WO2023048160A1 - 半導体基板、半導体デバイス、半導体基板の製造方法、および半導体デバイスの製造方法 - Google Patents
半導体基板、半導体デバイス、半導体基板の製造方法、および半導体デバイスの製造方法 Download PDFInfo
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- WO2023048160A1 WO2023048160A1 PCT/JP2022/035083 JP2022035083W WO2023048160A1 WO 2023048160 A1 WO2023048160 A1 WO 2023048160A1 JP 2022035083 W JP2022035083 W JP 2022035083W WO 2023048160 A1 WO2023048160 A1 WO 2023048160A1
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- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/20—Deposition of semiconductor materials on a substrate, e.g. epitaxial growth solid phase epitaxy
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- H01L21/71—Manufacture of specific parts of devices defined in group H01L21/70
- H01L21/76—Making of isolation regions between components
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- H01L29/40—Electrodes ; Multistep manufacturing processes therefor
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- H01L29/40—Electrodes ; Multistep manufacturing processes therefor
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Definitions
- the present invention relates to a semiconductor substrate, a semiconductor device, a method for manufacturing a semiconductor substrate, and a method for manufacturing a semiconductor device. More particularly, the present invention relates to a semiconductor substrate with a thermally conductive layer of diamond or polycrystalline silicon carbide, a semiconductor device, a method of manufacturing a semiconductor substrate, and a method of manufacturing a semiconductor device.
- Non-Patent Document 1 discloses a nitride semiconductor device comprising an SOI (Silicon On Insulator) substrate and a HEMT (High Electron Mobility Transistor) formed on a Si layer in the SOI substrate.
- SOI Silicon On Insulator
- HEMT High Electron Mobility Transistor
- Non-Patent Document 1 nitride semiconductor devices are generally formed on substrates having low thermal conductivity, such as SOI substrates, sapphire substrates, or Si (silicon) substrates. Therefore, the heat generated in the nitride semiconductor device during operation is less likely to dissipate through the substrate. As a result, the temperature of the nitride semiconductor device tends to rise, and the performance and reliability of the nitride semiconductor device tend to deteriorate.
- the SiO 2 (silicon oxide) layer in the SOI substrate has a significantly low thermal conductivity, which hinders the heat dissipation of the nitride semiconductor device.
- Non-Patent Document 2 below and Patent Documents 1 and 2 below disclose techniques for promoting heat dissipation in nitride semiconductor devices using a diamond layer. Due to its very high thermal conductivity, diamond is a promising candidate as a heat spreader material for nitride semiconductor devices.
- Non-Patent Document 2 below discloses a diamond layer, a SiC (silicon carbide) layer formed on the diamond layer via a metal layer made of Ti (titanium), and a HEMT formed on the SiC layer.
- a nitride semiconductor device is disclosed.
- the structure of Non-Patent Document 2 below is produced by the following method. A nitride semiconductor layer is epitaxially grown on the surface of the SiC substrate containing the micropipes.
- a nitride semiconductor device including a HEMT is manufactured by processing this nitride semiconductor layer.
- a SiC layer with a thickness of 50 ⁇ m is produced by cutting the back surface of the SiC substrate.
- the back surface of the SiC layer and the diamond layer are bonded via a metal layer made of Ti having a thickness of 10 nm.
- Patent Document 1 discloses a semiconductor device comprising a support substrate made of diamond, a single-crystal SiC layer having a resistivity of 10 6 to 10 12 ⁇ cm and a thickness of 1 to 30 ⁇ m, and a nitride semiconductor layer. is disclosed.
- this semiconductor device one surface of the single-crystal SiC layer is bonded to the support substrate.
- the monocrystalline SiC layer has micropipes.
- the nitride semiconductor layer is formed on the other surface of the single crystal SiC layer.
- the structure of Patent Document 1 below is produced by the following method. A single crystal SiC substrate is provided.
- a hydrogen ion-implanted layer is formed in the single-crystal SiC substrate by implanting hydrogen ions from the surface of the single-crystal SiC substrate.
- a surface of a single-crystal SiC substrate is bonded to a supporting substrate made of diamond.
- the single-crystal SiC substrate is divided by the hydrogen ion-implanted layers.
- the remaining portion of the single crystal SiC substrate becomes a single crystal SiC layer.
- the hydrogen ion implanted layer remaining on the back surface of the single crystal SiC layer is removed by CMP (Chemical Mechanical Polishing).
- a nitride semiconductor layer is formed by epitaxial growth on the back surface of the single-crystal SiC layer.
- Patent Document 2 discloses the following method for manufacturing a nitride semiconductor substrate.
- a diamond layer is formed on the Si substrate.
- a single-crystal SiC layer is formed by thinning the Si substrate and carbonizing the Si portion remaining after the thinning.
- a nitride semiconductor layer is formed on the surface of the single-crystal SiC layer on which the diamond layer is not formed.
- JP 2016-139655 A Japanese Patent Application Laid-Open No. 2018-203587 (Patent No. 6763347)
- the conventional technique of promoting heat dissipation from a semiconductor device using a heat conductive layer made of diamond or the like has a problem that the quality of the nitride semiconductor layer is low.
- Non-Patent Document 2 and Patent Document 1 a bulk SiC substrate is used as the SiC layer.
- bulk SiC substrates have a 4H crystal structure and contain micropipes. Therefore, the quality of the nitride semiconductor layer formed on the SiC layer has deteriorated under the influence of the micropipes included in the SiC layer.
- the nitride semiconductor layer is formed after the single crystal SiC layer and the support substrate are bonded. Since the single-crystal SiC layer is heated to a high temperature during the formation of the nitride semiconductor layer, the bonding between the single-crystal SiC layer and the support substrate is weakened, resulting in a significant drop in the reliability of the semiconductor device.
- a single crystal SiC layer is formed by carbonizing a Si substrate. It is difficult to obtain a thick and high-quality SiC layer by carbonizing the Si substrate. Therefore, a SiC layer having sufficient thickness and crystallinity to epitaxially grow a nitride semiconductor layer cannot be formed, and the quality of the grown nitride semiconductor layer deteriorates.
- An object of the present invention is to provide a semiconductor substrate, a semiconductor device, a semiconductor substrate manufacturing method, and a semiconductor device manufacturing method capable of improving the quality of a nitride semiconductor layer. to provide.
- Another object of the present invention is to provide a semiconductor substrate, a semiconductor device, a method for manufacturing a semiconductor substrate, and a method for manufacturing a semiconductor device that can improve the performance of the device.
- a semiconductor substrate includes a heat conductive layer made of diamond or polycrystalline silicon carbide, a silicon carbide layer having a 3C-type crystal structure formed on one main surface side of the heat conductive layer, a heat A bonding layer formed between a conductive layer and a silicon carbide layer, and a nitride semiconductor layer formed on one main surface of the silicon carbide layer.
- the silicon carbide layer and the nitride semiconductor layer are in contact with each other, and no amorphous layer exists between the silicon carbide layer and the nitride semiconductor layer.
- the heat conductive layer is made of diamond
- the bonding layer includes a first amorphous layer containing carbon as a main component and a first amorphous layer formed on one main surface of the heat conductive layer. and a second carbon- and silicon-based amorphous layer formed between the silicon carbide layer.
- the silicon carbide layer is a single crystal
- the heat conductive layer is made of diamond
- the bonding layer contains at least polycrystalline grains of silicon carbide.
- the heat conductive layer is made of diamond
- the bonding layer includes a carbon atom density decreasing region
- the carbon atom density in the carbon atom density decreasing region is lower than that of the heat conductive layer to the silicon carbide layer.
- the thickness of the carbon atom density decreasing region is 2 nm or more.
- the bonding layer preferably contains silicon oxide.
- the silicon carbide layer preferably does not contain micropipes.
- the silicon carbide layer preferably has a thickness of 0.1 ⁇ m or more and 5 ⁇ m or less.
- one main surface of the silicon carbide layer preferably has a plane orientation of (1,1,1), (-1,-1,-1), or (1,0,0).
- the heat conductive layer is made of diamond and has a resistivity of 5 ⁇ 10 3 ⁇ cm or more and 1 ⁇ 10 16 ⁇ cm or less.
- the silicon carbide layer has an electron concentration of 1 ⁇ 10 15 /cm 3 or more and 1 ⁇ 10 21 /cm 3 or less.
- the nitride semiconductor layer is a first nitride semiconductor layer formed on one main surface side of the silicon carbide layer, the first nitride semiconductor layer including an insulating or semi-insulating layer, and Al x
- the thickness of the nitride semiconductor layer is 6 ⁇ m or more and 10 ⁇ m or less.
