Capacitor with high aspect radio silicon cores
10510828 ยท 2019-12-17
Assignee
Inventors
Cpc classification
H03H3/00
ELECTRICITY
H01L28/88
ELECTRICITY
H03H1/00
ELECTRICITY
H01L21/0217
ELECTRICITY
H01L28/92
ELECTRICITY
H01L21/283
ELECTRICITY
International classification
H01L21/02
ELECTRICITY
H03H1/00
ELECTRICITY
H01L27/01
ELECTRICITY
H01L21/283
ELECTRICITY
H03H3/00
ELECTRICITY
Abstract
High aspect ratio passive electrical components are presented formed from a single-piece silicon (Si) substrate having a textured surface with at least one high aspect ratio structure. The high aspect ratio structure includes a Si core having a width (C.sub.X), a height (C.sub.Z), and a minimum aspect ratio of C.sub.Z-to-C.sub.X of at least 5:1. An electrical conductor layer overlies the Si core. The electrical component may be a capacitor, inductor, or transmission line. In the case of a capacitor, the substrate textured first surface is made up of a plurality of adjacent high aspect ratio conductor-dielectric-Si (CDS) structures. Each CDS structure includes: a Si core, a dielectric layer overlying the Si core, and an electrical conductor layer overlying the dielectric layer. The Si cores may be formed in the geometry of parallel ridges, columns, or as a honeycomb. Each Si core comprises at least 90% of the CDS structure height.
Claims
1. A high aspect ratio capacitor comprising: a single-piece silicon (Si) substrate having a first surface and a second surface; a plurality of at least three Si cores extending from the substrate first surface, each Si core have a height (C.sub.Z) and an equal spacing (S.sub.X) between adjacent Si cores by a spacing (S.sub.X), with a spacing aspect ratio (a.sub.SPACE) of C.sub.Z-to-S.sub.X of at least 5:1; a dielectric layer conformally coating the Si cores; an electrical conductor layer conformally coating the dielectric layer; and an electrode formed on the substrate second surface, underlying the plurality of Si cores.
2. The capacitor of claim 1 wherein the combination of each Si core, overlying dielectric layer, and overlying electrical conductor form a conductor-dielectric-silicon (CDS) structure having an overall height (T.sub.Z), where each Si core height (C.sub.Z) comprises at least 90% of the overall height (T.sub.Z).
3. The capacitor of claim 2 wherein a first plurality of adjacent CDS structures have a first CDS structure height per area and a first capacitance between adjacent first plurality CDS structures; and wherein a second plurality of adjacent CDS structures have a second CDS structure height per area, greater than the first CDS structure height per area, and a second capacitance between adjacent second plurality CDS structures, greater than the first capacitance.
4. The capacitor of claim 2 wherein a first plurality of adjacent CDS structures each have a first CDS Si core aspect ratio per area and a first capacitance between adjacent first plurality CDS structures; and wherein a second plurality of adjacent CDS structure each have a second CDS Si core aspect ratio per area, greater than the first CDS Si core aspect ratio and a second capacitance between adjacent second plurality CDS structures, greater than the first capacitance.
5. The capacitor of claim 2 wherein a first plurality of adjacent CDS structures have a first dielectric layer thickness, a first capacitor breakdown voltage, and a first capacitance per unit area; and wherein a second plurality of adjacent CDS structures have a second dielectric layer thickness greater than the first dielectric layer thickness, a second capacitor breakdown voltage greater than the first capacitor breakdown voltage, and a second capacitance per unit area less than the first capacitance per unit area.
6. The capacitor of claim 2 wherein the electrical conductor layer overlying a first plurality of CDS structures forms a first textured conductive surface area with a first capacitance density; and wherein the electrical conductive layer overlying a second plurality of CDS structures forms a second textured surface area, greater than the first textures surface area, with a second capacitance density greater than the first capacity density.
7. The capacitor of claim 1 wherein each Si core has a length (C.sub.Y) and a width (C.sub.X), where C.sub.Y>C.sub.X.
8. The capacitor of claim 1 wherein the CDS Si cores have an aspect ratio (a) of C.sub.Z-to-C.sub.X of at least 5:1.
9. The capacitor of claim 1 wherein the Si cores have a width (C.sub.X), an aspect ratio (a) C.sub.Z-to-C.sub.X of at least 5:1, and where the aspect ratio (a) is equal to the spacing aspect ratio (a.sub.SPACE).
10. The capacitor of claim 1 wherein the substrate is an interposer integrated circuit (IC); the capacitor further comprising: a first electrically conductive terminal connected to the electrical conductor layer; and a second electrically conductive terminal connected to the electrode formed on the substrate second surface.
11. The capacitor of claim 1 wherein each Si core vertical surface comprises a series of sidewall scallops aligned in a z-plane, where each scallop is responsive to a separate step of etching.
12. A high aspect ratio conductor-dielectric-silicon (CDS) capacitor comprising: a single-piece silicon (Si) substrate having a textured first surface and a second surface; a textured electrode conformally coating the substrate textured first surface comprising a plurality of adjacent high aspect ratio CDS structures, each CDS structure including: a Si core; a dielectric layer overlying the Si core; an electrical conductor layer overlying the dielectric layer; a planar electrode formed on the substrate second surface, underlying the textured electrode; and wherein the CDS Si cores have a width (C.sub.X), a height (C.sub.Z), and an aspect ratio (a) of C.sub.Z-to-C.sub.X of at least 5:1, and wherein adjacent CDS structure Si core centers are separated by a spacing (S.sub.X) and have a spacing aspect ratio (a.sub.SPACE) of C.sub.Z-to-S.sub.X of at least 5:1.
13. The capacitor of claim 12 wherein each CDS Si core has a length (C.sub.Y), where C.sub.Y>C.sub.X.
14. The capacitor of claim 13 wherein the textured electrode forms a plurality of parallel trenches between adjacent CDS structures.
15. The capacitor of claim 12 wherein the Si core comprises at least 90% of the CDS structure height.
16. The capacitor of claim 12 wherein the plurality of adjacent CDS structures includes a first plurality of adjacent CDS structures having a first CDS structure height per area and a first capacitance between adjacent first plurality CDS structures; and wherein the plurality of adjacent CDS structures includes a second plurality of adjacent CDS structures having a second CDS structure height per area, greater than the first CDS structure height per area, and a second capacitance between adjacent second plurality CDS structures, greater than the first capacitance.
17. The capacitor of claim 12 wherein the plurality of adjacent CDS structures includes a first plurality of adjacent CDS structures having a first CDS Si core aspect ratio per area and a first capacitance between adjacent first plurality CDS structures; and wherein the plurality of adjacent CDS structures includes a second plurality of adjacent CDS structure having a second CDS Si core aspect ratio per area, greater than the first CDS Si core aspect ratio, and a second capacitance between adjacent second plurality CDS structures, greater than the first capacitance.
