U.S. patent application number 14/831009 was filed with the patent office on 2015-12-10 for fabrication of iii-nitride power semiconductor device.
The applicant listed for this patent is International Rectifier Corporation. Invention is credited to Robert Beach, Paul Bridger, Michael A. Briere.
Application Number | 20150357182 14/831009 |
Document ID | / |
Family ID | 37882467 |
Filed Date | 2015-12-10 |
United States Patent
Application |
20150357182 |
Kind Code |
A1 |
Beach; Robert ; et
al. |
December 10, 2015 |
Fabrication of III-Nitride Power Semiconductor Device
Abstract
A method of fabricating a III-nitride power semiconductor device
that includes growing a transition layer over a substrate using at
least two distinct and different growth methods.
Inventors: |
Beach; Robert; (La
Crescenta, CA) ; Briere; Michael A.; (Scottsdale,
AZ) ; Bridger; Paul; (Altadena, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
International Rectifier Corporation |
El Segundo |
CA |
US |
|
|
Family ID: |
37882467 |
Appl. No.: |
14/831009 |
Filed: |
August 20, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14515449 |
Oct 15, 2014 |
9117671 |
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14831009 |
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14135425 |
Dec 19, 2013 |
8865575 |
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14515449 |
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11534855 |
Sep 25, 2006 |
8614129 |
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14135425 |
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60722510 |
Sep 30, 2005 |
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Current U.S.
Class: |
438/479 ;
438/478 |
Current CPC
Class: |
H01L 21/0254 20130101;
H01L 21/02425 20130101; H01L 29/2003 20130101; H01L 29/7787
20130101; H01L 21/02458 20130101; H01L 21/0262 20130101; H01L
21/02631 20130101; H01L 29/66462 20130101; H01L 21/0242 20130101;
H01L 21/02507 20130101; H01L 21/02381 20130101; H01L 21/02502
20130101; H01L 21/02378 20130101 |
International
Class: |
H01L 21/02 20060101
H01L021/02 |
Claims
1-62. (canceled)
63: A method of fabricating a power semiconductor device,
comprising: providing a substrate; growing a first III-nitride
layer using a growth method selected from the group consisting of
MBE and HVPE, and a second III-nitride layer over said first
III-nitride layer using a MOCVD growth method; forming an active
semiconductor region, wherein at least one of said first and second
III-nitride layers act to transition lattice mismatch between said
substrate and said active semiconductor region.
64: The method of claim 63, wherein at least one of said first and
second III-nitride layers further acts to transition thermal
expansion characteristics between said substrate and said active
semiconductor region.
65: The method of claim 63, wherein said active semiconductor
region comprises first and second III-nitride semiconductor
bodies.
66: The method of claim 63, wherein said substrate comprises
material selected from the group consisting of silicon, silicon
carbide, and sapphire.
67: The method of claim 63, wherein said first III-nitride layer
has a uniform composition.
68: The method of claim 63, wherein said first III-nitride layer
has a graded composition.
69: The method of claim 63, wherein said second III-nitride layer
has a uniform composition.
70: The method of claim 63, wherein said second III-nitride layer
has a graded composition.
71: A method of fabricating a power semiconductor device,
comprising: providing a substrate; growing a first III-nitride
layer using a MOCVD growth method, and a second III-nitride layer
over said first III-nitride layer using a growth method selected
from the group consisting of HVPE and MBE; forming an active
semiconductor region, wherein at least one of said first and second
III-nitride layers act to transition lattice mismatch between said
substrate and said active semiconductor region.
72: The method of claim 71, wherein at least one of said first and
second III-nitride layers further acts to transition thermal
expansion characteristics between said substrate and said active
semiconductor region.
73: The method of claim 71, wherein said active semiconductor
region comprises first and second III-nitride semiconductor
bodies.
74: The method of claim 71, wherein said substrate comprises
material selected from the group consisting of silicon, silicon
carbide, and sapphire.
75: The method of claim 71, wherein said first III-nitride layer
has a uniform composition.
76: The method of claim 71, wherein said first III-nitride layer
has a graded composition.
77: The method of claim 71, wherein said second III-nitride layer
has a uniform composition.
78: The method of claim 71, wherein said second III-nitride layer
has a graded composition.
Description
RELATED APPLICATION
[0001] This application claims benefit of U.S. Provisional
Application Ser. No. 60/722,510, filed Sep. 30, 2005, entitled
Method for Improving the Quality of an Aluminum Nitride Layer in a
III-Nitride Semiconductor Device, to which a claim of priority is
hereby made and the disclosure of which is incorporated by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for fabricating a
semiconductor device.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to semiconductor devices and
more particularly to III-nitride semiconductor devices and methods
of fabricating III-nitride semiconductor devices.
