and the velocity. Note, however, that both the electric current value that is three-digit lowered and the velocity that is three-digit increased are set beyond a range of the specifications of the apparatus. Thus, it is impossible to form a low carrier concentration semiconductor layer with use of the present apparatus. A semiconductor layer that can be formed with use of the present apparatus is limited to a high carrier concentration semiconductor layer.
[0143] (Further Increase in Area)
[0144] As described earlier, a range of scanning carried out one time is limited to 25 m.sup.2. Thus, in order to enlarge the range, it is necessary to carry out scanning a plurality of times. However, though it takes 30 minutes to carry out measurement one time, it takes a long time to carry out measurement a plurality of times. A further increase in area will be separately discussed.
[0145] (Another Method for Increase in Area)
[0146] According to the semiconductor layers described earlier, a pn junction is formed by simultaneously generating a p-type semiconductor and an n-type semiconductor by a spark method. Such a method cannot necessarily be said to be a method that is suitable for mass production so that the pn junction actually serves as a semiconductor device (e.g., a diode or a transistor) or an oscillation element.
[0147] The present semiconductor device is desirably configured to (i) allow a thin film to be formed by sputtering, which is a conventional semiconductor manufacturing technique, and (ii) allow a device structure to be formed by photolithography and etching. Under the circumstances, the following description discusses a method for obtaining a semiconductor layer of an aspect of the present invention by sputtering.
[0148] For example, as illustrated in
[0149] A pn junction can be obtained by this method in a case where, for example, a semiconductor layer in which Al.sup.3+ is in excess is used as a target material to form an n-type semiconductor thin film on an aluminum substrate (serving also as a cathode electric current collecting material) by sputtering, a semiconductor layer in which O.sup.2 is in excess is subsequently used as a target material to form a p-type semiconductor thin film on the n-type semiconductor thin film by sputtering, and a cathode terminal is further attached to a p-type semiconductor layer.
[0150] A carrier concentration of a semiconductor layer can be controlled by changing an amount of electricity flowing during a spark. It is also possible to manufacture a semiconductor device such as a MOS-FET by using another material and repeating sputtering, photolithography, and etching.
Embodiment 3
[0151] (Oscillation Element)
[0152] Embodiment 3 of the present invention is described below with reference to
[0153] (Comparison with Patent Literature 1)
[0154] First, before specifically describing a semiconductor layer in accordance with an aspect of the present invention, the following description discusses an overview of an oscillation element including the semiconductor layer. The inventor of the present invention specifically describes the oscillation element in Patent Literature 1. The following description of the oscillation element is a part of a disclosure of Patent Literature 1. Thus, a reader of the present specification is advised to see Patent Literature 1 for further details of the oscillation element.
[0155]
[0156]
[0157] An oscillation element can be formed by making the depletion layer extremely thin. The depletion layer needs to have a thickness of not more than 1 nm. A size of one molecule of Al.sub.2O.sub.3 is calculated here. In a case where Avogadro's number is 6.02210.sup.23 (1/mol) and Al.sub.2O.sub.3 has a molecular weight of 101.96 (g/mol) and a density of 4.010.sup.3 (kg/m.sup.3), a volume occupied by one molecule of Al.sub.2O.sub.3 is 4.2310.sup.29 (m.sup.3). In a case where the volume occupied by one molecule of Al.sub.2O.sub.3 is assumed to be a cube and a length d.sub.m of substantially one side of the cube is calculated, d.sub.m is 3.510.sup.10 (m), i.e., 0.35 nm. Oscillation is considered to occur under a condition that the depletion layer has a thickness x.sub.dep that is not more than 3 times greater than d.sub.m. Thus, the depletion layer desirably has a thickness x.sub.dep of not more than 1 nm.
