Method for manufacturing single-crystal silicon
09611566 ยท 2017-04-04
Assignee
Inventors
Cpc classification
C30B15/10
CHEMISTRY; METALLURGY
C30B15/005
CHEMISTRY; METALLURGY
C30B15/02
CHEMISTRY; METALLURGY
International classification
C30B15/02
CHEMISTRY; METALLURGY
C30B15/00
CHEMISTRY; METALLURGY
C30B35/00
CHEMISTRY; METALLURGY
C30B15/10
CHEMISTRY; METALLURGY
Abstract
Single crystal silicon ingots are grown by the multi-pulling method in a single crucible with minimization of dislocations by incorporating barium as a quartz crystallization inhibitor in amounts proportional to the diameter of the Czochralski crucible in which the crystal is grown. In at least one of the crystal pulling steps, a magnetic field is applied.
Claims
1. A method for manufacturing single-crystal silicon using a multi-pulling method for pulling up a plurality of pieces of single-crystal silicon from a material melt in an identical crucible within a chamber by a Czochralski method, the method comprising the steps of: preparing said material melt in said crucible, wherein the crucible has a diameter of 24 inches or more, and a layer containing barium is formed on an inner wall of the crucible in an amount related to the diameter of the crucible such that the amount of barium is about 2.210.sup.14 atoms.Math.cm.sup.2 for a crucible of 24 inch diameter, 5.410.sup.13 atoms.Math.cm.sup.2 or more and 2.210.sup.14 atoms.Math.cm.sup.2 or less for a crucible of 32 inch diameter, and 1.110.sup.13 atoms.Math.cm.sup.2 or more and 5.410.sup.13 atoms.Math.cm.sup.2 or less for a crucible of 40 inch diameter; pulling up a single-crystal silicon from the material melt; additionally charging a polycrystalline material into a material melt remaining after pulling up the single-crystal silicon and melting the polycrystalline material in the material melt while continuing heating of the material melt; and pulling up a further single-crystal silicon from the material melt having had the polycrystalline material additionally charged and melted therein, wherein the step of additionally charging and melting the polycrystalline material and the step of pulling up the further single-crystal silicon are repeated one or more times, wherein in at least one of the steps of pulling up a single-crystal silicon or the step of pulling up a further single-crystal silicon, which is repeated one or more times, the single-crystal silicon is grown in a magnetic field.
2. The method for manufacturing single-crystal silicon of claim 1, wherein at least one of the steps of pulling up a single-crystal silicon or the step of pulling up a further single-crystal silicon, which is repeated one or more times, includes a step of omitting at least a part of formation of a tail part of the single-crystal silicon and separating the single-crystal silicon from the material melt.
3. The method for manufacturing single-crystal silicon using a multi-pulling method of claim 1, wherein the crucible selected a is 32 inch nominal diameter crucible having a layer containing barium on the inner wall of the crucible in an amount of from 5.410.sup.13 atoms.Math.cm.sup.2 to 2.210.sup.14 atoms.Math.cm.sup.2.
4. The method for manufacturing single-crystal silicon using a multi-pulling method of claim 1, wherein the crucible selected is a 40 inch nominal diameter crucible having a layer containing barium on the inner wall of the crucible in an amount of from 1.110.sup.13 atoms.Math.cm.sup.2 to 5.410.sup.13 atoms.Math.cm.sup.2.
5. The method for manufacturing single-crystal silicon using a multi-pulling method of claim 1, wherein the layer containing barium is prepared by spraying an aqueous solution of a barium salt onto the inside of the previously formed crucible.
6. The method of claim 5, wherein the aqueous solution of a barium salt is an aqueous solution of barium carbonate or barium hydroxide.
