U.S. patent application number 12/814308 was filed with the patent office on 2010-12-16 for device structure of carbon fibers and manufacturing method thereof.
This patent application is currently assigned to FUJITSU LIMITED. Invention is credited to Akio KAWABATA, Shintaro Sato.
Application Number | 20100316558 12/814308 |
Document ID | / |
Family ID | 38540839 |
Filed Date | 2010-12-16 |
United States Patent
Application |
20100316558 |
Kind Code |
A1 |
KAWABATA; Akio ; et
al. |
December 16, 2010 |
DEVICE STRUCTURE OF CARBON FIBERS AND MANUFACTURING METHOD
THEREOF
Abstract
An aggregate structure of carbon fibers, organized by a
plurality of carbon fibers, includes, an aggregate of the carbon
fibers aligned in a lengthwise direction, in which a density of the
carbon fibers at one side end is different from a density of the
carbon fibers at the other side end.
Inventors: |
KAWABATA; Akio; (Kawasaki,
JP) ; Sato; Shintaro; (Kawasaki, JP) |
Correspondence
Address: |
Fujitsu Patent Center;Fujitsu Management Services of America, Inc.
2318 Mill Road, Suite 1010
Alexandria
VA
22314
US
|
Assignee: |
FUJITSU LIMITED
Kawasaki-shi
JP
|
Family ID: |
38540839 |
Appl. No.: |
12/814308 |
Filed: |
June 11, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12237020 |
Sep 24, 2008 |
7736615 |
|
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12814308 |
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PCT/JP2007/054549 |
Mar 8, 2007 |
|
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12237020 |
|
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Current U.S.
Class: |
423/447.1 |
Current CPC
Class: |
H01L 23/373 20130101;
H01L 2924/14 20130101; H05K 2201/0281 20130101; H01L 23/5226
20130101; H01L 2224/48247 20130101; B82Y 10/00 20130101; H01L
21/76885 20130101; H01L 2224/48247 20130101; H01L 2224/49175
20130101; H01L 24/13 20130101; D01F 9/127 20130101; B82Y 30/00
20130101; H01L 2224/49175 20130101; H01L 2224/45144 20130101; H01L
23/485 20130101; Y10S 977/742 20130101; H01L 2224/45144 20130101;
H01L 2924/00 20130101; H01L 2924/00 20130101; H01L 2924/00014
20130101; H01L 2924/00 20130101; H01L 23/53276 20130101; H05K
2201/026 20130101; H01L 2221/1094 20130101; H01L 2224/48091
20130101; H05K 2201/0323 20130101; H01L 2224/48091 20130101; H05K
3/4007 20130101; H01L 2924/14 20130101 |
Class at
Publication: |
423/447.1 |
International
Class: |
D01F 9/12 20060101
D01F009/12 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 26, 2006 |
JP |
PCT/JP2006/305954 |
Claims
1.-8. (canceled)
9. A method of manufacturing an aggregate structure of carbon
fibers, comprising: a step of growing an aggregate of the carbon
fibers aligned in a lengthwise direction substantially in a
vertical direction from a substrate surface; and a densifying step
of densifying the carbon fibers at one side end of the aggregate of
the carbon fibers in the lengthwise direction.
10. The method of manufacturing an aggregate structure of carbon
fibers according to claim 9, wherein the densifying step includes:
a step of making a solvent containing an adhesive substance
different from the carbon fibers permeate through the aggregate of
the carbon fibers; and a step of evaporating the solvent.
11. The method of manufacturing an aggregate structure of carbon
fibers according to claim 9, wherein the densifying step includes:
a step of making a solvent permeate through the aggregate of the
carbon fibers; and a step of drying the aggregate of the carbon
fibers and the solvent.
12. A method of manufacturing an aggregate structure of carbon
fibers, comprising: a step of growing an aggregate of the carbon
fibers aligned in a lengthwise direction substantially in a
vertical direction from a substrate surface of a first substrate; a
densifying step of densifying one side ends of the aggregate of the
carbon fibers in the lengthwise direction; a step of tightly
fitting the other side ends of the aggregate of the carbon fibers
in the lengthwise direction to a substrate surface of a second
substrate; a step of peeling the aggregate of the carbon fibers
grown on the substrate surface of the first substrate from the
substrate surface of the first substrate; and a densifying step of
densifying the other side ends of the aggregate of the carbon
fibers in the lengthwise direction.
13. The method of manufacturing an aggregate structure of carbon
fibers according to claim 12, wherein the densifying step includes:
a step of making a solvent permeate through the aggregate of the
carbon fibers; and a step of drying the aggregate of the carbon
fibers and the solvent.
14. The method of manufacturing an aggregate structure of carbon
fibers according to claim 12, wherein the densifying step includes:
a step of making a solvent containing an adhesive substance
different from the carbon fibers permeate through the aggregate of
the carbon fibers; and a step of evaporating the solvent.
15. The method of manufacturing an aggregate structure of carbon
fibers according to claim 13, wherein the solvent is selected from
a group of N,N-dimethylformamide, dichloroethane, isopropyl
alcohol, ethanol and methanol.
16. The method of manufacturing an aggregate structure of carbon
fibers according to claim 13, wherein the solvent contains
interfacial active agents or functional macromolecules.
17.-20. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of Application PCT/JP2007/054549,
filed on Mar. 8, 2007, now pending, the contents of which are
herein wholly incorporated by reference.
BACKGROUND
[0002] The present disclosure relates to a device structure of
carbon fibers and a manufacturing method thereof.
[0003] Carbon nanotubes (CNT) are excellent in terms of electric
conductivity, thermal conductivity and a mechanical characteristic
and therefore take trial applications to a variety of fields.
Hence, an expectation is that the carbon nanotubes will be applied
to an electronic device, a heat radiation device, wiring for an LSI
(Large Scale Integration), a channel of a transistor, a heat
radiation bump and an electron emission source. It is also expected
that especially the carbon nanotubes grown in vertical alignment
will be applied to the wiring and the heat radiation. Note that a
mainstream method of attaining the vertically-aligned growth of the
carbon nanotubes is a chemical vapor deposition (CVD) method at the
present, and it is generally practiced that the carbon nanotubes
(CNT) are grown directly on a desired substrate. The method of
attaining the vertically-aligned growth of the carbon nanotubes is
exemplified such as a thermal CVD method, a plasma CVD method and a
hot filament CVD method. Further, a thermal decomposition method of
SiC is exemplified as a method of acquiring the carbon nanotubes
close to closest packing.
[0004] In the application to the carbon nanotubes, the carbon
nanotubes grown in vertical alignment on the substrate are utilized
in many cases. Applied examples of the carbon nanotubes are, e.g.,
the wiring for the LSI and the heat radiation bumps. In the case of
applying the carbon nanotubes, it is desirable that the carbon
nanotubes having the highest possible density be grown on the
substrate in terms of reducing a wiring resistance and improving
heat radiation efficiency. The carbon nanotubes grown in vertical
alignment by the conventional technique have, however, a low
density. Further, some segments of the neighboring carbon nanotubes
abut on each other, however, all of the carbon nanotubes are not
necessarily brought into contact with each other. Namely, a problem
is that an interval between the neighboring carbon nanotubes is
expanded. The growth of the carbon nanotubes having the high
density is not generally easy, and a volume occupancy rate of the
carbon nanotubes grown in vertical alignment by the conventional
technique is on the order of 10%. Further, in the thermal
decomposition method of SiC, a thermal treatment temperature is
1200.degree. C.-2200.degree. C. It is therefore difficult to select
the substrate and make process matching with other devices.
SUMMARY
[0005] According to an aspect of an embodiment, there is an
aggregate structure (a fibril structure) of carbon fibers
(carbonaceous fibers), organized by a plurality of carbon fibers,
includes: an aggregate of the carbon fibers aligned in a lengthwise
direction, in which a density of the carbon fibers at one side end
is different from a density of the carbon fibers at the other side
end. According to the present disclosure, the density, at both side
ends, of the aggregate of the carbon fibers differs at one side end
and the other side end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a view illustrating a case in which carbon
nanotubes 1 are grown in vertical alignment by a conventional
technique.
[0007] FIG. 2 is a front view of the carbon nanotubes 1 in the case
where the carbon nanotubes 1 are grown in vertical alignment by the
conventional technique.
[0008] FIG. 3 is atop view of the carbon nanotubes 1 in the case
where the carbon nanotubes 1 are grown in vertical alignment by the
conventional technique.
[0009] FIG. 4 is a view showing a growth method of the carbon
nanotubes 1 in a first embodiment.
[0010] FIG. 5 is a view showing an example in which a carbon
nanotube group 5 is grown.
[0011] FIG. 6 is a view showing how the carbon nanotube group is
dipped into a container 6 filled with a resin containing an organic
solvent.
[0012] FIG. 7 is a view showing how the carbon nanotube group 5 is
dipped into the container 6 filled with the resin containing the
organic solvent.
[0013] FIG. 8 is a view showing how the carbon nanotube group 5 is
dipped into the container 6 filled with the resin containing the
organic solvent.
[0014] FIG. 9 is a view showing how the carbon nanotube group 5 is
dipped into the container 6 filled with the resin containing the
organic solvent.
[0015] FIG. 10 is a front view of the carbon nanotube group 5 in
which one side ends of the carbon nanotubes 1 are so formed as to
lean on each other.
[0016] FIG. 11 is a top view of the carbon nanotube group 5 in
which one side ends of the carbon nanotubes 1 are so formed as to
lean on each other.
[0017] FIG. 12 is a front view of the carbon nanotube group 5 in
which one side ends of the carbon nanotubes 1 are so formed as to
lean on each other.
[0018] FIG. 13 is a top view of the carbon nanotube group 5 in
which one side ends of the carbon nanotubes 1 are so formed as to
lean on each other.
[0019] FIG. 14 is a view showing a space where none of the carbon
nanotubes 1 exist.
[0020] FIG. 15 is a view showing a plurality of carbon nanotube
groups 5 having different densities.
[0021] FIG. 16 is a front view showing a case in which the
plurality of carbon nanotube groups 5 having the different
densities is aligned so that the highly-densified side ends are
disposed in alternate directions.
[0022] FIG. 17 is a view showing a post-patterning iron film 8.
[0023] FIG. 18 is a view showing the carbon nanotube groups 5 that
are grown in vertical alignment on a silicon substrate 7 with an
oxide film.
[0024] FIG. 19 is a view showing a process of adhering a solvent to
the carbon nanotube groups 5.
[0025] FIG. 20 is a view showing the process of adhering the
solvent to the carbon nanotube groups 5.
[0026] FIG. 21 is a view showing the process of adhering the
solvent to the carbon nanotube groups 5.
[0027] FIG. 22 is a view showing the process of adhering the
solvent to the carbon nanotube groups 5.
[0028] FIG. 23 is a view showing the process of adhering the
solvent to the carbon nanotube groups 5.
[0029] FIG. 24 is a view showing the process of adhering the
solvent to the carbon nanotube groups 5.
[0030] FIG. 25 is a front view of the carbon nanotube groups 5 in
which one side ends of the carbon nanotubes 1 are so formed as to
lean on each other.
[0031] FIG. 26 is a view showing the highly-densified carbon
nanotube groups 5 and a substrate 20.
[0032] FIG. 27 is a view showing the substrate 20 and a structure
of a substrate 23.
[0033] FIG. 28 is a view showing a structure in which a substrate
23 with a low-melting metal film and the substrate 20 are
superposed on each other.
