TWI597391B - Method of fabricating semiconductor sheet - Google Patents

Method of fabricating semiconductor sheet Download PDF

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TWI597391B
TWI597391B TW101147065A TW101147065A TWI597391B TW I597391 B TWI597391 B TW I597391B TW 101147065 A TW101147065 A TW 101147065A TW 101147065 A TW101147065 A TW 101147065A TW I597391 B TWI597391 B TW I597391B
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mold
semiconductor material
pressure
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wafer
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TW201422857A (en
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藍崇文
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製造半導體薄片之方法 Method of manufacturing a semiconductor wafer

本發明係關於一種製造半導體薄片(semonductor sheet)之方法,並且特別地,關於無切割(kerf-free)、直接製造供製造太陽能電池(solar cell)之用的矽晶圓之方法。 The present invention relates to a method of manufacturing a semonduct sheet, and in particular, to a method of kerf-free, directly manufacturing a tantalum wafer for use in manufacturing a solar cell.

關於本發明之相關技術背景,請參考以下所列之技術文獻:[1] EPIA, Global Market Outlook for Photovoltaics until 2014, May 2010; [2] EPIA, Global Market Outlook for Photovoltaics until 2016, May 2012; [3] RTS Newsletters, Japan, May, 2012; [4] T. F. Ciszek, J. Crystal Growth 66, 1984, p. 655; [5] J. C. Brice, Crystal Growth Processes, New York, Wiley, 1986; [6] B. Chalmers, High Speed Growth of Sheet Crystals, J. Crystal Growth 70, 1984, pp. 3-10; [7] G. Hahn, A. Schonecker, A. Gutjahrm New Crystalline Si Ribbon Materials for Photovoltaics, Ch. 2 in Crystal Growth for Solar Cells, Edited by K. Nakajima and N. Usami, Springer, Berlin, 2009; [8] H. Mitsuyasu, S. Goma, R. Oishi, K. Yoshida, in Proceedings of the 23rd EU PVSEC, Valencia, 2008, p. 1497; [9]美國專利公告號第6521827號;[10]美國專利公告號第7071489號;[11]美國專利公告號第7659542號;[12]美國專利公開號第2012/0067273號;[13]美國專利公告號第5496416號;[14]美國專利公告號第7572334號;[15] A. Grenko, R. Jonczyk, J. Rand, Single Wafer Casting, 2006 IEEE Solar Specialist Conference Proceeding, p. 1415; [16] A. Briglio, K. Dumas, M. Leipold, A. Morrison, Flar- Plate Solar Array Project, Final Report, JPL/DOE, Oct. 1986; [17] M. Tajima, The 4th International Conference on Crystalline Silicon Solar Cells, Taipei, 2010; [18] T. Trupke, K. R. McIntosh, J. W. Weber, W. McMillan, L. Ryves, J. Haunschild, C. Shen, H. Kampwerth, Inline Photoluminescence Imaging for Industrial Wafer- and Cell Manufacturing, the 22nd NREL Workshop on Silicon Material, July 22, 2012;以及[19] Z. Yuan, W. L. Huang, K. Mukai, Wettability and reactivity of molten silicon with various substrates, Appl. Phys. A 78, 2004, pp. 617-622。 For the related technical background of the present invention, please refer to the technical documents listed below: [1] EPIA, Global Market Outlook for Photovoltaics until 2014, May 2010; [2] EPIA, Global Market Outlook for Photovoltaics until 2016, May 2012; 3] RTS Newsletters, Japan, May, 2012; [4] TF Ciszek, J. Crystal Growth 66, 1984, p. 655; [5] JC Brice, Crystal Growth Processes, New York, Wiley, 1986; [6] B Chalmers, High Speed Growth of Sheet Crystals, J. Crystal Growth 70, 1984, pp. 3-10; [7] G. Hahn, A. Schonecker, A. Gutjahrm New Crystalline Si Ribbon Materials for Photovoltaics, Ch. 2 in Crystal Growth for Solar Cells, Edited by K. Nakajima and N. Usami, Springer, Berlin, 2009; [8] H. Mitsuyasu, S. Goma, R. Oishi, K. Yoshida, in Proceedings of the 23rd EU PVSEC, Valencia, 2008, p. 1497; [9] US Patent Publication No. 6521827; [10] US Patent Publication No. 7071489; [11] US Patent Publication No. 7559542; [12] U.S. Patent Publication No. 2012/0067273; [13] U.S. Patent Publication No. 5,496,416; [14] U.S. Patent Publication No. 7,572,334; [15] A. Grenko, R. Jonczyk, J. Rand, Single Wafer Casting, 2006 IEEE Solar Specialist Conference Proceeding, p. 1415; [16] A. Briglio, K. Dumas, M. Leipold, A. Morrison, Flar- Plate Solar Array Project, Final Report, JPL/DOE, Oct. 1986; [17] M. Tajima, The 4th International Conference on Crystalline Silicon Solar Cells, Taipei, 2010; [18] T. Trupke, KR McIntosh, JW Weber, W. McMillan, L. Ryves, J. Haunschild, C. Shen, H. Kampwerth, Inline Photoluminescence Imaging for Industrial Wafer- and Cell Manufacturing, the 22nd NREL Workshop on Silicon Material, July 22, 2012; and [19] Z. Yuan, WL Huang, K. Mukai, Wettability and reactivity of molten silicon with Various substrate s, Appl. Phys. A 78, 2004, pp. 617-622.

目前太陽能電池的材料大部份都是以矽材為主,主要是因矽材為目前地球上最容易取到的第二多元素,並且其具有材料成本低廉、沒有毒性、穩定性高等優點,並且其在半導體的應用上已有深厚的基礎。 At present, most of the materials of solar cells are mainly coffins, mainly because coffins are the second most easily available elements on the earth, and they have the advantages of low material cost, no toxicity, and high stability. And it has a solid foundation in the application of semiconductors.