7. The method of claim 5, wherein the aqueous solution of a barium salt is an aqueous solution of barium hydroxide.
8. The method of claim 5, wherein the amount of barium is varied at different portions of the inner crucible walls by varying the amount of the aqueous solution of barium salt sprayed onto the inside of the crucible at different portions of the inner crucible walls.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9) As a result of earnest study, the inventors of the present invention have found that occurrences of dislocations of single-crystal silicon is affected by an amount (dose amount) of added barium on an inner wall surface of a crucible. When the amount (dose amount) of added barium is large, the rate of occurrence of dislocations of the single-crystal silicon is high. On the other hand, when the amount (dose amount) of added barium is small, the rate of occurrence of dislocations of the single-crystal silicon is low. When the amount (dose amount) of added barium becomes smaller than a certain amount (dose amount), the rate of occurrence of dislocation of the single-crystal silicon becomes high.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(10) The reason why the rate of occurrence of dislocation of the single-crystal silicon is high when the amount (dose amount) of added barium is large is considered to be as follows. First, barium is melted into a silicon melt from a denitrification promoter and the like adhered to the surface of the crucible. When single-crystal silicon is pulled up to a certain length from the silicon melt having the barium melted thereinto, and then, the single-crystal silicon is separated, silicon solidifies before cristobalite released into the silicon melt flows down from a tail part to the silicon melt, and the cristobalite is taken into the silicon as an impurity. As a result, dislocation occurs in the single-crystal silicon and the silicon is dislocated.
(11) On the other hand, when the amount (dose amount) of added barium is extremely small, the rate of occurrence of dislocation of the single-crystal silicon is high. One of the reasons for this is considered to be as follows. When the amount (dose amount) of added barium is small, uniform crystallization of quartz on the inner wall of the crucible is not achieved, and thus, the cristobalite is released into the silicon melt and taken into the single-crystal silicon.
(12) When the crucible has a large size, the temperature of the crucible during growth of the single-crystal silicon is high. High temperature of the crucible promotes crystallization. Therefore, the amount of barium melted into the silicon melt varies depending on the size of the crucible. Furthermore, even in the crucibles of the same size, the temperature of the crucible during growth of the single-crystal silicon is higher when the single-crystal silicon is pulled up with a magnetic field applied to the crucible than when a magnetic field is not applied to the crucible. Application of the magnetic field to the silicon melt allows suppression of convection of the silicon melt. Therefore, in order to maintain a condition similar to that when the magnetic field is not applied to the silicon melt, the temperature of the crucible must be raised.
(13) The present invention has been made based on the above-mentioned findings. A method for manufacturing single-crystal silicon according to the present invention is directed to a method for manufacturing single-crystal silicon using a multi-pulling method for pulling up a plurality of pieces of single-crystal silicon from a material melt in an identical crucible within a chamber by a Czochralski method, the method having the following steps. The material melt is prepared in the crucible having a diameter of 24 inches. Single-crystal silicon is pulled up from the material melt. A polycrystalline material is additionally charged into and melted in the remaining material melt while continuing heating of the material melt. Next single-crystal silicon is pulled up from the material melt having the polycrystalline material additionally charged and melted therein. The step of additionally charging and melting the polycrystalline material and the step of pulling up next single-crystal silicon are repeated one or more times. In at least one of the step of pulling up single-crystal silicon and the step of pulling up next single-crystal silicon, which is repeated one or more times, the single-crystal silicon is grown in a magnetic field. A layer containing barium is formed on an inner wall of the crucible, and an amount of the barium added is 2.210.sup.14 atoms.Math.cm.sup.2 or more and 1.110.sup.15 atoms.Math.cm.sup.2 or less.
(14) The amount of added barium herein refers to an amount of added barium on the inner surface of the crucible per unit area. The layer containing barium may be a layer of barium alone or a layer of a barium compound such as barium carbonate or barium hydroxide. Furthermore, the layer containing barium may be a barium-rich layer obtained by injecting barium onto the surface of the crucible.
(15) A method for manufacturing single-crystal silicon according to the present invention is directed to a method for manufacturing single-crystal silicon using a multi-pulling method for pulling up a plurality of pieces of single-crystal silicon from a material melt in an identical crucible within a chamber by a Czochralski method, the method having the following steps. The material melt is prepared in the crucible having a diameter of 32 inches. Single-crystal silicon is pulled up from the material melt. A polycrystalline material is additionally charged into and melted in the remaining material melt while continuing heating of the material melt. Next single-crystal silicon is pulled up from the material melt having the polycrystalline material additionally charged and melted therein. The step of additionally charging and melting the polycrystalline material and the step of pulling up next single-crystal silicon are repeated one or more times. In at least one of the step of pulling up single-crystal silicon and the step of pulling up next single-crystal silicon, which is repeated one or more times, the single-crystal silicon is grown in a magnetic field. A layer containing barium is formed on an inner wall of the crucible, and an amount of the barium added is 5.410.sup.13 atoms.Math.cm.sup.2 or more and 2.210.sup.14 atoms.Math.cm.sup.2 or less.
