U.S. patent application number 10/878904 was filed with the patent office on 2005-02-03 for crystal growth method, crystal growth apparatus, group-iii nitride crystal and group-iii nitride semiconductor device.
Invention is credited to Aoki, Masato, Sarayama, Seiji, Shimada, Masahiko, Yamane, Hisanori.
Application Number | 20050026318 10/878904 |
Document ID | / |
Family ID | 27344968 |
Filed Date | 2005-02-03 |
United States Patent
Application |
20050026318 |
Kind Code |
A1 |
Sarayama, Seiji ; et
al. |
February 3, 2005 |
Crystal growth method, crystal growth apparatus, group-III nitride
crystal and group-III nitride semiconductor device
Abstract
A crystal growth method, comprising the steps of: a) bringing a
nitrogen material into a reaction vessel in which a mixed molten
liquid comprising an alkaline metal and a group-III metal; and b)
growing a crystal of a group-III nitride using the mixed molten
liquid and the nitrogen material brought in by the step a) in the
reaction vessel, wherein a provision is made such as to prevent a
vapor of the alkaline metal from dispersing out of the reaction
vessel.
Inventors: |
Sarayama, Seiji; (Miyagi,
JP) ; Shimada, Masahiko; (Miyagi, JP) ;
Yamane, Hisanori; (Miyagi, JP) ; Aoki, Masato;
(Miyagi, JP) |
Correspondence
Address: |
COOPER & DUNHAM, LLP
1185 AVENUE OF THE AMERICAS
NEW YORK
NY
10036
|
Family ID: |
27344968 |
Appl. No.: |
10/878904 |
Filed: |
June 28, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10878904 |
Jun 28, 2004 |
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|
09981848 |
Oct 16, 2001 |
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6780239 |
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Current U.S.
Class: |
438/22 |
Current CPC
Class: |
C30B 11/002 20130101;
C30B 29/403 20130101; C01B 21/06 20130101; C30B 29/406
20130101 |
Class at
Publication: |
438/022 |
International
Class: |
H01L 021/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 19, 2000 |
JP |
2000-318723 |
Oct 19, 2000 |
JP |
2000-318988 |
Oct 24, 2000 |
JP |
2000-324272 |
Claims
1-6. (canceled).
7. A crystal growth apparatus, comprising: a reaction vessel
holding a mixed molten liquid comprising an alkaline metal and a
group-III metal; a first heating device heating the mixed molten
liquid so as to enable crystal growth therein; and a second heating
device heating above the surface of the mixed molten liquid so as
to prevent the vapor of the alkaline metal above the surface of the
mixed molten liquid from condensing.
8. A crystal growth apparatus comprising: a reaction vessel holding
a mixed molten liquid comprising an alkaline metal and a group-III
metal; and a heating device heating a zone through which a nitrogen
material is supplied externally into said reaction vessel.
9. The apparatus as claimed in claim 7, wherein: another reaction
vessel is provided outside of said reaction vessel; the nitrogen
material is brought into the inner reaction vessel through the
thus-provided outer reaction vessel; and a provision is made such
as to allow the nitrogen material to be brought into said inner
reaction vessel from said outer reaction vessel, and, also, to
cause the vapor of the alkaline metal to stay inside said inner
reaction vessel.
10. The apparatus as claimed in claim 8, wherein the nitrogen
material is supplied horizontally or from a direction below the
horizontal direction.
11-18. (canceled).
19. A crystal growth apparatus comprising: a reaction vessel in
which crystal growth is performed of a group-i nitride comprising a
group-III metal and a nitrogen from an alkaline metal, a substance
comprising the group-III metal, and a substance comprising the
nitrogen; and a unit maintaining a growth condition for a crystal
of the group-III nitride at a condition at which the crystal growth
starts; then, maintaining the growth condition at a condition at
which the crystal growth stops; and, then, again setting the
condition at which the crystal growth starts.
20. The apparatus as claimed in claim 19, wherein said unit
comprises a heating device heating a zone in which a crystal of the
group-III nitride grows.
21. The apparatus as claimed in claim 19, wherein said unit
comprises a pressure control device controlling an effective
pressure of the substance comprising the nitrogen in a form of a
gas in a zone in which a crystal of the group-III nitride
grows.
22-27 (canceled).
28. A crystal growth apparatus, comprising: a liquid holding vessel
in which a mixed molten liquid comprising an alkaline metal and a
substance comprising a group-III metal is formed; and a unit
growing in said liquid holding vessel a crystal of a group-III
nitride comprising the group-III metal and nitride from the mixed
molten liquid and a substance comprising the nitride, wherein said
liquid holding vessel has an inner shape such as to create a local
concentration distribution of dissolved nitrogen in the mixed
molten liquid.
29. The apparatus as claimed in claim 28, wherein said inner shape
of said liquid holding vessel is such that the cross sectional area
becomes smaller downward.
30. The apparatus as claimed in claim 28, wherein said inner shape
of said liquid holding vessel is such that the cross sectional area
is reduced partially.
31. The apparatus as claimed in claim 28, wherein said inner shape
of said liquid holding vessel is such that the cross sectional area
becomes smaller downward first, and, then, the cross sectional area
is uniform downward from the mid level.
32. The apparatus as claimed in claim 28, wherein said inner shape
of said liquid holding vessel is such that the cross sectional area
becomes smaller downward first, and, then, the cross sectional area
becomes larger downward from the mid level.
33. The apparatus as claimed in claim 28, wherein said unit
comprises a heating device heating the temperature inside said
liquid holding vessel so as to enable the crystal growth
therein.
34. The apparatus as claimed in claim 31, wherein said unit
comprises a plurality of heating devices for creating a
predetermined temperature difference between an upper part and a
lower part of said liquid holding vessel.
35-58 (canceled).
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a crystal growth method, a
crystal growth apparatus, a group-III nitride crystal, and a
group-III nitride semiconductor device. In particular, the present
invention relates to a crystal growth method and a crystal growth
apparatus for a group-III nitride crystal, the group-III nitride
crystal, and a group-III nitride semiconductor device employing the
group-III nitride crystal applicable to a blue light source for an
optical disk drive, for example.
[0003] 2. Description of the Related Art
[0004] Now, a InGaAlN-family (group-III nitride) device used as
violet through blue through green light sources is produced by a
crystal growth process employing an MO-CVD method (organic metal
chemical vapor phase growth method), an MBE method (molecular beam
crystal growth method), etc. on a sapphire or SiC substrate in most
cases. In using sapphire or SiC as a substrate, crystal defect
caused due to a large expansivity difference and/or lattice
constant difference from a group-III nitride may occur frequently.
By this reason, there is a problem that the device characteristic
may become worth, it may be difficult to lengthen the life of the
light-emission device, or the electric power consumption may become
larger.
[0005] Furthermore, since a sapphire substrate has an insulating
property, drawing of an electrode from the substrate like in
another conventional light-emission device is impossible, and
therefore, drawing the electrode from the nitride semiconductor
surface on which crystal was grown is needed. Consequently, the
device area may have to be enlarged, and, thereby, the costs may
increase. Moreover, chip separation by cleavage is difficult for a
group-III nitride semiconductor device produced on a sapphire
substrate, and it is not easy to obtain a resonator end surface
needed for a laser diode (LD) by cleavage, either. By this reason,
a resonator end surface formation according to dry etching, or,
after grinding a sapphire substrate to the thickness of 100
micrometers or less, a resonator end surface formation in a way
near cleavage should be performed. Also in such a case, it is
impossible to perform formation of a resonator end surface and chip
separation easily by a single process like for another conventional
LD, and, also, complication in process, and, thereby, cost increase
may occur.
[0006] In order to solve these problems, it has been proposed to
reduce the crystal defects by employing a selective lateral growth
method and/or another technique for forming a group-III nitride
semiconductor film on a sapphire substrate.
[0007] For example, a document `Japanese Journal of Applied
Physics, Vol. 36 (1967), Part 2, No. 12A, pages L1568-1571`
(referred to as a first prior art, hereinafter) discloses a laser
diode (LD) shown in FIG. 1. This configuration is produced as
follows: After growing up a GaN low-temperature buffer layer 2 and
a GaN layer 3, one by one, on a sapphire substrate 1 by an MO-VPE
(organometallic vapor phase epitaxy) apparatus, an SiO.sub.2 mask 4
for selective growth is formed. This SiO.sub.2 mask 4 is formed
through photo lithography and etching process, after depositing a
SiO.sub.2 film by another CVD (chemistry vapor phase deposition)
apparatus. Next, on this SiO.sub.2 mask 4, again, a GaN film 3' is
grown up to a thickness of 20 micrometers by the MO-VPE apparatus,
and, thereby, GaN grows laterally selectively, and, as a result,
the crystal defects are reduced as compared with the case where the
selective lateral growth is not performed. Furthermore, prolonging
of the crystal defect toward an activity layer 6 is prevented by
provision of a modulation doped strained-layer superlattice layer
(MD-SLS) 5 formed thereon. Consequently, as compared with the case
where the selective lateral growth and modulation doped
strained-layer superlattice layer are not used, it becomes possible
to lengthen the device life.
[0008] In the case of this first prior art, although it becomes
possible to reduce the crystal defects as compared with the case
where the selective lateral growth of a GaN film is not carried out
on a sapphire substrate, the above-mentioned problems concerning
the insulating property and cleavage by using a sapphire substrate
still remain. Furthermore, as the SiO.sub.2 mask formation process
is added, the crystal growth by the MO-VPE apparatus is needed
twice, and, thereby, a problem that a process is complicated newly
arises.
[0009] As another method, for example, a document `Applied Physics
Letters, Vol. 73, No. 6, pages 832-834 (1998)` (referred to as a
second prior art, hereinafter) discloses application of a GaN thick
film substrate. By this second prior art, a GaN substrate is
produced, by growing up a 200-micrometer GaN thick film by an H-VPE
(hydride vapor phase growth) apparatus after 20-micrometer
selective lateral growth according to the above-mentioned first
prior art, and, then, grinding the GaN substrate thus having grown
to be the thick film from the side of the sapphire substrate so
that it may have the thickness of 150 micrometers. Then, the MO-VPE
apparatus is used on this GaN substrate, crystal growth processes
required for a LD device are performed, one by one, and, thus, the
LD device is produced. Consequently, it becomes possible to solve
the above-mentioned problems concerning the insulating property and
cleavage by using the sapphire substrate in addition to solving the
problem concerning the crystal defects.
[0010] A similar method is disclosed by Japanese Laid-Open Patent
Application No. 11-4048. FIG. 7 shows a typical figure thereof.
[0011] However, further, the process is more complicated in the
second prior art, and, requires the higher costs, in comparison to
the first prior art. Moreover, in growing up the no less than 200
micrometer GaN thick film by the method of the second prior art, a
stress occurring due to a lattice constant difference and a
expansivity difference from the sapphire of the substrate becomes
large, and a problem that the curvature and the crack of the
substrate arise may newly occur. Moreover, even by performing such
a complicated process, the crystal defective density can be reduced
to only on the order of 10.sup.6/cm.sup.2. Thus, it is not possible
to obtain a practical semiconductor device.
[0012] In order to avoid this problem, setting to 1 mm or more
thickness of an original substrate (sapphire and spinel are the
most desirable materials as the substrate) from which a thick film
grows is proposed by Japanese Laid-Open Patent Application No.
10-256662. According thereto, no curvature nor crack arise in the
substrate even when the GaN film grows in 200 micrometers of
thickness by applying this substrate having the thickness of 1 mm
or more. However, a substrate thick in this way has a high cost of
the substrate itself, and it is necessary to spend much time on
polish thereof, and leads to the cost rise of the polish process.
That is, as compared with the case where a thin substrate is used,
the cost becomes higher by using the thick substrate. Moreover,
although no curvature nor crack arise in the substrate after
growing up the thick GaN film in using the thick substrate,
curvature and/or crack may occur as stress relief occurs during the
process of polish. By this reason, even when the thick substrate is
used, the GaN substrate having a high crystal quality and having
such a large area that it can be practically used for an ordinary
semiconductor device manufacturing process cannot be easily
produced.
[0013] A document `Journal of Crystal Growth, Vol. 189/190, pages.
153-158 (1998)` (referred to as a third prior art, hereinafter)
discloses that a bulk crystal of GaN is grown up, and it is used as
a homoepitaxial substrate. According to this technique, under the
high temperature in the range between 1400 and 1700.degree. C., and
under the very high nitrogen pressure of 10 kilobars, crystal
growth of the GaN is performed from a Ga liquid. In this case, it
becomes possible to grow up a group-III nitride semiconductor film
required for a device by using this GaN substrate. Therefore, it is
possible to provide the GaN substrate without needing the process
complicate like in the above-described first and second prior
arts.