[0034] FIG. 29 is a view showing a structure in which the carbon
nanotube groups 5 is peeled off the substrate 20, and the substrate
23 with the low-melting metal film is tightly fitted to the carbon
nanotube groups 5.
[0035] FIG. 30 is a view showing a step in a case where a
densification process shown in a third embodiment is executed on
the carbon nanotube groups 5.
[0036] FIG. 31 is a view showing the step in the case where the
densification process shown in the third embodiment is executed on
the carbon nanotube groups 5.
[0037] FIG. 32 is a view showing the step in the case where the
densification process shown in the third embodiment is executed on
the carbon nanotube groups 5.
[0038] FIG. 33 is a view showing the step in the case where the
densification process shown in the third embodiment is executed on
the carbon nanotube groups 5.
[0039] FIG. 34 is a structural view illustrating conventional
transistor packaging.
[0040] FIG. 35 is a structural view showing flip-chip
packaging.
[0041] FIG. 36 is a structural view showing the flip-chip
packaging.
[0042] FIG. 37 is a view showing a structure of an aluminum nitride
substrate 50 formed with electrodes 51.
[0043] FIG. 38 is a view showing the structure of the aluminum
nitride substrate 50 formed with the carbon nanotube groups 5.
[0044] FIG. 39 is a view showing the structure of the aluminum
nitride substrate 50 formed with the highly-densified carbon
nanotube groups 5.
[0045] FIG. 40 is a view showing the structure of the aluminum
nitride substrate 50 formed with the carbon nanotube groups 5 in
which lengths of the carbon nanotubes 1 are not uniform.
[0046] FIG. 41 is a view showing the structure of the aluminum
nitride substrate 50 on which an interlayer insulating film 60 is
deposited so as to cover the carbon nanotube groups 5.
[0047] FIG. 42 is a view showing the structure of the aluminum
nitride substrate 50 after polishing the carbon nanotube groups 5
and interlayer insulating film 60.
[0048] FIG. 43 is a view showing the structure of the aluminum
nitride substrate 50 provided with a high-power transistor chip
40.
[0049] FIG. 44 is a view showing a structure of an LSI (Large Scale
Integrated Circuit) 70.
[0050] FIG. 45 is a view showing a structure of a substrate 74 and
an LSI substrate 75 on which the carbon nanotube groups 5 are
grown.
[0051] FIG. 46 is a view showing a structure in which the substrate
74 and the LSI substrate 75 are superposed on each other.
[0052] FIG. 47 is a view showing a structure in which a gap between
the substrate 74 and the LSI substrate 75 is filled with an
interlayer insulating film 80.
[0053] FIG. 48 is a view showing a structure of the substrate 74 on
which the interlayer insulating film 80 is deposited so as to cover
the carbon nanotube groups 5.
[0054] FIG. 49 is a view showing a structure in which distal ends
of the carbon nanotube groups 5 are protruded.
[0055] FIG. 50 is a view showing the structure of the LSI substrate
75, in which the carbon nanotube groups 5 and the interlayer
insulating film 80 are polished.
[0056] FIG. 51 is a view showing the structure of the LSI substrate
75 formed with copper wiring 71.
[0057] FIG. 52 is a view showing the structure of the LSI substrate
75 formed with copper wiring 71 and a structure of the substrate
74.
[0058] FIG. 53 is a view showing a structure in which the substrate
74 and the LSI substrate 75 formed with the copper wiring 71 are
superposed on each other.
[0059] FIG. 54 is a view showing a structure in which the carbon
nanotube groups 5 are tightly fitted to the copper wiring 71 formed
on the LSI substrate 75.
[0060] FIG. 55 is a view showing the structure of the LSI substrate
75, in which the carbon nanotube groups 5 and the interlayer
insulating film 80 are polished.
DETAILED DESCRIPTION
[0061] A best mode (which will hereinafter be termed an embodiment)
for carrying out the present disclosure will hereinafter be
described with reference to the drawings. Configurations in the
following embodiments are exemplifications, and the present
disclosure is not limited to the configurations in the
embodiments.
[0062] FIG. 1 is a diagram illustrating a case of a
vertically-aligned growth of carbon nanotubes 1 by the conventional
technique. As illustrated in FIG. 1, a large quantity of carbon
nanotubes 1 are grown. Some neighboring carbon nanotubes 1 are not,
however, brought into contact with each other. FIG. 2 is a front
view of the carbon nanotubes 1 in the case of the
vertically-aligned growth of the carbon nanotubes 1 by the
conventional technique. FIG. 3 is a top view of the carbon
nanotubes 1 in the case of the vertically-aligned growth of the
carbon nanotubes 1 by the conventional technique. As shown in FIGS.
2 and 3, there are intervals between the neighboring carbon
nanotubes 1. Namely, gaps occur between the neighboring carbon
nanotubes 1. All the carbon nanotubes 1 are not, however,
necessarily isolated without abutting on each other. The
vertically-aligned growth entails the contact portions as the case
may be. Especially if the carbon nanotubes are thinned, the
vertically-aligned growth is hard to be attained unless some
contact portions are produced. Even in this case, the gaps occur
between the adjacent carbon nanotubes 1.
First Embodiment
[0063] A growth technique of the carbon nanotubes 1 according to a
first embodiment will be illustrated with reference to FIGS. 4
through 11. As shown in FIG. 4, a titanium (Ti) layer 3 is formed
on a silicon substrate 2. Then, a cobalt (Co) layer 4 is formed on
the titanium layer 3. In this case, the cobalt layer 4 undergoes
patterning on the order of 1 .mu.m in diameter. In the first
embodiment, the cobalt layer 4 undergoes the patterning on the
order of 1 .mu.m in diameter and may also, without being limited to
this size, be subjected to the patterning to an any size. The
patterning of the cobalt layer 4 enables the control of positions
where the carbon nanotubes 1 are grown.
[0064] Next, the silicon substrate 2 formed with the titanium layer
3 and the cobalt layer 4 is introduced into a thermal CVD chamber.
Then, a mixture gas (9:1) of argon (Ar) and acetylene (C2H2) is
introduced under 1 kPa into the thermal CVD chamber.
[0065] Moreover, after stabilizing a pressure within the thermal
CVD chamber, the silicon substrate 2 is heated at 510.degree. C.
for 30 min. Next, the silicon substrate 2 is kept in a state of
being heated at 510.degree. C. Through the process described above,
the carbon nanotubes 1 are grown on the cobalt layer 4. FIG. 5 is a
view showing a carbon nanotube group 5 grown on the cobalt layer 4.
The carbon nanotube group 5 represents an aggregation of the carbon
nanotubes 1 grown on the cobalt layer 4.
[0066] As illustrated in FIG. 5, the carbon nanotubes 1 on the
cobalt layer 4 are grown in the vertical direction. FIG. 5 shows an
example of how the carbon nanotube group 5 is grown, however, the
number of the carbon nanotubes 1 is not limited to this illustrated
number. Further, in the first embodiment, the growth of the carbon
nanotubes 1 involves using cobalt as a catalyst metal. The catalyst
metal is not, however, limited to cobalt, and may involve employing
transition metals such as iron (Fe) and nickel (Ni). Moreover, the
growth method of the carbon nanotubes 1 may involve using a
chemical vapor deposition (CVD) method, a hot filament CVD method
and a plasma CVD method.
[0067] Next, the carbon nanotube group 5 is dipped in a resin
containing an organic solvent (which is a solvent containing an
adhesive substance different from the carbon nanotube). To be
specific, the carbon nanotube group 5 shown in FIG. 5 is dipped
into a container 6 filled with the resin containing the organic
solvent. In the case of dipping the carbon nanotube group 5 in the
resin containing the organic solvent, the carbon nanotube group 5
is dipped together with the silicon substrate 2. FIG. 6 is a view
showing that the carbon nanotube group 5 is dipped in the resin
containing the organic solvent.
[0068] For example, as illustrated in FIG. 6, the carbon nanotube
group 5 is dipped up to A-segments into the container 6 filled with
the resin containing the organic solvent. Further, for instance, as
shown in FIG. 7, the carbon nanotube group 5 is dipped up to
B-segments into the container 6 filled with the resin containing
the organic solvent. FIGS. 6 and 7 are views each showing a state
immediately after the carbon nanotube group 5 has been dipped into
the container 6 filled with the resin containing the organic
solvent.
[0069] In FIG. 6, the dipped segment of the carbon nanotube 1 is
set to approximately half a length of the carbon nanotube 1. The
dipped segment connotes a dipped portion of the carbon nanotube 1
when dipped into the container 6 filled with the resin containing
the organic solvent. In FIG. 7, the dipped segment extends to
approximately 20% of the length of the carbon nanotube 1. The
dipped segment can be properly varied corresponding to a type of
the organic solvent and a type of the resin.
[0070] In FIGS. 6 and 7, the proximal portions (one side ends
abutting on the silicon substrate 2) of the carbon nanotube group 5
corresponds to the dipped segments. Further, in the case of dipping
the carbon nanotube group 5 into the container 6 filled with the
resin containing the organic solvent, the distal portions (the
other side ends which do not abut on the silicon substrate 2) can
be also dipped.
[0071] For example, as illustrated in FIG. 8, the distal portion of
each carbon nanotube 1 is used as the dipped segment. In this case,
as illustrated in FIG. 8, the carbon nanotube group 5 is dipped up
to C-segments into the container 6 filled with the resin containing
the organic solvent. Moreover, for instance, as illustrated in FIG.
9, the carbon nanotube group 5 is dipped up to D-segments into the
container 6 filled with the resin containing the organic solvent.
FIGS. 8 and 9 are views each showing a state immediately after the
carbon nanotube group 5 has been dipped into the container 6 filled
with the resin containing the organic solvent. In FIG. 8, the
dipped segment of the carbon nanotube 1 is set to approximately
half a length of the carbon nanotube 1. In FIG. 9, the dipped
segment extends to approximately 20% of the length of the carbon
nanotube 1.
[0072] A period of time, for which the carbon nanotube group 5 is
dipped in the resin containing the organic solvent, is set to
approximately 1 min. In the first embodiment, the time, for which
the carbon nanotube group 5 is dipped in the resin containing the
organic solvent, is set to approximately 1 min, however, the
dipping time is not limited to this length of time. Accordingly,
the dipping time may be properly changed depending on a structure
and the number of the carbon nanotubes 1.
[0073] For instance, alcohol such as methanol and ethanol is used
as the organic solvent. Further, for example, a thermosetting resin
and a photohardening resin are employed as the resin. The more
specific resin involves, e.g., an epoxy resin.
[0074] As shown in FIGS. 6 and 7, in the case of dipping the carbon
nanotube group 5 into the container 6 filled with the resin
containing the organic solvent, the resin containing the organic
solvent fills the gaps between the neighboring carbon nanotubes 1.
Then, in the carbon nanotube group 5 on the silicon substrate 2,
one side ends of the respective carbon nanotubes 1 are formed as if
leaning on each other.
[0075] In the case of dipping the carbon nanotube group 5 into the
container 6 filled with the resin containing the organic solvent,
the resin containing the organic solvent moves by a capillarity to
the undipped segments of the carbon nanotubes 1. Then, the resin
containing the organic solvent moves up to the side ends of the
carbon nanotubes 1. When the resin containing the organic solvent
moves up to the side ends of the carbon nanotubes 1, the carbon
nanotubes 1 comes to a state of being covered with the resin
containing the organic solvent.
[0076] When the resin containing the organic solvent moves up to
the side ends of the carbon nanotubes 1, the neighboring carbon
nanotubes 1 lean on each other by dint of a surface tension.