- the heat conductive layer is made of diamond
- the nitride semiconductor layer has a thickness of 0.5 ⁇ m or more and less than 6 ⁇ m
- the heat conductive layer has a thickness of 5 ⁇ 10 3 ⁇ cm or more and 1 ⁇ 10 It has a resistivity of 16 ⁇ -cm or less
- the silicon carbide layer has a resistivity of 1 ⁇ 10 3 ⁇ -cm or more and 1 ⁇ 10 16 ⁇ -cm or less.
- a semiconductor device includes the semiconductor substrate described above, and first and second electrodes formed on one main surface side of a silicon carbide layer, wherein the first electrode and the silicon carbide layer are electrically connected.
- the nitride semiconductor layer includes a via hole reaching the silicon carbide layer from one main surface of the nitride semiconductor layer, the first electrode is formed on the one main surface of the nitride semiconductor layer, A conductor layer electrically connecting the first electrode and the silicon carbide layer and formed in the via hole is further provided.
- each of the silicon carbide layer, the nitride semiconductor layer, and the first and second electrodes is preferably plural, and each of the plural silicon carbide layers is provided on one main surface side of the heat conductive layer.
- Each of the plurality of nitride semiconductor layers formed and insulated from each other is formed on one main surface of each of the plurality of silicon carbide layers, and the plurality of first electrodes and the plurality of second electrodes. Each is formed on one main surface side of each of the plurality of silicon carbide layers.
- a semiconductor device comprises the above semiconductor substrate, a source electrode and a gate electrode formed on one main surface of a nitride semiconductor layer, and a drain formed on one main surface of a silicon carbide layer. and an electrode.
- a method of manufacturing a semiconductor substrate comprises the steps of: forming a silicon carbide layer having a 3C-type crystal structure on one main surface of a silicon substrate; removing the silicon substrate from the silicon carbide layer; and bonding the other major surface of the silicon carbide layer to one major surface of a thermally conductive layer made of diamond or polycrystalline silicon carbide. and a step of performing.
- the step of forming a silicon carbide layer includes the step of forming a first silicon carbide layer by carbonizing one main surface of the silicon substrate; and forming a second silicon carbide layer by crystal-growing silicon carbide on the main surface.
- a method of manufacturing a semiconductor device includes the steps of manufacturing a semiconductor substrate and forming first and second electrodes on one main surface side of a silicon carbide layer by the method of manufacturing a semiconductor substrate described above. and electrically connecting the first electrode and the silicon carbide layer.
- a method of manufacturing a semiconductor device comprises the steps of: forming a silicon carbide layer having a 3C-type crystal structure on one main surface of a silicon substrate; After the step of fabricating a semiconductor substrate, the step of fabricating a device on the semiconductor substrate, and the step of fabricating a device, the other main part of the silicon carbide layer is removed by removing the silicon substrate. After the step of exposing the surface and the step of exposing the other major surface of the silicon carbide layer, the other major surface of the silicon carbide layer and one major surface of the thermally conductive layer made of diamond or polycrystalline silicon carbide. and a step of joining.
- a semiconductor substrate, a semiconductor device, a semiconductor substrate manufacturing method, and a semiconductor device manufacturing method that can improve the quality of a nitride semiconductor layer. Further, it is possible to provide a semiconductor substrate, a semiconductor device, a method for manufacturing a semiconductor substrate, and a method for manufacturing a semiconductor device, which can improve the performance of the device.
- FIG. 1 is a cross-sectional view showing the configuration of a semiconductor substrate NS1 in the first embodiment of the invention
- FIG. FIG. 4 is a cross-sectional view showing the first step of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing a second step of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing the third step of the method of manufacturing the semiconductor substrate NS1 in the first embodiment of the present invention, and is a cross-sectional view in the case of using the surface activated bonding method.
- FIG. 4 is a cross-sectional view showing the first step of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing a second step of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing
- FIG. 10 is a cross-sectional view showing a fourth step of the method for manufacturing the semiconductor substrate NS1 in the first embodiment of the present invention, and is a cross-sectional view in the case of using the surface activated bonding method.
- FIG. 6 is an enlarged view of a main portion of FIG. 5; In the first embodiment of the present invention, it is a cross-sectional view of the main part showing the structure of the joint portion 3 when the joint layer 3 is subjected to heat treatment after the joining is performed using the surface activation joining method.
- 3 is a first diagram showing C atom density along the thickness direction in the bonding layer 3.
- FIG. 3 is a second diagram showing the C atom density along the thickness direction in the bonding layer 3.
- FIG. 10 is a cross-sectional view showing the third step of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention, and is a cross-sectional view in the case of using the hydrophilic bonding method.
- FIG. 10 is a cross-sectional view showing a fourth step of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention, and is a cross-sectional view in the case of using a hydrophilic bonding method.
- FIG. 12 is an enlarged view of a main portion of FIG. 11;
- FIG. 4 is a comparison diagram between the band lineup of 3C-SiC/GaN and the band lineup of 4H-SiC/GaN.
- FIG. 10 is a cross-sectional view showing a first step of a first modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing the second step of the first modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention, and is a cross-sectional view in the case of using the surface activated bonding method
- FIG. 10 is a cross-sectional view showing the third step of the first modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention, and is a cross-sectional view in the case of using the surface activated bonding method
- FIG. 10 is a cross-sectional view showing a first step of a first modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing a first step of a first modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention,
- FIG. 14 is a cross-sectional view showing a fourth step of the first modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 12 is a cross-sectional view showing a first step of a second modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing a second step of the second modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention, and is a cross-sectional view in the case of using the surface activated bonding method;
- FIG. 12 is a cross-sectional view showing a first step of a second modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention
- FIG. 10 is a cross-sectional view showing a second step of the second modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention, and is a cross-sectional view in the case of using the surface activated bonding
- FIG. 10 is a cross-sectional view showing the third step of the second modification of the method of manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention, and is a cross-sectional view in the case of using the surface activated bonding method;
- FIG. 14 is a cross-sectional view showing a fourth step of the second modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention; It is a sectional view showing composition of semiconductor device ND1 in a 2nd embodiment of the present invention.
- FIG. 10 is a cross-sectional view showing a first step of a method for manufacturing a semiconductor device ND1 according to a second embodiment of the present invention; It is sectional drawing which shows the 2nd process of the manufacturing method of semiconductor device ND1 in the 2nd Embodiment of this invention.
- FIG. 14 is a cross-sectional view showing a third step of the method for manufacturing the semiconductor device ND1 according to the second embodiment of the present invention;
- FIG. 14 is a cross-sectional view showing a fourth step of the method for manufacturing the semiconductor device ND1 in the second embodiment of the invention; It is sectional drawing which shows the 5th process of the manufacturing method of semiconductor device ND1 in the 2nd Embodiment of this invention.
- FIG. 14 is a cross-sectional view showing a sixth step of the method for manufacturing the semiconductor device ND1 according to the second embodiment of the present invention; It is sectional drawing which shows the 7th process of the manufacturing method of semiconductor device ND1 in the 2nd Embodiment of this invention. It is a sectional view showing composition of semiconductor device ND2 in a 3rd embodiment of the present invention. It is sectional drawing which shows the 1st process of the manufacturing method of semiconductor device ND2 in the 3rd Embodiment of this invention. It is a sectional view showing the 2nd process of the manufacturing method of semiconductor device ND2 in a 3rd embodiment of the present invention. It is a sectional view showing composition of semiconductor device ND3 in a 4th embodiment of the present invention.
- FIG. 10 is a diagram showing distribution of Al composition ratio inside a first nitride semiconductor layer 410 according to a fourth embodiment of the present invention
- 4 is a diagram schematically showing two-dimensional growth of GaN forming a C-GaN layer 421.
- FIG. It is a top view which shows the structure of semiconductor substrate NS2 in the 4th Embodiment of this invention. It is sectional drawing which shows the 1st process of the modification of the manufacturing method of semiconductor device ND3 in the 4th Embodiment of this invention. It is sectional drawing which shows the 2nd process of the modification of the manufacturing method of semiconductor device ND3 in the 4th Embodiment of this invention.