18. The capacitor of claim 12 wherein the plurality of adjacent CDS structures includes a first plurality of adjacent CDS structures having a first dielectric layer thickness, a first capacitor breakdown voltage, and a first capacitance per unit area; and wherein the plurality of adjacent CDS structures includes a second plurality of adjacent CDS structures having a second dielectric layer thickness greater than the first dielectric layer thickness, a second capacitor breakdown voltage greater than the first capacitor breakdown voltage, and a second capacitance per unit area less than the first capacitance per unit area.
19. The capacitor of claim 12 wherein the CDS structure conductor layer thickness is less than or equal to four times the conductor skin depth at the capacitor operating frequency.
20. The capacitor of claim 12 wherein the substrate is an interposer integrated circuit (IC); the capacitor further comprising: a first electrically conductive terminal connected to the textured electrode; and a second electrically conductive terminal connected to the planar electrode.
21. The capacitor of claim 12 wherein the combination of a first plurality of CDS structure electrical conductor layers forms a first textured conductive surface area with a first capacitance density; and wherein the combination of a second plurality of CDS structure electrical conductor layers forms a second textured surface area, greater than the first textures surface area, with a second capacitance density greater than the first capacity density.
22. The capacitor of claim 12 wherein the CDS structure electrical conductor layer is a material selected from the group consisting of metal, polycrystalline semiconductor, a doped semiconductor, and a doped polycrystalline semiconductor.
23. The capacitor of claim 12 wherein the CDS Si cores have an aspect ratio (a) of C.sub.Z-to-C.sub.X of at least 10:1.
24. The capacitor of claim 12 wherein the aspect ratio (a) is equal to the spacing aspect ratio (a.sub.SPACE).
25. The capacitor of claim 12 wherein the dielectric layer conformally coats the substrate textured first surface underlying the plurality of adjacent Si cores.
26. A high aspect ratio conductor-dielectric-silicon (CDS) capacitor comprising: a single-piece silicon (Si) substrate having a textured first surface and a second surface, with adjacent Si cores extending from the textured first surface; a dielectric layer conformally coating the Si cores; a textured electrode conformally coating the dielectric layer; a planar electrode formed on the substrate second surface, underlying the textured electrode; and wherein the Si cores have a width (C.sub.X), a height (C.sub.Z), an aspect ratio (a) of C.sub.Z-to-C.sub.X of at least 5:1, extending at a right angle with respect to the substrate first surface.
27. The capacitor of claim 26 wherein the spacing (S.sub.X) between Si core centers is identical.
28. The capacitor of claim 26 wherein the Si cores have a spacing between Si cores in an x-plane where the spacing is equal to C.sub.X.
29. A high aspect ratio conductor-dielectric-silicon (CDS) capacitor comprising: a single-piece silicon (Si) substrate having a textured first surface and a second surface; a textured electrode conformally coating the substrate textured first surface comprising a plurality of adjacent high aspect ratio CDS structures, each CDS structure including: a Si core; a dielectric layer overlying the Si core; an electrical conductor layer overlying the dielectric layer; a planar electrode formed on the substrate second surface, underlying the textured electrode; and wherein the CDS Si cores have a width (C.sub.X), a height (C.sub.Z), and an aspect ratio (a) of C.sub.Z-to-C.sub.X of at least 5:1, and wherein adjacent CDS structure Si cores are separated in an x-plane by a spacing equal to C.sub.X.
30. The capacitor of claim 29 wherein each Si core has a length (C.sub.Y), where C.sub.Y>C.sub.X.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
DETAILED DESCRIPTION
(31)
(32)
(33)
(34) The CDS Si cores have a width (C.sub.X), a height (C.sub.Z), and an aspect ratio () of C.sub.Z-to-C.sub.X of at least 5:1. As explained below, aspect ratios of 25 to 50 are not uncommon. Adjacent CDS structure Si core 816 centers are separated by a spacing (S.sub.X) and have a spacing aspect ratio (.sub.SPACE) of C.sub.Z-to-S.sub.X of at least 5:1.
(35) Typically, the Si core 608 comprises at least 90% of the CDS structure height (T.sub.Z), and any increase in CDS structure height per area results in an increase in capacitance between adjacent CDS structures 612. The CDS structure conductor layer thickness 820 is typically less than or equal to four times the conductor skin depth at the capacitor operating frequency. Likewise, an increase in CDS Si core aspect ratio () per area results in an increase in capacitance between adjacent CDS structures 612. Ideally, the dielectric thickness is uniform across all surfaces, but in some aspects the dielectric thickness at the top (horizontal) portion of the Si cores is greatest, becoming thinner along the Si core (vertical) sidewalls, with the greatest non-uniformity occurring at the corners. However, non-uniformities in the dielectric thickness can be mitigated if a slow dielectric growth rate is used. Alternatively stated, the combination of the plurality of CDS structure conductive layers 816 forms a textured conductive surface area, and an increase in capacitance density results from an increase in textured conductive surface area. An increase in the CDS structure dielectric layer thickness 822 results in an increase in capacitor breakdown voltage and a decrease in capacitance per unit area.
(36)
(37)
(38)
(39)
(40)
(41) The inductor 1308 comprises a high aspect ratio conductor-silicon (CS) structure 606 having a first terminal 1310 connected to the textured electrode 808 and a second terminal (not shown). The inductor 1308 and capacitor 800 can be connected directly on top of the substrate (as shown) or under the dielectric layer as routing layer. Multi-layer routing can also be used, but for many applications a single layer or maximum of 2 layers of routing is enough. The CS structure 606 comprises a single second Si core 608 formed as a winding. Here the winding is depicted as generally spiral in shape, but it should be understood that the winding is not limited to any particular geometry. An electrical conductor layer 816 overlies the second Si core 608, as shown in
(42) The first Si cores 608 of the capacitor have a width (C.sub.X1), a trench depth (C.sub.Z1), and an aspect ratio (.sub.1) of C.sub.Z1-to-C.sub.X1 of at least 5:1. The second Si core 608 of the inductor has a width (C.sub.X2), a trench depth (C.sub.Z2), and an aspect ratio (.sub.2) of C.sub.Z2-to-C.sub.X2 of at least 5:1. Since the inductor trench is deeper, in some aspects the second core aspect ratio may be slightly greater than 5:1. Adjacent first Si core centers of the capacitor are separated by a spacing (S.sub.X1) and a spacing aspect ratio (.sub.SPACE1) of C.sub.Z1-to-S.sub.X1 of at least 5:1. These details are not shown in this figure, see
(43) In this example, the Si substrate 1302 is a silicon-on-insulator (SOI) substrate comprising a Si top layer 1312 having a Si top layer thickness (d1), greater than C.sub.Z1, and a silicon dioxide layer 1314 with z thickness (d2) underlying the Si top layer. C.sub.Z2 is greater than d1, but less than (d1+d2). In some aspects not shown, a second Si layer may underlie the dielectric layer 1314. Although an SOI substrate is used in this example, the filter network can also be enabled on relatively thick Si substrates that do not have an insulating layer. As would be understood in the art, the capacitor and inductor may be connected in either series of shunt arrangements. Further, the filter network may include multiple connected inductors and/or capacitors.