Moreover, in the case of volatilizing the organic solvent, the
carbon nanotubes 1 come to the state of being covered with the
resin. Then, the respective carbon nanotubes 1 covered with the
resin lean on each other by dint of volume shrinkage when the
organic solvent is volatilized. Namely, when the organic solvent is
volatized from the resin containing the organic solvent, only the
resin covers the respective carbon nanotubes 1. Consequently, the
individual carbon nanotubes 1 covered with the resin further lean
on each other.
[0077] Accordingly, the respective carbon nanotubes 1 covered with
the resin lean on each other, thereby organizing the carbon
nanotube group 5. Moreover, when the carbon nanotube 1 abuts on the
neighboring carbon nanotube 1, these carbon nanotubes 1 are kept in
the state of leaning on each other. Namely, the carbon nanotubes 1
are kept in the state of leaning on each other by dint of the resin
covering the respective carbon nanotubes 1. In other words, the
neighboring carbon nanotubes 1 are kept in a state of being fixed
to each other by the resin covering the respective carbon nanotubes
1.
[0078] FIG. 10 is a front view of the carbon nanotube group 5, in
which the side ends of the individual carbon nanotubes 1 are so
formed as to lean on each other. FIG. 10 is the view showing a
state after the carbon nanotube group 5 has been dipped into the
container 6 filled with the resin containing the organic solvent
and pulled up from the container 6.
[0079] FIG. 11 is a top view of the carbon nanotube group 5, in
which the side ends of the individual carbon nanotubes 1 are so
formed as to lean on each other. FIG. 11 is the view showing a
state after the carbon nanotube group 5 has been dipped into the
container 6 filled with the resin containing the organic solvent
and pulled up from the container 6.
[0080] As shown in FIGS. 10 and 11, in the case of dipping the
carbon nanotube group 5 into the container 6 filled with the resin
containing the organic solvent, one side ends of the respective
carbon nanotubes 1 are formed as to lean on each other.
[0081] In place of dipping the carbon nanotube group 5 into the
resin containing the organic solvent, the resin containing the
organic solvent may be dropped into the carbon nanotube group 5.
Further, the resin containing the organic solvent may be dropped
into the carbon nanotube group 5 by use of a spin coat method.
[0082] In the case of dropping the resin containing the organic
solvent into the carbon nanotube group 5, the resin is dropped so
that the respective carbon nanotubes 1 are covered with the resin
containing the organic solvent. To be specific, the resin
containing the organic solvent is dropped into the segments of the
carbon nanotubes 1. In the case of dropping the resin containing
the organic solvent into the segments of the carbon nanotubes 1,
the resin containing the organic solvent moves by the capillarity
to the segments into which the resin containing the organic solvent
is not dropped. When the resin containing the organic solvent moves
to the segments into which the resin containing the organic solvent
is not dropped, the carbon nanotubes come to a state of being
covered with the resin containing the organic solvent.
[0083] When the resin containing the organic solvent moves to the
segments into which the resin containing the organic solvent is not
dropped, the neighboring carbon nanotubes 1 lean on each other by
dint of the surface tension. Further, in the case of volatizing the
organic solvent, the carbon nanotubes 1 become the state of being
covered with the resin. Then, the respective carbon nanotubes 1
covered with the resin lean on each other by dint of the volume
shrinkage when the organic solvent is volatilized. Namely, when the
organic solvent is volatized from the resin containing the organic
solvent, only the resin covers the respective carbon nanotubes 1.
Consequently, the individual carbon nanotubes 1 covered with the
resin further lean on each other.
[0084] Accordingly, the respective carbon nanotubes 1 covered with
the resin lean on each other, thereby organizing the carbon
nanotube group 5. Moreover, when the carbon nanotube 1 abuts on the
neighboring carbon nanotube 1, these carbon nanotubes 1 are kept in
the state of leaning on each other. Namely, the carbon nanotubes 1
are kept in the state of leaning on each other by dint of the resin
covering the respective carbon nanotubes 1. In other words, the
neighboring carbon nanotubes 1 are kept in a state of being fixed
to each other by the resin covering the respective carbon nanotubes
1.
[0085] Thus, one side ends of the respective carbon nanotubes 1
covered with the resin are so formed as to lean on each other. As a
result, a density of the carbon nanotubes 1 of the carbon nanotube
group 5 is different on the distal end side and the proximal end
side of the carbon nanotube group 5. Namely, the carbon nanotube
group 5, in which the density of the carbon nanotubes 1 differs at
one side end and the other side end, is formed. The density of the
carbon nanotubes 1 on the distal end side of the carbon nanotube
group 5 is higher than the density of the carbon nanotubes 1 on the
proximal end side of the carbon nanotube group 5.
[0086] For example, in the case of using ethanol as the organic
solvent and the epoxy resin as the resin, the resin containing the
organic solvent is the epoxy resin diluted with ethanol. Further, a
ratio of ethanol and the epoxy resin is set arbitrarily. A scheme
is, however, such that all of the gaps between the neighboring
carbon nanotubes 1 are not filled with the epoxy resin. If all of
the gaps between the neighboring carbon nanotubes 1 are filled with
the epoxy resin, the neighboring carbon nanotubes 1 do not lean on
each other. As a result, in the respective carbon nanotubes 1
covered with the resin, one side ends thereof do not be so formed
as to lean on each other. Consequently, a volume of the resin
containing the organic solvent is set smaller than a volume of the
carbon nanotube group 5. With this contrivance, it does not happen
that all of the gaps between the neighboring carbon nanotubes 1 are
filled with the epoxy resin.
[0087] The first embodiment has exemplified the combination of the
organic solvent and the resin, however, the resin may be replaced
with a microcrystalline material such as nanoporous silica
(dielectric material). With this scheme, it is feasible to organize
the carbon nanotubes taking the form of leaning on each other with
not only the resin but also the dielectric material.
Second Embodiment
[0088] A second embodiment of the present disclosure will
hereinafter be described with reference to the drawing in FIGS. 12
and 13. The first embodiment has exemplified the method of
organizing the carbon nanotube group 5, in which the density of the
carbon nanotubes 1 differs at one side end and the other side end
by covering the individual carbon nanotubes 1 with the resin
containing the organic solvent. The second embodiment will
exemplify a method of organizing the carbon nanotube group 5, in
which the density of the carbon nanotubes 1 differs at one side end
and the other side end by covering the individual carbon nanotubes
1 with a metal. Other configurations and operations are the same as
those in the first embodiment. Such being the case, the same
components are marked with the same numerals and symbols as those
in the first embodiment, and their explanations are omitted.
Further, the discussion will refer to the drawings in FIGS. 5
through 11 as the necessity may arise.
[0089] To begin with, the carbon nanotube group 5 is grown on the
silicon substrate 2 formed with the titanium layer 3 and the cobalt
layer 4 shown in FIG. 5. The growth method of the carbon nanotube
group 5 is the same as in the first embodiment, and its description
thereof is omitted herein. Next, a metal is deposited on each of
the carbon nanotubes 1. For instance, the metal deposited on each
of the carbon nanotubes 1 involves using gold (Au). Further, the
metal deposited on each of the carbon nanotubes 1 may also involve
using, e.g., copper (Cu), aluminum (Al), lead (Pb), solder,
etc.
[0090] In the case of deposing gold on each of the carbon nanotubes
1, gold is deposited up to a thickness of about 1 nanometer (nm) on
the surface of each of the carbon nanotubes 1 by a sputtering
method. The use of the sputtering method enables gold to be
deposited precisely on each of the carbon nanotubes 1. For example,
in the case of employing a sputtering apparatus, a layer thickness
of gold to be deposited is set to 1 nanometer (nm), thereby
depositing gold to the layer thickness of 1 nanometer (nm) over
each of the carbon nanotubes 1. In this case, the gold-deposited
segments of the carbon nanotubes 1 may be set arbitrarily.
Moreover, a volume of gold to be deposited is determined based on
the volume of the deposition-target carbon nanotube group 5.
Moreover, in place of depositing the metal on the respective carbon
nanotubes 1, the carbon nanotubes 1 may also be dipped into the
melted metal.
[0091] Next, the carbon nanotube group 5 is subjected to a thermal
treatment at approximately 300.degree. C. A melting point of gold
is normally over 1000.degree. C. If gold is reduced down to a
nano-size, however, the melting point of gold is lowered.
Accordingly, if the carbon nanotube group 5 is subjected to the
thermal treatment at approximately 300.degree. C., gold deposited
on the carbon nanotubes 1 is melted. Then, the carbon nanotubes 1
are covered with the melted gold. A temperature of the thermal
treatment may be obtained empirically or in simulation in the case
of using copper (Cu), aluminum (Al), lead (Pb) and solder as the
metal to be deposited on the carbon nanotubes 1.
[0092] When gold deposited on the carbon nanotubes 1 gets melted,
the neighboring carbon nanotubes 1 covered with gold lean on each
other by the surface tension. Then, the carbon nanotubes 1 covered
with gold are so formed as to lean on each other. Accordingly, the
carbon nanotubes 1 covered with gold lean on each other, thereby
organizing the carbon nanotube group 5. Further, when the carbon
nanotube 1 abuts on the neighboring carbon nanotube 1, these carbon
nanotubes 1 are kept in the state of leaning on each other. Namely,
the carbon nanotubes 1 are kept in the state of leaning on each
other by dint of gold covering the respective carbon nanotubes 1.
In other words, the neighboring carbon nanotubes 1 are kept in a
state of being fixed to each other by gold covering the respective
carbon nanotubes 1.
[0093] Thus, one side ends of the respective carbon nanotubes 1
covered with gold are so formed as to lean on each other. As a
result, a density of the carbon nanotubes 1 of the carbon nanotube
group 5 is different on the distal end side and the proximal end
side of the carbon nanotube group 5. Namely, the carbon nanotube
group 5, in which the density of the carbon nanotubes 1 differs at
one side end and the other side end, is organized. The density of
the carbon nanotubes 1 on the distal end side of the carbon
nanotube group 5 is higher than the density of the carbon nanotubes
1 on the proximal end side of the carbon nanotube group 5.
[0094] FIG. 12 is a front view of the carbon nanotube group 5, in
which the side ends of the individual carbon nanotubes 1 are so
formed as to lean on each other. FIG. 13 is a top view of the
carbon nanotube group 5, in which the side ends of the individual
carbon nanotubes 1 are so formed as to lean on each other. As shown
in FIGS. 12 and 13, the carbon nanotubes 1 are covered with gold,
thereby organizing the carbon nanotube group 5, in which the
density of the carbon nanotubes 1 differs at one side end and the
other side end. Thus, the process of increasing the density of the
carbon nanotubes 1 of the carbon nanotube group 5 is termed a
densification process.
[0095] Moreover, the method according to the second embodiment may
also be executed together with the method according to the first
embodiment. To be specific, the carbon nanotubes 1 are covered with
the metal, while the carbon nanotubes 1 are covered with the resin
containing the organic solvent. If more of the metal is deposited
on the distal end side of the carbon nanotubes 1, the carbon
nanotube group 5 is dipped into the resin containing the organic
solvent. This process enables acceleration for forming the carbon
nanotubes 1 so that one side end thereof lean on each other. The
carbon nanotube group 5, in which the density of the carbon
nanotubes 1 differs at one side end and the other side end, can be
utilized for, e.g., an electron source of field emission etc.