[0014] However, by this third prior art, crystal growth in high
temperature and high pressure is needed, and, thus, there is a
problem that a reaction vessel which can resist these conditions
should be very expensive. In addition, even when such a growth
method is employed, the size of the crystal obtained has the
problem of being too small, i.e., at most on the order of 1 cm,
and, thus, it is too small to put it in practical use of
semiconductor device manufacture.
[0015] The GaN crystal growth method using Na which is an alkaline
metal as a flux is proposed by a document `Chemistry of Materials,
Vol. 9 (1977), pages 413-416` (referred to as a fourth prior art,
hereinafter) as a technique of solving the problem of GaN crystal
growth in the above-mentioned high temperature and high pressure.
According to this technique, sealing sodium azide (NaN.sub.3) and
Ga metal used as a flux and a material into a reaction vessel made
from stainless steel (vessel inner dimension: diameter=7.5 mm and
length=100 mm) in nitrogen atmosphere, and the reaction vessel is
maintained in the temperature in the range between 600 and
800.degree. C. for 24 to 100 hours to grow up a GaN crystal. In the
case of this fourth prior art, crystal growth at the comparatively
low temperature in the range between 600 and 800 C can be achieved,
and, also, the require pressure inside the vessel should be only on
the order of 100 kg/cm.sup.2, which is comparatively lower than the
case of the third prior art. However, in this fourth prior art, the
size of the crystal obtained is small as less than 1 mm which is
too small to be put into practical use in semiconductor device
manufacture, like in the case of the third prior art.
[0016] Therefore, the applicant of the present application has
proposed a method of enlarging a group-III nitride crystal.
However, in the method, nucleus generation initiates of the crystal
growth is natural nucleus generation, and, thus, a large number of
nucleus are undesirably generated. In order to control this nucleus
generation, the applicant has proposed to utilize a seed crystal in
the U.S. patent application Ser. No. 09/590,063, filed on Jun. 8,
2000, by Seiji Sarayama et al. (the entire contents of which are
hereby incorporated by reference). However, there is a problem that
a required crystal growth apparatus becomes complicated. Therefore,
it has been demanded to realize a method for effectively
controlling nucleus generation, while achieving a simple apparatus
configuration of a conventional flux method, in order to solve this
problem.
[0017] Further, Japanese Laid-Open Patent Application No.
2000-327495 discloses a fifth prior art combining the
above-mentioned fourth prior art and an epitaxial method utilizing
a substrate. In this method, a substrate on which GaN or AlN is
grown previously is used, and, thereon, a GaN film according to the
fourth prior art is grown. However, in this method, as it is
basically the epitaxial method, the problem of crystal defects
occurring in the above-mentioned first and second prior art cannot
be solved. Further, as the GaN film or AlN film should be grown on
the substrate previously, the process becomes complicated, and,
thereby, the costs increase.
[0018] Furthermore, recently, Japanese Laid-Open Patent
Applications Nos. 2000-12900 and 2000-22212 disclose a sixth prior
art in which a GaAs substrate is used and a GaN thick-film
substrate is produced. In this method, a GaN film having a thickens
in a range between 70 .mu.m and 1 mm is selectively grown on a GaAs
substrate by using an SiO.sub.2 film or SiN film as a mask as in
the above-mentioned first prior art, as shown in FIGS. 3A through
3C, The crystal growth there is performed by the H-VPE apparatus.
Then, the GaAs substrate is etched and thus removed by using aqua
regia. Thus, the GaN self-standing substrate is produced, as shown
in FIG. 3D. By using this GaN-self standing substrate, a GaN
crystal having a thickness of several tens of millimeters is grown
by vapor phase epitaxy by the H-VPE apparatus again, as shown in
FIG. 4A. Then, this GaN crystal of several tens millimeters is cut
into wafer shapes by a slicer, as shown in FIG. 4B. Thus, GaN
wafers are produced, as shown in FIG. 4C.
[0019] According to this sixth prior art, the GaN self-standing
substrate can be obtained, and, also, the GaN crystal having the
thickness of several tens of millimeters can be obtained. However,
this method has the following problems:
[0020] {circle over (1)} As the SiN film or SiO.sup.2 film is used
as a mask for selective growth, the manufacturing process becomes
complicated, and, thus, the costs increase;
[0021] {circle over (2)} When the GaN crystal having the thickness
of several tens millimeters is grown by the H-VPE apparatus, GaN
crystals (in monocrystal or polycrystal) or amorphous GaN having a
similar thickness adhere to the inner wall of the reaction vessel.
Accordingly, the productivity is degraded thereby.
[0022] {circle over (3)} As the GaAs substrate is etched and
removed every time of the crystal growth as a sacrifice substrate,
the costs increase thereby.
[0023] {circle over (4)} With regard to the crystal quality,
problems of lattice mismatch due to crystal growth on a
different-substance substrate, and a high defect density due to
difference in expansivity remain.
SUMMARY OF THE INVENTION
[0024] An object of the present invention is to achieve a group III
nitride crystal having a sufficient size such that a semiconductor
device, such as a high-efficient light emitting diode or LD can be
produced therefrom, without complicating the process which is the
problem in the above-mentioned first or the second prior art,
without using an expensive reaction vessel which is the problem in
the third prior art, and without provision of insufficient size of
the crystal which is the problem in the third and fourth prior
arts, and, also, solving the above-mentioned problems in the fifth
and sixth prior arts, and a crystal growth method and a crystal
growth apparatus by which such a group-III nitride crystal can be
manufactured, and a high-performance group-III nitride
semiconductor device.
[0025] A crystal growth method according to the present invention,
includes the steps of:
[0026] a) providing a nitrogen material into a reaction vessel in
which a mixed molten liquid comprising an alkaline metal and a
group-III metal; and
[0027] b) growing a crystal of a group-III nitride using the mixed
molten liquid and the nitrogen material provided in the step a) in
the reaction vessel,
[0028] wherein a provision is made such as to prevent a vapor of
the alkaline metal from dispersing out of the reaction vessel.
[0029] Thereby, when growing up the group-III nitride crystal in
the reaction vessel especially using the alkaline metal and the
mixed molten liquid which contains group-III metal at least and the
nitrogen material brought from the outside of the reaction vessel,
the alkaline metal vapor is prevented from dispersing out of the
reaction vessel. Thereby, evaporation of the alkaline metal out of
the reaction vessel and condensation thereof can be prevented and
it becomes possible to avoid obstruction against supply of the
nitrogen material., and thus change of material composition.
Consequently, the crystal growth can be well controlled, and a
satisfactory group-III nitride crystal can be grown up stably.
[0030] A crystal growth method according to another aspect of the
present invention includes the steps of:
[0031] a) providing a nitrogen material into a reaction vessel in
which a mixed molten liquid comprising an alkaline metal and a
group-III metal; and
[0032] b) growing a crystal of a group-III nitride using the mixed
molten liquid and the nitrogen material provided in the step a) in
the reaction vessel,
[0033] wherein a provision is made such as to prevent a vapor of
the alkaline metal from blocking a zone through which the nitrogen
material is supplied from the outside of the reaction vessel.
[0034] Thereby, the nitrogen material brought in from the outside
of the reaction vessel can be prevented from being blocked by the
condensed alkaline metal.
[0035] Consequently, the crystal growth can be well controlled,
and, a satisfactory group-III nitride crystal can be grown up
stably.
[0036] For this purpose, the temperature in the reaction vessel
above the surface of the mixed molten liquid may be preferably
controlled so as to prevent the vapor of the alkaline metal from
condensing.
[0037] The temperature of the above-mentioned zone may preferably
be controlled for the same purpose.
[0038] Further, another reaction vessel may be provided outside of
the reaction vessel;
[0039] the nitrogen material may be brought into the reaction
vessel through this outer reaction vessel; and
[0040] a provision may preferably be made such as to allow the
nitrogen material to be brought into the originally provided inner
reaction vessel from the outer reaction vessel, and, also, to
prevent the vapor of the alkaline metal from dispersing out of the
inner reaction vessel, for the above-mentioned object.
[0041] The nitrogen material may be preferably supplied
horizontally or from a direction below the horizontal
direction.
[0042] Thereby, condensation of the alkaline metal vapor in the
zone through which the nitrogen material is supplied can be
prevented.
[0043] A crystal growth apparatus according to the present
invention includes:
[0044] a reaction vessel holding a mixed molten liquid comprising
an alkaline metal and a group-III metal;
[0045] a first heating device heating the mixed molten liquid so as
to enable crystal growth therein; and
[0046] a second heating device heating above the surface of the
mixed molten liquid so as to prevent the vapor of the alkaline
metal above the surface of the mixed molten liquid from
condensing.
[0047] A crystal growth apparatus according to another aspect of
the present invention includes:
[0048] a reaction vessel holding a mixed molten liquid comprising
an alkaline metal and a group-III metal; and
[0049] a heating device heating a zone through which a nitrogen
material is supplied externally into the reaction vessel.
[0050] Thereby, a complicated process described above for the first
or second prior art is not needed, but it becomes possible to
obtain a high-quality group-III nitride crystal at low cost.
Furthermore, the required growth temperature is as low as less than
100.degree. C., and, also, the required growth pressure is as low
as less than 100 kg/cm.sup.2, for the crystal growth of the
group-III nitride. Accordingly, it is not necessary to use an
expensive reaction vessel which can resist a super-high pressure
and a super-high temperature as in the above-mentioned third prior
art. Consequently, it becomes possible at low cost to obtain a
group-III nitride crystal. Moreover, since it is low temperature
and low pressure needed for the crystal growth, it becomes possible
by using a seed crystal as a nucleus to enlarge the size of the
group-III nitride crystal by carrying out crystal growth.
[0051] A crystal growth method according to another aspect of the
present invention includes the steps of:
[0052] a) carrying out crystal growth in a reaction vessel of a
group-III nitride comprising a group-III metal and a nitrogen from
an alkaline metal, a substance comprising the group-III metal, and
a substance comprising the nitrogen; and
[0053] b) maintaining a growth condition for a crystal the
group-III nitride at a condition at which the crystal growth
starts; then,
[0054] c) maintaining the growth condition at a condition at which
the crystal growth stops; and, then,
[0055] d) again setting the condition at which the crystal growth
starts.
[0056] Thus, by setting the crystal growth condition enabling the
crystal growth and then setting the other crystal growth condition
not enabling the crystal growth, a crystal nucleus can be grown
selectively. That is, by setting again the crystal growth condition
enabling the crystal growth, the crystal growth progresses further
from this crystal nucleus. By repeating such a control of the
crystal growth condition as that the crystal growable condition is
entered and exited from, it is possible to control generation of
crystal nucleus, in comparison to a case where no such a control is
performed. Thus, it becomes possible to grow the group-III nitride
crystal to have a large size effectively, and thus to effectively
utilize the materials therefor. As a result, it is possible to
obtain a large-sized group-III nitride crystal at low cost.
[0057] Further, in comparison to a seed-crystal method in the
related art in which a position of a crystal nucleus supplied
externally as a seed crystal is controlled, the apparatus is not
needed to be so complicated, and, thus, the total cost can be
reduced, according to the present invention.
[0058] Specifically, the step b) may maintain the temperature of a
zone in which a crystal of the group-III nitride grows at a
temperature at which the crystal growth starts;
[0059] the step c) may lower the temperature of the zone to a
temperature such that no alloy is formed between the group-III
metal and another metal, and maintaining this temperature; and
[0060] the step d) may increase the temperature to the temperature
at which the crystal growth starts again.
[0061] The increase and decrease of the temperature may be
preferably performed several times.
[0062] The substance comprising the nitrogen may be of a gas, and
the gas may be supplied into the reaction vessel continuously at a
predetermined pressure. Thereby, it is possible to control the
crystal growth reaction only by control of the temperature. As a
result, it is possible to control a change in growth parameter in
the crystal growth, and, also, by continuously supplying the
nitrogen material, a high-quality group-III nitride crystal can be
grown with little nitrogen loss.
[0063] The substance comprising the group-III metal may preferably
be additionally provided at a time of the temperature is
lowered.
