Ultraviolet photodetectors and methods of making ultraviolet photodetectors
09865766 ยท 2018-01-09
Assignee
Inventors
- Rhonda R. Willigan (Manchester, CT)
- Jose L. Santana (Vernon, CT, US)
- Marcin Piech (East Hampton, CT)
- Joseph V. Mantese (Ellington, CT, US)
Cpc classification
C23C18/1279
CHEMISTRY; METALLURGY
C09D1/00
CHEMISTRY; METALLURGY
C01G9/006
CHEMISTRY; METALLURGY
C23C18/1225
CHEMISTRY; METALLURGY
International classification
H01L31/18
ELECTRICITY
C09D1/00
CHEMISTRY; METALLURGY
Abstract
A method of making an ultraviolet sensor includes applying a metal-containing solution to a substrate using a spin coating technique to form a metal-containing coat. The metal-containing coat is baked and pyrolyzed to form a metal-containing oxide film on the substrate. The metal-containing oxide film has a cubic crystalline structure suitable for ultraviolet photodetectors in flame detection applications.
Claims
1. A method of making an ultraviolet (UV) photodetector, comprising: applying a metal-containing solution to a substrate using a spin coat technique to form a metal-containing coat, wherein the metal-containing solution comprises a stabilizer; baking the metal-containing coat; pyrolyzing the metal-containing coat to form a metal-containing oxide film according to Mg.sub.xZn.sub.(1-x)O with a cubic crystalline structure; and calcining the metal-containing oxide film to form a metal-containing oxide layer.
2. The method as recited in claim 1, wherein applying the metal-containing solution includes applying the metal-containing solution over a metal-containing oxide film.
3. The method as recited in claim 1, wherein the metal-containing oxide film is a first metal-containing oxide film, and further including: applying a metal-containing solution having magnesium and zinc to the first metal-containing oxide film using a spin coat technique; and pyrolyzing the applied metal-containing solution to form a second metal-containing oxide film overlaying the first metal-containing oxide film.
4. The method as recited in claim 3, further including calcining the metal-containing oxide film to form a second metal-containing oxide layer.
5. The method as recited in claim 1, wherein baking includes a predetermined baking temperature of about 150 degrees Celsius and a predetermined baking time interval of about five (5) minutes.
6. The method as recited in claim 1, wherein pyrolyzing the metal-containing coat includes placing the metal-containing coat in a furnace and flowing an inert gas over the metal-containing coat to decompose, but not oxidize or make volatile organic ligands in the metal-containing coat.
7. The method as recited in claim 6, wherein the inert gas includes a gas from a group nitrogen, argon, and helium.
8. The method as recited in claim 6, further including pyrolyzing the metal-containing coat at a temperature that is between about 450 degrees Celsius and about 550 degrees Celsius.
9. The method as recited in claim 6, further including pyrolyzing the metal-containing coat for a pyrolyzing time interval that is between about five (5) minutes and about thirty (30) minutes.
10. The method as recited in claim 6, further including pyrolyzing the metal-containing coat at about 500 degrees Celsius for about five (5) minutes.
11. The method as recited in claim 4, wherein calcining includes placing the metal-containing oxide film in a furnace with oxygen-containing atmosphere to oxidize and remove interstitial zinc from the metal-containing oxide film.
12. The method as recited in claim 11, wherein the oxygen-containing atmosphere comprises oxygen at a concentration that twenty (20) percent or greater.
13. The method as recited in claim 4, wherein calcining includes placing the metal-containing oxide film in a furnace pre-heated to a calcining temperature of between about 650 degrees Celsius and about 750 degrees Celsius.
14. The method as recited in claim 4, wherein calcining includes placing the metal-containing oxide film in a furnace for a calcining time interval of between about ten (10) minutes and about thirty (30) minutes.
15. The method as recited in claim 4, wherein calcining includes placing the metal-containing oxide film in a furnace pre-heated to about 750 degree Celsius for about ten (10) minutes.
16. The method as recited in claim 1, further including annealing the metal-containing oxide film.
17. The method as recited in claim 16, wherein annealing includes placing the metal-containing oxide layer in a furnace with a static atmosphere.
18. The method as recited in claim 16, wherein annealing includes placing the metal-containing oxide layer in a furnace with a temperature between about 200 degrees Celsius and about 400 degrees Celsius for between about thirty (30) minutes and about four (4) hours.
19. The method as recited in claim 1, further including quenching the metal-containing oxide film.
20. The method as recited in claim 1, wherein the metal-containing solution includes an organometallic magnesium source, and organometallic zinc source, a solvent, and a stabilizer.
21. The method as recited in claim 1, wherein the metal-containing solution includes at least one of diethanolamine, toluene, zinc 2-ethylhexanoate, and magnesium 2-ethylhexanoate.
22. The method as recited in claim 1, wherein the metal-containing solution includes magnesium and zinc in a ratio range between about 0.5 to 0.5 and about 0.8 to 0.2.