Third Embodiment
[0096] A third embodiment of the present disclosure will be
described with reference to the drawing in FIG. 14. The first
embodiment and the second embodiment have exemplified the method of
organizing the carbon nanotube group 5, in which the density of the
carbon nanotubes 1 differs at one side end and the other side end.
The carbon nanotube group 5 having the different densities of the
carbon nanotubes 1 is organized by forming one side ends so as to
lean on each other. The carbon nanotube group 5 having the
different densities of the carbon nanotubes 1 connotes the carbon
nanotube group 5 in which the density of the carbon nanotubes 1
differs as one side end and the other side end.
[0097] The carbon nanotube group 5 having the different densities
of the carbon nanotubes 1 includes spaces where none of the carbon
nanotubes 1 exist. Namely, as illustrated in FIG. 14, E-areas
correspond to the spaces where none of the carbon nanotubes 1
exist. In the aggregate structure of carbon fibers according to the
present disclosure, a space may be provided between the neighboring
aggregates of the carbon fibers. According to the present
disclosure, the density, at both side ends, of the aggregate of the
carbon fibers differs at one side end and the other side end.
Therefore, the space is provided between the neighboring aggregates
of the carbon fibers. As a result, the aggregate structure of
carbon fibers according to the present disclosure enables the space
between the neighboring aggregates of the carbon fibers to be
effectively utilized. Further, in the aggregate structure of carbon
fibers according to the present disclosure, a substance different
from the carbon fibers may be provided between the neighboring
aggregates of the carbon fibers. According to the present
disclosure, the density, at both side ends, of the aggregate of the
carbon fibers differs at one side end and the other side end.
Hence, the substance different from the carbon fibers can be
provided between the neighboring aggregates of the carbon fibers.
As a result, the aggregate structure of carbon fibers according to
the present disclosure enables the aggregate of the carbon fibers
to be combined with the substance different from the carbon
fibers.
[0098] The third embodiment will exemplify a method of how the
spaces where none of the carbon nanotubes 1 exist are utilized. A
scheme in the third embodiment is that dielectric films are formed
in the spaces where none of the carbon nanotubes 1 exist. Namely,
the dielectric films are formed in the E-areas in FIG. 14. Thus,
the dielectric films are formed in the spaces where none of the
carbon nanotubes 1 exist, whereby the carbon nanotube group 5
having the different densities of the carbon nanotubes 1 can be
utilized as a reinforcing material for the strength of the
dielectric film. For example, nanoporous silica functioning as the
dielectric film is weak in its mechanical strength. Such being the
case, the carbon nanotube group 5 having the different densities of
the carbon nanotubes 1 is used as the reinforcing material for the
strength of the dielectric film, thereby enabling the mechanical
strength of the dielectric film to be reinforced.
[0099] Further, a plating metal may also be formed in the space
where none of the carbon nanotubes 1 exist. Namely, a metallic
layer may be formed in the space where none of the carbon nanotubes
1 exist. Furthermore, the resin may also fill the space where none
of the carbon nanotubes 1 exist. For example, an organic substance
is given as the resin that fills the space where none of the carbon
nanotubes 1 exist. Moreover, an insulating film composed of
SiO.sub.2 etc may be formed in the space where none of the carbon
nanotubes 1 exist.
[0100] Thus, the dielectric film, the metallic layer, the resin and
the insulating film are formed in the spaces where none of the
carbon nanotubes 1 exist, thereby enabling a device characteristic,
a heat radiation characteristic and a device strength to be
improved. In the aggregate structure of carbon fibers according to
the present disclosure, a substance different from the carbon
fibers may be any one of a dielectric body, an organic substance, a
metal and an insulator.
Fourth Embodiment
[0101] An fourth embodiment of the present disclosure will be
described with reference to the drawings in FIGS. 15 and 16. The
fourth embodiment will exemplify a method of combining the carbon
nanotube groups 5 having the different densities of the carbon
nanotubes 1, which are organized according to the first embodiment
or the second embodiment.
[0102] At the first onset, a plurality of carbon nanotube groups 5
having the different densities of the carbon nanotubes 1 is
disposed on the same straight line. In this case, the carbon
nanotube groups 5 are disposed so that the other side ends
exhibiting the higher density than that of one side ends are
oriented in the same direction. As illustrated in FIG. 15, the
plurality of carbon nanotube groups 5 having the different
densities of the carbon nanotubes 1 is disposed on the same
straight line. Further, the other side ends exhibiting the higher
density than that of one side ends are so disposed as to be
oriented in the same direction. Herein, with respect to the side
ends of the carbon nanotube group 5, the other side end exhibiting
the higher density of the carbon nanotube 1 than that of one side
end, is called a high-density side end.
[0103] Next, the carbon nanotube group 5 having the different
densities of the carbon nanotubes 1 is further interposed between
the plurality of carbon nanotube groups 5 having the different
densities of the carbon nanotubes 1 disposed on the same straight
line. In this case, the carbon nanotube group 5 having the
different densities of the carbon nanotubes 1 is further disposed
so that the high-density side end is oriented in the direction
opposite to the high-density side ends of the plurality of
already-arranged carbon nanotube groups 5 having the different
densities of the carbon nanotubes 1. Namely, the pluralities of
carbon nanotube groups 5 having the different densities of the
carbon nanotubes 1 are disposed on the same straight lines so that
the high-density side ends alternate with each other in their
directions. FIG. 16 is a front view showing a case where the
pluralities of carbon nanotube groups 5 having the different
densities of the carbon nanotubes 1 are disposed on the same
straight lines so that the high-density side ends alternate with
each other in their directions.
[0104] The carbon nanotube group 5 having the different densities
of the carbon nanotubes 1 is further disposed in the space where
none of the carbon nanotubes 1 exist, whereby the density of the
carbon nanotube groups 5 can be increased. Namely, the high-density
carbon nanotube groups 5 can be organized. In the aggregate
structure of carbon fibers according to the present disclosure, the
neighboring aggregates of the carbon fibers may be aligned in
different directions. According to the present disclosure, the
density, at both side ends, of the aggregate of the carbon fibers
differs at one side end and the other side end. Therefore, the
aggregate of the carbon fibers can be aligned in the different
directions between the neighboring aggregates of the carbon fibers.
As a result, the aggregate structure of carbon fibers according to
the present disclosure enables the aggregate of the carbon fibers
and the aggregate of the carbon fibers aligned in the different
direction to be combined.
Fifth Embodiment
[0105] A fifth embodiment of the present disclosure will
hereinafter be described with reference to the drawings in FIGS. 17
through 25. The growth method of the carbon nanotubes 1 in the
fifth embodiment will be described with reference to the drawings
in FIGS. 17 and 18. At first, a catalyst is deposited on a silicon
substrate 7 with an oxide film. In this case, a particulated
catalyst may also be used, and a film-like catalyst deposited by
the sputtering method may also be employed.
[0106] The fifth embodiment will be explained by using iron as the
catalyst to be deposited on the silicon substrate 7 with the oxide
film. Moreover, the fifth embodiment will be described by using the
sputtering method as the method of depositing the iron catalyst on
the silicon substrate 7 with the oxide film. A iron film 8 having a
thickness of 1 nm is deposited by the sputtering method on the
silicon substrate 7 with the oxide film, and undergoes patterning
to obtain the iron film 8 that is approximately 5 .mu.m in
diameter. FIG. 17 shows the post-patterning iron film 8. As
illustrated in FIG. 17, the iron film 8 taking substantially a
circular shape is formed by the patterning on the silicon substrate
7 with the oxide film. The diameter of the iron film 8 is given as
an exemplification, and the present disclosure, without being
limited to this diameter, may involve patterning the iron film 8 in
any size.
[0107] The silicon substrate 7 with the oxide film, on which the
post-patterning iron film 8 is formed, is placed on a heating stage
within the normal thermal CVD furnace, and vacuum evacuation is
conducted. Then, the silicon substrate 7 with the oxide film is
heated till a temperature of the silicon substrate 7 with the oxide
film reaches 590.degree. C. Thereafter, a mixture gas of argon (Ar)
and acetylene (C2H2) is introduced into the thermal CVD furnace for
30 min. In this case, a pressure of the mixture gas of argon (Ar)
and acetylene (C2H2) is set to 1 kPa. Thus, the vertically-aligned
growth of the carbon nanotubes 1 on the silicon substrate 7 with
the oxide film is attained.
[0108] FIG. 18 shows the carbon nanotube groups 5 grown in vertical
alignment on the silicon substrate 7 with the oxide film. Each
individual carbon nanotube 1 is on the order of 10 nm in diameter
and on the order of 20 .mu.m in length. Further, the density of the
carbon nanotubes 1 of the carbon nanotube group 5 is approximately
1E11 pieces/cm2. The density of the carbon nanotubes each having
the diameter of 10 nm in a closest packing state is approximately
1E12 piece/cm2, and therefore an occupancy rate is merely 10%.
[0109] Next, a process of highly densifying the carbon nanotubes 1
of the carbon nanotube group 5 will be described with reference to
the drawings in FIGS. 19 through 25. At first, the carbon nanotube
group 5 is dipped into a solvent 9. The solvent 9, into which the
carbon nanotube group 5 is dipped, involves using organic solvents
such as DMF (N,N-dimethylformamide), dichloroethane, isopropyl
alcohol, ethanol, methanol, and inorganic solvents such as
water.
[0110] Specifically, the solvent 9 kept at a room temperature is
poured into a container 10 in a size capable of accommodating the
silicon substrate 7 with the oxide film. Then, the silicon
substrate 7 with the oxide film is inserted vertically or laterally
into the container 10 containing the solvent 9, thus dipping the
carbon nanotube groups 5 into the solvent 9.
[0111] FIGS. 19 through 21 are views showing a process of adhering
the solvent 9 to the carbon nanotube groups 5. In this process, the
silicon substrate 7 with the oxide film is inserted laterally into
the container 10 containing the solvent 9 and is, after dipping the
carbon nanotube groups 5 into the solvent 9, pulled up from the
container 10 containing the solvent 9. To be specific, as
illustrated in FIG. 19, the silicon substrate 7 with the oxide film
is disposed laterally. Then, as shown in FIG. 20, the silicon
substrate 7 with the oxide film is dipped into the container 10
containing the solvent 9. In this case, the whole of the carbon
nanotube groups 5 are dipped into the solvent 9. Namely, the
solvent 9 is adhered to the whole of the carbon nanotube groups
5.
[0112] Next, after the carbon nanotube groups 5 have been dipped
into the solvent 9 for about one minute, as illustrated in FIG. 21,
the carbon nanotube groups 5 are pulled out of the solvent 9. A
period of time for which the carbon nanotube groups 5 are dipped
into the solvent 9 is not limited to one minute, however, the
dipping time is properly adjusted, depending on a state of how much
the solvent 9 is adhered to the carbon nanotube groups 5.
[0113] FIGS. 22 through 24 are views showing a process of adhering
the solvent 9 to the carbon nanotube groups 5. In this process, the
silicon substrate 7 with the oxide film is inserted vertically into
the container 10 containing the solvent 9 and is, after dipping the
carbon nanotube groups 5 into the solvent 9, pulled up from the
container 10 containing the solvent 9. To be specific, as
illustrated in FIG. 22, the silicon substrate 7 with the oxide film
is disposed vertically. Then, as shown in FIG. 23, the silicon
substrate 7 with the oxide film is dipped into the container 10
containing the solvent 9. In this case, the whole of the carbon
nanotube groups 5 are dipped into the solvent 9. Namely, the
solvent 9 is adhered to the whole of the carbon nanotube groups
5.