(44) Modified HARMS Process for Achieving Large Capacitance Per Unit Area
(45) In some aspects, the devices disclosed herein are the result of a modified HARMS process. The parallel plate capacitance formula as given in (1.2) has only 3 parameters that can be adjusted to improve the capacitance per unit area. These are;
(46) i) The area; Area,
(47) ii) The relative dielectric constant; .sub.r
(48) iii) The spacing; s between the capacitor plates.
(49) In the modified HARMS process all 3 parameters are changed favorably to create a much larger capacitance per unit area.
(50) Increasing the Area of the Capacitor (Parameter: Area)
(51) In the modified HARMS process the area between the capacitor plates is increased by generating an ordered topography or texture along z axes again using the Bosch process. There are many choices of layout creating any topography using Bosch process. The simplest one is creating high aspect ratio trenches, as is done for the inductor, which do not go all the way down to the insulator substrate, as shown in
(52) After the Bosch trenching, the surface of the silicon where the CDS capacitors are built is no longer flat, with the surface area being greatly increased due to the topography introduced, giving a larger capacitance per area value as desired. The capacitance per unit area increase by Bosch trenching can be calculated as a function of the trenching parameter aspect ratio and as a function of the trench masking pattern parameters introduced on the silicon surface as shown in
(53)
(54) General Formulation Capacitance Per Unit Area as a Function of Pattern Dependent Etching
(55) Any pattern of Bosch etching having a non-zero trench depth increases the surface area of the CDS capacitor regions and can be mathematically formulated generally using very simple math. The geometrical origin of area increase by patterning is very straightforward. Any masking pattern at the surface of the silicon exposed to the Bosch process etching creates a number of isolated Si cores that may also be referred as right prisms. The depth of the Bosch etching is the height of the right prisms of silicon, where etching is blocked by masking. The additional silicon surface area, which is the additional capacitance gained by this etching-based process, is the total sidewall surface area of the prisms in any selected area of interest. The right prisms can be the result of organized or randomly generated masking patterns in one or many types of geometries. For example, the following shapes of right angle Si cores may be formed: organized or randomly generated repetitive triangles and rectangles of any type, squares, any type of polygons, circles, ellipses, or any combination of these geometries. The area selected for the CDS textured electrode capacitor can also be a well-defined area like a rectangle or a square, or any complex irregular polygon region which is suitable for capacitance-fill-in in a silicon interposer. Therefore, any masking patterned Bosch etch increases the surface area, and the magnitude of the increase in surface area is related to the depth of the etch, density of the etch pattern in the region, and its shape. In this patterned etch, or in other words mask controlled textured surface, the top of the prisms and the region between them, where the etch is performed (bottom of the etch), are ideally flat xy planes that share the common areas with the flat un-etched surface. Therefore, only prism sidewall surfaces are the cause of the increase in the surface area and capacitance increase, and they can be calculated and formulated.
(56) The right prism sidewall area S.sub.SW created by an etch process in any masking pattern is,
S.sub.SWPh(2.1)
where h and P is the height of the prism, corresponding to the etch depth from the surface and the circumference of the mask geometry respectively, which forms the top or bottom geometry of the etched prism. If the top or bottom geometry of the prism is square, in other words the masking pattern is a square, then P=4a, where a is the side of the square. If the top/bottom geometry is a rectangle, then P=2(a+b), where a and b are the sides of the rectangle. If the masking pattern is a circle, then P=2r, where r is the radius of the circle, etc. Assume that there is a combination of variety of k different type prisms each having P.sub.j sidewall areas and n.sub.j of them are formed in the selected area. The total sidewall area of the prisms in such an etched region is,
S.sub.TSW=.sub.j=1.sup.kn.sub.jP.sub.jh(2.2)
(57) If the region only has one size and one type of n prisms in the area A.sub.TOT, which is the intended for CDS capacitor region being built, the total sidewall area of the prisms in the area A.sub.TOT simply becomes,
S.sub.TSW=nPh(2.3)
(58) Larger values of n result in an increase in the sidewall area. Therefore, the density of the prisms, which is related to their size and how close they can be packed, along with the area of the masking patterns, are the important factors for maximum capacitance increase.
(59) Let the area where the region is patterned, etched, and the CDS capacitor built be called the capacitor cell and its area is A.sub.CELL. The rectangular capacitor cell regions are clearly seen in
S.sub.CELL=S.sub.T+S.sub.B(2.4)
(60) Writing A.sub.CELL explicitly in terms of P.sub.x and P.sub.y and S.sub.T in terms of n.sub.x, n.sub.y, c.sub.x and c.sub.y gives S.sub.B as,
S.sub.B=P.sub.xP.sub.yn.sub.xn.sub.yc.sub.xc.sub.y(2.5)
where n.sub.x, n.sub.y, c.sub.x and c.sub.y are number of right prisms, or vertical columns along x and y axes and the mask dimensions of the rectangles along x and y axes respectively. For the purpose of simplifying the mathematics, the terms Sx and Sy, as used in formulas 2.6 through 2.10, are approximated as being the space or distance between Si prisms, as opposed to the distance between Si prism centers. P.sub.x and P.sub.y are calculated with the notations used in
P.sub.x=n.sub.xc.sub.x+(n.sub.x1)s.sub.x2s.sub.xe(2.6)
P.sub.y=n.sub.yc.sub.y+(n.sub.y1)s.sub.y2s.sub.ye(2.7)
(61) Bosch process aspect ratio and .sub.SPACE relate the x, y dimensional values to the vertical column height dimension C.sub.Z, same as in the interdigitated capacitor case as,
(62)
(63) Solving n.sub.x, n.sub.y from (2.6) and (2.7) gives,
(64)
(65) For all practical purposes P.sub.x, P.sub.y>s.sub.x, s.sub.Y, s.sub.xe, s.sub.ye. Therefore, in (2.9) and (2.10), c.sub.x=c.sub.y=s.sub.x=s.sub.y, and n.sub.Z and n.sub.Y can be closely approximated by,
(66)
where for c.sub.x=c.sub.y, S.sub.T becomes,
S.sub.T=n.sub.xn.sub.yc.sub.x.sup.2(2.13)
(67) Solving S.sub.B from (2.4) gives,
S.sub.B=S.sub.CELLn.sub.xn.sub.yc.sub.x.sup.2(2.14)
(68) The right prism side-wall area S.sub.SW is,
S.sub.SW=4c.sub.xc.sub.zn.sub.xn.sub.y(2.15)
(69) The figure of merit , which is the CDS capacitor area to the total projected area occupied by the capacitor in the interposer S.sub.CELL achieved by patterning can be expressed as,
(70)
(71) Giving an always larger than 1 value for as,
(72)
(73) Writing (2.18) explicitly gives,
(74)
(75) Resulting in the very simple expression only the function of the Bosch processing parameter as,
(76)
(77) Expression (2.20), which is for square masking, can be generalized for any repetitive unit mask geometry by introducing its circumference P as,
(78)
(79) If the unit repetitive mask geometry is a circle, substituting C.sub.X with 2r will give the same spacing and etching rule as used for square as done earlier. For this case (2.19) explicitly becomes,
(80)
(81) As can be seen using a square prism or a square Bosch etching unit, a repetitive masking pattern with identical spacing is slightly better than circular patterns in terms of area increase, which shows the prism selection choice in the masked texturing.