23. The method as recited in claim 1, wherein the metal-containing solution includes magnesium and zinc in a ratio of about 0.72 to 0.28.
24. The method as recited in claim 1, wherein the stabilizer comprises a tri-functional chemical solution deposition additive having an amino alcohol.
25. The method as recited in claim 24, wherein the amino alcohol comprises one or more hydroxyl groups.
26. The method as recited in claim 24, wherein the amino alcohol comprises a primary amine.
27. The as recited in claim 24, wherein the amino alcohol comprises a secondary amine.
28. The method as recited in claim 24, wherein the amino alcohol comprises a tertiary amine.
29. The method as recited in claim 24, wherein the amino alcohol is monoethanolamine, diethanolamine, triethanolamine, hetpaminol, isoetarine, noepinephrine, propanolamine, shphingosine, or methanolamine.
30. The method as recited in claim 1, wherein the stabilizer comprises a tri-functional chemical solution deposition additive, and further comprising adding the tri-functional chemical solution deposition additive to a solution of organometallic precursor prior to deposition to form the metal-containing solution.
31. The method as recited in claim 30, wherein the organometallic precursor is a metal 2-ethylhexanoate.
32. The method as recited in claim 31, wherein the metal 2-ethylhexanoate is magnesium 2-ethyl hexanoate or zinc 2-ethylhexanoate.
33. The method as recited in claim 24, wherein the tri-functional chemical solution deposition additive includes diethanolamine.
34. The method as recited in claim 24, wherein the tri-functional chemical solution deposition additive is added to the organometallic precursor in a ratio of between 0.05 to 1 and 1 to 1 of additive to total weight of all metals in the solution.
35. The method as recited in claim 24, wherein the tri-functional chemical solution deposition additive is added to the organometallic precursor in a 1 to 1 ratio.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
(2)
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(4)
(5)
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(9) Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an exemplary embodiment of a an ultraviolet (UV) photodetector in accordance with the disclosure is shown in
(10) The one or more electrodes 30 are coupled to substrate 10 through film stack 50, and are electrically connected to film stack 50. UV photodetector 100 is configured to selectively redirect incident UV radiation to a photodetector 36 that determines whether flame is present via state circuitry and/or software (not shown for reasons of clarity).
(11) With reference to
(12) Metal-containing solution 200 includes an organometallic precursor, such as a metal ion ligated or chelated by an organic moiety. In embodiments, metal-containing solution 200 includes one or more organometallic precursors with both magnesium and zinc in a predetermined ratio. Metal-containing film 14 includes a magnesium and zinc in a ratio corresponding to the predetermined ratio metal-containing solution 200. Metal-containing oxide layer 16 includes magnesium and zinc in a ratio corresponding to metal-containing film 14. The ratio of magnesium to zinc in the metal-containing solution, metal-containing film, and metal-containing oxide layer generally corresponds to Mg.sub.xZn.sub.(1-x)O.
(13) With reference to
(14) Method 100 can include developing a film stack on the substrate by successively applying the metal-containing solution to the underlying metal-containing oxide film to form an overlying metal-containing coat, and pyrolyzing the overlying metal-containing coat to form an overlying metal-containing oxide film, as indicated by arrow 160. In this respect, subsequent to pyrolyzing a first metal-containing coat disposed on the substrate, a second metal-containing coat can be applied over the first metal-containing oxide film. The second metal-containing coat can be pyrolyzed, thereby forming a film stack comprising first and second metal-containing oxide films overlaying the substrate. The film stacks can thereafter be calcined to form a layer stack, e.g. layer stack 50 (shown in
(15) Gently baking the metal-containing solution coating 120 can be done immediately after applying the metal-containing solution coating 12 (shown in
(16) With continuing reference to
(17) Pyrolyzing the metal-containing coat can include placing the metal-containing coat in a furnace for between about five (5) minutes and ten (10) minutes after the furnace has been preheated to a predetermined pyrolyzing temperature that is between about 450 degrees Celsius and 550 degrees Celsius. Pyrolyzing the metal-containing coat at temperature in this range causes the metal-containing solution coating to begin to form a cubic crystalline structure, but is insufficient to cause the coating to fully crystallize in a cubic crystalline structure. As a result, a first metal-containing film formed from the pyrolysis operation has a polycrystalline structure with both cubic portions i and amorphous portions ii (both shown in
(18) Optionally, metal-containing oxide film 14 (shown in
(19) Calcining the metal-containing oxide film includes placing the metal-containing oxide film in a calcining furnace, e.g. calcining furnace 6 (shown in
(20) Optionally, method 100 may include an annealing operation, as shown with box 150. Annealing 150 generally includes placing calcined metal-containing oxide layer 16 (shown in
(21) With reference to
(22) Referring to
(23) Stabilizer 210 generally includes a tri-functional chemical solution deposition additive with an amino alcohol. The amino alcohol includes one or more hydroxyl groups and one or more amines. The amino alcohol also includes a primary amine, a primary amine and a secondary amine, or primary, secondary, and tertiary amines. The amino alcohol may include one or more of monoethanolamine, diethanolamine, triethanolamine, hetpaminol, isoetarine, noepinephrine, propanolamine, shphingosine, or methanolamine. The tri-functional chemical solution deposition additive can be diethanolamine. The tri-functional chemical solution deposition additive can be added to the organometallic precursor in a ratio of between about 0.05 to 1 and about 1 to 1 of additive to total weight of all metals in the solution. The tri-functional chemical solution deposition additive can be added to the organometallic precursor in a 1 to 1 ratio.