[0114] Next, after the carbon nanotube groups 5 have been dipped
into the solvent 9 for about one minute, as illustrated in FIG. 24,
the carbon nanotube groups 5 are pulled out of the solvent 9. A
period of time for which the carbon nanotube groups 5 are dipped
into the solvent 9 is not limited to one minute, however, the
dipping time is properly adjusted, depending on a state of how much
the solvent 9 is adhered to the carbon nanotube groups 5.
[0115] Moreover, if the adhering state of the solvent 9 to the
carbon nanotube groups 5 is not so well, the adhering state of the
solvent 9 to the carbon nanotube groups 5 is improved by adding, to
the solvent 9, interfacial active agents such as SDS (Sodium
Dodecyl Sulfate) or functional molecules such as pyrene, parylene,
anthracene, porphyrin, phthalocyanine and DNA.
[0116] The fifth embodiment has exemplified the method of inserting
the silicon substrate 7 with the oxide film into the container 10
containing the solvent 9 and, after dipping the carbon nanotube
groups 5 into the solvent 9, pulling up the silicon substrate 7
with the oxide film out of the container 10 containing the solvent
9. The present disclosure is not, however, limited to this method,
and the solvent 9 may also be adhered to the carbon nanotube groups
5 by dropping the solvent 9 into the carbon nanotube groups 5 by
use of a spin coating method.
[0117] After adhering the solvent 9 to the carbon nanotube groups
5, the carbon nanotube groups 5 are dried. A method of drying the
carbon nanotube groups 5 may involve employing a method of
naturally drying the carbon nanotube groups 5 and may involve using
a method of quickly drying the carbon nanotube groups 5 by heating
the silicon substrate 7 with the oxide film to a temperature of
approximately 200.degree. C.
[0118] In the process of drying the carbon nanotube groups 5, the
carbon nanotubes 1 provided at the distal end portions (the end
portions of the carbon nanotube groups 5, which do not abut on the
silicon substrate 7 with the oxide film) of the carbon nanotube
groups 5 are attracted to each other by dint of capillary
attraction. The carbon nanotubes 1 attracted to each other are
tightly fitted to each other by intermolecular force. Therefore, as
illustrated in FIG. 25, at the distal end portions of the carbon
nanotube groups 5, there occurs a state where the carbon nanotubes
1 lean on each other. Namely, the carbon nanotube groups 5 are
organized, in which the density of the carbon nanotubes 1 at the
distal end portions of the carbon nanotube groups 5 is different
from the density of the carbon nanotubes 1 at the proximal end
portions of the carbon nanotube groups 5 (which are the end
portions, abutting on the silicon substrate with the oxide film, of
the carbon nanotube groups 5).
[0119] The density of the carbon nanotubes 1 of the thus-organized
differs at the distal end portions and the proximal end portions of
the carbon nanotube groups 5. Namely, there are organized the
carbon nanotube groups, in which the density of the carbon
nanotubes 1 differs at one side ends and the other side ends of the
carbon nanotube groups 5. The density of the carbon nanotubes 1 at
the distal end portions of the carbon nanotube groups 5 becomes
higher than the density of the carbon nanotubes 1 at the proximal
end portions of the carbon nanotube groups 5. Accordingly, in the
carbon nanotube groups 5 illustrated in FIG. 25, the density of the
carbon nanotubes 1 at the distal end portions of the carbon
nanotube groups 5 is as high as the closest packing level.
Sixth Embodiment
[0120] A sixth embodiment of the present disclosure will be
described with reference to the drawings in FIGS. 26 through 33.
With respect to the carbon nanotube groups 5 organized by the
method described in the first embodiment, the second embodiment or
the fifth embodiment, the carbon nanotubes 1 provided at one side
ends of the side ends of the carbon nanotube groups 5 have the high
density. The sixth embodiment will exemplify a method of highly
densifying the carbon nanotubes 1 provided at both side ends of the
carbon nanotube groups 5. Explained specifically is a method of
generating a state where the carbon nanotubes 1 at both side ends
of the carbon nanotube groups 5 are so formed as to lean on each
other, and the carbon nanotubes 1 of the carbon nanotube groups 5
lean on each other on the whole.
[0121] At first, a substrate 20 on which the carbon nanotube groups
5 are grown is prepared. The sixth embodiment uses, as the
substrate 20, the silicon substrate 2 exemplified in the first
embodiment and the second embodiment or the silicon substrate 7
with the oxide film exemplified in the fifth embodiment. Herein,
the process of increasing the density of the carbon nanotubes 1 of
the carbon nanotube group 5, which has been explained in the first
embodiment, the second embodiment or the fifth embodiment, is
termed the densification process. Further, the carbon nanotube
groups 5, in which the carbon nanotubes 1 of the carbon nanotube
groups 5 are highly-densified, are referred to as the
highly-densified carbon nanotube groups 5. The carbon nanotube
groups 5 grown on the substrate 20 are subjected to the
densification process explained in the first embodiment, the second
embodiment or the fifth embodiment, thereby highly densifying the
carbon nanotubes 1 of the carbon nanotube groups 5. FIG. 26
illustrates the highly-densified carbon nanotube groups 5 and the
substrate 20.
[0122] Next, as shown in FIG. 27, there is prepared a substrate 21
taking the same size as that of the substrate 20 on which the
carbon nanotube groups 5 are grown. Then, a low-melting metal film
22 is deposited on the surface of the substrate 21. For example,
the low-melting metal film 22 is solder, indium, etc. A thickness
of the low-melting metal film 22 deposited on the surface of the
substrate 21 is set to several micrometers (.mu.m). Thus, a
substrate 23 with the low-melting metal film is manufactured by
depositing the low-melting metal film 22 on the surface of the
substrate 21.
[0123] Then, as shown in FIG. 28, the substrate 23 with the
low-melting metal film and the substrate 20 are superposed on each
other in a way that interposes the carbon nanotube groups 5
therebetween. Specifically, the substrate 23 with the low-melting
metal film and the substrate 20 are superposed on each other so
that the low-melting metal film 22 deposited on the surface of the
substrate 21 abuts on the side ends (the side ends of the carbon
nanotube groups 5, which do not abut on the substrate 20) of the
carbon nanotube groups 5.
[0124] Then, the substrate 23 with the low-melting metal film is
heated so that the temperature of the substrate 23 with the
low-melting metal film reaches the melting point or above of the
low-melting metal film 22, and thereafter the substrate 23 with the
low-melting metal film is cooled. After cooling the low-melting
metal film 22, the substrate 23 with the low-melting metal film and
the substrate 20 are separated from each other. In the case of
separating the substrate 23 with the low-melting metal film and the
substrate 20 from each other, there occurs a state in which the
carbon nanotube groups 5 are tightly fitted to the substrate 23
with the low-melting metal film. Namely, the carbon nanotube groups
5 are peeled off the substrate 20 but tightly fitted to the
substrate 23 with the low-melting metal film. As shown in FIG. 29,
the carbon nanotube groups 5 are peeled off the substrate 20 but
tightly fitted to the substrate 23 with the low-melting metal
film.
[0125] If the tight-fitting between the substrate 20 and the carbon
nanotube groups 5 is strong, the carbon nanotube groups 5 are
neither peeled off the substrate 20 nor tightly fitted to the
substrate 23 with the low-melting metal film. In the first
embodiment, the second embodiment and the fifth embodiment, the
extremely thin catalyst layer (which is several nanometers (nm) or
under in thickness) is deposited on the silicon substrate 2 or the
silicon substrate 7 with the oxide film, and thereafter the carbon
nanotube groups 5 are grown thereon. In the sixth embodiment, the
silicon substrate 2 or the silicon substrate 7 with the oxide film
is used as the substrate 20. Accordingly, if the extremely thin
catalyst layer is deposited on the substrate 20, the tight-fitting
force between the substrate 20 and the carbon nanotube groups 5 is
weak. Therefore, such a problem does not arise that the carbon
nanotube groups 5 are not peeled off the substrate 20.
[0126] As shown in FIG. 29, the side ends, abutting on the
substrate 23 with the low-melting metal film, of the side ends of
the carbon nanotube groups 5 tightly fitted to the substrate 23
with the low-melting metal film have the higher density of the
carbon nanotubes 1 than the density of the other side ends (the
side ends, not abutting on the substrate 23 with the low-melting
metal film, of the side ends of the carbon nanotube groups 5). As
the carbon nanotube groups 5 get distanced farther from the
substrate 23 with the low-melting metal film, a horizontal width of
every carbon nanotube group 5 expands. Namely, as the carbon
nanotube groups 5 get distanced farther from the substrate 23 with
the low-melting metal film, the carbon nanotubes 1 of the carbon
nanotube groups 5 have a lower density.
[0127] The densification process explained in the first embodiment,
the second embodiment or the fifth embodiment is executed on the
substrate 23 with the low-melting metal film, to which the
high-density side ends of the carbon nanotubes 1 are tightly
fitted, in the both side ends of the carbon nanotube groups 5.
Namely, the densification process explained in the first
embodiment, the second embodiment or the fifth embodiment is
executed on the low-density side ends of the carbon nanotubes 1 in
the both side ends of the carbon nanotube groups 5.
[0128] When the densification process is executed on the
low-density side ends of the carbon nanotubes 1 in the both side
ends of the carbon nanotube groups 5, thereby organizing the carbon
nanotube groups 5 in which the carbon nanotubes 1 at both side ends
of the carbon nanotube groups 5 have the high densities.
[0129] FIG. 30 shows a process of dipping the carbon nanotube
groups 5 tightly fitted to the substrate 23 with the low-melting
metal film into the container 10 containing the solvent 9. FIG. 31
shows a process of pulling up the carbon nanotube groups 5 tightly
fitted to the substrate 23 with the low-melting metal film from the
container 10 containing the solvent 9. The densities of the carbon
nanotubes 1 at the both side ends of the carbon nanotube groups 5
illustrated in FIG. 31 are as high as the closest packing
level.
[0130] Moreover, in the case of utilizing low-melting metals
(alloy) having different melting points, the highly-densified
carbon nanotube groups 5 can have a much higher density. A method
of giving the much higher density to the carbon nanotube groups 5,
in which the carbon nanotubes 1 at the both side ends of the carbon
nanotube groups 5 are highly densified, will be described with
reference to FIGS. 32 and 33.
[0131] As shown in FIG. 32, there is prepared the substrate 23 with
the low-melting metal film that is tightly fitted with the carbon
nanotube groups 5 in which the carbon nanotubes 1 at both side ends
of the carbon nanotube groups 5 are highly densified, and a
substrate 30 with the low-melting metal film. The size of the
substrate 23 with the low-melting metal film is the same as that of
the substrate 30 with the low-melting metal film. The substrate 30
with the low-melting metal film is constructed by depositing a
low-melting metal film 32 on the surface of the substrate 31. For
example, the low-melting metal film 32 is solder, indium, etc. In
this case, the low-melting metal film 32 having the higher melting
point than that of the low-melting metal film 22 deposited on the
substrate 30 with the low-melting metal film, is deposited on the
surface of the substrate 31. Further, the thickness of the
low-melting metal film 32 deposited on the surface of the substrate
31 is set to several micrometers (.mu.m).
[0132] Next, as shown in FIG. 33, the substrate 23 with the
low-melting metal film and the substrate 30 with the low-melting
metal film are superposed on each other. Specifically, the
substrate 23 with the low-melting metal film and the substrate 30
with the low-melting metal film are superposed on each other so
that the side ends (the side ends, not abutting on the substrate 23
with the low-melting metal film, of the side ends of the carbon
nanotube groups 5) of the carbon nanotube groups 5 abut on the
low-melting metal film 32 deposited on the surface of the substrate
31.