以矽材為主的太陽能電池有單晶矽、多晶矽以及非晶矽三大類。以多晶矽做為太陽能電池的原材,主要是基於成本的考量,因為相較於以現有的拉晶法(Czochralski method,CZ method)以及浮動區域法(floating zone method,FZ method)所製造的單晶矽,多晶矽價格相對地便宜許多。使用在製造太陽能電池上的多晶矽,傳統上是利用一般鑄造製程來生產。鑄造完成的矽晶鑄錠,須經切割才能獲得能製成太陽能電池型態的矽晶圓。 The solar cells based on coffins include three types: single crystal germanium, polycrystalline germanium and amorphous germanium. The use of polycrystalline germanium as a raw material for solar cells is mainly based on cost considerations because it is compared to the conventional CZ method and the floating zone method (FZ method). Crystal germanium, polycrystalline germanium prices are relatively cheaper. The use of polycrystalline germanium in the manufacture of solar cells has traditionally been produced using conventional casting processes. The cast twine ingots must be cut to obtain a tantalum wafer that can be made into a solar cell type.

目前儘管多晶矽的價格已快速跌落,然而晶片製造仍需長晶與切割,這使得多晶矽晶圓的成本很難進一步下降。特別是切割成本目前已經高於長晶成本非常多,約長晶成本的兩倍。而切割用的切割線、碳化矽以及切割液的成本高。再加上矽晶鑄錠經晶圓切割後的損失高達40%以上,不但沒有效率、成本高,且造成環境的負擔。因此,無切割晶圓製造技術一直都是長晶技術很重視的領域。但是現有無切割技術製造晶圓的品質多半不如預期。例如,線狀矽晶帶法(String Ribbon,RS)[4-6]已發展三十年,仍難在市場佔有一席之地。 Although the price of polysilicon has fallen rapidly, wafer fabrication still requires wafer growth and dicing, which makes it difficult to further reduce the cost of polysilicon wafers. In particular, the cost of cutting is currently much higher than the cost of crystal growth, which is about twice the cost of crystal growth. The cutting wire, the tantalum carbide, and the cutting liquid for cutting are expensive. In addition, the loss of the twin-crystal ingot after wafer cutting is as high as 40% or more, which is not only inefficient, high in cost, but also burdens the environment. Therefore, the technology of non-cut wafer fabrication has always been an area that is highly valued by the long crystal technology. However, the quality of existing wafers without cutting technology is mostly less than expected. For example, the String Ribbon (RS) [4-6] has been in development for 30 years and it is still difficult to gain a foothold in the market.

無切割晶圓製造技術就長晶的凝固方向與晶圓或是晶帶移動方向來分成第一型態以及第二型態兩大類[7]。關於第一型態,其凝固方向與晶圓移動方向平行,而第二類型其凝固方向與晶圓移動方向則幾乎垂直。比較有名的線狀矽晶帶技術屬於第一型態技術。而第二型態無切割晶圓製造技術的代表是基板矽晶帶法(Ribbon Growth on Substrate,RGS)。第一型 態技術還有商業化最早的邊緣成膜矽晶帶法(Edge-Defined Film-Fed growth,EFG)。但是利用RS法及EFG法製造的矽晶圓其後續正成太陽能電池的光電轉化效率都不是很高,平均在15%左右。而第二類型技術多半在發展中。由於其晶體生長缺陷多半沿著生長方向產生,且會惡化與蔓延,所以缺陷多半與晶圓表面平行。由於電池的少數載子傳遞方向與晶圓表面垂直,因此,少數載子被捕捉的機會較高,易造成電池轉換效率低落。所以過去十年,新提出的方法,多半以第二類型技術為主,即缺陷生長方向與少數載子傳遞方向相同。例如,Sharp公司從1997年發展的浸潤基板上結晶法(Crystallization on Dipped Substrate,CDS)[8-11],以及1366公司提出的鑄造晶圓法(Cast Wafer)[12],都相當接近。然而,以CDS法製造的矽晶圓其最大的問題在晶粒過小,且缺陷密度過高,矽晶圓厚度很難低於300微米。當然這與其生長機制息息相關。Sharp提出基板設計的專利[9-11],其基板上具有突出體,讓晶體成核在突出體的突出點,由點連成面的生長方式生長而成,這種點接觸的方式讓晶片容易脫離,但也造成晶粒過小的問題。1366公司的鑄造晶圓法與Sharp的CDS法很類似,只是在基板上做些改良,利用多孔材質,透過差壓來控制矽晶圓與基板的黏著力[12]。 The non-cut wafer fabrication technology is divided into a first type and a second type according to the solidification direction of the crystal growth and the direction of movement of the wafer or the ribbon [7]. Regarding the first type, the solidification direction is parallel to the wafer moving direction, and the second type is almost perpendicular to the wafer moving direction. The more famous linear twin ribbon technology belongs to the first type of technology. The second type of non-cut wafer fabrication technology is represented by the Ribbon Growth on Substrate (RGS). First type The state of the art also commercialized the earliest Edge-Defined Film-Fed growth (EFG). However, the photoelectric conversion efficiency of the subsequent solar cells fabricated by the RS method and the EFG method is not very high, and the average is about 15%. The second type of technology is mostly in development. Since most of its crystal growth defects occur along the growth direction and deteriorate and spread, the defects are mostly parallel to the wafer surface. Since the minority carrier transfer direction of the battery is perpendicular to the wafer surface, the chances of a small number of carriers being captured are high, which may cause the battery conversion efficiency to be low. Therefore, in the past ten years, most of the newly proposed methods are based on the second type of technology, that is, the direction of defect growth is the same as that of the minority carriers. For example, Sharp's Crystalization on Dipped Substrate (CDS) [8-11] developed in 1997 and the Cast Wafer [12] proposed by 1366 are quite close. However, the biggest problem with germanium wafers fabricated by the CDS method is that the grains are too small and the defect density is too high, and the germanium wafer thickness is hard to be less than 300 μm. Of course this is closely related to its growth mechanism. Sharp proposed the patent for substrate design [9-11], which has a protrusion on the substrate, allowing the crystal to nucleate at the protruding point of the protrusion, which is grown by the growth of the point-to-face. This point contact makes the wafer It is easy to get rid of, but it also causes the problem of too small a grain. 1366's foundry wafer method is similar to Sharp's CDS method, except that the substrate is modified to use a porous material to control the adhesion of the wafer to the substrate through differential pressure [12].