[0064] Thereby, it is possible to avoid a situation of unexpected
interruption of the crystal growth occurring due to exhaustion of
the group-III material. Furthermore, it is possible to effectively
prevent change of the ratio in amount among the group-III material
and group-V material, and the alkaline metal used as the flux. As a
result, it is possible to achieve stable crystal growth wherein the
crystal quality is fixed stably, and, thus, it is possible to grow
up a high-quality group-III nitride crystal.
[0065] Furthermore, as the timing of the additional supply of the
group-III material is in an interval in which the crystal growth is
terminated, it is possible to effectively control change in grow
parameter such as temperature change, material amount ratio change
and so forth which may otherwise adversely affect the proper
crystal growth. Also by this point, the crystal growth for a
high-quality group-III nitride crystal can be more positively
achieved.
[0066] The above-mentioned step b) may instead maintain an
effective pressure of the substance comprising the nitride in a
form a gas in a zone in which a crystal of the group-III nitride
grows at a pressure at which the crystal growth starts;
[0067] the step c) may lower the effective pressure of the nitrogen
gas in the zone to a pressure such that the crystal growth stops,
and maintaining this pressure; and
[0068] the step d) may increase the effective pressure of the
nitrogen gas to the pressure at which the crystal growth starts
again.
[0069] Further, a crystal growth apparatus which carries out
crystal growth of the group-III nitride crystal which has the
features described above can be realized at low cost in addition to
the above-mentioned effects.
[0070] Furthermore, by carrying out the crystal growth according to
any one of the above-described methods and/or the above-mentioned
apparatuses, it becomes possible to realize a large-sized group-III
nitride crystal by which a semiconductor device may be produced in
a practical manner at low cost.
[0071] Furthermore, by producing the group-III nitride
semiconductor device using the group-III nitride crystal mentioned
above, a highly efficient device is realizable at low cost. This
group-III nitride crystal is a high-quality crystal having few
crystal defects, as mentioned above. Thus, a highly efficient
device is realizable by device production from thin film growth
using this group-III nitride crystal, or using it as a substrate of
the device. That is, a high output which has not been realized
conventionally can be provided by the device and a long life of the
device is achieved in a case of production of a semiconductor laser
or a light emitting diode therefrom. In a case of production of an
electronic device therefrom, low power consumption, low noise,
high-speed operation, and high temperature operation are achievable
therefrom. In a case of light receiving device, low noise and a
long life can be obtained therefrom.
[0072] A crystal growth method according to another aspect of the
present invention includes the steps of:
[0073] a) forming a mixed molten liquid comprising an alkaline
metal and a substance comprising a group-III metal in a liquid
holding vessel;
[0074] b) growing in the liquid holding vessel a crystal of a
group-III nitride comprising the group-III metal and nitride from
the mixed molten liquid and a substance comprising the nitride;
[0075] c) creating a local concentration distribution of dissolved
nitrogen in the mixed molten liquid in the liquid holding vessel
during the step b).
[0076] Thereby, without making the process complicated as in the
first and second prior arts described above, since the local
concentration distribution of the dissolved nitrogen is produced in
the mixed molten liquid, it becomes possible to avoid use of an
expensive reaction vessel as in the third prior art, and the size
of the produced crystal can be enlarged in contrast to the third
and fourth prior art. Thus, the group-III nitride crystal of a
practical size for producing semiconductor devices, such as a
highly efficient light emitting diode and LD, can be grown up.
[0077] Furthermore, the necessary growth temperature is as low as
1000 degrees C. or less, and, also, the necessary growth pressure
is as low as approximately 100 or less atm. Thereby, it is not
necessary to use an expensive reaction vessel which can resist a
super-high pressure and a super-high temperature as in the third
prior art. Consequently, it becomes possible to realize the device
using the group-III nitride crystal at low cost.
[0078] Furthermore, by producing the local concentration (uneven)
distribution of the dissolved nitrogen in the mixed molten liquid,
it becomes possible to limit a location of occurrence of nucleus
generation of the group-III nitride crystal to a specific part of
the mixed molten liquid, and the group-III nitride crystal having a
large size can thus be grown up.
[0079] The liquid holding vessel may have an inner shape such as to
produce the local concentration distribution of the dissolved
nitrogen in the mixed molten liquid.
[0080] The inner shape of the liquid holding vessel may be such
that the cross sectional area becomes smaller downward.
[0081] The inner shape of the liquid holding vessel may instead be
such that the cross sectional area is reduced partially (at a
specific height).
[0082] The inner shape of the liquid holding vessel may future
instead be such that the cross sectional area becomes smaller
downward first, and, then, the cross sectional area is uniform
downward from the mid level (height).
[0083] The inner shape of the liquid holding vessel may further
instead be such that the cross sectional area becomes smaller
downward first, and, then, the cross sectional area becomes larger
downward from the mid level.
[0084] A crystal growth apparatus according to another aspect of
the present invention includes:
[0085] a liquid holding vessel in which a mixed molten liquid
comprising an alkaline metal and a substance comprising a group-III
metal is formed; and
[0086] a unit growing in the liquid holding vessel a crystal of a
group-III nitride comprising the group-III metal and nitride from
the mixed molten liquid and a substance comprising the nitride,
and,
[0087] wherein the liquid holding vessel has an inner shape such as
to produce a local concentration distribution of dissolved nitrogen
in the mixed molten liquid (as mentioned above in the crystal
growth methods)
[0088] The above-mentioned unit may include a heating device
heating the temperature inside the liquid holding vessel so as to
enable the crystal growth therein.
[0089] The unit may include a plurality of heating devices for
creating a predetermined temperature difference between an upper
part and a lower part of the liquid holding vessel
independently.
[0090] Thus, since the cross sectional area of the vessel becomes
smaller downward, and, then, it is uniform from the mid level, or
it becomes larger from the mid level, the mixed molten liquid may
be held to this zone. Consequently, the group-III metal can be
continuously supplied therefrom to a specific zone in which the
crystal nucleus is generated, and, thereby, it becomes possible to
grow up a large-sized group-III nitride crystal.
[0091] Moreover, the group-III nitride crystal thus produced has a
high quality (few crystal defects), and also, has a large size such
as to be practically utilized for producing a semiconductor device,
and such a group-III nitride crystal can be produced at low
cost.
[0092] Moreover, since it is the semiconductor device produced
using the group-III nitride crystal according to the present
invention described above, a highly efficient group-III nitride
semiconductor device can be offered at low cost.
[0093] Furthermore, by producing the group-III nitride
semiconductor device using the group-III nitride crystal mentioned
above, a highly efficient device is realizable at low cost. As this
group-III nitride crystal is a high-quality crystal having few
crystal defects, as mentioned above, a highly efficient device is
realizable by device production from thin film growth using this
group-III nitride crystal, or using it as a substrate of the
device. That is, a high output which has not been realized
conventionally can be provided and a long life is provided in a
case of production of a semiconductor laser or a light emitting
diode. In a case of production of an electronic device, low power
consumption, low noise, high-speed operation, and high temperature
operation are achievable. In a case of light receiving device, low
noise and a long life can be obtained.
[0094] Moreover, according to the present invention, the
semiconductor device may be a light-emission device which emits
light of the wavelength shorter than 400 nm, and can emit light at
high efficiency also in this wavelength region. That is, since the
semiconductor device thus obtained has few crystal defects and few
impurities consequently, it becomes possible to realize the
efficient light-emission characteristic wherein light emission from
a deep level is well controlled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0095] Other objects and further features of the present invention
will become more apparent from the following detailed description
when read in conjunction with the following accompanying
drawings.
[0096] FIG. 1 shows a side-elevational sectional view of a
semiconductor laser in the first prior art;
[0097] FIG. 2 shows a side-elevational sectional view of a
semiconductor laser in the second prior art;
[0098] FIGS. 3A through 3D and 4A through 4C illustrate the sixth
prior art;
[0099] FIG. 5 shows a side-elevational sectional view of a crystal
growth apparatus in a first embodiment of the present
invention;
[0100] FIG. 6 shows a side-elevational sectional view of a crystal
growth apparatus in a second embodiment of the present
invention;
[0101] FIG. 7 shows a side-elevational sectional view of a crystal
growth apparatus in a third embodiment of the present
invention;
[0102] FIG. 8 shows a side-elevational sectional view of a crystal
growth apparatus in a fourth embodiment of the present
invention;
[0103] FIG. 9 shows a perspective view of one example of a
semiconductor laser to which a group-III nitride semiconductor
device according to the present invention is applied;
[0104] FIG. 10 shows a side-elevational sectional view of a crystal
growth apparatus in a fifth embodiment of the present
invention;
[0105] FIG. 11 illustrates a temperature control sequence in the
fifth embodiment of the present invention;
[0106] FIG. 12 shows a side-elevational sectional view of a crystal
growth apparatus in a first variant embodiment of the fifth
embodiment of the present invention;
[0107] FIG. 13 illustrates a temperature control sequence in the
first variant embodiment of the fifth embodiment of the present
invention;
[0108] FIG. 14 illustrates a pressure control sequence in a second
variant embodiment of the fifth embodiment of the present
invention;
[0109] FIG. 15 illustrates a pressure control sequence in a third
variant embodiment of the fifth embodiment of the present
invention;
[0110] FIG. 16 shows a side-elevational sectional view of a crystal
growth apparatus in a sixth embodiment of the present
invention;
[0111] FIG. 17 shows an elevational sectional view of a first
example of a mixed molten liquid vessel in the crystal growth
apparatus in the sixth embodiment of the present invention;
[0112] FIG. 18 shows an elevational sectional view of a second
example of the mixed molten liquid vessel in the crystal growth
apparatus in the sixth embodiment of the present invention;
[0113] FIG. 19 shows a side-elevational sectional view of a crystal
growth apparatus in a seventh embodiment of the present
invention;
[0114] FIG. 20A shows an elevational sectional view of a first
example of a mixed molten liquid vessel in the crystal growth
apparatus in the seventh embodiment of the present invention;
and
[0115] FIG. 20B shows an elevational sectional view of a second
example of the mixed molten liquid vessel in the crystal growth
apparatus in the seventh embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0116] Hereafter, embodiments of the present invention will now be
described with reference to the figures.
[0117] The present invention is characterized by preventing
alkaline-metal vapor from dispersing out of a first reaction
vessel, while a group-III nitride crystal is grown within the first
reaction vessel using a mixed molten liquid which contains at least
an alkaline metal and a group-III metal and a nitrogen material
brought from the outside of the first reaction vessel.
[0118] By the crystal growth method according to the present
invention, a mixed molten liquid which at least contains an
alkaline metal and a group-III metal is present in the first
reaction vessel, and temperature control of this first reaction
vessel is carried out so that crystal growth can be performed. A
nitrogen material is brought from the exterior of this first
reaction vessel, then, the alkaline metal, group-III metal, and
nitrogen material react, and thus, a crystal of the group-III
nitride grows. The nitrogen material means nitrogen molecules,
nitrogen atoms, and/or nitrogen molecules and/or nitrogen atoms
generated from a compound containing nitrogen.
[0119] In a temperature range in which a crystal of the group-III
nitride grows, the alkaline metal has a certain vapor pressure.
According to the present invention, the thus-generated
alkaline-metal vapor is prevented from dispersing out of the first
reaction vessel.
[0120] In particular, in a first embodiment of the present
invention, a zone through which the nitrogen material passes in the
first reaction vessel is prevented from being blocked by the
alkaline-metal vapor, while a group-III nitride crystal is grown
within the first reaction vessel using a mixed molten liquid which
contains at least an alkaline metal and a group-III metal, and a
nitrogen material brought from the outside of the first reaction
vessel.
[0121] To prevent the zone through which the nitrogen material
passes in the first reaction vessel from being blocked by the
alkaline-metal vapor may include not only to prevent the alkaline
metal from condensing in this zone but also to remove
(mechanically) the alkaline metal condensed there.
[0122] In order to prevent condensation of the alkaline metal, when
growing the group-III nitride crystal in the first reaction vessel
using the mixed molten liquid which contains the alkaline metal and
group-III metal, and the nitrogen material brought from the outside
of the first reaction vessel, controlling is made such as to
prevent the temperature of a portion above the surface of the mixed
molten liquid which contains the group-III metal with the alkaline
metal from decreasing from the temperature below which the alkaline
metal vapor may condense in the first embodiment. In this case, the
temperature above the surface of the mixed molten liquid in the
first reaction vessel is not to be made lower than the temperature
of the mixed molten liquid including the surface of the mixed
molten liquid.