[0133] Then, the substrate 23 with the low-melting metal film and
the substrate 30 with the low-melting metal film are heated so that
a temperature of the substrate 23 with the low-melting metal film
and a temperature of the substrate 30 with the low-melting metal
film are equal to or higher than the melting point of the
low-melting metal film 32. Thereafter, the substrate 23 with the
low-melting metal film and the substrate 30 with the low-melting
metal film are cooled. In this case, the substrate 23 and the
substrate 30 are cooled so that the temperature of the substrate 23
with the low-melting metal film and the temperature of the
substrate 30 with the low-melting metal film are equal to or higher
than the melting point of the low-melting metal film 22 but equal
to or lower than the melting point of the low-melting metal film
32.
[0134] Then, the substrate 23 with the low-melting metal film and
the substrate 30 with the low-melting metal film are separated from
each other. When the substrate 23 with the low-melting metal film
and the substrate 30 with the low-melting metal film are separated
from each other, there occurs a state where the carbon nanotube
groups 5 are tightly fitted to the substrate 30 with the
low-melting metal film. Namely, the carbon nanotube groups 5 are
peeled off the substrate 23 with the low-melting metal film but are
tightly fitted to the substrate 30 with the low-melting metal
film.
[0135] When equal to or higher than the melting point of the
low-melting metal film 22 but equal to or lower than the melting
point of the low-melting metal film 32, the low-melting metal film
22 deposited on the substrate 23 with the low-melting metal film is
in a melting state. Therefore, the tight-fitting between the carbon
nanotube groups 5 and the substrate 30 with the low-melting metal
film is stronger than the tight-fitting between the carbon nanotube
groups 5 and the substrate 23 with the low-melting metal film.
Accordingly, the carbon nanotube groups 5 are peeled off the
substrate 23 with the low-melting metal film but tightly fitted to
the substrate 30 with the low-melting metal film.
[0136] Then, the carbon nanotube groups 5 bonded to the substrate
30 with the low-melting metal film undergo the densification
process explained in the first embodiment, the second embodiment or
the fifth embodiment, whereby the carbon nanotubes 1 of the carbon
nanotube groups 5 can be further highly densified. This process can
be repeated a plural number of times, and the density of the carbon
nanotubes 1 of the carbon nanotube groups 5 can be made much
higher.
[0137] According to the sixth embodiment, the carbon nanotubes 1 of
the carbon nanotube groups 5 can be highly densified throughout the
carbon nanotube groups 5.
Seventh Embodiment
[0138] A seventh embodiment of the present disclosure will be
described with reference to the drawings in FIGS. 34 through 43.
The seventh embodiment will exemplify a method of applying, to a
heat radiation bump, the carbon nanotube groups 5 highly densified
by the densification process explained in the first embodiment, the
second embodiment or the fifth embodiment.
[0139] A face-up structure of joining a high-power transistor chip
40 directly to a package 41 has hitherto been employed. FIG. 34
illustrates conventional transistor packaging. The high-power
transistor chip 40 and the package 41 are connected by
wire-bonding. To be specific, electrodes 42 formed on the surface
of the high-power transistor chip 40 are connected to electrodes
(unillustrated) formed on the package 41 by wires such as gold
wires. The transistor packaging illustrated in FIG. 34 uses the
face-up structure and ensures a heat radiation property by
radiating the heat via the high-power transistor chip 40.
[0140] Moreover, flip-chip packaging is that the high-power
transistor chip 40 is reversed, and the electrodes 42 formed on the
surface of the high-power transistor chip 40 are connected to the
electrodes on the package 41 by carbon nanotube bumps 43. As
illustrated in FIG. 35, the flip-chip packaging is that the
electrodes 42 formed on the surface of the high-power transistor
chip 40 are connected to the electrodes (unillustrated) formed on
the surface of the package 41 by reversing the high-power
transistor chip 40. Namely, with the surface of the high-power
transistor chip 40 being directed to the package 41, the electrodes
42 formed on the surface of the high-power transistor chip 40 are
connected to the electrodes formed on the package 41. Herein, the
bump is a terminal formed in a protruded shape. The carbon nanotube
bumps 43 are the terminals provided by forming the carbon nanotube
groups 5 in the protruded shapes.
[0141] As illustrated in FIG. 36, the carbon nanotube bumps 43
connect the electrodes 42 (unillustrated) formed on the surface of
the high-power transistor chip 40 to the electrodes formed on the
package 41. In FIG. 36, the high-power transistor chip 40 is
reversed, and the electrodes 42 (unillustrated) formed on the
surface of the high-power transistor chip 40 are directed to the
package 41. Further, the carbon nanotube bumps 43 have a role of
heat radiation paths for radiating the heat generated by the
high-power transistor chip 40. The sufficient radiation of the heat
generated by the high-power transistor chip 40 entails increasing
the density of the carbon nanotubes 1 of the carbon nanotube bumps
43. The occupancy rate of the carbon nanotubes 1 of the
conventional carbon nanotube bumps 43 is on the order of 10%, and
hence the density of the carbon nanotubes 1 of the conventional
carbon nanotube bumps 43 has been desired to be increased.
[0142] The seventh embodiment applies, to the carbon nanotube bumps
43, the carbon nanotube groups 5 highly densified by the
densification process explained in the first embodiment, the second
embodiment or the fifth embodiment. To be specific, the electrodes
42 formed on the surface of the high-power transistor chip 40 are
connected to the electrodes formed on the package 41 by employing
the highly-densified carbon nanotube groups 5 as the carbon
nanotube bumps 43. Moreover, in the seventh embodiment, the
substrate on which the carbon nanotubes 1 are grown involves using
an aluminum nitride substrate 50. The aluminum nitride substrate 50
is used as a material for manufacturing the package 41. The
aluminum nitride substrate 50 used as the substrate on which the
carbon nanotubes 1 are grown are an exemplification, and the
present disclosure is not limited to this substrate.
[0143] As shown in FIG. 37, electrodes 51 are each formed of a
metal such as gold on the aluminum nitride substrate 50. Aluminum
is deposited up to a thickness of 5 nm on the electrodes 51. Then,
iron is deposited up to a thickness of 1 nm on aluminum deposited
on the electrodes 51. In this case, aluminum and iron are used as
catalysts for growing the carbon nanotubes 1.
[0144] Aluminum deposited on the electrodes 51 and iron deposited
on aluminum undergo patterning. In this case, patterning shapes of
aluminum and iron are set the same as the shape of the electrodes
42 formed on the surface of the high-power transistor chip 40.
Further, central positions of aluminum and iron shaped by the
patterning are set the same as the central positions of the
electrodes 42 formed on the surface of the high-power transistor
chip 40. Sizes of aluminum and iron shaped by the patterning may be
the same as or several times as large as the size of the electrodes
42 formed on the surface of the high-power transistor chip 40.
[0145] Next, the carbon nanotube groups 5 each having a length
equal to or longer than 20 .mu.m are grown on the aluminum nitride
substrate 50 by use of the method explained in the first embodiment
or the fifth embodiment. FIG. 38 illustrates the carbon nanotube
groups 5 grown on the aluminum nitride substrate 50. The occupancy
rate of the carbon nanotubes 1 of the carbon nanotube groups 5
shown in FIG. 38 is approximately 10%.
[0146] Then, the carbon nanotubes 1 at the side ends of the carbon
nanotube groups 5, which do not abut on the aluminum nitride
substrate 50, are highly densified by use of the densification
process described in the first embodiment, the second embodiment or
the fifth embodiment. In this case, the carbon nanotube groups 5
are grown so that a size of the diameter of the side ends of the
highly-densified carbon nanotubes 1 in the side ends of the carbon
nanotube groups 5, is set the same as the size of the electrodes 42
on the high-power transistor chip 40 or set smaller than the size
of the electrodes 42 on the high-power transistor chip 40.
[0147] A size of the catalyst deposited on the aluminum nitride
substrate 50 can be changed, thereby it is possible to change the
size of the diameter of the side ends of the highly-densified
carbon nanotubes 1 in the side ends of the carbon nanotube groups
5. Accordingly, on the occasion of patterning the catalyst
deposited on the aluminum nitride substrate 50 on which the carbon
nanotube groups 5 are grown, the size of the catalyst is changed by
taking into consideration the size of the electrodes 42 on the
high-power transistor chip 40. A relationship between the size of
the catalyst deposited on the aluminum nitride substrate 50 and the
size of the diameter of the side ends of the highly-densified
carbon nanotubes 1 in the side ends of the carbon nanotube groups
5, maybe obtained empirically or in simulation.
[0148] FIG. 39 shows the highly-densified carbon nanotube groups 5
and the aluminum nitride substrate 50. In the carbon nanotube
groups 5 organized by the method described in the first embodiment,
the second embodiment or the fifth embodiment, the carbon nanotubes
1 have different lengths. To be specific, there is a high
possibility that the carbon nanotube groups 5 are grown with
irregularity in the lengths of the carbon nanotubes 1. If the
irregularity in the lengths of the respective carbon nanotubes 1 of
the carbon nanotube groups 5 is large, a process of equalizing the
lengths of the carbon nanotubes 1 of the carbon nanotube groups 5
is carried out.
[0149] The process of equalizing the lengths of the carbon
nanotubes 1 of the carbon nanotube groups 5 will be described with
reference to FIGS. 40 through 43. As illustrated in FIG. 40, the
carbon nanotube groups 5 grown on the aluminum nitride substrate 50
are not uniform in terms of the lengths of the carbon nanotubes 1.
The carbon nanotube groups 5 shown in FIG. 40 are subjected to the
densification process described in the first embodiment, the second
embodiment or the fifth embodiment.
[0150] To begin with, an interlayer insulating film 60 is deposited
on the aluminum nitride substrate 50 in a way that covers the
carbon nanotube groups 5. The interlayer insulating film 60
involves using a porous silica film, an SOG (Spin On Glass) film,
etc. After depositing the interlayer insulating film 60 on the
aluminum nitride substrate 50, the interlayer insulating film 60 is
solidified by heating the aluminum nitride substrate 50 and the
interlayer insulating film 60. FIG. 41 is a view showing a
structure of the aluminum nitride substrate 50 on which the
interlayer insulating film 60 is deposited so as to cover the
carbon nanotube groups 5.
[0151] The interlayer insulating film 60 is deposited on the
aluminum nitride substrate 50, and, when executing a heating
treatment, the carbon nanotube groups 5 are hardened together with
the interlayer insulating film 60. After the carbon nanotube groups
5 have been hardened together with the interlayer insulating film
60, the carbon nanotube groups 5 and the interlayer insulating film
60 are polished by a chemical mechanical polishing (CMP) process.
In this case, the carbon nanotube groups 5 and the interlayer
insulating film 60 are polished till the lengths of the carbon
nanotubes 1 of the carbon nanotube groups 5 get uniform. FIG. 42
illustrates the aluminum nitride substrate 50 after the carbon
nanotube groups 5 and the interlayer insulating film 60 have been
polished.
[0152] Thereafter, the interlayer insulating film 60 deposited on
the aluminum nitride substrate 50 is removed. If unnecessary for
removing the interlayer insulating film 60 deposited on the
aluminum nitride substrate 50, the interlayer insulating film 60
deposited on the aluminum nitride substrate 50 may not be
removed.