除此之外,GE Solar公司也使用早期AstroPower公司提出的模造晶圓法(Molded Wafer)(早期稱矽膜法(Silicon film))的技術[13-14]。此種技術的特點是利用顆粒狀的矽材料先塗佈在基板上,然後利用區融的方式連續成核長晶成柱狀晶粒。值得注意的是,這算是固體進料,而長晶界面與晶片拉出方向比較平行,而矽晶粒主要藉由下方未融的矽顆粒成核且往上成長為柱狀晶,比較接近第二型態技術的生長。 In addition, GE Solar also used the technology of the Molded Wafer (early known as Silicon Film) proposed by the early AstroPower company [13-14]. This technique is characterized in that a granular ruthenium material is first coated on a substrate, and then nucleated into a columnar crystal by continuous nucleation. It is worth noting that this is a solid feed, and the long crystal interface is parallel to the direction in which the wafer is pulled out, and the germanium grains are mainly nucleated by the underlying unmelted germanium particles and grow up into columnar crystals, which is closer to the first The growth of type II technology.

過去發展無切割晶圓製造技術多半強調產率,然而,過 去三十多年的發展,最大的問題仍是在矽晶圓的品質[16]。以往在多晶矽價格下降,且在電池加工價格仍高的情況下,製成電池的光電轉換效率低的矽晶圓變得毫無競爭力。換言之,至今現有無切割晶圓製造技術所製成的矽晶圓,相較於多晶矽鑄碇,缺陷密度都過高,因此,電池的轉換效率難與多晶矽鑄碇切割的矽晶圓之電池的轉換效率相抗衡。然而,目前的電池加工價格已變得低廉,反而是切割的成本過高,因此,這類無切割、直接製成矽晶圓的技術逐漸受到重視。只是這仍進一步提高長晶技術,來得到低缺陷的矽晶圓。 In the past, the development of non-cut wafer manufacturing technology mostly emphasized productivity, however, After more than 30 years of development, the biggest problem is still the quality of the wafer [16]. In the past, when the price of polycrystalline silicon fell, and the battery processing price was still high, the germanium wafer with low photoelectric conversion efficiency of the battery became uncompetitive. In other words, the germanium wafers produced by the current non-cut wafer fabrication technology have a defect density that is too high compared to polycrystalline germanium castings. Therefore, the conversion efficiency of the battery is difficult to be compared with that of a polycrystalline silicon germanium-cut silicon wafer. Conversion efficiency is counterbalanced. However, current battery processing prices have become cheaper, but the cost of cutting is too high. Therefore, such non-cutting, direct-made wafers are gaining attention. It is only this that will further improve the crystal growth technology to obtain low defect germanium wafers.

因此,本發明所欲解決的技術問題在於提供一種製造半導體薄片之方法,特別是製造供製造太陽能電池之用的矽晶圓之方法。本發明之方法係無切割、直接製造半導體薄片之方法,並且半導體晶粒的長晶速度可以控制,協助製造的基板(模)汙染少且容易讓半導體薄片容易脫模,製造出的半導體薄片的厚度與均勻性容易控制,半導體薄片內缺陷生成方向與電池少數載子傳輸平行(與第二型態技術的相同)。 Accordingly, the technical problem to be solved by the present invention is to provide a method of manufacturing a semiconductor wafer, particularly a method of manufacturing a germanium wafer for use in manufacturing a solar cell. The method of the present invention is a method of directly cutting a semiconductor wafer without cutting, and the crystal growth rate of the semiconductor crystal grain can be controlled, assisting in manufacturing a substrate (mold) with less contamination and easily allowing the semiconductor wafer to be easily released, and manufacturing the semiconductor wafer. Thickness and uniformity are easily controlled, and the direction of defect formation in the semiconductor wafer is parallel to the minority carrier transport of the cell (same as the second type technique).

根據本發明之一較佳具體實施例之製造半導體薄片之方法,首先,係於第一模與第二模之間,形成熔融的半導體原料。第一模提供第一成型表面,第二模提供與第一成型表面相對之第二成型表面。接著,本發明之方法係控制關於第一模及第二模之至少一熱場參數,致使熔融的半導體原料從第一成型表面或第一模之中心開始成核且成長成多個半導體晶粒。接著,本發明之方法係繼續控制至少一熱場參數,致使多個半導體晶粒朝向第二成型表面或由內向外繼續成長至熔融的半導體原料完全凝固為止。最後,本發明之方法係將完全凝固的半導體材料脫模、取出,即獲得半導體薄片。 According to a preferred embodiment of the present invention, a method of fabricating a semiconductor wafer is first formed between a first mold and a second mold to form a molten semiconductor material. The first mold provides a first forming surface and the second mold provides a second forming surface opposite the first forming surface. Next, the method of the present invention controls at least one thermal field parameter with respect to the first mode and the second mode, such that the molten semiconductor material nucleates from the first molding surface or the center of the first mode and grows into a plurality of semiconductor grains . Next, the method of the present invention continues to control at least one thermal field parameter such that the plurality of semiconductor grains continue to grow toward the second forming surface or from the inside to the outside until the molten semiconductor material is completely solidified. Finally, the method of the present invention demolds and removes the fully solidified semiconductor material to obtain a semiconductor wafer.

於一具體實施例中,第一模之內壁及第二模之內壁皆被覆脫模劑。於實際應用中,脫模劑可以是氮化矽、氮化硼、碳化矽、碳化硼、氧化矽、氧化硼、氧化鋁、氟化鈣或上述化合物之混合物。 In one embodiment, the inner wall of the first mold and the inner wall of the second mold are coated with a release agent. In practical applications, the release agent may be tantalum nitride, boron nitride, tantalum carbide, boron carbide, tantalum oxide, boron oxide, aluminum oxide, calcium fluoride or a mixture of the above compounds.

於一具體實施例中,第一模與第二模可以由碳化矽、碳化硼、石墨、氮化硼、氮化矽、氧化矽、氧化鋁或上述化合物之混合物所製成。 In one embodiment, the first mode and the second mode may be made of tantalum carbide, boron carbide, graphite, boron nitride, tantalum nitride, cerium oxide, aluminum oxide or a mixture of the above compounds.

於一具體實施例中,於控制至少一熱場參數過程中,第一模與第二模施加在熔融的半導體原料之壓力並且被控制。 In one embodiment, the first mode and the second mode are applied to the pressure of the molten semiconductor material and controlled during the control of the at least one thermal field parameter.