- FIG. 3 shows structures ST1 and ST2 in a first embodiment of the invention
- FIG. 5 is a diagram showing the relationship between the gate-drain distance LDG and the breakdown voltage of each of samples 1 to 5 in the first embodiment of the present invention
- FIG. 4 shows structures ST3 and ST4 in a second embodiment of the invention
- FIG. 9 is a graph showing the overall thermal resistance of each of Samples 6-8 in the second example of the invention
- FIG. FIG. 10 is a table showing the thermal resistance of each of a plurality of layers constituting each of Samples 6 to 8 in the second example of the invention and the overall thermal resistance
- FIG. FIG. 10 is a diagram showing the relationship between the thermal resistance of each of samples 6 and 8 and the thickness D of nitride semiconductor layer 1013 in the second example of the present invention
- FIG. 10 is a TEM image of a cross section of the bonding layer of sample 9 in the third example of the present invention
- FIG. FIG. 10 is a TEM image of a cross section of the bonding layer of sample 10 in the third example of the present invention
- FIG. 11 is a TEM image of a cross section of the bonding layer of sample 11 in the third example of the present invention
- FIG. FIG. 10 is a diagram showing the atomic density distribution along the distance in the depth direction from the surface of the SiC layer of each of samples 9 to 11 in the third example of the present invention
- the expression “formed on the main surface” means formed in contact with the main surface.
- the expression “formed on the main surface side” means formed in contact with the main surface and formed without contact with the main surface (at a distance from the main surface). means both
- FIG. 1 is a cross-sectional view showing the configuration of a semiconductor substrate NS1 according to the first embodiment of the present invention.
- the bonding layer 3 is drawn thicker than the actual thickness.
- a semiconductor substrate NS1 (an example of a semiconductor substrate) in the first embodiment is a substrate for fabricating a semiconductor device. 2 (an example of a silicon carbide layer), a bonding layer 3 (an example of a bonding layer), and a nitride semiconductor layer 4 (an example of a nitride semiconductor layer).
- the diamond substrate 1 is a heat conductive layer made of diamond. Diamond substrate 1 is, for example, polycrystalline. Diamond substrate 1 has a thickness of, for example, 100 ⁇ m or more and 6000 ⁇ m or less. Diamond substrate 1 has main surfaces 1a and 1b. The main surface 1a of the diamond substrate 1 faces upward in FIG. The main surface 1b of the diamond substrate 1 faces downward in FIG.
- the SiC layer 2 is formed on the main surface 1a side of the diamond substrate 1 .
- SiC layer 2 is bonded to diamond substrate 1 .
- the SiC layer 2 is a single crystal and has a 3C-type crystal structure.
- SiC layer 2 includes two main surfaces 2a and 2b.
- the principal surface 2a of the SiC layer 2 faces upward in FIG. 1, and the principal surface 2b of the SiC layer 2 faces downward in FIG.
- the main surface 2a of the SiC layer 2 has, for example, a (111), (-1-1-1), or (100) plane orientation, preferably (111) or (-1-1-1). has a plane orientation of
- the SiC layer 2 preferably has a thickness of 0.1 ⁇ m or more and 5 ⁇ m or less, more preferably 0.5 ⁇ m or more and 1.5 ⁇ m or less, and still more preferably 0.7 ⁇ m or more. It has a thickness of less than 0.0 ⁇ m (eg, 0.9 ⁇ m or less).
- the thickness of SiC layer 2 By setting the thickness of SiC layer 2 to 0.1 ⁇ m or more, preferably 0.5 ⁇ m or more, and further preferably 0.7 ⁇ m or more, the crystal quality of SiC layer 2 can be further improved. As a result, the crystal quality of nitride semiconductor layer 4 formed with SiC layer 2 as a base can be improved.
- SiC layer 2 may contain intentionally doped n-type impurities (for example, N (nitrogen), P (phosphorus), etc.).
- the bonding layer 3 is formed on the main surface 1 a of the diamond substrate 1 .
- Bonding layer 3 is formed between diamond substrate 1 and SiC layer 2 .
- the bonding layer 3 has a thickness of, for example, 1 nm or more and 10 nm or less.
- Nitride semiconductor layer 4 is formed on main surface 2 a of SiC layer 2 .
- Nitride semiconductor layer 4 includes a plurality of layers having mutually different components made of, for example, InxAlyGa1 -xyN (0 ⁇ x ⁇ 1, 0 ⁇ y ⁇ 1, 0 ⁇ x+y ⁇ 1). , has an arbitrary layered structure.
- the nitride semiconductor layer 4 includes an AlGaN (aluminum gallium nitride)/GaN layer heterostructure.
- the main surface 4a of the nitride semiconductor layer 4 faces upward in FIG.
- the semiconductor substrate NS1 When the semiconductor substrate NS1 is used for power applications (applications for integrated circuits), the semiconductor substrate NS1 preferably has the following first configuration.
- the diamond substrate 1 In the first configuration, the diamond substrate 1 is semi-insulating or insulating. Specifically, the diamond substrate 1 has a resistivity of 5 ⁇ 10 3 ⁇ cm or more and 1 ⁇ 10 16 ⁇ cm or less.
- the SiC layer 2 In the first configuration, has conductivity, and is 1 ⁇ 10 15 pieces/cm 3 or more and 1 ⁇ 10 21 pieces/cm 3 or less, preferably 1 ⁇ 10 18 pieces/cm 3 or more and 1 ⁇ 10 18 pieces/cm 3 or more. It preferably has an electron concentration of 10 21 /cm 3 or less.
- the semiconductor substrate NS1 when used for high frequency applications, it is preferable that the semiconductor substrate NS1 have the following second or third configuration.
- the diamond substrate 1 has a resistivity of 5 ⁇ 10 3 ⁇ cm or more and 1 ⁇ 10 16 ⁇ cm or less.
- the SiC layer 2 has a resistivity of 1 ⁇ 10 3 ⁇ cm or more and 1 ⁇ 10 16 ⁇ cm or less.
- Nitride semiconductor layer 4 may have a thickness of 0.5 ⁇ m or more and less than 6 ⁇ m.
- FIGS. 2 to 9 are cross-sectional views showing the method of manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention.
- a Si substrate 90 is prepared with reference to FIG. Si substrate 90 is made of, for example, p-type Si.
- a main surface 90a of the Si substrate 90 faces upward in FIG.
- the plane orientation of main surface 90a of Si substrate 90 is, for example, the (111) plane.
- the plane orientation of the main surface 90a of the Si substrate 90 may be the (100) plane, the (110) plane, or the like.
- Si substrate 90 has, for example, a diameter of 6 inches and a thickness of 1000 ⁇ m.
- a single crystal SiC layer 2 is formed on the main surface 90 a of the Si substrate 90 .
- the principal surface 2a of the SiC layer 2 faces upward in FIG. 2, and the principal surface 2b of the SiC layer 2 faces downward in FIG.
- the SiC layer 2 is formed on a base layer made of SiC obtained by carbonizing the main surface 90a of the Si substrate 90, using an MBE method, a CVD (Chemical Vapor Deposition) method, an LPE (Liquid Phase Epitaxy) method, or the like. and may be formed by homoepitaxially growing SiC.
- the SiC layer 2 includes a SiC layer 21 formed by carbonization and a SiC layer 22 epitaxially grown on the underlying SiC layer 21 .
- the C (carbon) concentration of SiC layer 21 and the C concentration of SiC layer 22 are different from each other.
- the SiC layer 2 may be formed by heteroepitaxial growth on the main surface 90a of the Si substrate 90 (or with a buffer layer interposed therebetween).
- SiC layer 2 is formed on main surface 90a of Si substrate 90 by any one of carbonization, homoepitaxial growth, and heteroepitaxial growth, SiC layer 2 has a 3C-type crystal structure.
- Nitride semiconductor layer 4 is formed on main surface 2 a of SiC layer 2 .
- Nitride semiconductor layer 4 is formed by heteroepitaxial growth on main surface 2a of SiC layer 2 using the CVD method or the like. Therefore, there is no trace of bonding (amorphous layer continuous with each of SiC layer 2 and nitride semiconductor layer 4, SiO 2 layer, etc.) between SiC layer 2 and nitride semiconductor layer 4 .
- Nitride semiconductor layer 4 includes a main surface 4a. The main surface 4a of the nitride semiconductor layer 4 faces upward in FIG.
- a support substrate 95 is fixed to the main surface 4a of the nitride semiconductor layer 4. As shown in FIG. The support substrate 95 plays a role of holding the SiC layer 2 and the nitride semiconductor layer 4 during bonding, which will be described later. Support substrate 95 is made of any material.
- the Si substrate 90 By selectively etching the Si substrate 90, the entire Si substrate 90 is removed from the SiC layer 2 (in FIG. 3, the removed Si substrate 90 is indicated by a dashed line). After removing Si substrate 90, main surface 2b of SiC layer 2 is exposed.
- a diamond substrate 1 is prepared with reference to FIG.
- the principal surface 1a of the diamond substrate 1 faces upward in FIG. 4, and the principal surface 1b of the diamond substrate 1 faces downward in FIG.
- the main surface 1a of the diamond substrate 1 and the main surface 2b of the SiC layer 2 are joined.