[0153] Thus, the lengths of the carbon nanotubes 1 of the carbon
nanotube groups 5 are equalized, thereby enabling the carbon
nanotube groups 5 to be stably bonded to the high-power transistor
chip 40.
[0154] Given next is a description of a method of connecting the
electrodes 42 formed on the surface of the high-power transistor
chip 40 to the electrodes formed on the package 41 by employing the
carbon nanotube groups 5 as the carbon nanotube bumps 43.
[0155] To start with, the aluminum nitride substrate 50 utilized
for manufacturing the package 41 is prepared. The carbon nanotube
groups 5 are grown on the aluminum nitride substrate 50 by the
growth method of the carbon nanotube groups 5, which has been
explained in the first embodiment or the second embodiment. The
carbon nanotube groups 5 formed on the aluminum nitride substrate
50 are subjected to the densification process described in the
first embodiment, the second embodiment or the fifth embodiment.
Moreover, the carbon nanotube groups 5 formed on the aluminum
nitride substrate 50 may also be subjected to the process of
equalizing the lengths of the carbon nanotubes 1.
[0156] Next, gold is deposited up to a thickness of 1 .mu.m on the
carbon nanotube groups 5 formed on the aluminum nitride substrate
50. The thickness of gold deposited on the carbon nanotube groups 5
is an exemplification, and the present disclosure is not limited to
this thickness. Moreover, in the carbon nanotube groups 5 formed on
the aluminum nitride substrate 50, gold may be deposited on
portions desired to be bonded to the electrodes 42 formed on the
surface of the high-power transistor chip 40.
[0157] Then, the gold-deposited carbon nanotube groups 5 are bonded
to the electrodes 42 formed on the surface of the high-power
transistor chip 40 by use of a normal flip-chip bonder. The carbon
nanotube groups 5 are bonded to the electrodes 42 formed on the
surface of the high-power transistor chip 40 under a pressure of 6
kg/cm2 at a temperature of 345.degree.. The pressure and the
temperature are exemplifications, and the present disclosure is not
limited to these values.
[0158] FIG. 43 is a view showing a structure of the aluminum
nitride substrate 50 provided with the high-power transistor chip
40. In FIG. 43, the carbon nanotube groups 5 are employed as the
carbon nanotube bumps 43. The electrodes 42 formed on the surface
of the high-power transistor chip 40 are connected to electrodes 51
on the aluminum nitride substrate 50 via the carbon nanotube groups
5. The carbon nanotubes 1 at the side ends, bonded to the
high-power transistor chip 40, of the side ends of the carbon
nanotube groups 5, have a 10-fold density as high as the density of
the carbon nanotubes 1 at the side ends that are not bonded to the
high-power transistor chip 40. Therefore, the carbon nanotube bumps
43 have the higher heat radiation property than the conventional
carbon nanotube bumps 43 have. The highly-densified side ends of
the carbon nanotubes 1 in the side ends of the carbon nanotube
groups 5 are bonded to the electrodes 42 formed on the high-power
transistor chip 40, whereby the heat of the high-power transistor
chip 40 is radiated via the carbon nanotube groups 5.
[0159] Moreover, the electrodes 42 formed on the surface of the
high-power transistor chip 40 can be also connected to the
electrodes 51 on the aluminum nitride substrate 50 by use of the
carbon nanotube groups 5 including the highly-densified carbon
nanotubes 1 throughout. The carbon nanotube groups 5 including the
highly-densified carbon nanotubes 1 throughout can be manufactured
by the method explained in the sixth embodiment. A degree of
freedom of a design of the substrate for wiring can be expanded by
use of the carbon nanotube groups 5 including the highly-densified
carbon nanotubes 1 throughout.
Eighth Embodiment
[0160] An eighth embodiment of the present disclosure will be
described with reference to the drawings in FIGS. 44 through 51. At
the present, wiring for an LSI is multi-layered wiring such as 10-
or more-layered wiring, and copper is normally used as the wiring
material. As a current density increases accompanying a decrease in
wiring width of the LSI, an anxiety is disconnection due to
electromigration. Therefore, one scheme is that the vertical wiring
(via wiring) for the LSI is replaced with the carbon nanotubes 1
endurable against a much higher current density. FIG. 44
illustrates a structure of LSI 70. As illustrated in FIG. 44, the
LSI 70 is constructed of insulating films 72 in between a copper
wiring 71 is interposed and vias 73 each electrically connecting
the copper wiring 71 to another copper wiring 71.
[0161] The eighth embodiment will exemplify a method of applying,
to the LSI wiring, the carbon nanotube groups 5 that are highly
densified by the densification process described in the first
embodiment, the second embodiment or the fifth embodiment. In the
eighth embodiment, the vias 73 building up the LSI 70 shown in FIG.
44 are replaced with the highly-densified carbon nanotube groups 5.
A method of replacing the vias 73 building up the LSI 70 with the
highly-densified carbon nanotube groups 5, will be described with
reference to the drawings in FIGS. 45 through 51.
[0162] At the first onset, as illustrated in FIG. 45, a substrate
74 on which the carbon nanotube groups 5 are grown is prepared. In
this case, the silicon substrate 2 or the silicon substrate 7 with
the oxide film may also be used as the substrate 74, and another
substrate may also be available. The carbon nanotube groups 5 are
grown on the substrate 74 by employing the growth method of the
carbon nanotubes 1, which is shown in the first embodiment or the
fifth embodiment. Moreover, the carbon nanotube groups 5 are highly
densified by the densification process described in the first
embodiment, the second embodiment or the fifth embodiment. In the
eighth embodiment, a catalyst for growing the carbon nanotube
groups 5 on the substrate 74 involves using cobalt, iron and other
metals.
[0163] It is required that the carbon nanotube groups 5 be grown on
the substrate 74 for enabling the carbon nanotube groups 5 to be
disposed in positions of the vias 73 building up the LSI 70. Hence,
in the eighth embodiment, the catalyst undergoes patterning so as
to enable the carbon nanotube groups 5 to be disposed in the
positions of the vias 73 building up the LSI 70, and the carbon
nanotube groups 5 are grown on the substrate 74.
[0164] Next, a cobalt film 77 is deposited up to a thickness of 5
nm on electrodes 76 of the LSI substrate 75, then a tantalum film
78 is deposited up to a thickness of 5 nm on the cobalt film 77,
and a titanium film 79 is deposited up to a thickness of 5 nm on
the tantalum film 78. Note that an iron film, a nickel film, etc
may also be used as a substitute for the cobalt film 77. Further,
the cobalt film 77 may also be replaced with a film composed of a
cobalt alloy, an iron alloy or a nickel alloy.
[0165] The substrate 74 is superposed on the LSI substrate 75 on
which the cobalt film 77, the tantalum film 78 and the titanium
film 79 are deposited. Specifically, as shown in FIG. 46, the
substrate 74 and the LSI substrate 75 are superposed on each other
so that the side ends (the side ends, not abutting on the substrate
74, of the side ends of the carbon nanotube groups 5) of the carbon
nanotube groups 5 are brought into contact with the electrodes 76
of the LSI substrate 75. In this case, the substrate 74 and the LSI
substrate 75 are superposed on each other so that a longitudinal
direction of the substrate 74 becomes substantially parallel with a
longitudinal direction of the LSI substrate 75. Moreover, the
substrate 74 and the LSI substrate 75 are superposed on each other
by optical alignment so that the side ends of the carbon nanotube
groups 5 abut on the electrodes 76 of the LSI substrate 75.
[0166] The substrate 74 and the LSI substrate 75 in the state of
being superposed on each other are carried into the CVD furnace.
The vacuum evacuation is conducted within the CVD furnace, and
thereafter the stage on which the substrate 74 and the LSI
substrate 75 are placed is heated. Then, after a temperature within
the CVD furnace has been stabilized, a process gas (mixture gas) is
introduced under 1 kPa into the CVD furnace. In the eighth
embodiment, the process gas involves using argon (Ar) and acetylene
(C2H2). A hydrocarbon gas such as methane (CH4) and ethylene (C2H4)
or alcohol may be added to the process gas of argon (Ar) and
acetylene (C2H2). Further, the hydrocarbon gas such as methane
(CH4) and ethylene (C2H4) or alcohol may be used in place of
acetylene (C2H4) in the process gas. Moreover, the process gas may
consist of plural types of hydrocarbon gasses and may also consist
of the plural types of hydrocarbon gasses and alcohol.
[0167] The process gas is introduced into the CVD furnace, whereby
the cobalt film 77 deposited on the electrodes 76 of the LSI
substrate 75 comes to a melting state. Therefore, the carbon
nanotube groups 5 are firmly joined to the electrodes 76 of the LSI
substrate 75.
[0168] A temperature of the stage within the CVD furnace is
desirably a temperature (e.g., a temperature of 350.degree. C.) of
such a degree that though reacting on the cobalt film 77 and the
process gas, the carbon nanotubes 1 of the carbon nanotube groups 5
are not grown. Note that the temperature of the stage within the
CVD furnace can fluctuate depending on the type of the process gas
and the thickness of the film deposited on the LSI substrate
75.
[0169] After joining the carbon nanotube groups 5 to the electrodes
76 of the LSI substrate 75, the substrate 74 and the LSI substrate
75 are taken out of the CVD furnace. Then, the substrate 74 and the
LSI substrate 75 are separated from each other. In the case of
separating the substrate 74 and the LSI substrate 75 from each
other, there occurs a state in which the carbon nanotube groups 5
are tightly fitted to the electrodes 76 of the LSI substrate 75.
Namely, the carbon nanotube groups 5 are peeled off the substrate
74 but are tightly fitted to the electrodes 76 of the LSI substrate
75.
[0170] In the eighth embodiment, the carbon nanotube groups 5 are
grown on the substrate 74 by use of the growth method of the carbon
nanotubes 1 explained in the first embodiment or the fifth
embodiment. To be specific, an extremely thin catalyst layer (which
is several nanometers (nm) or under in thickness) is deposited on
the substrate 74, and thereafter the carbon nanotube groups 5 are
grown thereon. The extremely thin catalyst layer is deposited on
the substrate 74, and hence the tight-fitting force between the
substrate 74 and the carbon nanotube groups 5 is weak. Therefore,
such a problem does not arise that the carbon nanotube groups 5 are
not peeled off the substrate 74.
[0171] Further, as shown in FIG. 47, a gap between the substrate 74
and the LSI substrate 75 is filled with an interlayer insulating
film 80 such as the SOG film or the porous silica film, and
thereafter the substrate 74 and the LSI substrate 75 may be
separated. In this case, the interlayer insulating film 80 is
dissolved in a proper solvent, thus setting the interlayer
insulating film 80 in a liquid state.
[0172] Then, the substrate 74 and the LSI substrate 75 are dipped
in the liquid interlayer insulating film 80, thereby filling the
gap between the substrate 74 and the LSI substrate 75 with the
interlayer insulating film 80. Further, in place of this scheme,
the liquid interlayer insulating film 80 is instilled in the gap
between the substrate 74 and the LSI substrate 75, thus filling the
gap between the substrate 74 and the LSI substrate 75 with the
interlayer insulating film 80.
[0173] Then, the substrate 74 and the LSI substrate 75 are
subjected to the thermal treatment, thereby solidifying the
interlayer insulating film 80 and forming the interlayer insulating
film 80 between the substrate 74 and the LSI substrate 75.