於一具體實施例中,第一模之成型表面上具有多個突出體,以協助多個半導體晶粒之成核。 In one embodiment, the molding surface of the first mold has a plurality of protrusions thereon to assist in nucleation of the plurality of semiconductor grains.

於一具體實施例中,第一模之第一成型表面為第一多孔表面,以提供第一差壓區域,致使於控制至少一熱場參數過程中,第一成型表面之至少一部份處之壓力係小於熔融的半導體原料之壓力。進一步,於將完全凝固的半導體材料脫模、取出過程中,降低第一差壓區域之壓力,以讓半導體薄片脫模、取出。 In a specific embodiment, the first molding surface of the first mold is a first porous surface to provide a first differential pressure region, such that at least a portion of the first molding surface is controlled during the control of at least one thermal field parameter The pressure is less than the pressure of the molten semiconductor material. Further, during the process of demolding and taking out the completely solidified semiconductor material, the pressure in the first differential pressure region is lowered to demold and take out the semiconductor wafer.

於一具體實施例中,第二模之第二成型表面為第二多孔表面,以提供第二差壓區域,致使於控制至少一熱場參數過程中,第二成型表面之至少一部份處之壓力係小於熔融的半導體原料之壓力。 In a specific embodiment, the second molding surface of the second mold is a second porous surface to provide a second differential pressure region, such that at least a portion of the second molding surface is controlled during the control of the at least one thermal field parameter The pressure is less than the pressure of the molten semiconductor material.

於一具體實施例中,至少一熱場參數可以包含第一模至第二模之第一溫度梯度、第一模至第二模之熱傳輸通量以及第一模之中心至周邊之第二溫度梯度......等。 In one embodiment, the at least one thermal field parameter may include a first temperature gradient from the first mode to the second mode, a heat transfer flux of the first mode to the second mode, and a second to a periphery of the first mode Temperature gradient...etc.

與無切割晶圓製造先前技術相較,根據本發明之方法所 製造的半導體薄片,其雜質少、容易脫模、厚度與均勻性容易控制、其內缺陷生成方向與電池少數載子傳輸平行,為品質佳的半導體薄片。 Compared to the prior art of dicing wafer fabrication, the method according to the invention The manufactured semiconductor wafer has a small amount of impurities, is easy to be released from the mold, is easy to control in thickness and uniformity, and has a defect-generating direction in parallel with the minority carrier transport of the battery, and is a semiconductor wafer of good quality.

關於本發明之優點與精神可以藉由以下的發明詳述及所附圖式得到進一步的瞭解。 The advantages and spirit of the present invention will be further understood from the following detailed description of the invention.

請參閱圖1至圖6,係以截面視圖示意地繪示本發明之製造半導體薄片的方法之一較佳具體實施例。執行本發明之方法的設備1之一範例也繪示於圖中。本發明之方法可無切割、直接製造供製造太陽能電池之用的矽晶圓。在此,半導體薄片即涵蓋矽晶圓。 Referring to FIGS. 1 through 6, a preferred embodiment of a method of fabricating a semiconductor wafer of the present invention is schematically illustrated in a cross-sectional view. An example of an apparatus 1 for performing the method of the present invention is also illustrated in the figures. The method of the present invention can directly produce a tantalum wafer for use in the manufacture of solar cells without cutting. Here, the semiconductor wafer covers the germanium wafer.

如圖1至圖6所示,執行本發明之方法的設備1之構造包含由上外罩14a與下外罩14b構成的外爐體以及由上內罩15a與下內罩15b構成的內爐體。上外罩14a與下外罩14b構成的外爐體可由不鏽鋼製成,並且配置水冷卻系統。上內罩15a與下內罩15b可由不鏽鋼製成。上內罩15a的外壁上安裝滑軌16a,讓上外罩14a可以相對上內罩15a做上、下移動。下內罩15b的外壁上安裝滑軌16b,讓下外罩14b可以相對下內罩15b做上、下移動。上內罩15a的頂部與上外罩14a之間安裝彈簧19做支撐。上內罩15a內安裝硬絕熱襯墊17a以及軟絕熱襯墊18a。下內罩15b內安裝硬絕熱襯墊17b以及軟絕熱襯墊18b。硬絕熱襯墊17a與硬絕熱襯墊17b可以由Al2O3製成。軟絕熱襯墊18a與軟絕熱襯墊18b可以由石墨/碳纖維複合材料製成。 As shown in Figs. 1 to 6, the structure of the apparatus 1 for carrying out the method of the present invention comprises an outer furnace body composed of an upper outer cover 14a and a lower outer cover 14b, and an inner furnace body composed of an upper inner cover 15a and a lower inner cover 15b. The outer furnace body composed of the upper outer cover 14a and the lower outer cover 14b may be made of stainless steel and provided with a water cooling system. The upper inner cover 15a and the lower inner cover 15b may be made of stainless steel. A slide rail 16a is attached to the outer wall of the upper inner cover 15a so that the upper outer cover 14a can be moved up and down with respect to the upper inner cover 15a. A slide rail 16b is attached to the outer wall of the lower inner cover 15b, so that the lower outer cover 14b can be moved up and down with respect to the lower inner cover 15b. A spring 19 is attached between the top of the upper inner cover 15a and the upper outer cover 14a for support. A hard insulating spacer 17a and a soft insulating spacer 18a are attached to the upper inner cover 15a. A hard insulating spacer 17b and a soft insulating spacer 18b are attached to the lower inner cover 15b. The hard insulating gasket 17a and the hard insulating gasket 17b may be made of Al 2 O 3 . The soft insulating gasket 18a and the soft insulating gasket 18b may be made of a graphite/carbon fiber composite material.