[0158] The depletion layer can be made thin by increasing a concentration of carriers (holes) of the p-type semiconductor, a concentration of carriers of the n-type semiconductor, or a concentration of carriers of both the p-type semiconductor and the n-type semiconductor. Note here that a thickness X.sub.p of a p side depletion layer and a thickness X.sub.n of an n side depletion layer can be found by the following equations where N.sub.A is an acceptor concentration and N.sub.D is a donor concentration. Note, however, that a higher carrier concentration is considered to cause a greater error and the following equations merely serve as a rough standard and are not strict formulas.
[0159] The thickness of the p side depletion layer is expressed by the following equation:
[0160] The thickness of the n side depletion layer is expressed by the following equation:
[0161] However,
[0162] where V.sub.bi is built-in potential (V), n.sub.i is a carrier concentration (m.sup.3) of an intrinsic semiconductor, X.sub.p is a width (m) of a depletion layer of a p-type region, X.sub.n is a width (m) of a depletion layer of an n-type region, k.sub.B is Boltzmann constant (1.3810.sup.23 (J/K)), T is a temperature (K), q is an elementary electric charge of 1.60210.sup.19 (C), .sub.r is a relative dielectric constant, and .sub.0 is a dielectric constant under vacuum (8.85410.sup.12 (F/m)).
[0163] In a case where a bias voltage is V.sub.D (V), the thickness x.sub.dep of the depletion layer as a whole is expressed as below.
[0164] Assuming here that N=N.sub.A=N.sub.D, a carrier concentration N in which x.sub.dep is 1 nm was found. In a case where Cr of Al.sub.2O.sub.3 is 8.9 and V.sub.D=0 (V), N=2.610.sup.27 (m.sup.3). In general, in a case where a carrier concentration is increased by an ion implantation method, a high carrier concentration frequently refers to a carrier concentration of not less than 110.sup.27 (m.sup.3). Thus, this N value can also be said to be a high carrier concentration.
[0165] In contrast, in order to maximize an amplitude of an oscillating electric current, it is necessary to make the depletion layer thinner as illustrated in
[0166] (a) and (b) of
[0167] In the I-V characteristic of
[0168] (Estimation of Oscillation Mechanism)
[0169] Next, the following description discusses how the inventor considers an oscillation mechanism. A mechanism of electric current oscillation of the present oscillation element is merely hypothetical. It should be noted that it is necessary to carry out more in-depth research in order to obtain an overall picture of the mechanism.
[0170] The following description more specifically discusses the configuration of the depletion layer at the pn junction (see
[0171] In contrast,
[0172] The following description estimates the reason why a bias voltage that oscillates (0.1 V to +0.1 V) and bias voltages that do not oscillate (0.6 V to 0.1 V and +0.1 V to +0.6 V) are generated in the I-V characteristic of
[0173] The following description more specifically describes the present invention with reference to Examples. Note, however, that the present invention is not limited to the Examples.
EXAMPLE 1
[0174] First, Example 1 prepared an aluminum plate (1085 material, 12 mm30 mm, a thickness of 0.2 mm). This sample was dipped in pure water heated to 95 C., and a boehmite-treated film having a thickness of approximately 20 nm was formed on the aluminum plate. Next, the manual prober 20 was prepared. A probe obtained by (i) sharpening a tip of a platinum wire (H material) having a diameter of 0.2 mm so that the tip has a diameter of 0.02 mm and (ii) causing a root of the platinum wire to be in coil form was used. The apparatus 10 illustrated in
[0175] The electric current limiting resistor 15 was set to 100, the shunt resistor 14 was set to 100, an output of a direct current stabilizing power supply was set to 36 V, and the switch of the switch box 13 was closed after a probe tip was brought into contact with the sample in atmosphere. A spark was carried out between the probe tip and the aluminum plate. In a part with which the probe tip had been brought into contact, a semiconductor layer having a thickness of approximately 30 nm was formed. A change in voltage applied to the sample in this case and a change in electric current flowing to the sample in this case were measured with use of the oscilloscope 12. Immediately after an electric current flowed to the sample, a voltage of 36 V was momentarily applied to the sample, but the voltage decreased to approximately 10 V immediately. An electric current was approximately 0.1 A. This state continued for 0.3 s.