[0174] If the substrate 74 and the LSI substrate 75 are separated
from each other before forming the interlayer insulating film 80 in
the gap between the substrate 74 and the LSI substrate 75, the
interlayer insulating film 80 is formed with respect to the LSI
substrate 75 to which the carbon nanotube groups 5 are tightly
fitted. Specifically, the liquid interlayer insulating film 80 is
applied over the LSI substrate 75 to which the carbon nanotube
groups 5 are tightly fitted by making use of the spin coating,
thereby forming the interlayer insulating film 80 with respect to
the LSI substrate 75.
[0175] Further, after forming the interlayer insulating film 80 on
the substrate 74, the substrate 74 and the LSI substrate 75 may be
superposed on each other. Namely, the substrate 74 and the LSI
substrate 75 are superposed on each other by use of the substrate
74 on which the interlayer insulating film 80 has already be
formed. In this case, the interlayer insulating film 80 is formed
on the substrate 74 by the following method.
[0176] To begin with, the interlayer insulating film 80 is
deposited on the substrate 74 in a way that covers the carbon
nanotube groups 5. After depositing the interlayer insulating film
80 on the substrate 74, the heating treatment is conducted, and the
interlayer insulating film 80 is thus solidified. FIG. 48 is a view
showing a structure of the substrate 74 on which the interlayer
insulating film 80 is deposited in a way that covers the carbon
nanotube groups 5. The interlayer insulating film 80 is deposited
on the substrate 74, and the heating treatment is carried out,
whereby the carbon nanotube groups 5 are solidified together with
the interlayer insulating film 80. Thus, the interlayer insulating
film 80 is formed on the substrate 74.
[0177] Moreover, after the carbon nanotube groups 5 have been
solidified together with the interlayer insulating film 80, the
interlayer insulating film 80 is polished by the chemical
mechanical polishing (CMP) process. In this case, the interlayer
insulating film 80 is polished so that the distal ends of the
carbon nanotube groups 5 get exposed. Furthermore, if the lengths
of the carbon nanotubes 1 of the carbon nanotube groups 5 are not
uniform, the carbon nanotube groups 5 and the interlayer insulating
film 80 may also be polished till the lengths of the carbon
nanotubes 1 of the carbon nanotube groups 5 are equalized.
[0178] Moreover, in the case of superposing the substrate 74 and
the LSI substrate 75 by using the substrate 74 on which the
interlayer insulating film 80 has already been formed, the distal
ends of the carbon nanotube groups 5 may be protruded. Namely, as
illustrated in FIG. 49, the length of the carbon nanotube group 5
is set larger than a thicknesswise length of the interlayer
insulating film 80 formed on the substrate 74. To be specific, the
interlayer insulating film 80 is wet-etched or dry-etched, thus
cutting only the interlayer insulating film 80. The distal ends of
the carbon nanotube groups 5 can be protruded by cutting only the
interlayer insulating film 80.
[0179] The wet etching in the eighth embodiment involves using
liquid or gas dilute hydrogen fluoride. In the case of employing
the porous silica film as the interlayer insulating film 80, if the
wet etching is performed, only the interlayer insulating film 80 is
etched. Therefore, the distal ends of the carbon nanotube groups 5
can be protruded. In the case of cutting the interlayer insulating
film 80 by the dry etching, argon ions impinge on the interlayer
insulating film 80 by the sputtering method. When executing the dry
etching, only the interlayer insulating film 80 is etched.
Therefore, the distal ends of the carbon nanotube groups 5 can be
protruded.
[0180] Thus, after forming the interlayer insulating film 80 on the
substrate 74, the substrate 74 and the LSI substrate 75 are
superposed on each other and then separated from each other,
whereby the interlayer insulating film 80 is formed on the LSI
substrate 75, and there occurs a state in which the carbon nanotube
groups 5 are tightly fitted to the LSI substrate 75.
[0181] Next, the LSI substrate 75 formed with the interlayer
insulating film 80 is subjected to the chemical mechanical
polishing (CMP) process, and the carbon nanotube groups 5 and the
interlayer insulating film 80 are polished till the length of the
carbon nanotube group 5 and the thickness of the interlayer
insulating film 80 reach desired ranges. The LSI substrate 75
formed with the interlayer insulating film 80 may also be an LSI
substrate 75 that is formed with the interlayer insulating film 80
after separating the substrate 74 and the LSI substrate 75 from
each other, and may also be an LSI substrate 75 that is formed with
the interlayer insulating film 80 before separating the substrate
74 and the LSI substrate 75 from each other. FIG. 50 illustrates
the LSI substrate 75 after polishing the carbon nanotube groups 5
and the interlayer insulating film 80.
[0182] Next, copper wiring 71 is formed on the LSI substrate 75. To
be specific, copper is deposited on the carbon nanotube groups 5
tightly fitted to the LSI substrate 75, and further deposited on
the interlayer insulating film 80 formed on the LSI substrate 75.
Then, the deposited copper undergoes patterning, and the copper
wiring 71 is thus formed on the LSI substrate 75. The interlayer
insulating film 80 is formed between the copper wiring 71 and
another copper wiring 71. The interlayer insulating film 80 may not
be, however, formed at this stage. FIG. 51 illustrates the LSI
substrate 75 after forming the copper wiring 71.
[0183] A first wiring process is a process of forming the carbon
nanotube groups 5 and the interlayer insulating film 80 on the LSI
substrate 75, and forming the copper wiring 71 on the carbon
nanotube groups 5 and on the interlayer insulating film 80. After
executing the first wiring process, the carbon nanotube groups 5
are further formed on the LSI substrate 75. Namely, the carbon
nanotube groups 5 are formed on the copper wiring 71, thereby
obtaining the multi-layered LSI substrate 75. A process of forming
the carbon nanotube groups 5 on the copper wiring 71 will
hereinafter be described.
[0184] As shown in FIG. 52, the substrate 74, on which the carbon
nanotube groups 5 are grown, is prepared. The process of highly
densifying the carbon nanotube groups 5 grown on the substrate 74
is the same as the first wiring process. Further, the process of
patterning the catalyst so that the carbon nanotube groups 5 can be
disposed in the positions of the vias 73 building up the LSI
substrate 75 and growing the carbon nanotube groups 5 on the
substrate 74, is the same as the first wiring process. Moreover,
the process of patterning the catalyst so that the carbon nanotube
groups 5 can be disposed in the positions of the vias 73 building
up the LSI 70 and growing the carbon nanotube groups 5 on the
substrate 74, is the same as the first wiring process.
[0185] Next, the cobalt film 77 is deposited up to a thickness of 5
nm on the copper wiring 71, the tantalum film 78 is deposited up to
a thickness of 5 nm on the cobalt film 77, and the titan film 79 is
deposited up to a thickness of 5 nm on the tantalum film 78.
Incidentally, the film composed of iron, nickel, etc may be used as
a substitute for the cobalt film 77.
[0186] Then, the LSI substrate 75 formed with the copper wiring 71
and the substrate 74 are superposed on each other. To be specific,
as illustrated in FIG. 53, the substrate 74 and the LSI substrate
75 are superposed on each other so that the side ends of the carbon
nanotube groups 5, which do not abut on the substrate 74, are
brought into contact with the copper wiring 71. In this case, the
substrate 74 and the LSI substrate 75 are superposed on each other
so that the longitudinal direction of the substrate 74 becomes
substantially parallel with the longitudinal direction of the LSI
substrate 75. Moreover, the substrate 74 and the LSI substrate 75
are superposed on each other by the optical alignment so that the
side ends of the carbon nanotube groups 5 abut on the electrodes 76
of the LSI substrate 75.
[0187] Herein, the method of joining, to the copper wiring 71, the
side ends (the side ends, not abutting on the substrate 74, of the
carbon nanotube groups 5) of the carbon nanotube groups 5, is the
same as the method of joining the side ends of the carbon nanotube
groups 5 to the electrodes 76 in the first wiring process.
[0188] Then, after the gaps between the substrate 74 and the copper
wiring 71 has been filled with the interlayer insulating film 80,
the substrate 74 and the LSI substrate 75 are separated from each
other. When the substrate 74 and the LSI substrate 75 are separated
from each other, there occurs a state where the carbon nanotube
groups 5 and the copper wiring 71 are tightly fitted to each other.
Namely, the carbon nanotube groups 5 are peeled off the substrate
74 but tightly fitted to the copper wiring 71. FIG. 54 shows a
state in which the carbon nanotube groups 5 are peeled off the
substrate 74 but tightly fitted to the copper wiring 71 formed on
the LSI substrate 75.
[0189] Next, the LSI substrate 75 formed with the interlayer
insulating film 80 is subjected to the chemical mechanical
polishing (CMP) process, and the carbon nanotube groups 5 and the
interlayer insulating film 80 are polished till the length of the
carbon nanotube group 5 and the thickness of the interlayer
insulating film 80 reach the desired ranges. FIG. 55 illustrates
the LSI substrate 75 after polishing the carbon nanotube groups 5
and the interlayer insulating film 80.
[0190] Then, the copper wiring 71 is formed on the LSI substrate
75. The method of forming the copper wiring 71 on the LSI substrate
75 is the same as the first wiring process. A second wiring process
is a process of forming the carbon nanotube groups 5 and the
interlayer insulating film 80 on the copper wiring 71, and further
forming the copper wiring 71. The material and the method used for
the first wiring process can be employed for the second wiring
process.
[0191] In the eighth embodiment, there is executed the first wiring
process of forming the carbon nanotube groups 5 and the interlayer
insulating film 80 on the LSI substrate 75, and forming the copper
wiring 71 on the carbon nanotube groups 5 and on the interlayer
insulating film 80. Then, according to the eighth embodiment, there
is executed the second wiring process of forming the carbon
nanotube groups 5 and the interlayer insulating film 80 on the
copper wiring 71, and further forming the copper wiring 71. The
multi-layered LSI using the carbon nanotube groups 5 is organized
by repeating the second wiring process.
[0192] Further, the method of bonding the carbon nanotube groups 5
to the electrodes 76 or the copper wiring 71 by employing the
cobalt film 77, the tantalum film 78 and the titanium film 79 in
the eighth embodiment, can be applied to the seventh embodiment.
Namely, the carbon nanotube groups 5 may be bonded to the
electrodes formed on the surface of the high-power transistor chip
40 in the seventh embodiment by making use of the method of bonding
the carbon nanotube groups 5 to the electrodes 76 in the eighth
embodiment.
[0193] According to the eighth embodiment, the vias 73 building up
the LSI 70 are replaced with the highly-densified carbon nanotube
groups 5, thereby enabling the possibility of the disconnection due
to the electromigration to be reduced. Namely, it is feasible to
reduce the possibility of the disconnection between the electrodes
76 building up the LSI 70 and the copper wiring 71. Even when a
current density rises, it is possible to reduce a possibility of
disconnection between the electrodes and the conductive
material.
Modified Example
[0194] In the first embodiment through the eighth embodiment, a
carbon nanofiber may be employed in place of the carbon nanotube 1.
A growth method of the carbon nanofiber is the same as the growth
method of the carbon nanotube 1, and its description is herein
omitted. Further, the structures and the methods in the first
embodiment through the eighth embodiment of the present disclosure
can be applied to hyperfine line-shaped substances such as the
carbon nanotubes 1 and the carbon nanofibers. Moreover, the
structures and the methods in the first embodiment through the
eighth embodiment of the present disclosure can be applied to
carbon fibers. Still further, the structures and the methods in the
first embodiment through the eighth embodiment of the present
disclosure can be applied to hollowed carbon fibers and
non-hollowed carbon fibers. In the aggregate structure of carbon
fibers according to the present disclosure, the carbon fibers may
be hollowed.
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