(82) As explained in [1], the design is based on the etching of patterned silicon using DRE (Deep Reactive Etching), also known as the Bosch Process. Bosch processing [4-7] is a very widely used and very versatile method of making very high aspect ratio trenches and silicon through vias (STV), and is very widely used in many (MEMS) components since its invention in 1994 [28]. Originally developed by Bosch, an automotive electrical component manufacturer, the Bosch process has conventionally been used to manufacture automobile sensors for cars, not inductors or capacitors. As is well understood in the art, the primary application of the Bosch process has in the making of scribe lines, silicon through vias, and in applications such as accelerometers and other types of sensors that require deep trenches with high aspect ratios, but not in the fabrication of active or passive circuit Si components. Neither has the Bosch process been applied to the fabrication of IC trenches, as the trenches in IC's do not require very deep or high aspect ratios. Further, discrete component (e.g., capacitor) manufacturers, such as TDK or Murata, use multi-layer ceramic or low temperature co-fired ceramic (LTCC) processes, never silicon. As a result, there has been no suggestion in either the fabrication of conventional ICs or discrete passive electronic components that silicon can be etched in a manner that would be useful in the manufacture of high aspect ratio Si core inductors or capacitors.
(83) Reverse Mask Etching: Etching the Prism Regions and Leaving the Continuous Region S.sub.0
(84) To explain the texturing process and show the associated math in a simpler way, the mask that blocks the Bosch etching mask may create isolated regions of polygons that form the top and bottom surfaces of silicon prisms, with an etched continuous region in between prisms with an area of S.sub.0 as given above (see
(85) Decreasing the Distance Between Capacitor Plates (Parameter s)
(86) Instead of using the spacing based s on the aspect ratio of the Bosch process, as in the single layer interdigitated capacitors described in [1], the patterned silicon surface can be exposed to oxidation cycle and a much thinner layer of high quality silicon oxide (SiO.sub.2) can form the dielectric region of the CDS capacitor. In this way the dielectric thickness becomes completely independent from aspect ratio , which is the main reason for the lower capacitance per unit area in a comb type capacitor. Another choice of thermally grown dielectric material for the CDS capacitor is silicon nitride (Si.sub.3N4). Making very controllable thicknesses, high quality thermally grown very thin oxides and nitrides are probably the most mature processing steps in any form of silicon based semiconductor technology since 1965's. We owe this debt to Bruce E. Deal and Andy S. Grove's work [29, 30] on oxidation kinetics of SiO.sub.2, which made silicon based IC technology possible and creation of Silicon Valley through the offspring of the Fairchild Camera and Instrument Corporation, later known as Fairchild Semiconductor. The offspring of Fairchild are rightfully known as Fair Children, which include Intel, National, AMD, and LSI Logic. Today, high quality, thermally grown SiO.sub.2, from 2 nm (tunnel oxide) thicknesses to 2-3 and even thicker, is mass produced reliably [31].
(87) The electric field breakdown voltage for SiO.sub.2 and Si.sub.3N4 is 10.sup.7 V/m and this value determines the minimum thickness required for the oxide or nitride thickness in the modified HARMS process CDS capacitor. Assuming one dimensional electro-static fields [17-24], the minimum oxide thickness can be easily calculated for a given maximum voltage V.sub.MAX in an application. Solving t.sub.OX from,
(88)
(89) Since the electric fields in the convex corners of the capacitor structures are larger than the uniform electric field approximation in the parallel capacitor plate given in (2.8), a thicker SiO.sub.2 film must be grown by a proper safety margin as indicated with the in (2.9).
(90) As an example, for a 10V DC/DC application, equation (2.9) gives a SiO.sub.2 thickness of 10.sup.6 cm, which is 0.01 or 10 nm, or 100 . 120 nm SiO.sub.2 thickness was a very common MOS gate oxide thickness in 5V supply/0.5 gate length technologies of mid 1980-early 1990's. Easily produced 10-20 nm thick dielectric thicknesses were not even thinkable for interdigitated capacitors made using the conventional HARMS process and is even challenging for advanced and expensive deposition techniques like ALD today [25, 26].
(91) The relative dielectric constant .sub.r of thermally grown SiO.sub.2 and Si.sub.3N.sub.4 are 3.9 and 7.5, respectively. Both dielectrics have very good loss tangents [tg()0.001-0.002] needed for high frequency applications and are the highest quality dielectrics, as compared to any other deposition methods explained below.
(92) Using High Relative Dielectric Constant (Parameter .sub.r)
(93) Using high dielectric constant material deposition instead of thermally grown SiO.sub.2 or Si.sub.3N.sub.4 is another way of making CDS capacitors. TiO.sub.2, (.sub.r=85, loss tangent 510.sup.4) HfO.sub.2 (.sub.r=25) and Al.sub.2O.sub.3(.sub.r=9) are good examples of dielectric materials widely used in MEMS and IC technologies today. Very thin layers of high dielectric constant materials can be deposited using ALD techniques [25, 26] and are in wide use today where the cost is not a major factor. It must be also remembered that theoretically the dielectric quality of any deposition technique cannot be as good as the thermally grown dielectrics.
(94) Texturing Results
(95) Of concern is quantitatively finding the capacitance per unit area increase as a result of silicon texturing. Since the texture patterning can be done in an infinite number of ways, an exemplary analysis is provided for the structure shown in
(96)
(97)
(98)
(99) The number of square columns or holes, n.sub.x or n.sub.y in any direction is an integer number and this number is determined by the thickness and the aspect ratio and the square column dimension C.sub.X=C.sub.Y=C. The square side dimension C is also a number which is the integer multiple of a selected grid size in the layout system taken as 0.001. The combined effect of these variables creates the jagged curves as shown in
(100)
(101)
(102)
(103)
(104)
(105)
(w+s).sup.2w.sup.2=w.sup.2(2.28)
(106) The arithmetic yields,
w.sup.2+2ws+s.sup.2w.sup.2=w.sup.2(2.29)
(107) The relation between the s and w can be evaluated by re-arranging (2.30) giving the quadratic equation,
s.sup.2+2wsw.sup.2=0(2.30)
(108) The roots of (2.30) are,
(109)
(110) Simplifying (2.31) shows that one of the roots is positive and the other one is negative as,
(111)
(112) Since s and w are spacing and width, and they can only have positive values, the only valid solution of (2.30) is the root giving s>0 which can be explicitly written as,
s=w({square root over (2)}1).fwdarw.0.44w(2.33)
(113) As can be seen in (2.33) the valid solution for s is always less than w. Equation (2.30) is written for finding s versus w relations that satisfy equal areas for column top area S.sub.T and in-between areas S.sub.B. The resulting relation (2.33) states that for s>0.44w, S.sub.B the in-between area between the columns is always larger than the column top area S.sub.T. If both sides of the equation are divided by silicon thickness t.sub.Si as,
(114)
(115) Writing (2.34) in terms of the aspect ratios and .sub.SPACE gives,
(116)
(117) Manipulating (2.35) gives the conflicting result of (1.8) .sub.SPACE which has to be satisfied as long as the Bosch process is used. Solving (2.35) gives,
=({square root over (2)}1).sub.SPACE0.44.sub.SPACE(2.36)
(118) In other words, condition (2.36) cannot be achieved with Bosch process and Bosch process will always give in-between area S.sub.B between the columns as larger than the top column area S.sub.T, which guarantees that trench array capacitance series resistance is always smaller than the column array capacitors when confined to the same area.