[0176] (Result of I-V Measurement)
[0177] After electric conduction was finished, a state of the probe was maintained as it was, and a connection of the I-V measurement of
EXAMPLE 2
[0178] As in the case of Example 1, Example 2 prepared an aluminum plate (1085 material, 20 mm60 mm, a thickness of 0.18mm). This sample was dipped in pure water heated to 95 C., and a boehmite-treated film having a thickness of approximately 20 nm was formed on the aluminum plate.
[0179] The electric current limiting resistor 15 illustrated in
[0180] (Result of I-V Measurement)
[0181] Note here that
EXAMPLE 3
[0182] Example 3 prepared the following sample first. An aluminum plate (24 mm24 mm, a thickness of 0.1 mm) was used as a substrate, 5 N aluminum Al (manufactured by Furuuchi Chemical Corporation, 76 mm in diameter6 mm in thickness) was used as a target material, and sputtering was carried out for approximately 40 minutes under conditions of Ar+O.sub.2 gas and a full pressure of 0.4 Pa, so that an aluminum oxide film of approximately 30 nm was sputtered on the aluminum plate. A sputtering device used was SPC-350 manufactured by Nichiden Anelva Corporation.
[0183] Next, JSPM-5200 was used to form a semiconductor layer by a scanning method. A probe whose tip had a width of 1.0 m was prepared, and scanning was carried out at a scanning velocity of 14.6 m/s and an electric current value of 10 nA, so that an element having a size of 25 m25 m was formed.
[0184] (Result of I-V Measurement)
[0185] An I-V characteristic was measured by bringing a probe identical to that of Example 1 into contact with a surface of the element produced by sputtering. A linear relationship was obtained in a voltage range of 0.5 V to +0.5 V. It is considered that a tunnel current or an electric current caused by a metallized electron state of the film flowed between the aluminum plate and the probe in this voltage range. At a voltage of not more than 0.5 V and a voltage of not less than +0.5 V, little electric current flowed between the aluminum plate and the probe. Though no rectifying action was obtained, an I-V characteristic unique to the present semiconductor device in which a carrier concentration is high was obtained.
[0186] (Formation of Low Carrier Concentration Semiconductor Layer)
[0187] A case where a carrier concentration is made low (e.g., 110.sup.25 (m.sup.3)) was discussed. In this case, the concentration is three-digit lower than in the case of the high concentration. This makes it necessary to three-digit lower the electric current value, three-digit increase the velocity, or change setting of both the electric current value and the velocity. Note, however, that both the electric current value that is three-digit lowered and the velocity that is three-digit increased are set beyond a range of the specifications of the apparatus. Thus, it was impossible to form a low carrier concentration semiconductor layer with use of the present apparatus. A semiconductor layer that can be formed with use of the present apparatus is limited to a high carrier concentration semiconductor layer.
EXAMPLE 4
[0188] Example 4 prepared the following sample. An aluminum plate (24 mm24 mm, a thickness of 0.1 mm) was used as a substrate, 5 N aluminum Al (manufactured by Furuuchi Chemical Corporation, 76 mm in diameter6 mm in thickness) was used as a target material, and sputtering was carried out for approximately 40 minutes under conditions of Ar+O.sub.2 gas and a full pressure of 0.4 Pa, so that an aluminum oxide thin film of approximately 30 nm was sputtered on the aluminum plate. A sputtering device used was SPC-350 manufactured by Nichiden Anelva Corporation.