執行本發明之方法的設備1並且包含第一模10以及第二模12。第一模10提供第一成型表面102,第二模12提供與 第一成型表面102相對之第二成型表面122。於圖1至圖6中,為了說明方便,第一模10做為上模,第二模12做為下模,但本發明之方法不以此為限。於圖1至圖6中,第一模10係由硬絕熱襯墊17a支撐,第二模12係由硬絕熱襯墊17b支撐。執行本發明之方法的設備1並且包含上加熱器13a以及下加熱器13b。上加熱器13a貫穿在第一模10與軟絕熱襯墊18a之間,用以加熱第一模10。下加熱器13b貫穿在第二模12與軟絕熱襯墊18b之間,用以加熱第二模12。於一具體實施例中,上加熱器13a與下加熱器13b可以由石墨製成。 The apparatus 1 for carrying out the method of the invention also comprises a first mould 10 and a second mould 12. The first mold 10 provides a first forming surface 102, and the second mold 12 provides The first forming surface 102 is opposite the second forming surface 122. In FIG. 1 to FIG. 6, for convenience of description, the first mold 10 is used as the upper mold, and the second mold 12 is used as the lower mold, but the method of the present invention is not limited thereto. In FIGS. 1 to 6, the first die 10 is supported by a hard insulating spacer 17a, and the second die 12 is supported by a hard insulating spacer 17b. The apparatus 1 for carrying out the method of the invention also comprises an upper heater 13a and a lower heater 13b. The upper heater 13a penetrates between the first mold 10 and the soft insulation gasket 18a for heating the first mold 10. The lower heater 13b penetrates between the second mold 12 and the soft insulation gasket 18b for heating the second mold 12. In a specific embodiment, the upper heater 13a and the lower heater 13b may be made of graphite.

執行本發明之方法的設備1並且包含分別貫通上外罩14a與上內罩15a之惰性氣體導管L1,惰性氣體導管L1的末端p0連接至真空幫浦。惰性氣體導管L1其上並安裝壓差調節閥V1與壓差調節閥V2,用以分別調控近第一模10處之末端p3的壓力以及末端p1(上外罩14a與上內罩15a之間)的壓力。執行本發明之方法的設備1並且包含分別貫通下外罩14b與下內罩15b之惰性氣體導管L2,惰性氣體導管L2的末端p0同樣連接至真空幫浦。惰性氣體導管L2其上並安裝壓差調節閥V3,用以調控近第二模12處之末端p2的壓力。 The apparatus 1 for carrying out the method of the invention also comprises an inert gas conduit L1 which extends through the upper outer casing 14a and the upper inner casing 15a, respectively, to which the end p0 of the inert gas conduit L1 is connected. The inert gas conduit L1 is provided with a differential pressure regulating valve V1 and a differential pressure regulating valve V2 for respectively regulating the pressure of the end p3 near the first die 10 and the end p1 (between the upper outer cover 14a and the upper inner cover 15a) pressure. The apparatus 1 for carrying out the method of the invention also comprises an inert gas conduit L2 which extends through the lower outer casing 14b and the lower inner casing 15b, respectively, and the end p0 of the inert gas conduit L2 is likewise connected to the vacuum pump. The inert gas conduit L2 is provided with a differential pressure regulating valve V3 for regulating the pressure of the end p2 near the second die 12.

如圖1至圖3所示,首先,本發明之方法係於第一模10與第二模12之間,形成熔融的半導體原料22。於一範例中,固態半導體原料20先行放置在第二模12的第二成型表面122上,如圖1所示。於實際應用中,固態半導體原料20可以是塊料、碎料或顆粒。以本發明之方法製成矽晶圓為例,固態半導體原料20可以是純度高的矽塊料、矽碎料或矽顆粒。接著,第二模12的溫度升至高於固態半導體原料20的熔點,讓固態半導體原料20熔成熔融的半導體原料22,如圖2所示。接著,於圖3中,第一模10與第二模12壓 合。於一具體實施例中,第一模10與第二模12之構造可以構成模穴,讓熔融的半導體原料22填充在模穴內。於另一具體實施例中,第一模10之第一成型表面102與第二模12之第二成型表面122大體上為平面,第二模12之第二成型表面122上可以具有限制熔融的半導體原料22不會溢出的凸出物,讓第一模10與第二模12壓合時熔融的半導體原料22填充在第一模10與第二模12形成的密閉空間。 As shown in FIGS. 1 to 3, first, the method of the present invention is between the first mold 10 and the second mold 12 to form a molten semiconductor material 22. In one example, the solid state semiconductor material 20 is placed first on the second forming surface 122 of the second mold 12, as shown in FIG. In practical applications, the solid state semiconductor feedstock 20 can be a block, scrap or granule. For example, in the case of a tantalum wafer produced by the method of the present invention, the solid semiconductor material 20 can be a high purity tantalum block, chopped material or tantalum particles. Next, the temperature of the second mold 12 rises above the melting point of the solid semiconductor material 20 to melt the solid semiconductor material 20 into the molten semiconductor material 22, as shown in FIG. Next, in FIG. 3, the first mold 10 and the second mold 12 are pressed. Hehe. In one embodiment, the configuration of the first die 10 and the second die 12 can form a cavity for filling the molten semiconductor material 22 within the cavity. In another embodiment, the first molding surface 102 of the first mold 10 and the second molding surface 122 of the second mold 12 are substantially planar, and the second molding surface 122 of the second mold 12 may have a melt-limited property. The semiconductor material 22, which is not overflowed by the semiconductor material 22, is filled in the sealed space formed by the first mold 10 and the second mold 12 when the first mold 10 and the second mold 12 are pressed together.

於本發明之另一變化中,先行讓第二模12的溫度升溫到半導體原料22的熔點以上,再滴入熔融的半導體原料22,再行讓第一模10與第二模壓合。壓合時,第一模10之成型表面102的溫度可以高於或是低於熔融的半導體原料22的熔點。第一模10之成型表面102之溫度高於熔融的半導體原料22之熔點的壓合是先成型,再進行凝固,但這樣的製造速率比較慢。也可以是讓第一模10之成型表面102之溫度低於熔融的半導體原料22之熔點,在壓合時同時進行成型與凝固。 In another variation of the present invention, the temperature of the second mold 12 is raised to a temperature higher than the melting point of the semiconductor material 22, and then the molten semiconductor material 22 is dropped, and the first mold 10 and the second mold are pressed together. When pressed, the temperature of the forming surface 102 of the first mold 10 may be higher or lower than the melting point of the molten semiconductor material 22. The pressing of the molding surface 102 of the first mold 10 at a temperature higher than the melting point of the molten semiconductor material 22 is first formed and then solidified, but such a manufacturing rate is relatively slow. Alternatively, the temperature of the molding surface 102 of the first mold 10 may be lower than the melting point of the molten semiconductor material 22, and molding and solidification may be simultaneously performed at the time of pressing.