[0123] FIG. 5 shows a configuration of a crystal growth apparatus
in the first embodiment of the present invention. In FIG. 5, in the
first reaction vessel 101, Na as the alkaline metal and a metal Ga
as a substance which contains a group-III metallic element at least
are contained, and they form a mixed molten liquid 102 at the
temperature range in which a crystal of the group-III nitride
crystal can grow.
[0124] There, the first reaction vessel 101 is made of a stainless
steel, and, the space zone 103 of the first reaction vessel 101 is
filled by a nitrogen gas (N.sub.2), as the substance which at least
contains a nitrogen element. This nitrogen gas 103 can be supplied
through a nitrogen supply pipe 104 from the outside of the first
reaction vessel 101. In order to adjust the pressure of the
nitrogen gas, a pressure adjustment mechanism 105 is provided. For
example, a pressure sensor, a pressure adjustment valve, etc. are
included in this pressure adjustment mechanism 105. This pressure
adjustment mechanism 105 controls the pressure of the nitrogen gas
in the first reaction vessel 101, for example, to 50 atm.
[0125] Moreover, in the crystal growth apparatus shown in FIG. 5, a
first heating device 106 is provided in the outside of the first
reaction vessel 101 in a range of height in which the mixed molten
liquid 102 of the alkaline metal Na and group-III metal Ga is held
such that the temperature of the mixed molten liquid 102 can be
controlled so that a crystal of the group-III nitride can grow
inside or the surface of this mixed molten liquid 102.
[0126] Furthermore, in the crystal growth apparatus shown in FIG.
5, a second heating device 107 is provided above the first heating
device 106 so that the temperature above the surface of mixed
molten liquid 102 can be controlled thereby.
[0127] Na which is the alkaline metal and Ga which is the group-III
metal material can form the mixed molten liquid 102 as a result of
control being made by the first heating device 106 into the
temperature (for example, 750.degree. C.) in which a crystal of the
group-III nitride crystal can grow. There, the temperature of the
upper part of the first reaction vessel 101 is controlled by the
second heating device 107 so that the temperature above the surface
of the mixed molten liquid 102 which includes Na which is the
alkaline metal and Ga which is the group-III metal material is not
less than the temperature of the mixed molten liquid 102. In this
state, a GaN crystal as the group-III nitride is grown in the mixed
molten liquid 108 and the surface 109 thereof, as Ga which is the
group-III metal is supplied from the mixed molten liquid 102, and
the growth temperature is thus maintained.
[0128] In the crystal growth apparatus shown in FIG. 5, inside 108
or in the surface 109 of the mixed molten liquid 102 of Na and Ga,
a continuous growth of the GaN crystal is performed as the nitrogen
gas and Ga react, or the nitrogen ingredient in the molten liquid
supplied from the nitrogen gas and Ga react, and thus, it is
possible to obtain a large size of the crystal.
[0129] Furthermore, in the crystal growth apparatus shown in FIG.
5, condensation of Na in the upper part of the first reaction
vessel 101 can be prevented as the temperature of the upper part of
the first reaction vessel 101 is controlled by the second heating
device 107 so that the temperature above the surface of the mixed
molten liquid 102 which includes Na which is the alkaline metal and
Ga which is the group-III metal material may be not less than the
temperature of the mixed molten liquid 102 itself. That is, since
the temperature above the mixed molten liquid 102 is higher than
the temperature of the mixed molten liquid 102 itself, condensation
of Na in the upper part of the first reaction vessel 101 can be
prevented. Consequently, it becomes possible to prevent
condensation of Na in the nitrogen supply pipe 104. That is, it is
possible to prevent supply of the nitrogen gas from being
obstructed by condensation of Na in the nitrogen supply pipe 104.
Moreover, the composition of the alkaline metal Na and the
group-III metal Ga in the mixed molten liquid 102 is thus hardly
changed, and, thus, stable crystal growth is attained. Thus, the
alkaline metal (alkaline-metal vapor) Na is prevented from
dispersing out of the first reaction vessel 101 by preventing the
alkaline-metal vapor from blocking the nitrogen pipe 104 by
properly heating the upper part of the reaction vessel 101.
[0130] In other words, when the temperature above the surface of
the mixed molten liquid 102 were lower than the temperature of the
mixed molten liquid 102, condensation of Na onto the inner wall of
the first reaction vessel 101 and/or the nitrogen supply pipe 104
might arise. Consequently, the composition of the alkaline metal Na
and the group-III metal Ga in the mixed molten liquid 102 might
change, or Na blocked the nitrogen supply pipe 104 so that the
nitrogen could not be supplied. In order to avoid such a situation,
the temperature of the upper part of the reaction vessel 101 is
controlled by the second heating device 107 so that the temperature
above the surface of the mixed molten liquid 102 should become more
than the temperature of the mixed molten liquid 102 itself
according to the present invention.
[0131] Further, in the crystal growth apparatus shown in FIG. 6,
temperature control of a more specific zone through which the
nitrogen material supplied externally passes into the first
reaction vessel 101 may be carried out.
[0132] FIG. 6 shows a crystal growth apparatus in a second
embodiment of the present invention in which temperature control of
a more specific zone through which the nitrogen material supplied
externally passes into the first reaction vessel 101 is
performed.
[0133] That is, in the crystal growth apparatus shown in FIG. 6, in
order that temperature control of the zone (in this case, namely,
the nitrogen supply pipe 104) through which the nitrogen material
supplied externally passes into the first reaction vessel 101, a
third heating device 110 is provided in the outside of the nitrogen
supply pipe 104.
[0134] In the crystal growth apparatus shown in FIG. 6, temperature
control of the nitrogen supply pipe 104 is attained by the third
heating device 110. That is, as the nitrogen supply pipe 104 is
directly heated by the third heating device 110, the alkaline metal
can be more positively prevented from condensing in the nitrogen
supply pipe 104 more effectively than in the crystal growth
apparatus shown in FIG. 5. Consequently, it becomes possible to
bring nitrogen much more smoothly into the inside of the reaction
vessel 101, and thus, more stable crystal growth can be
attained.
[0135] Thus, by the crystal growth apparatus shown in FIG. 6, the
alkaline metal can be prevented from condensing to the more
specific zone (nitrogen supply pipe 104) by heating this zone
(nitrogen supply pipe 104) through which the nitrogen material
supplied externally passes into the first reaction vessel 101.
Although the alkaline metal which adheres to this zone (nitrogen
supply pipe 104) may be removed (for example, mechanically) instead
of or in addition to preventing condensation of the alkaline metal
to the zone (nitrogen supply pipe 104) through which nitrogen
material passes as mentioned above, the configuration of the
crystal growth apparatus shown in FIG. 6 can perform the same
function in a simpler manner in consideration of the configuration
of the apparatus. Moreover, even when the alkaline metal condenses
to the nitrogen supply pipe 104, it becomes possible to
re-evaporate the thus-condensed alkaline metal by heating the
above-mentioned zone (nitrogen supply pipe 104), as the temperature
of the zone (nitrogen supply pipe 104) through which the nitrogen
material supplied externally passes can be controlled by the third
heating device 110.
[0136] Other than the configurations shown in FIGS. 5 and 6, it is
possible to realize the function of preventing the alkaline metal
vapor from dispersing out of the first reaction vessel. For
example, a second reaction vessel is provided in the outside of the
first reaction vessel, the nitrogen material is brought from the
outside of the second reaction vessel, and a configuration is
provided such that the alkaline metal vapor is prevented from
dispersing out of the first reaction vessel while the first
reaction vessel causes the nitrogen material supplied from the
second reaction vessel to pass inside therethrough.
[0137] In such a configuration, the nitrogen material is brought in
the second reaction vessel from the outside. The mixed molten
liquid which contains at least the alkaline metal and at least the
group-III metal is provided in the inside of the first reaction
vessel, and the nitrogen material passes inside through the first
reaction vessel and thus is brought into the first reaction vessel.
Thereby, the alkaline metal, group-III metal and nitrogen material
react in the first reaction vessel, and a crystal of the group-III
nitride grows. In the temperature range in which a crystal of the
group-III nitride grows, the alkaline metal has a certain vapor
pressure, and the thus-generated alkaline metal vapor is prevented
from dispersing out of the first reaction vessel.
[0138] FIG. 7 shows a crystal growth apparatus in a third
embodiment of the present invention. In this configuration, a
second reaction vessel 111 is provided outside of a first reaction
vessel 101, the nitrogen material (in a form of gas) is supplied
from the outside of the second reaction vessel 111, the first
reaction vessel 101 has a configuration such as to prevent the
alkaline metal vapor from dispersing out of the first reaction
vessel 101, while causes the nitrogen material provided from the
second reaction vessel 111 to pass therethrough into the inside of
the first reaction vessel 101. That is, in the crystal growth
apparatus shown in FIG. 7, the second reaction vessel 111 is in the
outside of the first reaction vessel 101.
[0139] For the above-mentioned purpose, in the configuration of
FIG. 7, a lid 112 is provided in the upper part of the first
reaction vessel 101. There, the material of the first reaction
vessel 101 is BN (boron nitride), and the second reaction vessel
111 is made of stainless steel.
[0140] In the first reaction vessel 101, Na as the alkaline metal,
and, a metal Ga as a substance at least containing the group-III
metallic element is contained. They form a mixed molten liquid 102
in the temperature range in which a crystal of the group-III
nitride grows. The space zone 103 in the first reaction vessel 101
and the space zone 113 in the second reaction vessel 111 are filled
by the nitrogen gas (N.sub.2) as a substance which at least
contains a nitrogen element. This nitrogen gas can pass through the
nitrogen supply pipe 104 pass, and thus can be supplied into the
second reaction vessel 111 externally. Furthermore, there is a fine
crevice between the first reaction vessel 101 and the lid 112 such
as to allow the nitrogen gas to pass therethrough and thus to be
supplied into the first reaction vessel 101 from the second
reaction vessel 111.
[0141] In addition, in order to adjust the nitrogen pressure, a
pressure adjustment mechanism 105 is provided in the apparatus
shown in FIG. 7. This mechanism includes, for example, a pressure
sensor, a pressure adjustment valve, etc., and this pressure
adjustment mechanism 105 controls the nitrogen pressure in the
second reaction vessel 111 and the first reaction vessel 101 into
50 atm., for example.
[0142] In the crystal growth apparatus shown in FIG. 7, a heating
device 116 is provided outside of the second reaction vessel 111
such that the temperature inside of or in the surface of the mixed
molten liquid 102 in the first reaction vessel 101 can be
controlled so that a crystal of the group-III nitride can grow
therein.
[0143] The mixed molten liquid 102 of Na which is the alkaline
metal, and Ga which is the group-III metal material is formed by
performing temperature control aiming at the temperature (for
example, 750.degree. C.) at which a crystal of the group-III
nitride can grow. In this state, a GaN crystal as a group-III
nitride can grow in the mixed molten liquid 108 and in the surface
of the mixed molten liquid 109 as Ga which is the group-III metal
is supplied by the mixed molten liquid, and the above-mentioned
growth temperature is maintained.
[0144] In the crystal growth apparatus shown in FIG. 7, in the
mixture molten liquid of Na and Ga 108, and in the surface thereof
109, continuous growth of the GaN crystal is achieved as the
nitrogen gas and Ga react or the nitrogen ingredient in the molten
liquid supplied from nitrogen gas and Ga react, and, thus, it
becomes possible to obtain a large size of the crystal.
[0145] Furthermore, in the crystal growth apparatus shown in FIG.
7, the alkaline metal can be prevented from dispersing out of the
first reaction vessel 101 almost completely as the first reaction
vessel 101 is provided with the lid 112. Thereby, change in the
composition of the alkaline metal and group-III metal is well
controlled, and it becomes possible to grow the group-III nitride
crystal with well controlled condition. At this time, condensation
of the alkaline metal into the nitrogen supply pipe 104 can also be
controlled (avoided).
[0146] Moreover, in controlling the temperature in the first
reaction vessel 101 so that the temperature above the surface of
the mixed molten liquid 102 which consists of Na which is the
alkaline metal, and Ga which is the group-III metal material
becomes more than the temperature of the mixed molten liquid 102
itself as described above for the crystal growth apparatus shown in
FIG. 5, it becomes possible to prevent dispersion of the alkaline
metal occurring due to condensation thereof in the supply pipe or
the like externally from the mixed molten liquid 102 more
positively.
[0147] Moreover, in any of the configurations of the crystal growth
apparatus shown in FIGS. 5, 6 and 7, the nitrogen material may
instead be brought into the reaction vessel 101 or 111 horizontally
of the first reaction vessel or second reaction vessel 111, or from
a direction below the horizontal direction thereof.