[0004] A III-V semiconductor is a semiconductor material that is
composed of a group III element and a group V element III-V
semiconductors are desirable for power applications, but have not
been exploited extensively due in part to difficulties in
fabrication.
[0005] For example, one commercially desirable III-V semiconductor
is III-nitride. Note that as used herein III-nitride semiconductor
or GaN-based semiconductor refers to a semiconductor alloy from the
InAlGaN system. Examples of alloys from the InAlGaN system include
GaN, AlGaN, AlN, InN, InGaN, and InAlGaN. Note that while nitrogen
is present in each alloy, the presence and proportion of In, Al, or
Ga can be varied to obtain an alloy in the InAlGaN system.
[0006] III-nitride semiconductor devices are desirable for power
applications due in large part to the high band gap of III-nitride
semiconductor materials. To fabricate a III-nitride semiconductor
device at least one III-nitride semiconductor alloy (i.e. an alloy
from the InAlGaN system) needs to be formed over a substrate. The
three well known substrate materials for III-nitride semiconductor
devices are sapphire, SiC and Si.
[0007] Silicon substrates are more desirable commercially because
of low cost, and high thermal conductivity. However, due to lattice
mismatch and differences in the thermal expansion characteristics
of III-nitride semiconductor alloys and silicon, thick III-nitride
semiconductor layers (e.g. more than 1 micron thick) either crack
or cause the silicon wafer to bend. It should be noted that the
cracking problem associated with thick III-nitride semiconductor
layers is not experienced only when a silicon substrate is used,
and thus the problem is not limited to III-nitride semiconductor
that is formed on silicon substrates.
[0008] To overcome the cracking problem a transition layer is
disposed between the active portion of the device and the
substrate. Referring thus to FIG. 1, a known III-nitride
semiconductor device includes an active semiconductor region 10
formed on transition layer 12, which is formed over substrate 14.
Substrate 14 is, for example, a silicon diode.
[0009] Active region 20 includes a first III-nitride semiconductor
body 16 of one band gap, and a second III-nitride semiconductor
body 18 of another band gap forming a heterojunction with first
III-nitride semiconductor body 16. A two dimensional electron gas
(2DEG) is formed at the heterojunction of first III-nitride
semiconductor body 16 and second III-nitride semiconductor body 18
through which current is conducted between first power electrode 20
(e.g. source electrode) and second power electrode 22 (e.g. drain
electrode) both electrically coupled to second III-nitride
semiconductor body 18. As is well known, application of a proper
voltage to gate electrode 24 can disrupt, or restore 2DEG in order
to control the current between first power electrode 20 and second
power electrode 22.
[0010] In order to obtain the best possible control over the
current between first power electrode 20, and second power
electrode 22, it is desirable to ensure that current cannot find
any alternative path but through the 2DEG. It has, however, been
observed that current can find a leakage path through transition
layer 12 and trough substrate 14, when substrate 14 is electrically
conductive.
[0011] It is desirable to reduce or eliminate the leakage paths
through transition layer 12 in order to improve the switching
characteristics of a III-nitride power semiconductor device.
SUMMARY OF THE INVENTION
[0012] To reduce or eliminate the leakage paths through the
transition layer a method according to the present invention
includes growing a first III-nitride layer over a substrate using
one growth technique and a second III-nitride layer over the first
III-nitride layer using a second distinct growth technique that is
different from the first growth technique.
[0013] According to another embodiment of the present invention, to
form the transition layer a third III-nitride body is grown over
the second III-nitride body using a third III-nitride growth
technique that is distinct and different from the first and the
second growth techniques.
[0014] The growth technique that can be used in a fabrication
method according to the present invention can be, for example,
molecular beam epitaxy (MBE), hydride vapor phase epitaxy (HVPE),
and metal organic chemical vapor deposition (MOCVD). These
techniques can be applied in any sequence to alternately form
III-nitride layers until the desire thickness has been
achieved.
[0015] Other features and advantages of the present invention will
become apparent from the following description of the invention
which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 shows a cross-sectional view of a III-nitride
semiconductor device according to the prior art.
[0017] FIG. 2 illustrates a portion of a semiconductor device
fabricated according to the first embodiment of the present
invention.
[0018] FIG. 3 illustrates a portion of a semiconductor device
fabricated according to a variation of the first embodiment of the
present invention.