- the main surface 2b of the SiC layer 2 faces downward.
- the arithmetic mean roughness Ra of the principal surface 2b of the SiC layer 2 is preferably greater than 0 and equal to or less than 1 nm.
- the arithmetic mean roughness Ra of the main surface 2b of the SiC layer 2 is more preferably greater than 0 and 0.5 nm or less.
- the warp of the main surface 2b of the SiC layer 2 is preferably more than 0 and 50 ⁇ m or less.
- the main surface 2b of the SiC layer 2 may be CMP-processed to improve the arithmetic mean roughness Ra of the main surface 2b of the SiC layer 2.
- a bonding intermediate layer (not shown) is interposed between the main surface 1a of the diamond substrate 1 and the main surface 2b of the SiC layer 2 to bond the main surface 1a of the diamond substrate 1 and the main surface 2b of the SiC layer 2.
- This bonding intermediate layer is made of an arbitrary material, and plays a role such as improving the bonding strength between the diamond substrate 1 and the SiC layer 2 .
- any method can be used for bonding the main surface 1a of the diamond substrate 1 and the main surface 2b of the SiC layer 2, and the surface activation bonding method is preferably used.
- the surface activation bonding method is used, the diamond substrate is bonded in an atmosphere of reduced pressure of 1 ⁇ 10 ⁇ 5 Pa or less, preferably 1 ⁇ 10 ⁇ 6 Pa or less and normal temperature (for example, a temperature of 10° C. or more and 30° C. or less).
- Main surface 1a of SiC layer 1 and main surface 2b of SiC layer 2 are each irradiated with energetic particles as indicated by arrow AW1.
- the energetic particles consist of, for example, ions, neutral atoms such as Ar (argon), Kr (krypton), or Ne (neon), or cluster ions.
- the energetic particles preferably consist of Ar.
- main surface 1a of diamond substrate 1 and main surface 2b of SiC layer 2 are each irradiated with energy particles
- main surface 1a of diamond substrate 1 and main surface 2b of SiC layer 2 each have, for example, Amorphous layers 3a and 3b each having a thickness of approximately 5 nm or less appear.
- the amorphous layer 3a (an example of the first amorphous layer) is obtained by amorphizing diamond present on the main surface 1a of the diamond substrate 1 by collision with energetic particles.
- Amorphous layer 3 a is continuous with diamond substrate 1 . Due to the appearance of the amorphous layer 3a, the main surface 1a of the diamond substrate 1 slightly recedes toward the main surface 1b.
- Amorphous layer 3b (an example of a second amorphous layer) is obtained by amorphizing SiC present on main surface 2a of SiC layer 2 by collision of energetic particles. Amorphous layer 3 b is continuous with SiC layer 2 . Due to the appearance of amorphous layer 3b, main surface 2b of SiC layer 2 slightly recedes toward main surface 2a.
- the amorphous layer 3a and the amorphous layer 3b are brought into contact with each other as indicated by arrow AW2.
- the principal surface 1a of the diamond substrate 1 and the principal surface 2b of the SiC layer 2 are bonded together, and the bonding layer 3 appears.
- bonding layer 3 is a trace of bonding diamond substrate 1 and SiC layer 2 together. Therefore, when the diamond substrate 1 and the SiC layer 2 are not bonded, the bonding layer 3 does not appear.
- the composition of the bonding layer 3 depends on the bonding method.
- the bonding layer 3 includes an amorphous layer 3a and an amorphous layer 3b.
- the amorphous layer 3a contains C and has C as its main component.
- Amorphous layer 3 a is formed on main surface 1 a of diamond substrate 1 .
- Amorphous layer 3b contains C and Si, and is mainly composed of C and Si.
- Amorphous layer 3 b is formed between amorphous layer 3 a and main surface 2 a of SiC layer 2 .
- the amorphous layers 3a and 3b can be observed by TEM (Transmission electron microscopy) or the like.
- the bonding layer 3 contains Si, C, elements existing in the bonding atmosphere, and the like.
- the bonding layer 3 may be heat-treated. Thereby, the strength of the bonding layer 3 can be improved.
- FIG. 7 shows the configuration of the bonding portion 3 when the bonding layer 3 is heat-treated after bonding using the surface activation bonding method in the first embodiment of the present invention. It is a partial sectional view.
- bonding layer 3 when bonding layer 3 is heat-treated at a temperature of, for example, 1000° C. or more and less than the melting point of silicon, atoms contained in amorphous layers 3a and 3b are recrystallized inside bonding layer 3. do.
- bonding layer 3 may include polycrystalline layer 3e.
- the polycrystalline layer 3e contains at least SiC polycrystalline grains, and is mainly composed of SiC polycrystalline grains.
- the polycrystalline layer 3e may further include polycrystalline grains containing atoms of the energy particles used for bonding.
- the bonding layer 3 When only some of the atoms contained in the amorphous layers 3a and 3b in the bonding layer 3 are recrystallized by heat treatment, the bonding layer 3 consists of the polycrystalline layer 3e and at least one of the amorphous layers 3a and 3b. can include one and the other. When all the atoms contained in the amorphous layers 3a and 3b in the bonding layer 3 are recrystallized by heat treatment, the bonding layer 3 does not include the amorphous layers 3a and 3b, and the bonding layer 3 as a whole becomes the polycrystalline layer 3e. can be more
- the bonding layer 3 includes a concentration-reduced region 3f.
- the concentration decreasing region 3f is a region where the C atom density monotonically decreases from the diamond substrate 1 toward the SiC layer 2 (along the thickness direction).
- the reduced concentration region 3f is generated over a wider range inside the bonding layer 3 than when the SiC layer is epitaxially grown on the diamond substrate.
- the reduced concentration region 3f has a thickness of 2 nm or more. The reduced concentration region 3f occurs regardless of whether the bonding layer 3 includes the amorphous layers 3a and 3b and whether it includes the polycrystalline layer 3e.
- FIG 8 and 9 are diagrams showing the C atom density in the bonding layer 3 along the thickness direction.
- the C atom density along the thickness direction in the bonding layer 3 changes depending on the presence or absence of the bonding intermediate layer, the C atom density inside the bonding intermediate layer, and the like.
- the C atom density along the thickness direction in the bonding layer 3 is as shown in FIG. 8(b).
- the reduced concentration region 3f occurs in a region including the interface between the SiC layer 2 and the bonding layer 3, but does not occur in the interface between the diamond substrate 1 and the bonding layer 3.
- the C atom density along the thickness direction in the bonding layer 3 is as shown in FIG. 9(a).
- the reduced concentration region 3 f occurs in the region including the interface between the diamond substrate 1 and the bonding layer 3 , but does not occur in the interface between the SiC layer 2 and the bonding layer 3 .
- the C atom density along the thickness direction in the bonding layer 3 is as shown in FIG. 9(b).
- the reduced concentration region 3f occurs in a region including the interface between the diamond substrate 1 and the bonding layer 3.
- the C atom density monotonically increases from the diamond substrate 1 toward the SiC layer 2 (along the thickness direction).
- hydrophilization bonding may be used instead of surface activation bonding.
- the hydrophilic bonding method is also called Fusion Bonding or Silicon Direct Bonding (SDB).
- SDB Silicon Direct Bonding
- CVD Chemical Vapor Deposition
- a SiO 2 layer 3 d is formed on the main surface 2 b of the SiC layer 2 .
- the SiO 2 layer 3d is formed by a method of forming the SiO 2 layer 3d on the main surface 2b of the SiC layer 2 using a CVD method or the like, a method of forming a Si layer on the main surface 2b of the SiC layer 2, and a method of thermally oxidizing the Si layer. Alternatively, it may be formed by a method of thermally oxidizing main surface 2b of SiC layer 2, or the like.
- Each of the SiO 2 layer 3c and the SiO 2 layer 3d is hydrophilized.
- SiO 2 layer 3c and SiO 2 layer 3d are brought into contact with each other as indicated by arrow AW2.
- the principal surface 1a of the diamond substrate 1 and the principal surface 2b of the SiC layer 2 are bonded together, and the bonding layer 3 appears.
- bonding layer 3 in which SiO 2 layers 3c and 3d are integrated is obtained after bonding.
- the bonding layer 3 contains SiO2 .
- the thermal conductivity of the SiO2 layer is relatively low.
- the bonding layer 3 in the case of using the surface activated bonding method does not contain the SiO 2 layer. From the viewpoint of ensuring high thermal conductivity, it is preferable to use the surface activated bonding method.
- SiC and diamond are Group IV semiconductors, they have high bonding affinity. Therefore, good bonding is realized regardless of the bonding method.
- the fact that the 3C-type single-crystal SiC layer 2 is formed on the main surface 1a of the diamond substrate 1 is a trace that the diamond substrate 1 and the SiC layer 2 are bonded to each other.