[0148] FIG. 8 shows a crystal growth apparatus in a fourth
embodiment of the present invention. In this configuration, the
nitrogen supply pipe 104 is connected to the second reaction vessel
111 at the bottom of the crystal growth apparatus, as shown in the
figure. Therefore, the nitrogen gas which is a nitrogen material is
supplied from the bottom of the second reaction vessel 111. The
inventor of the present invention confirmed experimentally that an
alkaline metal in a form of vapor was more likely to condense in an
upper part of a reaction vessel than in a lower part thereof.
Therefore, the nitrogen supply pipe 104 can be more positively
prevented from being blocked by the alkaline metal and can bring
the nitrogen gas toward the mixed molten liquid more positively, as
the nitrogen is supplied from the bottom as in the crystal growth
apparatus shown in FIG. 8. Consequently, it becomes possible to
ensure bringing (provision) of the nitrogen gas into the mixed
molten liquid, and, thereby, the control (control of the nitrogen
pressure) of crystal growth can be performed more positively.
[0149] In addition, in the example of FIG. 8, although the nitrogen
gas is brought inside from the bottom of the second reaction vessel
111, an embodiment of the present invention is not limited thereto,
and similar effect can be obtained as long as the nitrogen gas is
brought inside from a horizontal direction (as indicated by a
broken line 104' in FIG. 8) or from a direction lower than the
horizontal direction of the second reaction vessel 111.
[0150] Moreover, although the crystal growth apparatus shown in
FIG. 8 is an example corresponding to the embodiment shown in FIG.
7, an example corresponding to any of the configurations shown in
FIGS. 5 and 6 can be embodied in the same manner. That is, the
nitrogen gas may be brought horizontally into the first reaction
vessel 101 or second reaction vessel 111, or in a direction below
the horizontal direction thereinto, there (as indicated by a broken
line 104' in FIG. 5).
[0151] In addition, in the above-described embodiments, although Na
is used as a metal (alkaline metal) having a low melting point and
a high vapor pressure, potassium (K) etc. can also be used instead
of Na. That is, any alkaline metal may be used as long as, in the
temperature range in which a crystal of a group-III nitride can
grow, it is in a form of a molten liquid.
[0152] Moreover, in the above-described embodiments, at least, as a
substance at least containing a group-III metallic element, Ga is
used. However, another metal such as Al or In, a mixture thereof or
an alloy thereof may be used instead.
[0153] Moreover, although a nitrogen gas is used in the
above-described embodiments as a substance which at least contains
a nitrogen element, another gas, such as NH.sub.3, may also be used
instead of the nitrogen gas.
[0154] Moreover, although the first reaction vessel 101 is made of
stainless steel in the above-described embodiments, any material
can be used as the material of the first reaction vessel instead as
long as it can form a closed space separate from the exterior
atmosphere, and resists the temperature and pressure needed for
growing a group-III nitride crystal, and, also, does not react with
the alkaline metal, and thus is not melted as an impurity when the
group-III nitride crystal grows.
[0155] By employing the crystal growth apparatus in any of the
above-described first, second, third and fourth embodiments shown
in FIGS. 5, 6, 7 and 8, for growing a group-III nitride crystal,
such a large-sized group-III nitride crystal as that can be put
into practice in manufacture of semiconductor device can be
obtained at low cost.
[0156] As an example of a method of growing a group-III nitride
crystal according to the present invention, Ga is used as a
group-III metal, a nitrogen gas is used as a nitrogen material, Na
is used as a flux, the temperature of the reaction vessel and flux
vessel is made into 750.degree. C., and the nitrogen pressure is
fixed into 50 kg/cm.sup.2. Thereby, a GaN crystal can grow.
[0157] Moreover, by using a group-III nitride crystal thus grown up
by the growth method according to the present invention, a
group-III nitride semiconductor device can be produced.
[0158] FIG. 9 shows an example of configuration of such a
semiconductor device according to the present invention. The
semiconductor device shown in FIG. 9 is in a form of a
semiconductor laser. As shown in the figure, in this semiconductor
device, on an n-type GaN substrate 301 using a group-III nitride
crystal produced according to the above-described crystal growth
method according to the present invention, an n-type AlGaN clad
layer 302, an n-type GaN guide layer 303, an InGaN MQW (multiple
quantum well) activity layer 304, a p-type GaN guide layer 305, a
p-type AlGaN clad layer 306, and a p-type GaN contact layer 307 are
formed one by one through crystal growth processes. As the crystal
growth method therefor, a thin film crystal growth method, such as
an MO-VPE (organometallic vapor phase epitaxy) method, an MBE
(molecular beam epitaxy) method, or the like may be used.
[0159] Subsequently, a ridge structure is formed in the laminated
films of GaN, AlGaN, and InGaN, SiO.sub.2 insulating layer 308 is
formed only with a hole formed as a contact region, a p-side ohmic
electrode Au/Ni 309, and an n-side ohmic electrode Al/Ti 310 are
respectively formed on top and bottom thereof, and thus, a
semiconductor device (semiconductor laser) shown in FIG. 9 is
formed.
[0160] By injecting an electric current from the p-side ohmic
electrode Au/Ni 309 and n-side ohmic electrode Al/Ti 310 of this
semiconductor laser, it oscillates, and emits laser light in a
direction of an arrow A shown in FIG. 9.
[0161] Since the group-III nitride crystal (GaN crystal) according
to the present invention is used in this semiconductor laser as the
substrate 301, there are few crystal defects in the semiconductor
laser device, and it provides a large power output and has a long
life. Moreover, since the GaN substrate 301 is of n type, an
electrode 310 can be formed directly onto the substrate 301, thus
does not need to draw two electrodes of p side and n side only from
the obverse surface as in the prior art shown in FIG. 1, and, thus,
cost reduction can be achieved.
[0162] Furthermore, in the semiconductor device shown in FIG. 9, it
becomes possible to form a light emitting end surface by cleavage,
also, chip separation can be performed by cleavage. Thus, it is
possible to achieve a high-quality semiconductor device at low
cost.
[0163] With reference to FIGS. 10 through 15, a crystal growth
method in a fifth embodiment and variant embodiments thereof, of
the present invention for growing a group-III nitride crystal will
now be described.
[0164] (First Feature of the Fifth Embodiment of the Present
Invention)
[0165] In the crystal growth method in the fifth embodiment of the
present invention, a crystal of a group-III nitride including a
group-III metal and nitrogen is grown in a reaction vessel from an
alkaline metal, a substance at least containing the group-III
metal, and a substance at least containing the nitrogen. In
particular, a growth process is made such that a growth condition
is set in which the crystal growth stops after a growth condition
is set by which a group-III nitride crystal starts growing, and,
then, the growth condition is set by which the crystal growth
starts, again.
[0166] The alkaline metal, the substance which at least contains
the group-III metal, and the substance which at least contains the
nitrogen are present in the reaction vessel. They may be supplied
externally, or may be present in the reaction vessel originally.
This reaction vessel is provided with a temperature control
mechanism and a pressure control mechanism, and, thereby, it is
possible arbitrarily to raise the temperature in the reaction
vessel so as to enable crystal growth therein, raise the pressure
in the reaction vessel so as to enable crystal growth therein,
lower the temperature in the reaction vessel so as to stop the
crystal growth, to lower the pressure in the reaction vessel so as
to stop the crystal growth, and to maintain temperature/pressure in
the reaction vessel for a desired time interval.
[0167] Then, by setting the temperature in the reaction vessel so
as to cause it to satisfy the growth condition by which the
group-III nitride crystal can grow, crystal growth of the group-III
nitride begins. Immediately after the crystal growth of the
group-III nitride begins and thus nucleus generation starts, the
condition in the reaction vessel is made to enter a condition by
which the crystal growth stops, and thus the nucleus generating
stops. Next, by returning the temperature of the reaction vessel to
the condition by which the crystal growth starts again, the crystal
growth of the group-III nitride progresses utilizing the nucleus
generated before as a seed crystal.
[0168] The nitrogen material used the embodiment according to the
present invention is a nitrogen molecule, a nitrogen in a form of
atom and/or a nitrogen molecule, and/or a nitrogen molecule and/or
a nitrogen in a form of atom generated from a compound containing
nitrogen.
[0169] (Second Feature of the Fifth Embodiment of the Present
Invention)
[0170] In addition to the above-described first feature, after
setting and maintaining the temperature by which the crystal growth
starts in a zone in the reaction vessel in which the crystal of the
group-III nitride grows, the temperature in the reaction vessel is
lowered so that the crystal growth stops and also the group-III
metal and other metal do not form an alloy, and the thus-lowered
temperature is maintained. Then, after that, the temperature in the
reaction vessel is raised to the temperature at which the crystal
growth starts again.
[0171] An alkaline metal, a substance which at least contains a
group-III metal, and a substance which at least contains a nitrogen
are provided in the reaction vessel. They may be supplied
externally or may be provided in the reaction vessel originally.
This reaction vessel is provided with a unit for performing a
temperature control function, and, thereby, the temperature in the
reaction vessel is raised so that crystal growth may occur, is
lowered so that the crystal growth may stop, or the temperature in
the reaction vessel may be maintained for a desired time
interval.
[0172] By raising the temperature in the reaction vessel so that
the group-III nitride crystal may grow, crystal growth of the
group-III nitride begins. The nucleus generation stops by then
lowering the temperature in the reaction vessel so that the crystal
growth stops, immediately after the crystal growth of the group-III
nitride begins and nucleus generation starts. Next, by raising the
temperature in the reaction vessel so that the crystal growth may
start invention. FIG. 11 shows a temperature control sequence for
the reaction vessel in the fifth embodiment.
[0173] A mixed molten liquid 1102 of Ga as the group-III metal and
Na as the flux is provided in the reaction vessel 1101, shown in
FIG. 10. In the reaction vessel 1101, a heating device 1106 is
provided such that the temperature in the reaction vessel 1101 is
controlled so that crystal growth may occur. A nitrogen gas is used
as the nitrogen material. The nitrogen gas is supplied through a
nitrogen supply pipe 1104 into a space 1103 in the reaction vessel
1101 from the outside of the reaction vessel 1101. In order to
adjust the nitrogen pressure at this time, a pressure adjustment
mechanism 1105 is provided. This pressure adjustment mechanism 1105
includes a pressure sensor, a pressure adjustment valve, etc. In
this apparatus, a state by which the nitrogen gas is supplied to
the reaction vessel at a fixed pressure can be maintained
thereby.
[0174] Under such a condition, the temperature in the reaction
vessel is caused to increase to a temperature T1 (for example,
750.degree. C.) by which the crystal growth starts in a first
process, as shown in a FIG. 11. Then, this condition is maintained
for a predetermined time interval (for example, 30 minutes).
Thereby, a nucleus of a GaN crystal which is a group-III nitride is
generated in the reaction vessel 1101 shown in FIG. 10. Next, the
temperature in the reaction vessel 1101 is lowered to a temperature
T2 (for example, 400 degrees C.) at which the crystal growth stops.
Next, the temperature in the reaction vessel 1101 is caused to
increase to the temperature T1 by which the crystal growth starts
again, and this condition is maintained for 30 minutes, and, then,
the temperature in the reaction vessel 1101 is again lowered to the
temperature T2. A nucleus of the GaN crystal is again generated at
the time of this temperature increase.
[0175] Then, the temperature in the reaction vessel 1101 is again
increased to T1, and this temperature is maintained for a time such
that a required crystal size may be obtained. At this time, the
crystal growth progresses by utilizing the nucleus generated at the
first two times of temperature increase, the GaN crystal becomes
larger, and the GaN crystals 1107 and 1108 grow on the wall of the
reaction vessel 1101 and near a gas-liquid interface between the
mixed molten liquid 1102 of Ga and Na and the space 1103 in the
reaction vessel, as shown in FIG. 10.
[0176] When a case where the temperature increase and decrease for
controlling nucleus generation were performed according to the
present invention and a case where such temperature control was not
performed as in the prior art were experimentally compared, it was
seen that, in the case of controlling the temperature according to
the present invention, nucleus generation could be controlled
remarkably, and, thus, it became possible to obtain a large-sized
crystal, and, thereby, the GaN crystal which could be used more
practicality was obtained.