於本發明之另一變化中,成碎料的固態半導體原料20先行放置在第二模12的第二成型表面122上。接著,第一模10與第二模12密合構成模穴14。第一模10及/或第二模12的溫度升至高於固態半導體原料20的熔點,讓在模穴14中的固態半導體原料20熔成熔融的半導體原料22。 In another variation of the invention, the shredded solid semiconductor material 20 is placed first on the second forming surface 122 of the second mold 12. Next, the first die 10 and the second die 12 are brought into close contact to form the cavity 14. The temperature of the first mold 10 and/or the second mold 12 rises above the melting point of the solid semiconductor material 20 to melt the solid semiconductor material 20 in the cavity 14 into the molten semiconductor material 22.

接著,如圖4所示,本發明之方法係控制關於第一模10及第二模12之至少一熱場參數,致使熔融的半導體原料22從第一成型表面102或第一模10之中心開始成核且成長成多個半導體晶粒24。於圖4所示之範例中,多個半導體晶粒24係從上模之成型表面處開始成核,於本發明之另一變化中,多個半導體晶粒24可以從下模12之成型表面122處開始成核。 Next, as shown in FIG. 4, the method of the present invention controls at least one thermal field parameter with respect to the first mold 10 and the second mold 12 such that the molten semiconductor material 22 is from the center of the first molding surface 102 or the first mold 10. The nucleation begins and grows into a plurality of semiconductor dies 24. In the example shown in FIG. 4, a plurality of semiconductor dies 24 are nucleated from the molding surface of the upper mold. In another variation of the present invention, a plurality of semiconductor dies 24 may be formed from the molding surface of the lower mold 12. At 122, nucleation began.

接著,如圖5所示,本發明之方法係繼續控制至少一熱場參數,致使多個半導體晶粒24朝向第二成型表面122或由內向外繼續成長至熔融的半導體原料22完全凝固為止,即成半導體薄片2。大體上,半導體薄片2包含多個柱狀半導體晶粒24。藉由控制半導體晶粒24的成長方向,半導體薄片2其內缺陷生成方向與後續製成電池之少數載子傳輸平行。 Next, as shown in FIG. 5, the method of the present invention continues to control at least one thermal field parameter such that the plurality of semiconductor dies 24 continue to grow toward the second molding surface 122 or from the inside to the outside until the molten semiconductor material 22 is completely solidified. The semiconductor wafer 2 is formed. In general, the semiconductor wafer 2 comprises a plurality of columnar semiconductor dies 24. By controlling the growth direction of the semiconductor die 24, the direction in which the semiconductor wafer 2 is generated is parallel to the minority carrier transmission of the subsequent battery.

最後,如圖6所示,本發明之方法係將完全凝固的半導體材料(半導體薄片2)脫模、取出,即獲得半導體薄片2。藉由第一模10與第二模12的設計,半導體薄片2的厚度與均勻性可以容易控制。藉由本發明之方法,半導體薄片2的厚度可以在300 μm以下,甚至為150 μm,仍保有極佳的均勻性。 Finally, as shown in FIG. 6, the method of the present invention releases and removes the completely solidified semiconductor material (semiconductor sheet 2), that is, the semiconductor wafer 2 is obtained. By the design of the first mold 10 and the second mold 12, the thickness and uniformity of the semiconductor wafer 2 can be easily controlled. By the method of the present invention, the thickness of the semiconductor wafer 2 can be 300 μm or less, or even 150 μm, and excellent uniformity is maintained.

於一具體實施例中,若以本發明之方法製成矽晶圓,第一模10與第二模12可以由碳化矽、碳化硼、石墨、氮化硼、氮化矽、氧化矽、氧化鋁或上述化合物之混合物所製成。上述材料,以碳化矽或石墨為佳,碳化矽或石墨製成的第一模10及第二模12汙染低,並且固態半導體原料20的雜質少,可以製成雜質少的半導體薄片2。 In one embodiment, if the germanium wafer is formed by the method of the present invention, the first mold 10 and the second mold 12 may be made of tantalum carbide, boron carbide, graphite, boron nitride, tantalum nitride, tantalum oxide, and oxidation. Aluminium or a mixture of the above compounds. The above material is preferably tantalum carbide or graphite, and the first mold 10 and the second mold 12 made of tantalum carbide or graphite are low in contamination, and the solid semiconductor raw material 20 has less impurities, and the semiconductor wafer 2 having less impurities can be formed.

於一具體實施例中,第一模10之內壁及第二模12之內壁皆被覆脫模劑,以利半導體薄片2的脫模。於實際應用中,脫模劑可以是氮化矽、氮化硼、碳化矽、碳化硼、氧化矽、氧化硼、氧化鋁、氟化鈣或上述化合物之混合物。 In one embodiment, the inner wall of the first mold 10 and the inner wall of the second mold 12 are coated with a release agent to facilitate demolding of the semiconductor wafer 2. In practical applications, the release agent may be tantalum nitride, boron nitride, tantalum carbide, boron carbide, tantalum oxide, boron oxide, aluminum oxide, calcium fluoride or a mixture of the above compounds.

於一具體實施例中,於控制至少一熱場參數過程中,第一模10與第二模12施加在熔融的半導體原料22之壓力並且被控制。施加在熔融的半導體原料22之壓力能降低熔融的半導體原料22的熔點,有助於熔融的半導體原料22的凝固。但是,施加在熔融的半導體原料22之壓力必須控制,避免半 導體薄片2變形或有過多的晶格缺陷。 In one embodiment, during the control of at least one thermal field parameter, the first mold 10 and the second mold 12 are applied to the pressure of the molten semiconductor material 22 and are controlled. The pressure applied to the molten semiconductor material 22 can lower the melting point of the molten semiconductor material 22 and contribute to solidification of the molten semiconductor material 22. However, the pressure applied to the molten semiconductor material 22 must be controlled to avoid half The conductor sheet 2 is deformed or has excessive lattice defects.

於一具體實施例中,第一模10之成型表面102上具有多個突出體(未繪示於圖1至圖6中)。以協助多個半導體晶粒24容易在突出體的突出點處成核。 In one embodiment, the molding surface 102 of the first mold 10 has a plurality of protrusions (not shown in FIGS. 1 to 6). To assist the plurality of semiconductor dies 24 to easily nucleate at the protruding points of the protrusions.