- the plane orientation of the joint surface of the diamond substrate 1 and the plane orientation of the joint surface of the SiC layer 2 are different from each other, or the plane orientation of the joint surface of the diamond substrate 1 and the SiC layer 2 are different.
- the deviation in the rotational direction from the plane orientation of the joint surface is a trace of the fact that the single-crystal diamond substrate 1 and the SiC layer 2 were joined to each other. It is not easy to make the plane orientation of the joint surface of the single-crystal diamond substrate 1 and the plane orientation of the joint surface of the SiC layer 2 the same.
- the plane orientation of the joint surface of the single-crystal diamond substrate 1 and the plane orientation of the joint surface of the SiC layer 2 can be made the same, the plane orientation of the joint surface of the single-crystal diamond substrate 1 and the SiC layer 2, a deviation in the direction of rotation or a deviation in the direction of inclination occurs at the time of joining.
- the SiC layer 2 is a 3C type single crystal, and the plane orientation of the bonding surface (here, the main surface 2b) of the SiC layer 2 and the plane orientation of the bonding surface (here, the main surface 1a) of the diamond substrate 1 are are all substantially (111) planes.
- the vector in the [111] direction of the bonding surface of the SiC layer 2 and the [111] direction of the bonding surface of the diamond substrate 1 The angle formed by the vector of the direction, the angle formed by the vector in the [-111] direction of the bonding surface of the SiC layer 2 and the vector in the [-111] direction of the bonding surface of the diamond substrate 1, the [1-] of the bonding surface of the SiC layer 2 11] direction vector and the [1-11] direction vector of the bonding surface of the diamond substrate 1, and the [11-1] direction vector of the bonding surface of the SiC layer 2 and the bonding surface of the diamond substrate 1 [ 11-1], one of the four angles formed by the vector of the direction exceeds twice the value A. This is because a deviation occurs between the plane orientation of the bonding surface of the diamond substrate 1 and the plane orientation of the bonding surface of the SiC layer 2 .
- the value A is the larger of the X-ray rocking curve half-value width of the bonding surface of the SiC layer 2 and the X-ray rocking curve half-value width of the bonding surface of the diamond substrate 1 .
- Each of the above vectors is extracted in the following way.
- a pole figure of the bonding surface of the SiC layer 2 and a pole figure of the bonding surface of the diamond substrate 1 are created by X-ray diffraction method or EBSD (Electron Backscatter Diffraction) method.
- EBSD Electro Backscatter Diffraction
- the diffraction intensity at each of the diffraction peaks in the [111] direction, [-111] direction, [1-11] direction, and [11-1] direction is Extract the maximum point (4 points in total).
- the [111] direction, [ ⁇ 111] direction, [1-11] direction, and [11 ⁇ 1] extract each vector in the direction.
- the [111] direction, the [ ⁇ 111] direction, the [1-11] direction, and the [11 ⁇ 1] extract each vector in the direction.
- the entire support substrate 95 is removed. After removing support substrate 95, main surface 4a of nitride semiconductor layer 4 is exposed. Through the above steps, the semiconductor substrate NS1 is obtained.
- bulk SiC substrates have a 4H-type crystal structure and contain micropipes. It is difficult to manufacture bulk SiC substrates with a 3C-type crystal structure. It is also difficult to obtain bulk SiC substrates having a 3C-type crystal structure from the market.
- SiC layer 2 having a 3C-type crystal structure can be obtained by forming SiC layer 2 using Si substrate 90 as a base. It is known that SiC layers with a 3C-type crystal structure do not contain micropipes.
- the nitride semiconductor layer 4 is formed using the SiC layer 2 that does not contain micropipes as a base, it is possible to avoid the deterioration of the crystal quality of the nitride semiconductor layer 4 due to the micropipes. can be done. Further, according to the present embodiment, since it is not necessary to form SiC layer 2 only by carbonization, SiC layer 2 serving as the base of nitride semiconductor layer 4 can be made sufficiently thick. As a result, the crystal quality of the nitride semiconductor layer 4 can be improved, and a high-power device with high heat dissipation can be manufactured.
- SiC layer 2 has a 3C-type crystal structure. The occurrence can be effectively suppressed. As a result, device performance can be improved. This will be explained below.
- FIG. 13 is a comparison diagram between the 3C-SiC/GaN band lineup and the 4H-SiC/GaN band lineup.
- the bandgap is Eg
- the energy at the top of the valence band is Ev
- the energy at the bottom of the conduction band is Ec1, Ec2, or Ec3.
- the energy Ec1 at the bottom of the conduction band of 3C—SiC is equal to that of the conduction band of 2H—GaN (GaN having a 2H type crystal structure). It is lower than the lower end energy Ec2 by 0.5 eV. Therefore, electrons e1 generated from donors in the 3C-SiC layer are not distributed in the 2H-GaN layer. This indicates that electrons in the 3C-SiC layer are less likely to leak into the nitride semiconductor layer.
- the energy Ec3 of the lower end of the conduction band of 4H—SiC (SiC having a 4H-type crystal structure) is 0.00% lower than the energy Ec2 of the lower end of the conduction band of 2H—GaN. 57 eV higher. Therefore, electrons e2 generated from donors in the 4H-SiC layer are distributed in the 2H-GaN layer as indicated by dotted arrows. This indicates that electrons in the 4H--SiC layer tend to leak into the nitride semiconductor layer.
- the band lineup shown in FIG. 13(b) is also shown in the literature ("Demonstration of Common-Emitter Operation in AlGaN/SiC Heterojunction Bipolar Transistors," IEEE Electron Device Lett., 31, 942 (2010).).
- FIG. 14 to 17 are cross-sectional views showing a first modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention.
- a Si substrate 90 is prepared by the same method as the process shown in FIG.
- the principal surface 2a of the SiC layer 2 faces upward in FIG. 14, and the principal surface 2b of the SiC layer 2 faces downward in FIG.
- a diamond substrate 1 is prepared with reference to FIG.
- the principal surface 1a of the diamond substrate 1 faces upward in FIG. 15, and the principal surface 1b of the diamond substrate 1 faces downward in FIG.
- the principal surface 1a of the diamond substrate 1 and the principal surface 2a of the SiC layer 2 are bonded using a surface activated bonding method.
- main surface 1a of diamond substrate 1 and main surface 2a of SiC layer 2 are each irradiated with energetic particles as indicated by arrow AW1.
- Amorphous layers 3a and 3b appear on each of main surface 1a of diamond substrate 1 and main surface 2a of SiC layer 2, respectively.
- the amorphous layer 3a and the amorphous layer 3b are brought into contact with each other as indicated by arrows AW2 by a method similar to the process shown in FIG. As a result, the principal surface 1a of the diamond substrate 1 and the principal surface 2a of the SiC layer 2 are bonded, and the bonding layer 3 appears. Any bonding method may be used, and a hydrophilic bonding method or the like may be used.
- Si substrate 90 is entirely removed from SiC layer 2 by selectively etching Si substrate 90 in a manner similar to the process shown in FIG.
- the substrate 90 is shown in dashed lines). After removing Si substrate 90, main surface 2b of SiC layer 2 is exposed.
- a nitride semiconductor layer 4 is then formed on the main surface 2b of the SiC layer 2 by the same method as the process shown in FIG. Through the above steps, the semiconductor substrate NS1 is obtained. However, in the semiconductor substrate NS1 obtained in the first modification, the orientations of the main surfaces 2a and 2b of the SiC layer 2 are opposite to those in FIG.
- 18 to 22 are cross-sectional views showing a second modification of the method for manufacturing the semiconductor substrate NS1 according to the first embodiment of the present invention.
- a Si substrate 90 is prepared by the same method as the process shown in FIG.
- a support substrate 96 is fixed (attached) to the main surface 2a of the SiC layer 2 using an arbitrary method.
- the support substrate 96 plays a role of holding the SiC layer 2 during bonding, which will be described later.
- Support substrate 96 is made of any material.
- the Si substrate 90 is selectively etched to remove the entire Si substrate 90 from the SiC layer 2 (in FIG. 19, the removed Si substrate 90 is indicated by a dashed line). . After removing Si substrate 90, main surface 2b of SiC layer 2 is exposed.
- a diamond substrate 1 is prepared with reference to FIG.
- the principal surface 1a of the diamond substrate 1 faces upward in FIG. 20, and the principal surface 1b of the diamond substrate 1 faces downward in FIG.
- the principal surface 1a of the diamond substrate 1 and the principal surface 2b of the SiC layer 2 are bonded using a surface activated bonding method.