[0177] In this fifth embodiment of the present invention, although
a temperature rise of the reaction vessel for nucleus generation
sake, and temperature descent are repeated twice, it is effective
even by performing only once the same. However, it becomes possible
to generate a preferential crystal nucleus by performing the
repetition. In addition, the nitrogen pressure at this time is 50
atm., and is remarkably low as compared with the pressure in the
super-high-pressure method as in the above-mentioned second prior
art.
[0178] (Fifth Feature of the Fifth Embodiment of the Present
Invention)
[0179] In addition to the above-described fourth feature,
additional supply of the substance which at least contains the
group-III metal is made at the time the temperature is low.
[0180] A first variant embodiment of the above-described fifth
embodiment of the present invention will now be described with
reference to FIGS. 12 and 13. FIG. 12 shows a elevational sectional
view of a crystal growth apparatus in the first variant embodiment
of the fifth embodiment of the present invention, and FIG. 13 shows
a temperature control sequence for the reaction vessel of the
apparatus shown in FIG. 12.
[0181] In addition to the configuration shown in FIG. 10, a unit of
performing the additional supply of the group-III metal is provided
in the configuration as shown in FIG. 12. Only the unit which
carries out the additional supply of the group-III metal is the
difference from the configuration shown in FIG. 10 and will now be
described.
[0182] A metal Ga is used as the group-III metal, and in order to
carry out the additional supply of the metal Ga, a group-III metal
supply pipe 1310 is provided. At an projection end of the group-III
metal supply pipe 1310, the metal Ga 1309 for the additional supply
is held in a form of powder. This inner projection end of this the
group-III metal supply pipe 310 has a hole 1311. The opposite outer
end of the group-III metal supply pipe 1310 projects out of the
reaction vessel 1301, and, by applying a nitrogen pressure from
this end, the metal Ga 1309 at the inner end of the group-III metal
supply pipe 310 is supplied to the mixed molten liquid 1302 through
the hole 1311.
[0183] In this configuration, the temperature in the reaction
vessel 1301 is increased to the temperature T1 (for example,
750.degree. C.) at which the crystal growth starts at a first
process as shown in FIG. 13. Then, this state is maintained for a
predetermined time interval (for example, 30 minutes), thereby, a
nucleus of a GaN crystal which is the group-III nitride is
generated in the reaction vessel 1301 shown in FIG. 12. Next, the
temperature in the reaction vessel 1301 is lowered to the
temperature T2 (for example, 400 degrees C.) at which the crystal
growth stops. Then, the temperature in the reaction vessel 1301 is
increased to T1 again, and this temperature is maintained for a
time interval such that a certain crystal size is obtained. At this
time, the crystal growth progresses utilizing the nucleus generated
at the time of the first temperature increase, the GaN crystal
becomes larger, and the GaN crystal 1307 and the GaN crystal 1308
grow on the wall of the reaction vessel 1301 and near the
gas-liquid interface between the mixed molten liquid 1302 of Ga and
Na and the space 1303 in the reaction vessel 1301.
[0184] As mentioned above, the nitrogen gas which is the nitrogen
material can be supplied to the reaction vessel 1301 from the
outside continuously at the fixed pressure, and, thereby, the
nitrogen is not exhausted. However, Ga which is the group-III metal
material may be exhausted as the GaN crystal grows, or, the ratio
with Na which is the flux may be changed even when the exhaustion
does not actually occur. Thereby, a growth parameter may be changed
gradually, the crystal quality may be changed, and, thus, it may
become difficult to maintain stable crystal growth.
[0185] Then, after the crystal growth progresses to some extent,
the temperature in the reaction vessel 1301 is lowered to a
temperature at which the crystal growth stops, and, thus, it
becomes possible to control the quantity ratio of the group-III
metal and Na flux by carrying out the additional supply of the Ga
metal, as shown in FIG. 13. Consequently, stable growth of the GaN
crystal is attained, and it becomes possible to obtain the
high-quality crystal having few defects.
[0186] Furthermore, fluctuation in the crystal growth can be well
controlled by carrying out additional supply of the Ga at a timing
at which the crystal growth does not progress (temperature is low),
and it becomes possible to grow up a high-quality GaN crystal.
[0187] (Sixth Feature of the Fifth Embodiment of the Present
Invention)
[0188] In addition to the above-described first feature, the
substance which at least contains nitrogen is in a form of a gas,
after setting and maintaining the effective nitrogen pressure in a
zone where the group-III nitride crystal grows to a pressure at
which crystal growth starts, the effective nitrogen pressure is
then lowered to a pressure at which the crystal growth stops, and
the thus-lowered pressure is maintained. Then, after that, the
above-mentioned effective nitrogen pressure is increased to the
effective nitrogen pressure at which the crystal growth starts
again.
[0189] The alkaline metal, the substance which at least contains
the group-III metal, and the substance which at least contains the
nitrogen are provided in the reaction vessel. They may be supplied
from the outside or may be provided in the reaction vessel
originally.
[0190] A pressure control mechanism (1105 shown in FIG. 10) is
provided in this reaction vessel, and, thereby, raising the
effective nitrogen pressure to the pressure at which crystal growth
may occur, lowering the pressure to a pressure at which the crystal
growth may stop, and maintaining each pressure for a desired time
interval can be performed.
[0191] In this configuration, by raising the effective nitrogen
pressure in the reaction vessel to the pressure at which the
group-III nitride crystal may grow, crystal growth of the group-III
nitride begins. Then, the crystal-nucleus generation stops by
lowering the effective nitrogen pressure in the reaction vessel to
the pressure at which the crystal growth stops immediately after
the crystal growth of the group-III nitride begins and thus crystal
nucleus generation starts. Next, by raising the effective nitrogen
pressure in the reaction vessel to the pressure at which the
crystal growth starts again, crystal growth of the group-III
nitride progresses by utilizing the nucleus generated before as a
seed crystal.
[0192] (Seventh Feature of the Fifth Embodiment of the Present
Invention)
[0193] In addition to the above-described sixth feature, increase
and decrease of the effective nitrogen pressure are performed
several times.
[0194] By repeating the increase and decrease of the effective
nitrogen pressure according to the above-described sixth feature,
crystal growth of the group-III nitride progresses by utilizing the
crystal nucleus which has been finally obtained by the nucleus
generation as a seed crystal.
[0195] A second variant embodiment of the fifth embodiment having
the above-described sixth and seventh features will now be
described with reference to FIG. 14. In this variant embodiment,
the crystal growth apparatus shown in FIG. 10 is used.
[0196] The mixed molten liquid 1102 of Ga as the group-III metal
and Na as the flux is provided in the reaction vessel 1101. In the
reaction vessel 1101, a heating device 1106 is provided so that it
can control the temperature in the reaction vessel 1101 to the
temperature at which crystal growth may occur. Nitrogen gas is used
as the nitrogen material. The nitrogen gas is supplied through a
nitrogen supply pipe 1104, and is supplied to a space 1103 in the
reaction vessel 1101 from the outside of the reaction vessel 1101.
In order to adjust the nitrogen pressure at this time, a pressure
adjustment mechanism 1105 is provided. This pressure adjustment
mechanism 1105 includes a pressure sensor, a pressure adjustment
valve, etc.
[0197] In this configuration, the nitrogen pressure in the reaction
vessel 1101 is raised to a pressure P1 (for example, 50 atm.) at
which crystal growth may start, at a first process as shown in FIG.
14. This state is maintained for a predetermined time interval (for
example, 30 minutes.), then, a nucleus of a GaN crystal which is
the group III nitride is generated in the reaction vessel 1101.
Next, the nitrogen pressure in the reaction vessel 1101 is lowered
to a pressure P2 (for example, 10 atm.) at which the crystal growth
stops. Next, after increasing the nitrogen pressure in the reaction
vessel 1101 to the above-mentioned pressure P1 again, this state is
maintained for 30 minutes. Then, after that, the nitrogen pressure
in the reaction vessel 1101 is again lowered to the above-mentioned
pressure P2. The nucleus of the GaN crystal is generated again at
the time of this pressure increase.
[0198] Then, the nitrogen pressure in the reaction vessel 1101 is
increased to the pressure P1, and, then, the thus-raised pressure
is maintained till such a time has elapsed that a required crystal
size is obtained. At this time, the crystal growth progresses by
utilizing the nucleus generated through the first two times of
pressure increase, the GaN crystal becomes larger, and the GaN
crystals 1107 and 1108 grow on the wall of the reaction vessel 1101
and near the gas-liquid interface between the mixed molten liquid
1102 of Ga and Na and the space zone 1103 in the reaction vessel
1101.
[0199] When a case where pressure increase and decrease of the
nitrogen pressure for controlling nucleus generation according to
the present invention was performed and a case where such a
pressure control for controlling nucleus generation was not
performed as in the above-mentioned prior art were experimentally
compared, nucleus generation was greatly controlled (the number of
nucleuses generated could be effectively reduced) in the case where
the pressure control for controlling nucleus generation was
performed according to the present invention. Consequently, it
became possible to enlarge the crystal size and thus the GaN
crystal which can be used more practically could be obtained.
[0200] In this embodiment, although increase and decrease of the
nitrogen pressure in the reaction vessel for the purpose of
controlling nucleus generation are repeated twice, a similar effect
can be obtained even the same operation is performed only once. It
becomes possible to generate a preferential crystal nucleus as this
pressure increase and decrease operation is repeated. In addition,
the required temperature in the reaction vessel at this time is 750
degrees C., and is remarkably low as compared with the temperature
in the super-high-pressure method which is the above-described
second prior art.
[0201] (Eighth Feature of the Fifth Embodiment of the Present
Invention)
[0202] In addition to the above-described seventh feature,
additional supply of the substance which at least contains the
group-III metal is performed at the time the effective nitrogen
pressure is lowered.
[0203] A third variant embodiment of the fifth embodiment of the
present invention having the above-mentioned eighth feature will
now be described with reference to FIG. 15. The crystal growth
apparatus shown in FIG. 12 is used in the third variant embodiment
of the fifth embodiment. FIG. 15 shows a pressure control sequence
of the reaction vessel in this embodiment.
[0204] The nitrogen pressure in the reaction vessel 1301 is raised
to the pressure P1 (for example, 50 atm.) at which crystal growth
starts, in a first process. This state is maintained for a
predetermined time interval (for example, 30 minutes), and, then, a
nucleus of a GaN crystal which is the group-III nitride is
generated in the reaction vessel 1301. Next, the nitrogen pressure
in the reaction vessel 1301 is lowered to the pressure P2 (for
example, 10 atm.) at which the crystal growth stops. Then, the
nitrogen pressure in the reaction vessel 1301 is raised to the
above-mentioned pressure P1 again, and this pressure is maintained
till such a time interval has elapsed that a certain crystal size
is obtained. At this time, the crystal growth progresses utilizing
the nucleus generated at the time of the first pressure increase,
the GaN crystal thus becomes larger, and the GaN crystal 1307 and
the GaN crystal 1308 grow on the wall of the reaction vessel 1301
and near the gas-liquid interface between the mixed molten liquid
1302 of Ga and Na and the space 1303 in the reaction vessel
1301.
[0205] As described above, the nitrogen gas which is the nitrogen
material can be supplied from the outside, and the nitrogen thus is
not exhausted. However, Ga which is the group-III metal material
may be exhausted as the GaN crystal growth progresses, or, the
ratio thereof with the flux (Na) may be changed even when Ga is not
actually exhausted. Thereby, a growth parameter may be changed
gradually, and thus, the crystal quality may be changed and it may
become difficult to maintain stable crystal growth.
[0206] Then, after the crystal growth progresses to some extent,
the pressure of the nitrogen in the reaction vessel is lowered to
the pressure at which the crystal growth stops, and, thereby, it
becomes possible to control the quantity ratio of the group-III
metal and the Na flux by carrying out additional supply of the Ga
metal, as shown in FIG. 15. Consequently, stable crystal growth of
the GaN crystal is attained and it becomes possible to obtain a
high-quality crystal having few defects.
[0207] Furthermore, fluctuation in the crystal growth can be well
controlled by carrying out additional supply of the Ga at a timing
at which the crystal growth does not progress, and, thus, it
becomes possible to grow up a high-quality GaN crystal.
[0208] A crystal growth apparatus such that crystal growth is
performed thereby according to the crystal growth method having any
of the above-described first through eighth features of the fifth
embodiment of the present invention is included in the scope of the
present invention.
[0209] Furthermore, a group-III nitride crystal obtained through
the crystal growth method having the any of the above-described
first through eighth features of the fifth embodiment of the
present invention, and/or the above-mentioned crystal growth
apparatus is included in the scope of the present invention.