於一具體實施例中,第一模10之第一成型表面102為第一多孔表面(未繪示於圖1至圖6中)。利用惰性氣體通過第一多孔表面,以提供第一差壓區域,致使於控制至少一熱場參數過程中,第一成型表面102之至少一部份處之壓力係小於熔融的半導體原料22之壓力,熔融的半導體原料22會附著在第一成型表面102上。進一步,於將完全凝固的半導體材料(半導體薄片2)脫模、取出過程中,降低第一差壓區域之壓力,以讓半導體薄片2脫模、取出。 In one embodiment, the first molding surface 102 of the first mold 10 is a first porous surface (not shown in FIGS. 1 to 6). Passing an inert gas through the first porous surface to provide a first differential pressure region such that during control of the at least one thermal field parameter, the pressure at at least a portion of the first forming surface 102 is less than the molten semiconductor material 22 The molten, molten semiconductor material 22 will adhere to the first forming surface 102. Further, during the process of demolding and taking out the completely solidified semiconductor material (semiconductor sheet 2), the pressure in the first differential pressure region is lowered to release and take out the semiconductor wafer 2.

於一具體實施例中,第二模12之第二成型表面122為第二多孔表面(未繪示於圖1至圖6中)。利用惰性氣體通過第二多孔表面,以提供第二差壓區域,致使於控制至少一熱場參數過程中,第二成型表面122之至少一部份處之壓力係小於熔融的半導體原料22之壓力,熔融的半導體原料22會附著在第二成型表面122上。 In a specific embodiment, the second molding surface 122 of the second mold 12 is a second porous surface (not shown in FIGS. 1 to 6). Passing an inert gas through the second porous surface to provide a second differential pressure region such that during control of the at least one thermal field parameter, the pressure at least a portion of the second forming surface 122 is less than the molten semiconductor material 22 The molten, molten semiconductor material 22 will adhere to the second forming surface 122.

於一具體實施例中,至少一熱場參數可以包含第一模10至第二模12之第一溫度梯度、第一模10至第二模12之熱傳輸通量以及第一模10之中心至周邊之第二溫度梯度......等。 In one embodiment, the at least one thermal field parameter may include a first temperature gradient of the first die 10 to the second die 12, a heat transfer flux of the first die 10 to the second die 12, and a center of the first die 10. The second temperature gradient to the periphery...etc.

與無切割晶圓製造先前技術相較,根據本發明之方法所製造的半導體薄片,其雜質少、容易脫模、厚度與均勻性容易控制、其內缺陷生成方向與電池少數載子傳輸平行,為品質佳的半導體薄片。 Compared with the prior art of the non-cut wafer fabrication, the semiconductor wafer manufactured according to the method of the present invention has less impurities, is easy to demold, and is easy to control in thickness and uniformity, and the direction of defect formation therein is parallel to the minority carrier transmission of the battery. It is a good quality semiconductor wafer.

藉由以上較佳具體實施例之詳述,係希望能更加清楚 描述本發明之特徵與精神,而並非以上述所揭露的較佳具體實施例來對本發明之範疇加以限制。相反地,其目的是希望能涵蓋各種改變及具相等性的安排於本發明所欲申請之專利範圍的範疇內。因此,本發明所申請之專利範圍的範疇應該根據上述的說明作最寬廣的解釋,以致使其涵蓋所有可能的改變以及具相等性的安排。 With the details of the above preferred embodiments, it is hoped that it will be clearer. The invention is not limited by the scope of the invention as described in the preferred embodiments. On the contrary, the intention is to cover various modifications and equivalents within the scope of the invention as claimed. Therefore, the scope of the patented scope of the invention should be construed as broadly construed in the

1‧‧‧設備 1‧‧‧ Equipment

10‧‧‧第一模 10‧‧‧ first model

102‧‧‧第一成型表面 102‧‧‧First molding surface

12‧‧‧第二模 12‧‧‧ second mode

122‧‧‧第二成型表面 122‧‧‧Second molding surface

13a‧‧‧上加熱器 13a‧‧‧Upper heater

13b‧‧‧下加熱器 13b‧‧‧ Lower heater

14a‧‧‧上外罩 14a‧‧‧Upper cover

14b‧‧‧下外罩 14b‧‧‧ Lower cover

15a‧‧‧上內罩 15a‧‧‧Upper inner cover

15b‧‧‧下內罩 15b‧‧‧Under the inner cover

16a、16b‧‧‧滑軌 16a, 16b‧‧‧ slide rails

17a、17b‧‧‧硬絕熱襯墊 17a, 17b‧‧‧ Hard insulating gasket

18a、18b‧‧‧軟絕熱襯墊 18a, 18b‧‧‧soft insulation gasket

19‧‧‧彈簧 19‧‧‧ Spring

20‧‧‧固態半導體原料 20‧‧‧Solid semiconductor raw materials

22‧‧‧熔融的半導體原料 22‧‧‧fused semiconductor raw materials

24‧‧‧半導體晶粒 24‧‧‧Semiconductor grains

2‧‧‧半導體薄片 2‧‧‧Semiconductor sheet

L1、L2‧‧‧惰性氣體導管 L1, L2‧‧‧ inert gas conduit

V1、V2、V3‧‧‧壓差調節閥 V1, V2, V3‧‧‧ differential pressure regulating valve

p0、p1、p2、p3‧‧‧末端 End of p0, p1, p2, p3‧‧

圖1至圖6為本發明之製造半導體薄片的方法之一較佳具體實施例過程的截面視圖。 BRIEF DESCRIPTION OF THE DRAWINGS Figures 1 through 6 are cross-sectional views showing a process of a preferred embodiment of a method of fabricating a semiconductor wafer of the present invention.