- principal surface 1a of diamond substrate 1 and principal surface 2b of SiC layer 2 are each irradiated with energetic particles as indicated by arrows AW1 in the same manner as in the step shown in FIG.
- Amorphous layers 3a and 3b appear on each of main surface 1a of diamond substrate 1 and main surface 2b of SiC layer 2, respectively.
- the amorphous layer 3a and the amorphous layer 3b are brought into contact with each other as indicated by arrows AW2 by a method similar to the process shown in FIG. As a result, the principal surface 1a of the diamond substrate 1 and the principal surface 2b of the SiC layer 2 are bonded together, and the bonding layer 3 appears. Any bonding method may be used, and a hydrophilic bonding method or the like may be used.
- the entire support substrate 96 is removed (in FIG. 21, the removed support substrate 96 is indicated by a dashed line). After removing support substrate 96, main surface 2a of SiC layer 2 is exposed.
- a nitride semiconductor layer 4 is then formed on the main surface 2a of the SiC layer 2 by the same method as the process shown in FIG. Through the above steps, the semiconductor substrate NS1 is obtained.
- the main surface of the SiC layer 2 serving as the base of the nitride semiconductor layer 4 is the main surface 2b in the first modification, and the main surface 2b in the second modification. In a modification, it is the main surface 2a.
- atoms forming the outermost surfaces of main surface 2a and main surface 2b of SiC layer 2 are different from each other.
- the outermost surface of main surface 2a of SiC layer 2 is a Si surface (a surface composed of Si atoms)
- the outermost surface of main surface 2b is a C surface (a surface composed of C atoms).
- the Si face and the C face of the SiC layer 2 have different electrical properties. Therefore, by appropriately selecting the manufacturing method of the semiconductor substrate NS1, the electrical properties of the semiconductor substrate NS1 can be appropriately set.
- FIG. 22 is a cross-sectional view showing the configuration of a semiconductor device ND1 according to the second embodiment of the invention.
- a semiconductor device ND1 (an example of a semiconductor device) in the present embodiment is manufactured using the semiconductor substrate NS1 in the first embodiment. and diode DD1.
- Transistors TR1 and TR2 and diode DD1 each have a mesa structure.
- a trench 161 separates the transistor TR1 and the transistor TR2 from each other.
- Transistor TR2 and diode DD1 are separated from each other by trench 162 .
- the grooves 161 and 162 separate the bonding layer 3 into the bonding layers 31 to 33, the SiC layer 2 into the SiC layers 21 to 23, and the nitride semiconductor layer 4 into the nitride semiconductor layers 41 to 43. separated.
- Each of SiC layers 21-23 is electrically insulated from each other. The potential of each of SiC layers 21-23 may be floating or fixed.
- the transistor TR1 is, for example, a low-voltage side switch of a half-bridge circuit, and consists of a HEMT.
- the transistor TR1 includes a diamond substrate 1 (an example of a heat conductive layer), a SiC layer 21 (an example of a silicon carbide layer), a bonding layer 31 (an example of a bonding layer), and a nitride semiconductor layer 41 (an example of a nitride semiconductor layer).
- a conductive layer 51 an example of a conductive layer
- an interlayer insulating layer 61 a source electrode 71 (an example of a first electrode), a drain electrode 81 (an example of a second electrode), and a gate electrode 91 , an interlayer insulating layer 121 , and a conductive layer 131 .
- a bonding layer 31, a SiC layer 21, a nitride semiconductor layer 41, an interlayer insulating layer 61, and an interlayer insulating layer 121 are laminated in this order on the main surface 1a of the diamond substrate 1. As shown in FIG.
- the nitride semiconductor layer 41 includes via holes 41 a reaching the SiC layer 21 from the main surface 41 b of the nitride semiconductor layer 41 .
- Conductive layer 51 is formed inside via hole 41 a and electrically connects SiC layer 21 and source electrode 71 .
- Source electrode 71 , drain electrode 81 , gate electrode 91 and interlayer insulating layer 61 are formed on main surface 41 b of nitride semiconductor layer 41 .
- Source electrode 71 , drain electrode 81 and gate electrode 91 are each formed on main surface 21 a side of SiC layer 21 .
- Each of source electrode 71, drain electrode 81 and gate electrode 91 is spaced apart from each other.
- Source electrode 71 and SiC layer 21 are electrically connected.
- Source electrode 71 is grounded.
- Interlayer insulating layer 61 is formed to fill the spaces between source electrode 71 , drain electrode 81 and gate electrode 91 .
- Interlayer insulating layer 121 covers each of source electrode 71 , drain electrode 81 , gate electrode 91 and interlayer insulating layer 61 .
- Interlayer insulating layer 121 includes via hole 121 a reaching drain electrode 81 .
- the conductive layer 131 is formed inside the via hole 121 a and electrically connected to the drain electrode 81 .
- the transistor TR2 is, for example, a switch on the high voltage side of the half bridge circuit, and is made up of a HEMT.
- the transistor TR2 has substantially the same configuration as the transistor TR1.
- the transistor TR2 includes a diamond substrate 1 (an example of a heat conductive layer), a SiC layer 22 (an example of a silicon carbide layer), a bonding layer 32 (an example of a bonding layer), and a nitride semiconductor layer 42 (an example of a nitride semiconductor layer).
- a conductive layer 52 (an example of a conductive layer), an interlayer insulating layer 62, a source electrode 72 (an example of a first electrode), a drain electrode 82 (an example of a second electrode), and a gate electrode 92 , an interlayer insulating layer 122 , and a conductive layer 132 .
- a bonding layer 32, a SiC layer 22, a nitride semiconductor layer 42, an interlayer insulating layer 62, and an interlayer insulating layer 122 are laminated in this order on the main surface 1a of the diamond substrate 1. As shown in FIG.
- the nitride semiconductor layer 42 includes a via hole 42 a reaching the SiC layer 22 from the main surface 42 b of the nitride semiconductor layer 42 .
- the conductive layer 52 is formed inside the via hole 42 a and electrically connects the SiC layer 22 and the source electrode 72 .
- a source electrode 72 , a drain electrode 82 , a gate electrode 92 and an interlayer insulating layer 62 are formed on main surface 42 b of nitride semiconductor layer 42 .
- Source electrode 72 , drain electrode 82 and gate electrode 92 are each formed on main surface 22 a side of SiC layer 22 .
- Each of source electrode 72, drain electrode 82 and gate electrode 92 is spaced apart from each other.
- Source electrode 72 and SiC layer 22 are electrically connected.
- Interlayer insulating layer 62 is formed to fill the spaces between source electrode 72 , drain electrode 82 and gate electrode 92 .
- Interlayer insulating layer 122 covers each of source electrode 72 , drain electrode 82 , gate electrode 92 and interlayer insulating layer 62 .
- Interlayer insulating layer 122 includes a via hole 122 a reaching source electrode 72 .
- Conductive layer 132 is formed inside via hole 122 a and is electrically connected to source electrode 72 .
- the diode DD1 consists of a Schottky via diode.
- the diode DD1 includes a diamond substrate 1 (an example of a heat conductive layer), a SiC layer 23 (an example of a silicon carbide layer), a bonding layer 33 (an example of a bonding layer), and a nitride semiconductor layer 43 (a nitride semiconductor layer). an example), an interlayer insulating layer 63, a cathode electrode 10 (an example of a second electrode), an anode electrode 11 (an example of a first electrode), an interlayer insulating layer 123, conductive layers 133 and 134, and a conductive and layer 152 .
- SiC layer 23, nitride semiconductor layer 43, interlayer insulating layer 63, interlayer insulating layer 123, and conductive layer 152 are laminated in this order on main surface 1a side of diamond substrate 1. As shown in FIG.
- a cathode electrode 10, an anode electrode 11, and an interlayer insulating layer 63 are formed on the main surface 43b of the nitride semiconductor layer 43 respectively.
- Cathode electrode 10 and anode electrode 11 are each formed on main surface 23 a side of SiC layer 23 .
- Cathode electrode 10 and anode electrode 11 are each spaced apart from each other.
- Anode electrode 11 and SiC layer 23 are electrically connected.
- Interlayer insulating layer 63 is formed to fill a space between cathode electrode 10 and anode electrode 11 .
- Interlayer insulating layer 123 covers each of cathode electrode 10 , anode electrode 11 and interlayer insulating layer 63 .
- interlayer insulating layer 123 In each of interlayer insulating layer 123 , interlayer insulating layer 63 and nitride semiconductor layer 43 , via hole 43 a reaching SiC layer 23 from main surface 123 b of interlayer insulating layer 123 is formed.
- the conductive layer 133 is formed inside the via hole 43a.
- Interlayer insulating layer 123 includes via hole 123 a reaching anode electrode 11 .