(119)
(120)
(121)
(122)
(123)
(124)
(125)
(126) The increase in the capacitor value associated with the textured CDS capacitor is very significantly for any aspect ratio, in a given area. The 10 nm oxide thickness taken in the simulations yields a 10V breakdown voltage. The capacitance per unit area values are also higher compared to any on-chip MOS structure built giving the same breakdown voltage using the same MOS dielectric stack by (1+) rule as proven in (2.20), which results in 25-50 increase, which is a direct result of electrode texturing.
(127) The capacitance increases with aspect ratio and with silicon thickness, which is totally opposite from the result obtained in the comb capacitor case. The difference comes from the way the dielectric is formed. The minimum value of the comb capacitor plate-to-plate spacing is controlled by the spacing aspect ratio and silicon thickness in the HARMS process and it increases as the silicon thickness increases. On the other hand, the plate-to-plate spacing in the modified HARMS process is independent of the silicon thickness or aspect ratio. A very thin SiO.sub.2 gate oxide (5-15 nm) CDS capacitor can be fabricated, where dielectric thickness is only a function of desired maximum operating voltage.
(128)
(129) Series Resistance and High-Density Vertical RC Delay Line Applications
(130) Capacitance always comes with a series resistance that can also be tailored depending to the application. High capacitance per unit area is a requirement for a DC/DC converter, or PMICs in general. The state-of-the-art maximum frequencies currently used in research are typically below 200 MHz [34-40]. However, in a majority of the DC/DC converters, the switching frequencies rarely exceed 2 MHz.
(131)
(132) The general resistance formula for a prism is;
(133)
(134) Where , l, S are resistivity, length, and cross-sectional area where the current goes through respectively.
(135)
(136)
(137) On the hand the R.sub.TRENCH resistance in
(138)
(139) Its dependence to silicon thickness is shown in
(140)
(141) Since S.sub.B, the area between the columns, is larger than S.sub.T as shown in
(142) A good measure of the dynamics of the capacitor is given by the RC time constant and the Q factor. The RC time constant for the column array and trench array configuration is given in
(143) Q factor of a capacitor is formulated as,
(144)
(145)
(146) In the investigation of substrate resistance effects on the RC time constant and Q of the capacitor, temperature effects should also be taken into consideration. For this investigation the right variable of choice is doping concentration rather than substrate resistivity. Resistivity is not one of the independent variables of semiconductor carrier transport equations, it is an outcome given with,
(147)
where p, n, .sub.p and .sub.n are hole and electron concentration, and hole and electron mobilities, respectively.
(148)
(149)
(150) To this point the analysis of the CDS capacitor assumes an ideal capacitor formed by the gate oxide C.sub.OX in between metallization and silicon. However, this is not accurate. Rather, the gate capacitance can be modeled as series combination of 2 capacitors, one being the gate oxide capacitor C.sub.OX, as previously assumed, and a complex voltage dependent capacitor formed in silicon C.sub.Si, which requires some device physics more than electrostatics. The series equivalent of two capacitors C.sub.OX and C.sub.Si is,
(151)
(152) According to this formulation C.sub.MOS is always smaller than the smallest capacitor in series and this very important property must be remembered, as graphically depicted in
(153) MOS Capacitor Physics Overview
(154) The CDS capacitors built using the modified HARMS process are basically a MOS type capacitor, and the theory of the MOS capacitor is covered very extensively. MOS capacitor behavior differs from a conventional (e.g., ceramic) capacitor, and this difference becomes greater as the doping level in silicon is lowered. One important factor is the bias voltage dependence of the MOS capacitor. High doping levels create MOS capacitors that behave similarly to conventional capacitors, which have very small DC bias voltage dependencies.
(155) Even though the theory of MOS capacitors is well understood [16-24], all the excellent classical reference device physics and technology books and references in wide circulation explain the exact analytical solution of the Boltzmann-Poisson equation in a manner that is not as clear as it might be. The results given are the same, but the derivation is very short and with minimal mathematical detail [16-24]. To clarify this ambiguity in this work, a significant effort is given to derive the exact one-dimensional analytical solution of the Boltzmann-Poisson equation with no short-cuts, which is for better understanding the CDS capacitor used in this work. Since this requires many ignored derivations in the literature, it starts from semiconductor carrier transport equations.
(156) General Formulation of Semiconductor Transport Equations
(157) Semiconductor carrier transport equations are three coupled non-linear partial differential equations. The first one is the Poisson's equation which relates the charge density to the electro-static potential with the Maxwell's Equations variables written as [16-18],
{right arrow over (D)}= where {right arrow over (D)}={right arrow over (E)} and{right arrow over (E)}=(3.1)
where {right arrow over (D)} and {right arrow over (E)} are Displacement and Electric field vectors and =.sub.r.sub.0. For a region having non-homogeneous dielectric distribution, like in the MOS capacitor, Poisson's equation should be written as,
()=q(pn+N.sub.D.sup.+N.sub.A.sup.)(3.2)
where q and are electron charge and dielectric constant distribution in the region of interest, and p and n are the hole and electron concentration distribution in the region. N.sub.D.sup.+ and N.sub.D.sup. are the three-dimensional ionized donor and acceptor concentration distribution in the region. , p, and n are the main variables of the system which are functions of x, y, and z spatial coordinates as well. The continuity equation for holes is,
(158)
(159) The continuity equation for electrons is,
(160)
(161) Where in its simplest form R is the Shockley-Hole-Read generation-recombination term written as,
(162)
where n.sub.i, .sub.p, and .sub.n are intrinsic electron concentration, life times for holes, and electrons respectively, which are in the order of milliseconds in silicon. In the Shockley-Hole-Read generation-recombination term given in (3.5), the recombination centers are assumed to be located at the mid-gap level. The negative value of R (pn<n.sub.i.sup.2) corresponds to net generation of carriers, like in the depletion region, and a positive value for R (pn>n.sub.i.sup.2) corresponds to the net recombination of carriers. For large excess carrier concentrations, Auger recombination should also be added to the R term.