(16) A method for manufacturing single-crystal silicon according to the present invention is directed to a method for manufacturing single-crystal silicon using a multi-pulling method for pulling up a plurality of pieces of single-crystal silicon from a material melt in an identical crucible within a chamber by a Czochralski method, the method having the following steps. The material melt is prepared in the crucible having a diameter of 40 inches. Single-crystal silicon is pulled up from the material melt. A polycrystalline material is additionally charged into and melted in the remaining material melt while continuing heating of the material melt. Next single-crystal silicon is pulled up from the material melt having the polycrystalline material additionally charged and melted therein. The step of additionally charging and melting the polycrystalline material and the step of pulling up next single-crystal silicon are repeated one or more times. In at least one of the step of pulling up single-crystal silicon and the step of pulling up next single-crystal silicon, which is repeated one or more times, the single-crystal silicon is grown in a magnetic field. A layer containing barium is formed on an inner wall of the crucible, and an amount of the barium added is 1.110.sup.13 atoms.Math.cm.sup.2 or more and 5.410.sup.13 atoms.Math.cm.sup.2 or less.
(17) Preferably, in the above-mentioned method for manufacturing single-crystal silicon, at least one of the step of pulling up single-crystal silicon and the step of pulling up next single-crystal silicon, which is repeated one or more times, includes a step of omitting at least a part of formation of a tail part of the single-crystal silicon and separating the single-crystal silicon from the material melt.
(18) In the method for manufacturing single-crystal silicon according to the present invention, there can be reduced occurrence of dislocation of the single-crystal silicon when the single-crystal silicon is grown using the multi-pulling method for pulling up a plurality of pieces of single-crystal silicon from a material melt in an identical crucible.
(19) Embodiments of the present invention will be described hereinafter with reference to the drawings, in which the same or corresponding portions are denoted by the same reference characters and description thereof will not be repeated.
(20) First, a manufacturing device for manufacturing single-crystal silicon according to the present embodiment will be described with reference to
(21) As shown in
(22) Next, a method for manufacturing single-crystal silicon according to the present embodiment will be described with reference to
(23) As shown in
(24) In silicon melt preparation step S1, crucible 8 is filled with the solid silicon material, which is heated by heater 6 in order to melt the solid silicon material. Crucible 8 has a diameter of, for example, 18 inches, 24 inches, 32 inches, 40 inches and the like. The layer containing barium is formed on the inner wall of crucible 8. An amount (dose amount) of added barium varies depending on the size of crucible 8.
(25) The amount of added barium when the crucible has a diameter of 18 inches and the magnetic field is not applied during growth of the single-crystal silicon is 1.410.sup.16 atoms.Math.cm.sup.2 or more and 5.410.sup.16 atoms.Math.cm.sup.2 or less. The amount of added barium when the crucible has a diameter of 24 inches and the magnetic field is not applied during growth of the single-crystal silicon is 5.410.sup.15 atoms.Math.cm.sup.2 or more and 2.710.sup.16 atoms.Math.cm.sup.2 or less. The amount of added barium when the crucible has a diameter of 32 inches and the magnetic field is not applied during growth of the single-crystal silicon is 1.410.sup.15 atoms.Math.cm.sup.2 or more and 5.410.sup.15 atoms.Math.cm.sup.2 or less.
(26) As described below, the amount of added barium when the crucible has a diameter of 24 inches and the magnetic field is applied is 2.210.sup.14 atoms.Math.cm.sup.2 or more and 1.110.sup.15 atoms.Math.cm.sup.2 or less. The amount of added barium when the crucible has a diameter of 32 inches and the magnetic field is applied is 5.410.sup.13 atoms.Math.cm.sup.2 or more and 2.210.sup.14 atoms.Math.cm.sup.2 or less. The amount of added barium when the crucible has a diameter of 40 inches and the magnetic field is applied is 1.110.sup.13 atoms.Math.cm.sup.2 or more and 5.410.sup.13 atoms.Math.cm.sup.2 or less.
(27) In single-crystal silicon growth step S2, a seed crystal 17 attached to a seed chuck 16 is first moved down to the surface of silicon melt 7 and immersed in silicon melt 7. Thereafter, pulling-up wire 14 is wound up by pulling-up wire drive device 15 to pull up single-crystal silicon 1. After single-crystal silicon 1 attains a target diameter through growth of a cone part (extended part), a straight part 11 is grown to have a predetermined length.