- the conductive layer 134 is formed inside the via hole 123a.
- Conductive layer 152 covers each of conductive layers 133 and 134 .
- Conductive layers 133 , 152 and 134 (an example of a conductive layer) electrically connect SiC layer 23 and anode electrode 11 .
- An insulating layer 141 is formed along the side and bottom surfaces of the groove 161 .
- An insulating layer 142 is formed along the side and bottom surfaces of trench 162 .
- Conductive layer 151 is formed on main surface 121 b of interlayer insulating layer 121 , main surface 141 a of insulating layer 141 , and main surface 122 b of interlayer insulating layer 122 .
- the conductive layer 151 electrically connects the drain electrode 81 of the transistor TR1 and the source electrode 72 of the transistor TR2.
- the semiconductor device ND1 is an example of a device manufactured using the semiconductor substrate NS1.
- a device manufactured using the semiconductor substrate NS1 may have any configuration.
- the drain electrode may be electrically connected to the SiC layer instead of the source electrode.
- cathode electrode 10 may be electrically connected to SiC layer 23 instead of anode electrode 11 .
- 23 to 29 are cross-sectional views showing the manufacturing method of the semiconductor device ND1 according to the second embodiment of the present invention.
- a semiconductor substrate NS1 is prepared.
- Via holes 41a and 42a are formed in predetermined regions of main surface 4a of nitride semiconductor layer 4 using normal photolithography and etching techniques.
- SiC layer 2 is exposed at the bottom of each of via holes 41a and 42a.
- a conductive layer is formed inside each of via holes 41a and 42a and on main surface 4a of nitride semiconductor layer 4, and excess conductive layer on main surface 4a of nitride semiconductor layer 4 is removed. Thereby, conductive layers 51 and 52 are formed inside via holes 41a and 41b, respectively.
- source electrodes 71 and 72, drain electrodes 81 and 82, and cathode electrode 10 are formed in predetermined regions on main surface 4a of nitride semiconductor layer 4 by a method such as lift-off. At this time, each of source electrodes 71 and 72 is formed at a position in contact with each of conductive layers 51 and 52 . Thereby, each of source electrodes 71 and 72 and SiC layer 2 are electrically connected.
- gate electrodes 91 and 92 and anode electrode 11 are formed in predetermined regions on main surface 4a of nitride semiconductor layer 4 by a method such as lift-off.
- An insulating layer is formed on main surface 4a of nitride semiconductor layer 4 to cover source electrodes 71 and 72, drain electrodes 81 and 82, gate electrodes 91 and 92, cathode electrode 10 and anode electrode 11, respectively. Excess insulating layers on top of each of source electrodes 71 and 72, drain electrodes 81 and 82, gate electrodes 91 and 92, cathode electrode 10, and anode electrode 11 are removed.
- interlayer insulating layer 6 is formed in a region of main surface 4a of nitride semiconductor layer 4 excluding source electrodes 71 and 72, drain electrodes 81 and 82, gate electrodes 91 and 92, cathode electrode 10, and anode electrode 11. be.
- interlayer insulating layer 12 is formed on main surface 6a of interlayer insulating layer 6.
- Via holes 121a, 122a and 123a are formed in prescribed regions of interlayer insulating layer 12 using normal photolithography and etching techniques. Drain electrode 81, source electrode 72 and anode electrode 11 are exposed at the bottom of via holes 121a, 122a and 123a, respectively.
- a conductive layer is formed inside each of via holes 121 a , 122 a and 123 a and on main surface 12 a of interlayer insulating layer 12 . Excess conductive layers on main surface 12a of interlayer insulating layer 12 are removed. Thereby, conductive layers 131, 132 and 134 are formed inside via holes 121a, 122a and 123a, respectively.
- via holes 43a are formed in predetermined regions of interlayer insulating layer 12 using normal photomechanical technology and etching technology. SiC layer 2 is exposed at the bottom of via hole 43a. A conductive layer is formed inside via hole 43 a and on main surface 12 a of interlayer insulating layer 12 . Excess conductive layers on main surface 12a of interlayer insulating layer 12 are removed. Thereby, a conductive layer 133 is formed inside the via hole 43a.
- trenches 161 and 162 are formed in predetermined regions of interlayer insulating layer 12 using normal photolithography and etching techniques.
- Diamond substrate 1 is exposed at the bottom of each of grooves 161 and 162 .
- bonding layer 3 is separated into bonding layers 31-33
- SiC layer 2 is separated into SiC layers 21-23
- nitride semiconductor layer 4 is separated into nitride semiconductor layers 41-43.
- the interlayer insulating layer 6 is separated into interlayer insulating layers 61-63
- the interlayer insulating layer 12 is separated into interlayer insulating layers 121-123.
- insulation is provided between side surfaces and bottom surfaces of trenches 161 and 162, main surface 121b of interlayer insulating layer 121, main surface 122b of interlayer insulating layer 122, and main surface 123b of interlayer insulating layer 123.
- FIG. form a layer. Excess insulating layers on main surface 121b of interlayer insulating layer 121, main surface 122b of interlayer insulating layer 122, and main surface 123b of interlayer insulating layer 123 are removed. Thereby, insulating layers 141 and 142 are formed along the side and bottom surfaces of trenches 161 and 162, respectively.
- main surface 141a of insulating layer 141, main surface 142a of insulating layer 142, main surface 121b of interlayer insulating layer 121, main surface 122b of interlayer insulating layer 122, and main surface 122b of interlayer insulating layer 123 A conductive layer is formed on main surface 123b. Excess conductive layers on main surface 121b of interlayer insulating layer 121, main surface 122b of interlayer insulating layer 122, main surface 123b of interlayer insulating layer 123, and main surface 142a of insulating layer 142 are removed.
- conductive layer 151 is formed on main surface 121 b of interlayer insulating layer 121 , main surface 141 a of insulating layer 141 , and main surface 122 b of interlayer insulating layer 122 .
- Conductive layer 152 is formed on main surface 123 b of interlayer insulating layer 123 .
- Anode electrode 11 and SiC layer 23 are electrically connected.
- the semiconductor device ND1 is obtained by the above steps.
- the configuration and manufacturing method of the semiconductor device ND1 other than those described above are the same as the configuration and manufacturing method of the semiconductor substrate NS1 in the first embodiment, so description thereof will not be repeated.
- the withstand voltage of the transistors TR1 and TR2 and the diode DD1, which are devices included in the semiconductor device ND1 can be improved. Specifically, since the source electrode 71 of the transistor TR1 and the SiC layer 21 are electrically connected, they are at the same potential. Therefore, when the transistor TR1 is in the off state, part of the electric lines of force from the drain electrode 81 toward the gate electrode 91, which is an electrode adjacent to the drain electrode 81, is pulled toward the SiC layer 21, and the line of force is pulled toward the SiC layer 21. Head. The density of electric lines of force directed from the drain electrode 81 to the gate electrode 91 is relaxed, and the electric field between the gate electrode 91 and the drain electrode 81 is relaxed.
- the withstand voltage of the transistor TR1 is improved.
- the source electrode 72 and the SiC layer 22 of the transistor TR2 are at the same potential, the electric field between the drain electrode 82 and the gate electrode 92 is relaxed, and the breakdown voltage of the transistor TR2 is improved.
- the anode electrode 11 and the SiC layer 23 of the diode DD1 are at the same potential, the electric field between the anode electrode 11 and the cathode electrode 10 is relaxed, and the withstand voltage of the diode DD1 is improved. As a result, it is possible to increase the withstand voltage and output power of all the devices that constitute the integrated circuit.
- the thermal resistance of the semiconductor device ND1 can be improved. That is, in the semiconductor device ND1, heat is generated mainly inside and on the main surface of the nitride semiconductor layer. Specifically, the interior and main surface 41b of the nitride semiconductor layer 41 of the transistor TR1, the interior and main surface 42b of the nitride semiconductor layer 42 of the transistor TR2, and the interior and main surface 43b of the nitride semiconductor layer 43 of the diode DD1. heat is generated in SiC layers 21-23 and diamond substrate 1 have high thermal conductivity. Therefore, the heat is efficiently emitted to the main surface 1b side of the diamond substrate 1 via one of the SiC layers 21 to 23 and the diamond substrate 1. FIG.
- the SiC substrate is thinned by cutting the back surface of the SiC substrate, and a SiC layer with a thickness of 50 ⁇ m is produced.
- the lower limit of the thickness of the SiC layer is set to 50 ⁇ m from the viewpoint of preventing the SiC layer from being mechanically damaged during processing due to the cutting accuracy of the SiC substrate.
- the etching rate of SiC is slow, it is difficult to form element isolation (trenches 161 and 162 in this embodiment) by locally etching away a SiC layer with a thickness of 50 ⁇ m.
