CN102683280A - 半导体制程方法 - Google Patents
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Abstract
本发明提供一种半导体制程方法,包含下列步骤:提供一成长基板;在该成长基板上形成一半导体基板;在该半导体基板与该成长基板之间形成一第一凹凸结构;以及改变该成长基板与该半导体基板的温度。
Description
技术领域
本发明相关于一种半导体制程方法,尤指关于剥离半导体基板的半导体制程方法。
背景技术
在传统的发光二极管制程(Light-Emitting Diode;LED)中,为了在成长基板上成长出较高品质的氮化物半导体(例如:形成镓基(GaN-based)磊晶薄膜),一般会选择晶体结构与氮化镓的晶体结构类似的蓝宝石(Al-2O3)基板作为成长基板。但蓝宝石基板在导电性质与导热性质上是比较差的,因此氮化镓发光二极管在高电流、高功率、长时间操作下,存在着散热不佳、影响晶粒的发光效率与发光面积、可靠度不良等问题,因而对氮化镓发光二极管的制造与发光效率的提升造成阻碍与限制。
为了改善上述缺失,传统作法是去除蓝宝石基板,已知的技术是以晶圆接合技术将氮化物半导体元件从蓝宝石成长基板转移至接合基板,藉以使LED的元件特性提升,也就是将氮化镓元件磊晶层自蓝宝石基板剥离,转移至具有高导电率、高导热率的基板。在上述制程中,大部分以激光剥离(LaserLift Off)技术来去除蓝宝石成长基板。然而激光剥离法会使LED的元件特性劣化,影响LED元件的良率,而且激光剥离成本较高。因此,如果能在晶圆接合过程中将氮化物半导体元件从成长基板剥离,避免使用激光剥离技术,则能大大降低制造成本。
职是之故,申请人鉴于已知技术中所产生的缺失,经过悉心试验与研究,并一本锲而不舍的精神,终构思出本案“半导体制程方法”,能够克服上述缺点,以下为本案的简要说明。
发明内容
本发明提出一种新的制程技术,在制程中减少成长基板与氮化物半导体基板间的接触面积,在晶圆接合步骤因为加热而产生温度变化的过程中,因为成长基板与氮化物半导体的膨胀系数不同,产生应力集中,藉此导致氮化物半导体基板与成长基板剥离而制造出氮化物半导体元件。无需使用激光剥离技术来进行去除成长基板的制程,因而有效降低制程成本。
根据本发明的第一构想,提供一种半导体制程方法,包含下列步骤:提供一成长基板;在该成长基板上形成一半导体基板;在该半导体基板与该成长基板之间形成一第一凹凸结构;以及改变该成长基板与该半导体基板的温度。
较佳地,改变该成长基板与该半导体基板的温度更包括一晶圆接合步骤:加热该成长基板与该半导体基板,并施加一压力使该半导体基板接合至一接合基板。
较佳地,在改变该成长基板与该半导体基板的温度之前包括一步骤:在该半导体基板上形成一半导体元件。
较佳地,该接合基板的材质为一铜材质、一铝材质、一硅材质、一钻石材质、一铜合金材质或一铝合金材质其中之一。
较佳地,该半导体基板是一氮化物半导体基板,而该成长基板为一氧化铝材质、一蓝宝石(Sapphire)材质、一碳化硅(SiC)材质或一硅(Si)材质其中之一。
较佳地,在该半导体基板形成一第一凹凸结构是通过一化学湿式蚀刻或一干式蚀刻来图形化该半导体基板而形成该第一凹凸结构,以减少该半导体基板与该成长基板间的接触面积。
较佳地,该化学湿式蚀刻为使用一氢氧化钾(KOH)溶液进行蚀刻。
较佳地,在该成长基板上形成一半导体基板之前更包括以下步骤:在该成长基板上形成一介电层;以及在该介电层上以曝光、显影与蚀刻的方式形成一第二凹凸结构。
较佳地,在该半导体基板与该成长基板间形成一第一凹凸结构之前更包括以下步骤:在该第二凹凸结构上形成该半导体基板;以及以一湿式蚀刻方式去除该介电层以形成该第一凹凸结构。
较佳地,该湿式蚀刻方式为使用氟化氢(HF)溶液。
较佳地,该介电层为一二氧化硅材质。
较佳地,该第二凹凸结构裸露出该成长基板且为一连续凹凸结构。
根据本发明的第二构想,提供一种半导体制程方法,包含下列步骤:提供一第一基板,其具有一上表面;提供一第二基板,其具有一下表面;减少该上表面与该下表面间的一接触面积;以及加热该第一与该第二基板。