[0189] The electric current limiting resistor 15 was set to 100, the shunt resistor 14 was set to 100 0, an output of a direct current stabilizing power supply was set to 60 V, and the switch of the switch box 13 was closed after a probe tip was brought into contact with the sample in atmosphere. A spark was carried out between the probe tip and the aluminum plate. In a part with which the probe tip had been brought into contact, a semiconductor layer having a thickness of approximately 50 nm was formed. A change in voltage applied to the sample in this case and a change in electric current flowing to the sample in this case were measured with use of the oscilloscope 12. Immediately after an electric current flowed to the sample, a voltage of 60 V was momentarily applied to the sample, but the voltage decreased to approximately 10 V immediately. An electric current was approximately 0.2 A. This state continued for 0.3 s.
[0190] (Result of I-V Measurement)
[0191]
[0192] [Applications of the Present Invention]
[0193] An aluminum oxide in accordance with an aspect of the present invention which aluminum oxide is formed as a semiconductor layer is not Al.sub.2O.sub.3 (O/Al=1.5), which is a stoichiometric substance, but a p-type semiconductor in which Al is depleted or O is in excess (O/Al>1.5) and an n-type semiconductor in which Al is in excess or O is depleted (O/Al<1.5). A pn junction of a p-type semiconductor layer and an n-type semiconductor layer which pn junction is obtained by adjusting each of carrier concentrations of the p-type semiconductor layer and the n-type semiconductor layer to not more than 10.sup.27/m.sup.3 serves as a diode. In a case where (i) the p-type semiconductor layer and the n-type semiconductor layer whose carrier concentrations have been adjusted as appropriate and (ii) an insulator such as stoichiometric aluminum oxide are three-dimensionally combined, a semiconductor device such as a transistor or a thyristor is obtained. Such a semiconductor device can be expected to be used as a power semiconductor having a wide band gap. Furthermore, the semiconductor device with which characteristics of a transparent oxide semiconductor are combined is adaptable to a component of a solar battery and a display panel.
[0194] In contrast, a pn junction of a p-type semiconductor layer and an n-type semiconductor layer which pn junction is obtained by adjusting each of carrier concentrations of the p-type semiconductor layer and the n-type semiconductor layer to 10.sup.28 to 10.sup.29/m.sup.3 serves as an oscillation element and can be expected to be applied to an inverter that converts a direct electric current into an alternating electric current. The oscillation element with which characteristics of a transparent oxide semiconductor and an ultraviolet region light emitting diode are combined serves as a frequency variable inverter. This allows an inverter to be adapted in a wider range. Furthermore, since such a high carrier concentration metallizes a semiconductor layer electronic state, so that highly satisfactory electric conductivity is obtained. This makes it possible to expect the element to serve as a high performance electric conductor. Furthermore, the element with which characteristics of a transparent oxide semiconductor are combined can also be used as a transparent electric conductor.
[0195] A p-type semiconductor layer and an n-type semiconductor layer in accordance with an aspect of the present invention serve as an extremely high oxidizing agent or an extremely high reducing agent and thus are promising also as a new chemical substance. Furthermore, the p-type semiconductor layer and the n-type semiconductor layer with each of which characteristics of a transparent oxide semiconductor are combined may also be applicable to a fuel cell electrode material and a photosynthetic electrode. Moreover, the p-type semiconductor layer and the n-type semiconductor layer can be expected to be applied to a target material of a semiconductor.
[0196] The present invention is not limited to the embodiments, but can be altered by a skilled person in the art within the scope of the claims. The present invention also encompasses, in its technical scope, any embodiment derived by combining technical means disclosed in differing embodiments.
REFERENCE SIGNS LIST
[0197] 10 Apparatus
[0198] 11 Stabilized direct current power supply
[0199] 12 Oscilloscope
[0200] 13 Switch box
[0201] 14 Shunt resistor
[0202] 15 Electric current limiting resistor
[0203] 20 Manual prober
[0204] 21 Manipulator
[0205] 22 Switch
[0206] 23 I-V measuring device
[0207] 101 Probe
[0208] 101a Probe tip
[0209] 102 Aluminum oxide film
[0210] 103 Metallic aluminum
[0211] 201, 301 Aluminum oxide film surface
[0212] 202, 203, 302, 303 Semiconductor layer