(28) In single-crystal silicon separation step S3, straight part 11 is first grown to have the predetermined length, and then, winding-up of pulling-up wire 14 is stopped. Thereafter, crucible 8 is moved down to separate single-crystal silicon 1 from silicon melt 7. Although there are various methods as a method for separating the single-crystal silicon, it is preferable to separate the single-crystal silicon such that a tail part thereof is as short as possible, from the viewpoint of enhancing the yield. There is a method called free span method (tail-coneless method) as a method for separating the single-crystal silicon to achieve the short tail part. According to the free span method, when the length of the straight part reaches the predetermined length in pulling-up of single-crystal silicon 1, the crucible supporting shaft drive device starts moving up crucible 8. As shown in
(29) Next, polycrystalline material charge step S4 is performed. In the polycrystalline material charge step, after single-crystal silicon 1 is separated from silicon melt 7, a polycrystalline material is additionally charged through a not-shown supply port into silicon melt 7 remaining in crucible 8, and the polycrystalline material is melted. When the polycrystalline material is additionally charged, heater 6 heating crucible 8 is not turned off. As a result, the polycrystalline material is charged into crucible 8 while continuing heating of crucible 8.
(30) Next, single-crystal silicon growth step S5 is performed. In this step, next single-crystal silicon 1 is pulled up from the material melt (silicon melt 7) having the polycrystalline material additionally charged and melted therein. When straight part 11 reaches the predetermined length, single-crystal silicon 1 is separated from silicon melt 7.
(31) The single-crystal silicon separation step, the step of additionally charging and melting the polycrystalline material, and the step of pulling up the next single-crystal silicon are repeated one or more times. As a result, a plurality of pieces of single-crystal silicon 1 can be pulled up. In at least one of the steps of pulling up the plurality of pieces of single-crystal silicon 1, the single-crystal silicon is grown in the magnetic field. Preferably, all of the steps of pulling up the plurality of pieces of single-crystal silicon 1 are performed in the magnetic field. At least one of the steps of pulling up the plurality of pieces of single-crystal silicon 1 may include a step of omitting at least a part of formation of the tail part of single-crystal silicon 1 and separating single-crystal silicon 1 from the material melt (silicon melt 7). Omission of at least a part of formation of the tail part also includes the case of separating the single-crystal silicon by the free span method after partially forming the tail part.
(32) With reference to
(33) In the free span method, crucible 8 containing silicon melt 7 is moved up at the same speed as the pulling rate of single-crystal silicon 1 during growth. As a result, pulling-up of single-crystal silicon 1 is substantially stopped without considerable change in heat history of single-crystal silicon 1, and in this state, single-crystal silicon 1 is separated from silicon melt 7. Consequently, a lower end face (i.e., interface with silicon melt 7) of single-crystal silicon 1 can have the downwardly convex shape, and the single-crystal silicon can be separated from silicon melt 7 with the single-crystal silicon maintained in the dislocation-free state. With reference to
(34) With reference to
(35) Referring to
(36) With reference to
(37) As shown in
(38) With reference to
(39) As described with reference to
(40) The dose amount of added barium refers to an amount of barium adhered to or contained on the inner surface of crucible 8 per square centimeter surface area, which is expressed in the number of atoms.
(41) Next, description will be given to a method for forming the layer containing barium on the inner surface of crucible 8.
(42) First, a barium hydroxide aqueous solution, for example, is prepared as the layer containing barium (denitrification promoter). Next, the barium hydroxide aqueous solution is sprayed on quartz crucible 8 heated to 200 to 300 C. The barium hydroxide aqueous solution is applied using a spraying method while rotating crucible 8. An amount of adhering of the layer containing barium can be controlled in accordance with the spraying time and the like.
(43) The layer containing barium may be formed on the inner surface of crucible 8 at a uniform amount of addition, or may be formed at different amounts of addition depending on positions on the inner surface of crucible 8. For example, a large amount of barium may be added at the bottom of crucible 8, and a small amount of barium may be added at a sidewall part and the bottom of crucible 8.
(44) It should be understood that the embodiment disclosed herein is illustrative and not limitative in any respect. The scope of the present invention is defined by the terms of the claims, rather than the embodiment above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.