根据本发明的第三构想,提供一种半导体制程方法,包含下列步骤:提供一第一基板,其具有一上表面;提供一第二基板,其具有一下表面与该上表面接触;以及加热该第一与该第二基板,以使该上表面与该下表面处于分离状态。
附图说明
图1为本发明第一较佳实施例的流程图。
图2为说明第一较佳实施例的结构图。
图3为说明第一较佳实施例的结构图。
图4为说明第一较佳实施例的结构图。
图5为说明第一较佳实施例的结构图。
图6为本发明第一较佳实施例的流程图。
图7为说明第一较佳实施例的结构图。
图8(a)与图8(b)说明第一较佳实施例的结构图。
图9为说明第一较佳实施例的结构图。
图10为说明第一较佳实施例的结构图。
【主要元件符号说明】
1:成长基板
2:半导体基板
22:第一凹凸结构
2a:介电层
2a1:第二凹凸结构
3:半导体元件
31:半导体基板
33:第一凹凸结构
4:接合基板
具体实施方式
本案将可由以下的实施例说明而得到充分了解,使得熟习本领域的人士可以据以完成,但是本案的实施并非可由下列实施案例而被限制其实施型态。其中相同的标号始终代表相同的组件。
请参考图1至图5,其中图1为本发明第一较佳实施例的流程图,而图2至图5为说明第一较佳实施例的结构图。本发明的第一较佳实施例包含步骤S11~S15,以下分别作说明。
步骤S11:提供一第一基板如:成长基板1,成长基板1较佳为一氧化铝(Al2O3)材质、一蓝宝石(Sapphire)材质、一碳化硅(SiC)材质或一硅(Si)材质其中之一。
步骤S12:如图2所示,在该成长基板上形成一第二基板如:半导体基板2,而半导体基板2较佳为氮化物半导体材质,如:氮化镓(GaN)等。而其中成长基板1与半导体基板2可由传统半导体制程方法所形成。
步骤S13:通过一化学湿式蚀刻或一干式蚀刻来图形化半导体基板2,而在半导体基板2与成长基板1之间形成第一凹凸结构22,如图3所示,以减少半导体基板2与成长基板1间的接触面积。本领域具一般知识的技术人员可理解的是第一凹凸结构22可通过一化学湿式蚀刻(如使用氢氧化钾(KOH)溶液等)或一干式蚀刻来图形化半导体基板2而形成。
步骤S14:进行后续元件制作,在半导体基板2上形成半导体元件3。
步骤S15:如图4所示,进行晶圆接合,在晶圆接合过程中改变成长基板1与半导体基板2的温度,成长基板1与半导体基板2将被加热,且受到一压力使半导体基板2接合至接合基板4,其中接合基板4的材质较佳为一铜材质、一铝材质、一硅材质、一钻石材质、一铜合金材质或一铝合金材质其中之一。
如图5所示,在晶圆接合过程中,成长基板1与半导体基板2的温度改变,而由于成长基板1与半导体基板2的热膨胀系数不同,并产生应力集中,导致成长基板1自半导体基板2剥离。
而可以为本领域技术人员理解的是,第一凹凸结构22用于减少半导体基板2与成长基板1间的接触面积,因此第一凹凸结构22可在形成半导体基板2之后与晶圆接合之前的任一步骤形成。而第一凹凸结构22也不限于图2至图5所示规则排列的凹凸结构,只要是可以减少半导体基板2与成长基板1间的接触面积的凹凸结构皆可达到本发明的效果。
然而,形成上述第一凹凸结构的方法不限于第一实施例所提供的流程。请继续参考图6至图10,其中图6为本发明第二较佳实施例的流程图,而图7至图10为说明第二较佳实施例的结构图。第二实施例与第一较佳实施例类似,在半导体基板31与成长基板1相邻处形成第一凹凸结构33,以使半导体基板31与成长基板1间的接触面积减少,唯其第一凹凸结构33的形成方式与第一较佳实施例不同,其步骤如下。
步骤S21:提供一成长基板1,如第一较佳实施例所述,该成长基板1较佳为一氧化铝(Al2O3)材质、一蓝宝石(Sapphire)材质、一碳化硅(SiC)材质或一硅(Si)材质其中之一。
步骤S22:如图7所示,在成长基板1上形成介电层2a,并在介电层2a上以曝光、显影与蚀刻的方式形成第二凹凸结构2a1,而介电层2a较佳为采用二氧化硅材质。