(163) Current density equation for holes and electrons both having drift and diffusion terms are expressed as,
{right arrow over (J.sub.p)}=qp.sub.p{right arrow over (E)}qD.sub.pp(3.6)
{right arrow over (J.sub.n)}=qn.sub.n{right arrow over (E)}+qD.sub.nn(3.7)
where D.sub.p, D.sub.n, .sub.p, .sub.n, k, T, and q are diffusion coefficient for holes and electrons, hole and electron mobilities Boltzmann constant, temperature in Kelvin, and electron charge. Electron and hole mobilities .sub.p and .sub.n are functions of doping concentration, temperature, and electric field [43, 44]. Einstein relates the diffusion coefficient for holes and electrons, hole and electron mobilities as,
(164)
(165) Where q, T, and k are electron charge (1.6021810.sup.19 C), temperature in Kelvin, and Boltzmann constant (1.3806610.sup.23 J/K), respectively. Thermal voltage V.sub.T at 300 K is 0.02585 volts. Substituting (3.1) and (3.8) in the current density equations (3.6) and (3.7) gives,
{right arrow over (J.sub.p)}=qp.sub.pq.sub.pv.sub.T.sub.p(3.9)
{right arrow over (J.sub.n)}=qn.sub.p+q.sub.nv.sub.T.sub.n(3.10)
(166) Using Boltzmann statistics for non-degenerate doping levels, the electron and hole concentration are related to electrostatic potential , quasi Fermi potential for holes .sub.p, and electrons .sub.n [19, 21-24, 32, 33] as,
(167)
(168) Remembering the gradient of an exponential relation in calculus,
e.sup.u=e.sup.uu(3.13)
(169) And applying it to (3.11) and (3.12) gives,
(170)
(171) Substituting (3.14) and (3.15) in (3.9) and in (3.10) gives another formulation of hole and electron current density relations as,
{right arrow over (J.sub.p)}=q.sub.p.sub.p(3.16)
{right arrow over (J.sub.n)}=q.sub.pn.sub.n(3.17)
(172) As can be seen all these formulations are given in three dimensions. For a CDS capacitor the region of interest can be accurately modeled with only one-dimensional analysis where an analytical closed form solution is possible.
(173) One-Dimensional Mathematical Formulation of the Electric Field Versus Surface Potential in MOS Structures
(174) Electron and hole carrier concentrations in one dimension and for non-degenerate doping levels can be expressed with Boltzmann statistics [19, 21-24, 32, 33] as,
(175)
where n.sub.i, , n, and p are intrinsic carrier concentration, electro-static potential, and quasi Fermi potentials for electrons and holes. The thermal equilibrium enforces the relation,
p.Math.n=n.sub.i.sup.2(4.3)
(176) From the alternate formulation of current density relation given in (3.16) and (3.17), to have zero DC electron and hole current density distribution [J.sub.n (x)=J.sub.p(x)=0 for ALL x] for any electro-static potential distribution (x), the quasi-Fermi potentials n and p must satisfy,
(177)
(178) This relationship is not clear with the identical current density formulation given at (3.9) and (3.10), but becomes clear with the alternate formulation for current density relation given at (3.16) and (3.17). In this case n and p quasi-Fermi potentials can be replaced with a constant reference potential satisfying (4.4). Intrinsic electron concentration n.sub.i is also a complex function given as,
(179)
where N.sub.V and N.sub.C are effective density of states in the valance and conduction bands and E.sub.G is the semiconductor band-gap. The intrinsic electron concentration n.sub.i at 300 K is 1.4510.sup.10 cm.sup.3 for silicon. Band-gap versus temperature dependence can be represented by the empirical curve-fit formula [21],
(180)
where T, E.sub.G (0), , and are temperature in Kelvin, along with empirical constants 1.17 eV, 4.7310.sup.4, and 636 respectively for silicon [21]. The band gap in silicon at 300 K or E.sub.G (300) is 1.12 eV.
(181) The {square root over (N.sub.CN.sub.V)} in (4.7) is a function of temperature and can be replaced by a single temperature independent constant A as,
{square root over (N.sub.CN.sub.V)}=A.Math.T.sup.1.5(4.8)
(182) A in (3.8) is a constant contains complex functions of hole and electron effective masses in conduction and valance bands, as well as Boltzmann and Planck constants [21]. A can be taken as 7.13210.sup.15 for silicon. The net charge density (x) is,
(x)=p(x)n(x)+N.sub.D.sup.+(x)N.sub.A.sup.(x)(4.9)
(183) The analysis is performed for uniformly doped silicon, so therefore the x dependencies in N.sub.D.sup.+(x) and N.sub.A.sup.(x) can be removed in (3.9).
(184) Sufficiently far away from the SiO.sub.2-to-silicon interface at the surface, and towards the bulk where x.fwdarw., the charge density, , and the electric field are zero. Solving (4.9) with this assumption gives,
(185)
Where Sin h(t) in (3.11) and Cos h(t) in (3.25-3.27) is given by,
(186)
As a result, the one-dimension Poisson's Equation for non-homogeneous dielectric distribution becomes,
(187)
(188) It is useful to note that the magnitude of the electric field is related to the electro-static potential in one dimension by,
(189)
(190) Substituting (4.10) in (4.11) and for uniform dielectric distribution (4.11) and for thermal equilibrium condition can be written as,
(191)
(192) Substituting (4.12) in (4.13) gives,
(193)
(194) Since carrier concentrations p(x) and n(x) are exponentially related to the electro-static potential, (4.14) is a non-linear differential equation for which a closed form analytical solution does not exist. Substituting (3.11) in (3.14) gives the non-liner differential equation explicitly as,
(195)
(196) Equation (4.15) can only be solved using discrete variable methods numerically and the solution gives very valuable information [32, 33]. Since only the surface charge density as a function of surface potential .sub.S need be known to obtain many of the physical and electrical characteristics of the CDS capacitor or MOS devices in general, this approach is even more valuable and elegant.
(197) All the literature presented below points to the classic book of physics The Feynman's Lecture of Physics by Richard Feynman [18]. Reading all three marvelous volumes of freshman physics gives the feeling like learning physics all over again even for a seasoned physicist. In the Vol II, pp 7-9 Richard Feynman wrote, This equation is readily solved in general [multiply both sides by
(198)
and integrate with respect to x]. However, this way of arriving at the solution may be a bit indirect and confusing for many. A more systematic and rigorous way, like using the Leibnitz's chain rule, is,
(199)
(200) Focusing only on the left-hand side of the equation (4.15) for now and substituting (4.12) into (4.16) gives,
(201)
(202) On the right of the equation there is another
(203)
and substituting (4.12) in (4.17) one more time gives,
(204)
(205) This is the result given in all the literature using Feynman's hint, here derived by employing Leibnitz's chain rule instead of a magical constant and it can be generalized for many other applications as well. From here on the math and physics remain the same as published in the literature. Moving d to the right-hand side of (4.19) gives,
(206)
(207) As can be seen, the non-linearity in the equation (4.11) has disappeared, and both left and right-hand sides are analytically intergrable integrals in terms of E and as,
(208)
Where E.sub.S is the electric field in the SiO.sub.2-silicon interface at the surface and surface potential .sub.S. Integrating the left hand side is straightforward giving,
(209)
(210) The integration of the right-hand side can be explicitly written as,
(211)
(212) Integration constant K is solved with the boundary condition
(213)
finally,
(214)
where u is the sign of .sub.S.