[0210] A group-III nitride crystal semiconductor device produced by
using the above-mentioned group-III nitride crystal is also
included in the scope of the present invention.
[0211] An embodiment of a semiconductor laser to which the
above-mentioned semiconductor device is applied is shown in FIG. 9,
and, is the same as that already described above with reference
FIG. 9.
[0212] Also in this case, as described above, since a group-III
nitride crystal (GaN crystal) according to the present invention is
used in this semiconductor laser as the substrate 301, there are
few crystal defects in the semiconductor laser, and, thus, it
provides a large power output and has a long life. Moreover, since
the GaN substrate 301 is of n type, an electrode 310 can be formed
directly in the substrate 301, thus does not need to draw two
electrodes of p side and n side only from the obverse surface as in
the prior art shown in FIG. 1, and, thus, cost reduction can be
achieved.
[0213] Furthermore, in the semiconductor device shown in FIG. 9, it
becomes possible to form a light emitting end surface by cleavage,
also, chip separation can be performed by cleavage. Thus, it is
possible to achieve a high-quality semiconductor device at low
cost.
[0214] Hereafter, a sixth embodiment of the present invention will
now be described with reference to figures. In the sixth embodiment
of the present invention, a mixed molten liquid of an alkaline
metal and a substance which at least contains a group-III metal is
provided in a reaction vessel. When carrying out crystal growth of
the group-III nitride including the group-III metal and nitrogen
from the mixed molten liquid and a substance which at least
contains nitrogen, a local concentration distribution (or
concentration unevenness) of dissolved nitrogen is intentionally
created in the mixed molten liquid.
[0215] There, the local concentration distribution of dissolved
nitrogen can be produced in the mixed molten liquid by a specific
shape of a vessel holding the mixed molten liquid therein.
[0216] A growth method for group-III nitride crystal in the sixth
embodiment of the present invention will now be described in
detail. In a reaction vessel, an alkaline metal, a substance which
at least contains a group-III metal, and a substance which at least
contains nitrogen is provided. These materials may be supplied from
the outside or may be made to be provided in the reaction vessel
originally. A temperature control mechanism is prepared in this
reaction vessel, and, thereby, raising the temperature inside of
the reaction vessel to a temperature at which crystal growth may
occur, lowering the temperature in the reaction vessel to a
temperature at which the crystal growth may stop, and maintaining
any one of the above-mentioned temperatures in the reaction vessel
for a desired time interval can be performed. By thus setting the
temperature in the reaction vessel, and the effective nitrogen
partial pressure to the conditions by which an group-III nitride
crystal may grow, it is possible to make crystal growth of the
group-III nitride start.
[0217] When a predetermined temperature is set by the
above-mentioned temperature control mechanism, the alkaline metal
and the substance which at least contains the group-III metal form
a mixed molten liquid. Nitrogen is then dissolved in this mixed
molten liquid. There, the term `dissolving` means that the nitrogen
is present in the mixed molten liquid in a dissolved form.
[0218] The concentration of the dissolved nitrogen in the mixed
molten liquid is made to have a spatial (local) distribution
(spatial unevenness) in this stage in the sixth embodiment of the
present invention. It can be considered that the nitrogen moves
towards the inside of the mixed molten liquid from the surface of
the mixed molten liquid under a predetermined temperature in a
mixed molten liquid holding vessel, and, thereby, a local
concentration distribution of the dissolved nitrogen in the mixed
molten liquid occurs due to a specific shape of the mixed molten
liquid holding vessel which will be described later.
[0219] Then, it becomes possible to grow up a crystal of the
group-III nitride in a specific zone of the mixed molten liquid by
producing such a local concentration distribution of the dissolved
nitrogen in the mixed molten liquid. That is, a crystal nucleus is
generated at the time in an early stage of crystal growth
beginning, and, when the dissolved nitrogen concentration in the
mixed molten liquid has a local distribution (unevenness),
generation of crystal nucleuses may be limited to a specific zone
of the mixed molten liquid accordingly. Then, each crystal nucleus
act as a seed crystal, and crystal growth of the group-III nitride
progresses therefrom.
[0220] Then, after the crystal growth progresses so that a
predetermined size of crystal may be obtained thereby, the
temperature in the reaction vessel is lowered to such a temperature
that the crystal may be taken out from the reaction vessel.
[0221] There, the nitrogen mentioned above and below means nitrogen
molecules and nitrogen atoms produced from a compound containing
nitrogen molecules or nitrogen, and, groups of atoms and groups of
molecules containing nitrogen.
[0222] As described above, in the sixth embodiment of the present
invention, a local concentration distribution of dissolved nitrogen
is produced in the mixed molten liquid by an inner shape of a mixed
molten liquid holding vessel holding the mixed molten liquid
therein.
[0223] FIG. 16 shows an example of a configuration of a crystal
growth apparatus in the sixth embodiment of the present invention.
An alkaline metal and a substance which at least contains a
group-III metal (for example, Ga) form a mixed molten liquid in a
reaction vessel, and the crystal growth apparatus in the sixth
embodiment of the present invention is configured such that growth
of crystals of group-III nitride which includes the group-III metal
and nitrogen may be carried out from this mixed molten liquid and
the substance which at least contains the nitrogen (N).
[0224] That is, with reference to FIG. 16, the mixed molten liquid
holding vessel 2102 is set in the reaction vessel 2101. There, the
material of the mixed molten liquid holding vessel 2102 is BN
(boron nitride). Further, the mixed molten liquid holding vessel
2102 holds the mixed molten liquid 2103 including the group-III
metal (for example, Ga) and the alkaline metal (for example,
Na).
[0225] Moreover, with reference to FIG. 16, a heating device 2106
is provided in the reaction vessel 2101 such that the inside of the
reaction vessel 2101 can be controlled to have a temperature at
which crystal growth may occur. Moreover, a nitrogen supply pipe
2104 is provided such as to supply a nitrogen gas to a space zone
2108 of the reaction vessel 2101 from the outside of the reaction
vessel 2101, and, in order to adjust the nitrogen pressure in the
reaction vessel 2101, a pressure adjustment mechanism 2105 is
provided. This nitrogen pressure adjustment mechanism 2105 includes
a pressure sensor, a pressure adjustment valve, etc.
[0226] According to the sixth embodiment of the present invention,
the mixed molten liquid holding vessel 2102 has an inner shape such
as to create a local concentration distribution of dissolved
nitrogen in the mixed molten liquid.
[0227] FIG. 17 shows an elevational sectional view of one example
of the mixed molten liquid holding vessel 2102 shown in FIG. 16.
The mixed molten liquid holding vessel 2102 shown in FIG. 17 has an
inner wall 2102a shaped such that the inner volume (cross sectional
area) becomes smaller toward the bottom thereof. That is, the shape
of the inner wall 2102a of the mixed molten liquid holding vessel
2102 is a conic shape or a pyramid shape having the pointed vertex
thereof directed toward the bottom. That is, in the example shown
in FIG. 17, the mixed molten liquid 2103 is held at a portion
surrounded by the inner wall 2102a having the shape obtained from
being shaved off into a conic shape having the vertex directed to
the bottom.
[0228] In the crystal growth apparatus having the configuration
shown in FIGS. 16 and 17, the nitrogen pressure in the reaction
vessel 2101 is made into 50 atm., and the temperature therein is
increased to the temperature of 750 degrees C. by which crystal
growth starts. By maintaining this growth condition for a
predetermined time interval, a group-III nitride crystal (for
example, GaN crystal) 2109 grows in the mixed molten liquid holding
vessel 2102. A nucleus of the group-III nitride crystal (for
example, GaN crystal) 2109 is generated and the crystal growth
progresses therefrom at the earlier stage of the crystal growth,
and, a zone in which the group-III nitride crystal (for example,
GaN crystal) 2109 grows is only an upper part of the mixed molten
liquid holding vessel 2102 where the inner wall 2102a is inclined
as shown in FIG. 17.
[0229] If the shape of the inner wall 2102a of the mixed molten
liquid holding vessel 2102 did not have the shape shown in FIG. 17
(conic shape or pyramid shape) but a pillar shape (cylinder) or a
square pillar shape (prism), nucleuses of the group-III nitride
crystal (for example, GaN crystal) 2109 would grow all over the
inner wall 2102a of the mixed molten liquid holding vessel 2102,
and the group-III nitride crystal (for example, GaN crystal) 2109
in monocrystal would not become larger enough. In contrast thereto,
when the shape of the inner wall 2102a of the mixed molten liquid
holding vessel 2102 is such as that shown in FIG. 17, nucleus
generation of the group-III nitride crystal (for example, GaN
crystal) 2109 is limited to occur in a specific zone of the mixed
molten liquid 2103, it becomes possible to efficiently utilize the
group-III metal (for example, Ga) in the mixed molten liquid 2103
for the growth of the group-III nitride monocrystal (for example,
GaN single crystal), and, thus, it becomes possible to obtain a
large size of the crystal.
[0230] It can be considered that such a behavior occurs due to the
following mechanism: That is, the nitrogen from the nitrogen gas by
which the space zone 2108 of the reaction vessel 2101 is filled up
is dissolved into the mixed molten liquid 2103 from the surface
2103a of the mixed molten liquid 2103 (it moves by dispersion into
a deeper part of the mixed molten liquid 103 from the surface 2103a
of the mixed molten liquid 2103). When the shape of the inner wall
2102a of the mixed molten liquid holding vessel 2102 is such as
that shown in FIG. 17, the cross sectional shape of the inner wall
2102a of the mixed molten liquid holding vessel 2102 along a
direction perpendicular to the direction in which the nitrogen
moves in the mixed molten liquid 2103 to the inside of the mixed
molten liquid 2103 by dispersion from the surface 2103a of the
mixed molten liquid 2103 (namely, along the direction from the top
to the bottom) is changed. Thereby, the dissolved nitrogen
concentration in the inside of the mixed molten liquid 2103 has a
spatial difference (distribution), and, thus, the crystal nucleus
of the group-III nitride crystal (for example, GaN crystal) 2109 is
generated in the above-mentioned specific part of inner wall 2102a
of the mixed molten liquid holding vessel 2102.
[0231] That is, when the cross sectional area of the inner wall
2102a of the mixed molten liquid holding vessel 2102 is changed
(when the cross sectional area of the mixed molten liquid 103 is
changed by the shape of the inner wall 2102a of the vessel 2102),
the local distribution (unevenness) of the dissolved nitrogen
concentration arises in the mixed molten liquid 2103. Consequently,
generation of crystal nucleuses of the group-III nitride crystal
(for example, GaN crystal) 2109 occurs in a limited part in the
mixed molten liquid 2103. Growth of the group-III nitride crystal
(for example, GaN crystal) 2109 progresses further from the
generated crystal nucleus, and, thus, the crystal growth progresses
more preferentially from a crystal nucleus already generated once
than in a zone in which no crystal nucleus is present. At this
time, the temperature of the mixed molten liquid holding vessel
2102 and the mixed molten liquid 2103 of the inside thereof is
uniform. Therefore, from the surface 2103a of the mixed molten
liquid 2103, the nitrogen used as a group-V material for the
group-III nitride crystal (for example, GaN crystal) 2109 moves by
dispersion, and is consumed in crystal nucleuses of the III
group-III nitride crystal (for example, GaN crystal) 2109.
Consequently, the group-III nitride crystal (for example, GaN
crystal) 2109 grows up only in the specific part of the inner wall
2102a of the mixed molten liquid holding vessel 2102, and, thereby,
growth of the group-III nitride crystal 2109 into a large size of
crystal (for example, GaN crystal) is attained.
[0232] FIG. 18 shows a second example of the mixed molten liquid
holding vessel 2102 in the sixth embodiment of the present
invention. In the example shown in FIG. 18, the mixed molten liquid
holding vessel 2102 has a configuration such that a projection 2126
is formed from the inner wall 2102a of the mixed molten liquid
holding vessel 2102 at a level (height) below the surface 2103a of
the mixed molten liquid 2103.
[0233] When growing up the group-III nitride crystal (for example,
GaN crystal) 2109 using the mixed molten liquid holding vessel 2102
shown in FIG. 18, a nucleus of the group-III nitride crystal (for
example, GaN crystal) 2109 is generated centering near the
projection end of the projection 2126 of the inner wall 2102a of
the mixed molten liquid holding vessel 2102. Generation of the
nucleus of the group-III nitride crystal (for example, GaN crystal)
2109 occurs mainly near the projection end of the projection 2126
in the mixed molten liquid 103. Thereby, the crystal nucleus at
this location is mainly used for progress of growth of the
group-III nitride crystal (for example, GaN crystal) 2109, and,
thus, it becomes possible to grow up a large-sized crystal.