图8(b)所显示的是第二凹凸结构2a1在成长基板1上形成后的侧视示意图,而图8(a)是对应图8(b)的俯视示意图。如图8(a)与图8(b)所示,第二凹凸结构2a1裸露出成长基板1且较佳为一连续凹凸结构。
步骤S23:如图9所示,在第二凹凸结构2a1上形成半导体基板31。如第一较佳实施例所述,半导体基板31较佳为氮化物半导体材质,如:氮化镓(GaN)等。
步骤S24:以湿式蚀刻方式去除介电层2a所形成的第二凹凸结构2a1,而在半导体基板31的下表面处形成对应第二凹凸结构2a1的第一凹凸结构33。而前述湿式蚀刻方式较佳可使用氟化氢(HF)溶液来进行。
步骤S25:形成第一凹凸结构33之后,接续进行后续元件制作以及晶圆接合流程。与第一较佳实施例类似,成长基板1与半导体基板31在晶圆接合过程中被加热,使得成长基板1与半导体基板31的温度改变,而由于两者的热膨胀系数不同,并产生应力集中,导致成长基板1自半导体基板31剥离。
与第一较佳实施例类似,本实施例第二凹凸结构2a1图8(a)与图8(b)所显示的凹凸方式,而可以是任意排列方式的凹凸结构,使得对应形成的第一凹凸结构33不限于图10所示规则排列的凹凸结构,只要是可以减少半导体基板31与成长基板1间的接触面积的凹凸结构皆可达到本发明的效果。
总结而言,本案实为一难得一见,值得珍惜的难得发明,但以上所述者,仅为本发明的最佳实施例而已,当不能以之限定本发明所实施的范围。即大凡依本发明申请权利要求所作的均等变化与修饰,皆应仍属于本发明专利涵盖的范围内,谨请贵审查委员明鉴,并祈惠准,是所至祷。
Claims (14)
1.一种半导体制程方法,包含下列步骤:
提供一成长基板;
在该成长基板上形成一半导体基板;
在该半导体基板与该成长基板之间形成一第一凹凸结构;以及
改变该成长基板与该半导体基板的温度。
2.如权利要求1所述的制程方法,其中改变该成长基板与该半导体基板的温度更包括一晶圆接合步骤:加热该成长基板与该半导体基板,并施加一压力使该半导体基板接合至一接合基板。
3.如权利要求1所述的制程方法,其中在改变该成长基板与该半导体基板的温度之前包括一步骤:在该半导体基板上形成一半导体元件。
4.如权利要求3所述的制程方法,其中该接合基板的材质为一铜材质、一铝材质、一硅材质、一钻石材质、一铜合金材质或一铝合金材质其中之一。
5.如权利要求1所述的制程方法,其中该半导体基板是一氮化物半导体基板,而该成长基板为一氧化铝材质、一蓝宝石(Sapphire)材质、一碳化硅(SiC)材质或一硅(Si)材质其中之一。
6.如权利要求1所述的制程方法,其中在该半导体基板形成一第一凹凸结构是通过一化学湿式蚀刻或一干式蚀刻来图形化该半导体基板而形成该第一凹凸结构,以减少该半导体基板与该成长基板间的接触面积。
7.如权利要求6所述的制程方法,其中该化学湿式蚀刻为使用一氢氧化钾(KOH)溶液进行蚀刻。
8.如权利要求1所述的制程方法,其中在该成长基板上形成一半导体基板之前更包括以下步骤:
在该成长基板上形成一介电层;以及
在该介电层上以曝光、显影与蚀刻的方式形成一第二凹凸结构。
9.如权利要求8所述的制程方法,其中在该半导体基板与该成长基板间形成一第一凹凸结构之前更包括以下步骤:
在该第二凹凸结构上形成该半导体基板;以及
以一湿式蚀刻方式去除该介电层以形成该第一凹凸结构。
10.如权利要求9所述的制程方法,其中该湿式蚀刻方式为使用氟化氢(HF)溶液。
11.如权利要求8所述的制程方法,其中该介电层为一二氧化硅材质。
12.如权利要求8所述的制程方法,其中该第二凹凸结构裸露出该成长基板且为一连续凹凸结构。
13.一种半导体制程方法,包含下列步骤:
提供一第一基板,其具有一上表面;
提供一第二基板,其具有一下表面;
减少该上表面与该下表面间的一接触面积;以及
加热该第一与该第二基板。
14.一种半导体制程方法,包含下列步骤:
提供一第一基板,其具有一上表面;
提供一第二基板,其具有一下表面与该上表面接触;
加热该第一与该第二基板,以使该上表面与该下表面处于分离状态。
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