[0019] FIG. 4 illustrates a portion of a semiconductor device
fabricated according to the second embodiment of the present
invention.
[0020] FIG. 5 illustrates a portion of a semiconductor device
fabricated according to a variation of the second embodiment of the
present invention.
DETAILED DESCRIPTION OF THE FIGURES
[0021] According to the present invention, in order to reduce the
leakage path through the transition layer, the transition layer is
grown to its final thickness using at least two distinct growth
techniques.
[0022] Referring to FIG. 1, in a first embodiment of the present
invention a transition layer 13 is grown over a major surface of a
conductive substrate (e.g. Si, or SiC) by growing a first
III-nitride layer 26 using a first growth method, and then growing
a second III-nitride layer 28 over first III-nitride layer 26 using
a second distinct and different method of growth. Thereafter, an
active region can be grown over transition layer 13 fabricated
according to the present invention.
[0023] A growth method that can be used in a fabrication method
according to the present invention can be, for example, MBE, HVPE,
and MOCVD. These methods can be alternated in any desired manner.
Table 1 provides a few possible combinations.
TABLE-US-00001 TABLE 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 First
III- MBE MBE HVPE HVPE MOCVD MOCVD nitride layer 26 Second III-
HVPE MOCVD MBE MOCVD HVPE MBE nitride layer 28
[0024] It should be noted that transition layer 13 fabricated
according to the present invention is not restricted to two layers.
Rather, it may include multiple layers of first III-nitride
semiconductor layers 26 and second III-nitride semiconductor layers
28 alternately formed using distinct and different growth
techniques.
[0025] Referring now to FIG. 4, in a method according to another
embodiment of the present invention, transition layer 13 includes
first III-nitride layer 26 grown using a first growth technique,
second III-nitride layer 28 formed over first III-nitride layer 26
using a second growth technique distinct and different from the
first growth technique, and third III-nitride layer 30 formed over
second III-nitride layer 28 using a growth technique distinct and
different from first growth technique and second growth technique.
A distinct growth technique which may be used to form a transition
layer 13 according to the present invention can be, for example,
MBE, HVPE, and MOCVD. These methods can be alternated in any
desired sequence. Table 2 illustrates some possible examples.
TABLE-US-00002 TABLE 2 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 First
III- MBE MBE MOCVD MOCVD HVPE HVPE nitride layer 26 Second III-
HVPE MOCVD MBE HVPE MBE MOCVD nitride layer 28 Third III- MOCVD
HVPE HVPE MBE MOCVD MBE nitride layer 30
[0026] It should be noted that transition layer 13 is not
restricted to first III-nitride layer 26, second III-nitride layer
28, and III-nitride layer 30. Referring to FIG. 5, for example,
transition layer 13 can include a plurality of first III-nitride
layers 26, a plurality of second III-nitride layers 28, and a
plurality of third III-nitride layers grown alternately.
[0027] Note that although FIG. 5 shows a sequence including first
III-nitride layer 26, second III-nitride layer 28, third
III-nitride layer 30, first III-nitride layer 26, second
III-nitride layer 28, third III-nitride layer 30, a transition
layer according to the present invention can be grown using any
growth sequence. For example, transition layer may be formed to
have the sequence layer 26, layer 28, layer 30, layer 28, layer 26,
layer 30, and so on.
[0028] Note that the preferred material for a transition layer
according to the present invention is AlN. Thus, each III-nitride
layer in a transition layer 13 grown according to the present
invention may be comprised of AlN grown according to a distinct,
and different method.
[0029] Note also that each III-nitride layer in a transition layer
13 may have a uniform composition, or a varying composition (e.g.
graded composition). Moreover, each III-nitride layer can have a
different composition. For example, in a transition layer 13 first
III-nitride layer 26 may have a uniform composition, second
III-nitride layer 28 may have a graded composition, and third
III-nitride layer 30 may have a composition that varies in discrete
steps rather than smoothly and gradually as would be the case in a
graded composition.
[0030] A device fabricated according to the present invention would
include an active region formed over transition layer 13 that is
grown according to the present invention. The active region may
include a III-nitride heterojunction similar to the heterojunction
detailed above with reference to FIG. 1, or it may be any other
type of device.
[0031] Although the present invention has been described in
relation to particular embodiments thereof, many other variations
and modifications and other uses will become apparent to those
skilled in the art. It is preferred, therefore, that the present
invention be limited not by the specific disclosure herein, but
only by the appended claims.
* * * * *