(215)
(216) The gate voltage V.sub.G is given by the sum of Flat-Band Voltage V.sub.FB, Surface Potential .sub.S, and the voltage drop V.sub.OX across the gate oxide with a thickness of t.sub.OX. V.sub.OX is calculated by calculating the displacement vector in the oxide using the Gauss's pillbox method giving continuity of the normal component of the displacement vector [16, 17] stated as,
D.sub.1n=D.sub.2n.fwdarw..sub.SiE.sub.S=.sub.OXE.sub.OX(4.28)
where E.sub.OX is the electric field in the gate oxide. Since the electric field at the silicon-SiO.sub.2 interface is known as given in (4.27), E.sub.OX can be solved from (4.28) giving,
(217)
(218) The voltage across an electric field is calculated by the line integral of the electric field [16, 17]. For a parallel plate capacitor, the electric field is constant between the plates and equal to the voltage difference between plates divided by the plate separation t.sub.OX giving,
(219)
(220) As a result, the gate voltage becomes,
(221)
Where flat band voltage V.sub.FB is related to the work function differences between the gate and silicon .sub.MS and surface charge density at silicon-SiO.sub.2 interface, along with trapped fixed oxide charge density integral given as,
(222)
(223) The .sub.MS, work function differences between the gate and silicon is expressed as,
(224)
(225) Where .sub.M, .sub.S, , E.sub.C, E.sub.i, and q are gate work function, silicon work function, electron affinity of Silicon (4 eV), conduction band and intrinsic level energies, and electron charge respectively.
(226) .sub.F is the bulk potential in silicon which is related to the doping as,
(227)
Low Frequency Capacitance in MOS Capacitor, C.sub.S,LF
(228) Low frequency capacitance versus voltage is a very important characteristic for the MOS structure. There are 2 capacitors in series, C.sub.OX being voltage independent gate oxide capacitor between the gate and silicon, and C.sub.S,LF being gate bias voltage dependent capacitor in the silicon. The general relation of low frequency capacitance per unit area in the CDS or MOS capacitor is defined by [19-24],
(229)
(230) Charge Q.sub.S, can be calculated with the integral form of Poisson's equation and the auxiliary equations given at (4.10) as,
Q.sub.S=.sub.SiE.sub.S(.sub.S)(4.36)
(231) Q.sub.S and V.sub.G are functions of the surface potential .sub.S. Combining (4.36) in (4.35) and V.sub.G from (4.31) gives,
(232)
(233) Differentiation in (4.37) gives the low frequency capacitance of the MOS capacitor C.sub.S,LF explicitly as,
(234)
(235) Simplifying (4.38) gives and writing in terms of E.sub.S gives,
(236)
(237)
(238) Flat Band Capacitance
(239) Another important capacitance definition is the flat-band capacitance C.sub.FB when .sub.S=0, given using Debye Length as,
(240)
where extrinsic Debye Length is given as,
(241)
Deep Depletion Capacitance
(242) Another important capacitance mode that can be encountered in CDS or MOS capacitor is known as Deep Depletion Capacitance. If the gate voltage changes faster than the electrons can be generated at the SiSiO.sub.2 interface, there can be no inversion layer generation. This statement can be verified by solving the continuity equation for holes and electrons (4.3) and (4.4) for sinusoidal or transient boundary conditions. Measurement data also shows that low frequency curves are only for frequencies below 100 Hz, much lower frequencies than in most electronic devices in use. In this case the gate voltage causes the depletion layer to go deeper than the maximum depletion layer as defined on the onset of the strong inversion. For p type silicon, since this mode corresponds to no electron generation at the SiSiO.sub.2 interface, Poisson's equation without the electron concentration, and with only the hole concentration term in the charge expression, can be written as,
(243)
(244) With this charge relation the Poisson's equation that needs to be solved becomes,
(245)
(246) Applying the chain rule as above,
(247)
(248) Finally giving electric field at the interface as,
(249)
(250) The deep depletion gate voltage, V.sub.G,DD for this condition becomes,
(251)
(252) The resulting deep depletion capacitance C.sub.S,DD becomes,
(253)
High Frequency Capacitance
(254) The high frequency MOS capacitance function is the same as the deep depletion capacitance relation as given in (4.48), but at a different gate voltage given as,
(255)
(256)
(257)
(258) Minimum Capacitance Approximation
(259)
(260)
Processing the High-Density Capacitors Along with Inductors: Modified HARMS Process
(261) There are many ways of processing the capacitor structures along with inductors who are familiar with Silicon processing and Bosch process and HARMS process steps.
(262) Step 1. Picking the Right Substrate Resistivity and Thickness
(263) Substrate resistivity is not an issue of consideration for inductors built by using the HARMS process, as it does not affect the inductor performance. On the other hand, it can be a serious issue for high Q capacitors, which is important for PMIC applications. For other applications where having high Q capacitors are not an issue, like in capacitor applications in non-power RF applications, typical 10 .Math.cm high resistivity substrates can be used as a starting material. Using high resistivity substrates can even be desirable in building very small footprint delay line circuits, filters, varactor applications, snubber circuits, and similar circuits using this property.
(264) Therefore, the first step is to pick the right substrate doping level depending on the application. The thickness of the substrate is another consideration determined mainly by the inductor specification and Si core thickness effect on the inductor value, size, and performance as shown extensively in [1]. Typical silicon thicknesses are 50, 100, 200, and 300. Silicon thicknesses of 300 and higher don't require a bonded SOI wafer, as they can be built directly on the silicon wafer with 1-2 thermally grown SiO.sub.2 serving as the insulator base.
(265) Step 2. Making 2 Different Depth Trenches
(266) In the Modified HARMS process there can be two different trench depths in the same material. The inductor trench, which is also called deep trench, goes all the way to the bottom insulator region, which is the SiO.sub.2 layer at the substrate bottom where the inductors, transmission lines, comb capacitors, and high current stripes are built. The CDS capacitor trench, which may be referred to as the shallow trench, goes as deep as possible to the SiO.sub.2 layer at the bottom, but not touching it. The CDS capacitor trench is a shallower trench than the inductor trench, but still is a deep trench as far as conventional trenching is concerned, and is used to form the textured electrode. Typically, the CDS capacitor trench is 10-20% of the silicon thickness, whereas the inductor trench goes as deep as the silicon thickness to the top of the SiO.sub.2 layer at the bottom. In the conventional HARMS process there is only one trench depth, which goes all the way to the bottom insulator region formed by the SiO.sub.2 layer, corresponding to the inductor trench or the deep trench. There can be 2 methods of processing for making deep and shallow trenches.