[0234] In the crystal growth apparatus having the configuration
shown in FIGS. 16 and 18, the nitrogen pressure in the reaction
vessel 2101 is made into 50 atm., and the temperature therein is
increased to the temperature of 750 degrees C. at which crystal
growth starts. By maintaining this growth condition for a
predetermined time interval, the group-III nitride crystal (for
example, GaN crystal) 2109 grows in the mixed molten liquid holding
vessel 2102. At this time, a nucleus of the group-III nitride
crystal (for example, GaN crystal) 2109 is generated and crystal
growth progresses therefrom in the earlier stage of crystal growth,
and the zone at which the group-III nitride crystal (for example,
GaN crystal) 2109 grows is limited to only a zone near the
projection end of the projection 2126 of the inner wall 2102a of
the mixed molten liquid holding vessel 2102 as shown in FIG.
18.
[0235] It can be considered that such a behavior occurs by the
following mechanism: Namely, in the reaction vessel 2101, nitrogen
from the nitrogen gas by which the space zone 2108 is filled is
dissolved into the mixed molten liquid 2103 from the surface 2103a
of the mixed molten liquid 2103 (it moves by dispersion into the
mixed molten liquid 2103 deeper from the surface 2103a of the mixed
molten liquid 2103). In the case of the example shown in FIG. 18,
the cross sectional area inside the mixed molten liquid holding
vessel 2102 along the direction perpendicular to the direction of
movement of the nitrogen in the mixed molten liquid 103 is changed
by the projection 2126 formed from the inner wall 2102a of the
mixed molten liquid holding vessel 2102. Thereby, the concentration
of the dissolved nitrogen in the mixed molten liquid 2103 has a
spatial difference/unevenness (distribution), and the crystal
nucleus of the group-III nitride crystal (for example, GaN crystal)
2109 is generated centering in the neighborhood of the projection
2126. In this time, growth of the group-III nitride crystal (for
example, GaN crystal) 2109 progresses further from the generated
crystal nucleus, and thus, the crystal growth progresses more
preferentially from the crystal nucleus already generated than in a
zone in which no crystal nucleus is present. At this time, the
temperature in the mixed molten liquid holding vessel 2102 and the
mixed molten liquid 2103 of the inside thereof is uniform. Thereby,
from the surface 2103a of the mixed molten liquid 2103, the
nitrogen used as the group-V material for the group-III nitride
crystal (for example, GaN crystal) 2109 moves by dispersion, and is
consumed in the crystal nucleus of the group-III nitride crystal
(for example, GaN crystal) 2109. Consequently, the group-III
nitride crystal (for example, GaN crystal) 2109 grows up only in
the specific part on the inner wall 102a of the mixed molten liquid
holding vessel 2102, and, thus, growth of the group-III nitride
crystal 2109 into a large-sized crystal (for example, GaN crystal)
is attained.
[0236] In the example of FIG. 18, the projection 2126 is formed
from the inner wall 2102a of the mixed molten liquid holding vessel
2102. However, a measure may be provided instead of provision of
such a projection. Namely, the mixed molten liquid holding vessel
2102 should have a certain portion at which the cross sectional
area is changed in the inner wall 2102a.
[0237] FIG. 19 shows a configuration of a crystal growth apparatus
in a seventh embodiment of the present invention. In FIG. 19, the
same reference numerals as those of FIG. 16 are given to
corresponding parts/components. In the crystal growth apparatus
shown in FIG. 19, a first heating device 2116 and a second heating
device 2117 are provided such that the group-III nitride crystal
(for example, GaN crystal) 2109 in the reaction vessel 2101 can be
controlled to have a temperature by which crystal growth may occur.
There, temperature control can be performed individually by the
first heating device 2116 and the second heating device 2117.
[0238] FIG. 20A shows another example of the mixed molten liquid
holding vessel 2102, and the mixed molten liquid holding vessel
2102 shown in FIG. 20A is used in the crystal growth apparatus
shown in FIG. 19. With liquid holding vessel 2102. In this time, a
nucleus of the group-III nitride crystal (for example, GaN crystal)
109 is generated, and crystal growth progresses in the earlier
stage of the crystal growth therefrom, and only in the upper part,
the group-III nitride crystal (for example, GaN crystal) 2109 grows
in which the inner wall of the mixed molten liquid holding vessel
2102 is inclined as shown in FIG. 20A (only in the specific part on
the upper inner wall 2102a).
[0239] The crystal nucleus 2109 of the group-III nitride crystal
(for example, GaN crystal) is generated only in the specific part
on the upper inner wall 2102a of the mixed molten liquid holding
vessel 2102 same as in the example shown in FIG. 17. However,
differently from the example shown in FIG. 17, the inner wall of
the mixed molten liquid holding vessel 2102 has the cylindrical
lower part 2102b in which the cross sectional area is uniform, in
the mixed molten liquid holding vessel shown in FIG. 20A. As
mentioned above, when the inner wall of the mixed molten liquid
holding vessel were like a cylinder or a prism, nucleuses of the
group-III nitride crystal (for example, GaN crystal) 2109 would
grow all over the inner wall of the mixed molten liquid holding
vessel, and the group-III nitride crystal (for example, GaN
crystal) 2109 in monocrystal thus could not have a large size. When
the mixed molten liquid holding vessel is shaped as shown in FIG.
20A, nucleus generation is limited to effectively occur only in the
specific zone, the group-III metal in the mixed molten liquid (for
example, Ga) can thus be efficiently used for the growth of the
group-III nitride monocrystal (for example, GaN single crystal)
2109 from the nucleus thus generated in the limited zone, and
thereby, a large-sized crystal can be obtained therefrom.
Furthermore, in the configuration shown in FIG. 20A, the cross
sectional area of the inner wall of the mixed molten liquid holding
vessel 2102 becomes uniform below the mid height thereof. That is,
the lower inner wall 2102b has the uniform cross sectional area.
Thereby, growth of the group-III nitride crystal (for example, GaN
crystal) 2109 is controlled there, but the mixed molten liquid
which includes the group-III metal (Ga) and the alkaline metal (for
example, Na) is kept. Thereby, the zone of the lower inner wall
2102b acts as a zone for keeping the group-III metal (for example,
Ga) for the group-III nitride crystal (for example, GaN crystal)
2109, and, thereby, the group-III metal (for example, Ga) can be
continuously supplied therefrom, and the crystal can thus be grown
up continuously to a sufficient size.
[0240] Furthermore, in the crystal growth apparatus shown in FIGS.
19 and 20A, a convection arises in the mixed molten liquid 2103
because there is a difference in temperature between the upper part
and the lower part of the mixed molten liquid holding vessel 2102
as mentioned above. The group-III metal (for example, Ga) is
supplied from the lower part of the mixed molten liquid holding
vessel 2102 by this convection, and the nitrogen which is the
group-V material is supplied from the top, and, thus, efficient
crystal growth is attained.
[0241] In addition, in the example of the crystal growth apparatus
shown in FIG. 20A, although the shape of the inner wall of the
mixed molten liquid holding vessel 2102 is such that, first, the
cross sectional area thereof becomes smaller downward, and, then,
is uniform from the middle thereof as mentioned above, the shape of
the inner wall of the mixed molten liquid holding vessel 2102 may
be such that, as shown in FIG. 20B, first, the cross sectional area
may become smaller downward, and, then, from the middle height
thereof, it may become larger downward (like a tsuzumi or Japanese
hand drum).
[0242] Moreover, the inner shape of the mixed molten liquid holding
vessel 2102 is not necessarily limited to any one of those shown in
FIGS. 17, 18, 20A and 20B, but, should just be a shape such that,
thereby, a local distribution of dissolved nitrogen concentration
is produced in the mixed molten liquid 2103. Moreover, not only
providing a special shape of the inner wall of the mixed molten
liquid holding vessel 2102 but also some special member, such as a
jig, a mechanical device or the like, may be provided/attached,
other than the vessel 2102 itself, in the vessel 2102, for the same
purpose.
[0243] Moreover, in each of the above-mentioned embodiments, Na is
used as a metal (alkaline metal) having a low melting point and a
high vapor pressure. However, instead of Na, potassium (K) or the
like may be used. That is, as the alkaline metal, any alkaline
metal may be used as long as it becomes a molten liquid at a
temperature at which a crystal of a group-III nitride may grow.
[0244] Moreover, although a case where Ga is used as a substance
which at least contains a group-III metallic element has been
described in each of the above-mentioned embodiments, a metal of a
simple substance, such as Al, In, or any mixture thereof, an alloy,
etc. may also be used instead of Ga.
[0245] Moreover, although a nitrogen gas is used in each of the
above-mentioned embodiments as a substance which at least contains
a nitrogen element, another gas such as NH.sub.3 may be used
instead of the nitrogen gas.
[0246] By carrying out crystal growth of a group-III nitride
crystal using the crystal growth method according to the present
invention described above and the crystal growth apparatus
according to the present invention, a large-sized group-III nitride
crystal can be provided at low cost.
[0247] As an example of the growth method of a group-III nitride
crystal according to the present invention described above, Ga is
used as the group-III metal, a nitrogen gas is used as the nitrogen
material, Na is used as the flux, a temperature of the reaction
vessel and flux vessel is made into 750 degrees C., and the
nitrogen pressure is fixed at 50 kg/cm.sup.2. A GaN crystal can
grow under such conditions.
[0248] Moreover, a group-III nitride semiconductor device can be
produced using the group-III nitride crystal grown up by the growth
method according to the present invention.
[0249] FIG. 9 shows one example of a configuration of the
semiconductor device according to the present invention, which is
the same as that described above with reference to FIG. 9.
[0250] Since the group-III nitride crystal (GaN crystal) according
to the present invention is used for this semiconductor laser as
the substrate 301 shown in FIG. 9, there are few crystal defects in
this semiconductor laser device, and, thus, it has a large output
and a long life. Moreover, since the GaN substrate 301 is of n
type, the electrode 310 can be directly formed on the substrate
301, and, thus, there is no need to draw out two electrodes of the
p side and the n side only from the obverse surface as in the first
prior art (FIG. 1), and, thus, it becomes possible to attain cost
reduction.
[0251] Furthermore, in the semiconductor device of FIG. 9, it
becomes possible to form the light emitting end surface by
cleavage, and, also, it becomes possible to perform chip separation
by cleavage. Thus, it becomes possible to realize a high-quality
device at low cost.
[0252] In addition, although InGaN MQW is used as the activity
layer in the above-mentioned example, it is also possible to
shorten the wavelength of light emitted by using AlGaN MQW as the
activity layer, instead. According to the present invention, light
emission from a deep level is reduced as the GaN substrate thus has
few defects and few impurities. Accordingly, it is possible to thus
provide a light-emission device having a high efficiency even when
the wavelength of the light emitted is shortened.
[0253] Specifically, a light-emission device which emits light
having a wavelength shorter than 400 nm (light-emission device
which has a satisfactory performance even in the ultraviolet
region) as the group-III nitride semiconductor device can be
provided. That is, according to the prior art, the light-emission
spectrum of a GaN film is such that most of the light-emission is
made from a deep level. Accordingly, the device characteristic is
not satisfactory for the wavelength shorter than 400 nm. In
contrast thereto, according to the present invention, the
light-emission device having the satisfactory characteristic also
for the ultraviolet region can be provided.
[0254] Further, any combination of the above-described embodiments
may be included in the scope of the present invention.
[0255] Moreover, although each of the above-mentioned embodiments
is an application of the present invention to an optical device,
the present invention may also be applied to an electronic device.
That is, by using a GaN substrate with few defects according to the
present invention, a GaN-family thin film formed thereon by
epitaxial growth also has few crystal defects. Consequently, the
leak current can be well controlled, a career confining effect when
a quantum structure is made can be improved, for example. Thus, a
high-performance device can be achieved according to the present
invention.
[0256] Further, the present invention is not limited to the
above-described embodiments, and variations and modifications may
be made without departing from the scope of the present
invention.
[0257] The present application is based on Japanese priority
applications Nos. 2000-318723, 2000-318988 and 2000-324272, filed
on Oct. 19, 2000, Oct. 19, 2000 and Oct. 24, 2000, the entire
contents of which are hereby incorporated by reference.
* * * * *