1‧‧‧設備 1‧‧‧ Equipment

10‧‧‧第一模 10‧‧‧ first model

102‧‧‧第一成型表面 102‧‧‧First molding surface

12‧‧‧第二模 12‧‧‧ second mode

122‧‧‧第二成型表面 122‧‧‧Second molding surface

13a‧‧‧上加熱器 13a‧‧‧Upper heater

13b‧‧‧下加熱器 13b‧‧‧ Lower heater

14a‧‧‧上外罩 14a‧‧‧Upper cover

14b‧‧‧下外罩 14b‧‧‧ Lower cover

15a‧‧‧上內罩 15a‧‧‧Upper inner cover

15b‧‧‧下內罩 15b‧‧‧Under the inner cover

16a、16b‧‧‧滑軌 16a, 16b‧‧‧ slide rails

17a、17b‧‧‧硬絕熱襯墊 17a, 17b‧‧‧ Hard insulating gasket

18a、18b‧‧‧軟絕熱襯墊 18a, 18b‧‧‧soft insulation gasket

19‧‧‧彈簧 19‧‧‧ Spring

22‧‧‧熔融的半導體原料 22‧‧‧fused semiconductor raw materials

24‧‧‧半導體晶粒 24‧‧‧Semiconductor grains

L1、L2‧‧‧惰性氣體導管 L1, L2‧‧‧ inert gas conduit

V1、V2、V3‧‧‧壓差調節閥 V1, V2, V3‧‧‧ differential pressure regulating valve

p0、p1、p2、p3‧‧‧末端 End of p0, p1, p2, p3‧‧

Claims (10)

一種製造一半導體薄片之方法,包含下列步驟:(a)於一第一模與一第二模之間,形成一熔融的半導體原料,其中該第一模提供一第一成型表面,該第二模提供與該第一成型表面相對之一第二成型表面;(b)控制關於該第一模及該第二模之至少一熱場參數,致使該熔融的半導體原料從該第一成型表面或該第一模之中心開始成核且成長成多個半導體晶粒;(c)繼續控制該至少一熱場參數,致使該多個半導體晶粒朝向該第二成型表面或由內向外繼續成長至該熔融的半導體原料完全凝固為止;以及(d)將該完全凝固的半導體材料脫模、取出,即獲得該半導體薄片。 A method of fabricating a semiconductor wafer comprising the steps of: (a) forming a molten semiconductor material between a first mold and a second mold, wherein the first mold provides a first forming surface, the second The mold provides a second forming surface opposite the first forming surface; (b) controlling at least one thermal field parameter with respect to the first mold and the second mold, such that the molten semiconductor material is from the first forming surface or The center of the first mold begins to nucleate and grow into a plurality of semiconductor dies; (c) continues to control the at least one thermal field parameter such that the plurality of semiconductor dies continue to grow toward the second forming surface or from the inside to the outside The molten semiconductor material is completely solidified; and (d) the fully solidified semiconductor material is released and taken out to obtain the semiconductor wafer. 如請求項1所述之方法,其中該第一模之內壁及該第二模之內壁皆被覆一脫模劑。 The method of claim 1, wherein the inner wall of the first mold and the inner wall of the second mold are coated with a release agent. 如請求項2所述之方法,其中該脫模劑係選自由氮化矽、氮化硼、碳化矽、碳化硼、氧化矽、氧化硼、氧化鋁、氟化鈣以及上述化合物之混合物所組成之群組中之其一。 The method of claim 2, wherein the release agent is selected from the group consisting of tantalum nitride, boron nitride, tantalum carbide, boron carbide, cerium oxide, boron oxide, aluminum oxide, calcium fluoride, and a mixture of the foregoing compounds. One of the groups. 如請求項2所述之方法,其中該第一模與該第二模係由選自由碳化矽、碳化硼、石墨、氮化硼、氮化矽、氧化矽、氧化鋁以及上述化合物之混合物所組成之群組中之其一所製成。 The method of claim 2, wherein the first mode and the second mode are selected from the group consisting of cerium carbide, boron carbide, graphite, boron nitride, tantalum nitride, cerium oxide, aluminum oxide, and a mixture of the foregoing compounds. One of the group consisting of. 如請求項1所述之方法,其中於步驟(b)中,該第一模與該第二模施加在該熔融的半導體原料之一壓力被控制。 The method of claim 1, wherein in step (b), the pressure applied by the first mold and the second mold to the molten semiconductor material is controlled. 如請求項1所述之方法,其中該第一模之該成型表面上具有多個突出體,以協助該多個半導體晶粒之成核。 The method of claim 1, wherein the molding surface of the first mold has a plurality of protrusions to assist in nucleation of the plurality of semiconductor grains. 如請求項1所述之方法,其中該第一模之該第一成型表面為一第一多孔表面,以提供一第一差壓區域,致使於步驟(b)中,該第一成型表面之至少一部份處之壓力係小於該熔融的半導體原料之壓力。 The method of claim 1, wherein the first molding surface of the first mold is a first porous surface to provide a first differential pressure region, such that in the step (b), the first molding surface The pressure at at least a portion of the pressure is less than the pressure of the molten semiconductor material. 如請求項7所述之方法,其中於步驟(d)中,降低該第一差壓區域之壓力,以讓該半導體薄片脫模、取出。 The method of claim 7, wherein in the step (d), the pressure of the first differential pressure region is lowered to demold and take out the semiconductor wafer. 如請求項1所述之方法,其中該第二模之該第二成型表面為一第二多孔表面,以提供一第二差壓區域,致使於步驟(b)中,該第二成型表面之至少一部份處之壓力係小於該熔融的半導體原料之壓力。 The method of claim 1, wherein the second molding surface of the second mold is a second porous surface to provide a second differential pressure region, such that in the step (b), the second molding surface The pressure at at least a portion of the pressure is less than the pressure of the molten semiconductor material. 如請求項1所述之方法,該至少一熱場參數包含選自由該第一模至該第二模之一第一溫度梯度、該第一模至該第二模之一熱傳輸通量以及該第一模之中心至周邊之一第二溫度梯度所組成群組中之其一。 The method of claim 1, wherein the at least one thermal field parameter comprises a first temperature gradient selected from the first mode to the second mode, a heat transfer flux of the first mode to the second mode, and One of the group consisting of the second temperature gradient of the center of the first mode to the periphery.
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
TWI642819B (en) * 2017-12-08 2018-12-01 藍崇文 Method of manufacturing semiconductor sheet and manufacture equipment implementing such method

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
TWI642819B (en) * 2017-12-08 2018-12-01 藍崇文 Method of manufacturing semiconductor sheet and manufacture equipment implementing such method

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