(267) Step 2.1. Two Mask Bosch Etch Processes
(268) There can be several variations in the process, and one familiar with the technology can adapt the ideas given in this work. Let b.sub.Z be the depth difference between the inductor and CDS capacitor trenches and assume that b.sub.Z=2 as an example. The inductor trench region is patterned by a mask used for inductors, comb capacitors, and transmission lines, and is etched first by masking the regions of the wafer that will be used for capacitors. The first Bosch etch with a target depth of approximately b.sub.Z=2 is performed. Then, the capacitor regions may be patterned as trench array or column array, and the second Bosch etch is performed such that the inductor trench reaches the SiO.sub.2 layer at the bottom. As a result, the CDS capacitor trench bottom is at least b.sub.Z higher than the SiO.sub.2 layer at the bottom, and won't be touching the insulator. Here it should also be noted that the CDS capacitor trench density etch is always higher than the inductor trench density. This guarantees that the Bosch etch rate in the CDS capacitor etch region is slower than the inductor trench etch rate. This process creates a larger distance between the trench floor and SiO.sub.2 layer at the bottom than b.sub.Z=2. Fine tuning and control can create the desired b.sub.Z very precisely.
(269) Step 2.2. Single Mask Bosch Etch Process
(270) This is the simplest method of making trenches, using a single Bosch etch step and a single mask. The method is based on the density dependent Bosch etch rate explained above. Since the inductor trench region always has a larger etch area per unit area than the CDS capacitor trench, using the trench density dependent trench etch rate property of the Bosch process always assures deeper trench depths in the inductor regions than the CDS capacitor trench areas. This property allows the use of a single trench etch mask, resulting in 2 different depth trenches. Shallow trenches are formed in the capacitor regions and deep trenches, all the way to the insulator, are formed for the inductors, comb capacitors, transmission lines, and high current straps.
(271) Step 3. Insulator Growth
(272) This step is intended for forming the dielectric region of the CDS capacitor. It can be ALD type dielectric deposition or thermally grown higher quality SiO.sub.2 on the entire silicon wafer surface. After this step the entire surface of the silicon wafer is covered by the dielectric material of desired thickness based on the desired breakdown voltage of the capacitors. The insulator covers both the inductor silicon fence (core) and the CDS capacitor regions as well. Since silicon is very resistive compared to metal, an oxide or dielectric layer in between the metal and the silicon core does not create a current flow in the Si core parallel to the current in the metal, and therefore doesn't change the electrical performance of the inductor. Alternatively, the dielectric in the capacitor regions can be masked and dielectric overlying the inductor Si core can be removed in an etch step.
(273) Step 4. Top Electrode Conductor Deposition
(274) In this step Al, Cu, Ta, or other low resistivity metals, polycrystalline semiconductors, or doped semiconductors cover the dielectric everywhere using ALD or any other means capable of covering all the high aspect ratio texturing in the capacitor and inductor regions. The inductor winding cross-section is different than in the one explained in the HARMS process in [1], having an insulator between the Si core and the metal forming the winding.
(275)
(276) Step 2902 provides a Si substrate having a planar top surface and a planar bottom surface. Step 2904 etches the Si substrate top surface to form a textured surface including a plurality of adjacent high aspect ratio Si cores. Typically, the Bosch process may be used to perform this step. Step 2906 forms a dielectric layer overlying the Si substrate textured surface, by thermally growing a silicon oxide or nitride insulator or using the ALD process to deposit a dielectric insulator. For example, 10 nm-2,000 nm thick SiO.sub.2 can be very reliably and repetitively grown to create 10-200V breakdown voltages. Step 2908 conformally coats the dielectric layer with a top conductor layer forming a plurality of adjacent CDS structures. The top conductor layer typically has a thickness that is less than or equal to four times the conductor skin depth at the capacitor operating frequency, and it may be a metal, polycrystalline semiconductor, a doped semiconductor, or a doped polycrystalline semiconductor. Step 2910 forms a planar bottom conductor layer overlying the Si substrate bottom surface. Step 2912 forms first and second electrically conductive terminals respectively connected to the top and bottom conductive layers.
(277) As noted in detail above, forming the textured Si substrate top surface in Step 2904 includes forming Si cores having a width (C.sub.X), a height (C.sub.Z), with an aspect ratio () of C.sub.Z-to-C.sub.X of at least 5:1, separated by a spacing (S.sub.X) having a spacing aspect ratio (.sub.SPACE) of C.sub.Z-to-C.sub.X of at least 5:1.
(278) In one aspect, forming the textured Si substrate top surface in Step 2904 includes etching the Si substrate top surface to form unetched Si cores extending from an etched floor region. Then, forming the first conductive terminal in Step 2912 includes forming the first conductive terminal on the etched floor region, see
(279) In another aspect, forming the textured Si substrate top surface in Step 2904 includes forming Si cores having a height (C.sub.Z), and coating the dielectric layer with the top conductor layer in Step 2908 includes forming CDS structures having a height (T.sub.Z), where C.sub.Z0.9T.sub.Z.
(280)
(281) In one aspect, providing the Si substrate in Step 3002 includes providing a SOI substrate having a Si top layer thickness (d1) and a silicon dioxide layer thickness (d2) underlying the Si top layer. Etching the Si substrate top surface in Step 3004 includes forming first Si cores in the textured surface first region having a trench depth (C.sub.Z1) less than d1. Etching the Si substrate top surface in Step 3006 includes forming a second Si core in the textured surface second region having a trench depth (C.sub.Z2) that is greater than d1, but less than (d1+d2).
(282) In another aspect, forming the first Si cores in the textured surface first region (Step 3004) includes forming first Si cores having a width (C.sub.X1), a height (C.sub.Z1), with an aspect ratio (.sub.1) of C.sub.Z1-to-C.sub.X1 of at least 5:1, separated by a spacing (S.sub.X1) having a spacing aspect ratio (.sub.SPACE1) of C.sub.Z1-to-S.sub.X1 of at least 5:1. Forming the second Si core in the textured surface second region (Step 3006) includes forming a second Si core having a width (C.sub.X2), a height (C.sub.Z2), and an aspect ratio (.sub.2) of C.sub.Z2-to-C.sub.X2 of at least 5:1, where adjacent sections of the Si core winding are separated by a spacing (S.sub.X2) having a spacing aspect ratio (.sub.SPACE2) of C.sub.Z2-to-S.sub.X2 of at least 5:1.
(283) High aspect ratio passive electrical components and associated fabrication processes have been presented. Examples of particular geometries, materials, and process steps have been presented to illustrate the invention. However, the invention is not limited to merely these examples. Other variations and embodiments of the invention will occur to those skilled in the art.