(24) In an exemplary formulation, metal-containing solution 200 may have a total metal concentration of about 0.8 moles. In embodiments, metal-containing solution 200 includes 0.854 grams (0.009 moles) of diethanolamine, 3.58 milliliters of toluene, 4.829 grams (0.006 moles) of magnesium 2-ethylhexanoate (e.g. Strem 12-1260, 30-40 wt % in toluene, 2.9 wt % magnesium), and 0.647 grams (0.0022 moles) of zinc 2-ethylhexanoate.
(25) In certain formulations, stabilizer 210 includes diethanolamine at an equimolar concentration to that of magnesium and zinc together. The equimolar concentration of diethanolamine with magnesium and zinc in metal-containing solution 200 prevents absorbed moisture from destabilizing the respective bonds between metals and 2-ethylhexanoate in metal-containing solution 200. In this respect diethanolamine operates as an electron donor, donating its electrons to the respective metal center bound thereto, strengthening the metal to ligand bond therebetween.
(26) Stabilizer 210 includes diethanolamine. Diethanolamine enables metal-containing solution 200 to provide repeatable spin coat application during an extended shelf life interval. Diethanolamine, i.e. HN(CH.sub.2CH.sub.2OH).sub.2, is an amino alcohol like monoethanolamine, triethanolamine, hetpaminol, isoetarine, norepinephrine, propanolamine, sphingosine, and methanolamine that carry a hydroxide (OH) and an amino (NH2, NHR, or NR2) functional groups on an alkane backbone. When incorporated into metal-containing solution 200, diethanolamine performs three functions.
(27) First, diethanolamine functions as a structure stabilizer before and during spin coating that prevents moisture from the ambient environment attacking the organometallic precursors, particularly zinc sources such as zinc-2-ethylhexanoate compound. This prevents formation of 2-ethylexanoic acid and zinc ionswhich would then get reduced and precipitate from the solution as zinc or zinc hydroxide. Stabilizer 210 also acts an electron donor to the zinc atom attached to the 2-ethylhexanoate ligands, forming a stronger bond to the 2-ethylhexanoate ligands, and preventing decomposition and thus loss of zinc.
(28) Second, diethanolamine functions as a rheology aid before and during spin coating. In conventional form, metal sources such as metal 2-ethylhexanoates are relatively viscous and incompatible with conventional spin coating techniques. Viscosity is ordinarily reduced in such solutions using solvents like toluene, which is miscible with the organometallic precursor chemicals of metal-containing solution 200, has a low boiling point, and leaves substantially no additional elements or associated imperfections in films produced from solutions containing the solvent. Stabilizer compounds such as diethanolamine reduce the viscosity of metal sources like 2-ethylhexanoates more effectively than solvents like toluene, allowing for formulation of metal-containing solutions with greater metal source concentrations than otherwise possible using solvents like toluene.
(29) Finally, diethanolamine functions as a crystal growth aid. Magnesium-zinc oxides typically form with hexagonal crystalline structure (wurtzite) with interstitial zinc distributed within the crystal phase. The interstitial zinc must be liberated from the crystalline structure during the pyrolysis, calcination, and/or annealing in order for the crystalline structure to relax and adopt a cubic structurewhich is solar blind, as shown in
(30) In embodiments of methods described herein, methods for making metal-containing oxide layers with UV to visible spectra with peak absorption of about 185 nanometers, tunable peak width, and an absorption cutoff at about 290 nanometers using a chemical solution deposition process, like spin coating, are described. It is contemplated that metal-containing oxide layers made using the methods described herein can have substantially pure cubic structure, and may, in certain embodiments, have a composition of Mg.sub.0.79Zn.sub.0.21O. This can simplify the fabrication of the devices by reducing the need to make such coatings from chemical vapor deposition, molecular beam epitaxial, or sputtering techniques. It can also reduce the cost of UV photodetectors made from such methods, allowing the detection capability of such devices to be inserted in flame detection devices suitable for residential settings.
(31) The methods and systems of the present disclosure, as described above and shown in the drawings, provide methods for making UV photodetectors with superior properties including a process routes for making such devices with layers having a composition according to Mg.sub.xZn.sub.(x-1)O using CSD techniques. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.