- the SiC layer can be made thinner than 50 ⁇ m because the SiC substrate does not need to be cut when forming the SiC layer 2 . As a result, element isolation can be easily formed.
- FIG. 30 is a cross-sectional view showing the configuration of a semiconductor device ND2 according to the third embodiment of the invention.
- a semiconductor device ND2 (an example of a semiconductor device) in the present embodiment is manufactured using the semiconductor substrate NS1 in the first embodiment, and includes a transistor TR3 as a device. I'm in.
- the transistor TR3 consists of a vertical FET (Field Effect Transistor).
- the transistor TR3 includes a diamond substrate 1 (an example of a heat conductive layer), a SiC layer 2 (an example of a silicon carbide layer), a bonding layer 3 (an example of a bonding layer), and a nitride semiconductor layer 4 (a nitride semiconductor layer). an example), a source electrode 73 (an example of a source electrode), a drain electrode 83 (an example of a drain electrode), and a gate electrode 93 (an example of a gate electrode). Bonding layer 3 , SiC layer 2 , and nitride semiconductor layer 4 are laminated in this order on main surface 1 a of diamond substrate 1 .
- a source electrode 73 and a gate electrode 93 are formed on the main surface 4 a of the nitride semiconductor layer 4 .
- Source electrode 73 , drain electrode 83 and gate electrode 93 are each formed on main surface 2 a side of SiC layer 2 .
- Source electrode 73 surrounds gate electrode 93 when viewed from the main surface 4 a side of nitride semiconductor layer 4 .
- a drain electrode 83 is formed in a region of main surface 2a of SiC layer 2 where nitride semiconductor layer 4 is not formed. Drain electrode 83 surrounds nitride semiconductor layer 4 when viewed from the main surface 4a side of nitride semiconductor layer 4 .
- Drain electrode 83 is in contact with SiC layer 2 and is electrically connected to SiC layer 2 . The position of the source electrode 73 and the position of the drain electrode 83 may be interchanged.
- 31 and 32 are cross-sectional views showing the method of manufacturing the semiconductor device ND2 according to the third embodiment of the present invention.
- a semiconductor substrate NS1 is prepared with reference to FIG.
- a predetermined region of the nitride semiconductor layer 4 is removed using normal photomechanical technology and etching technology.
- Main surface 2a of SiC layer 2 is exposed at the portion where nitride semiconductor layer 4 is removed.
- a source electrode 73 is formed on the main surface 4a of the nitride semiconductor layer 4 and a drain electrode 83 is formed on the main surface 2a of the SiC layer 2 by a method such as lift-off.
- gate electrode 93 is formed on main surface 4a of nitride semiconductor layer 4 by a method such as lift-off.
- the semiconductor device ND2 is obtained by the above steps.
- the configuration and manufacturing method of the semiconductor device ND2 other than those described above are the same as the configuration and manufacturing method of the semiconductor substrate NS1 in the first embodiment or the configuration and manufacturing method of the semiconductor device ND1 in the second embodiment. Therefore, the description will not be repeated.
- the SiC layer 2 since the SiC layer 2 has conductivity, the SiC layer 2 can be regarded as part of the drain electrode 83 . That is, according to the present embodiment, the drain electrode can be formed directly below the nitride semiconductor layer 4 serving as the drift layer.
- a base substrate having a parasitic resistance exists directly below the nitride semiconductor layer 4, which serves as a drift layer, and a drain electrode is formed therebelow.
- the thickness of the underlying substrate having parasitic resistance is generally as large as 50 ⁇ m or more, and when a current flows through the device, a current path is created that penetrates the underlying substrate having this parasitic resistance, so heat is generated in this current path. degrades the efficiency of the device.
- drain electrode 83 and SiC layer 2 are in direct contact. Thereby, the drain electrode 83 of the transistor TR3 and the SiC layer 2 can be electrically connected by a simple method.
- FIG. 33 is a cross-sectional view showing the configuration of a semiconductor device ND3 according to the fourth embodiment of the invention.
- a semiconductor device ND3 (an example of a semiconductor device) in the present embodiment is manufactured using a semiconductor substrate NS2 (an example of a semiconductor substrate) and includes a transistor TR4 as a device.
- the transistor TR4 is made of a HEMT, and includes a diamond substrate 1 (an example of a heat conductive layer), a SiC layer 2 (an example of a silicon carbide layer), a bonding layer 3 (an example of a bonding layer), and a nitride semiconductor layer 4. (an example of a nitride semiconductor layer), a source electrode 74 , a drain electrode 84 and a gate electrode 94 .
- Bonding layer 3 , SiC layer 2 , and nitride semiconductor layer 4 are laminated in this order on main surface 1 a of diamond substrate 1 .
- a source electrode 74, a drain electrode 84, and a gate electrode 94 are formed on main surface 4a of nitride semiconductor layer 4 at intervals.
- the semiconductor substrate NS2 differs from the semiconductor substrate NS1 in that the configuration of the nitride semiconductor layer 4 is specifically defined.
- the nitride semiconductor layer 4 of the semiconductor substrate NS2 includes a first nitride semiconductor layer 410 (an example of a first nitride semiconductor layer) and a second nitride semiconductor layer 420 (an example of a second nitride semiconductor layer). ), an electron transit layer 430 (an example of an electron transit layer), and a barrier layer 440 (an example of a barrier layer).
- First nitride semiconductor layer 410 is formed on main surface 2 a of SiC layer 2 .
- the first nitride semiconductor layer 410 is made of Al x Ga 1-x N (0.1 ⁇ x ⁇ 1).
- the first nitride semiconductor layer 410 functions as a buffer layer that alleviates the difference in lattice constant between the SiC layer 2 and the second nitride semiconductor layer 420 .
- First nitride semiconductor layer 410 has a thickness of, for example, 600 nm or more and 4 ⁇ m or less, preferably 1 ⁇ m or more and 3 ⁇ m or less, more preferably 1.5 ⁇ m or more and 2.5 ⁇ m or less.
- the first nitride semiconductor layer 410 is formed using MOCVD (Metal Organic Chemical Vapor Deposition).
- MOCVD Metal Organic Chemical Vapor Deposition
- an Al (aluminum) source gas for example, TMA (Tri Methyl Aluminum) or TEA (Tri Ethyl Aluminum) is used.
- Ga (gallium) source gas for example, TMG (Tri Methyl Gallium), TEG (Tri Ethyl Gallium), or the like is used.
- NH 3 (ammonia) is used as the N source gas.
- the first nitride semiconductor layer 410 preferably has a thickness equal to or less than the thickness of the second nitride semiconductor layer 420 described later.
- the first nitride semiconductor layer 410 has insulating or semi-insulating properties. However, a region (lower layer) of the first nitride semiconductor layer 410 near the SiC layer 2 may have extremely low crystallinity. Therefore, the region of first nitride semiconductor layer 410 near SiC layer 2 does not have to be locally insulating or semi-insulating. Even in this case, the region (upper layer) of the first nitride semiconductor layer 410 close to the electron transit layer 430 has insulating or semi-insulating properties.
- the first nitride semiconductor layer 410 is composed of an unintentionally doped layer (uid layer), a C-doped layer, a transition metal-doped layer, or the like.
- a uid layer means a layer in which impurities are not intentionally introduced during formation of the layer.
- the uid layer contains a small amount of impurities (impurities in the atmosphere during formation of the layer) that were unintentionally introduced during formation of the layer.
- the first nitride semiconductor layer 410 may be composed of a plurality of layers made of different materials, as described later.
- the first nitride semiconductor layer 410 includes a first region made of Al x Ga 1-x N (0.4 ⁇ x ⁇ 1) and an Al x Ga 1-x N layer having a thickness of 0.5 ⁇ m or more. (0.1 ⁇ x ⁇ 0.4) and/or a second region.
- First nitride semiconductor layer 410 includes both a first region and a second region, and the distance between first region and SiC layer 2 is equal to the distance between second region and SiC layer 2 . It is preferably smaller than the distance.
- the first region of the first nitride semiconductor layer 410 has a Si concentration of 0/cm 3 or more and 5 ⁇ 10 17 /cm 3 or less, It has an O (oxygen) concentration of 0/cm 3 or more and 5 ⁇ 10 17 pieces/cm 3 or less and an Mg (magnesium) concentration of 0 pieces/cm 3 or more and 5 ⁇ 10 17 pieces/cm 3 or less.
- the second region of the first nitride semiconductor layer 410 has a Si concentration of 0/cm 3 or more and 2 ⁇ 10 16 /cm 3 or less and a Si concentration of 0/cm 3 or more and 2 ⁇ 10 16 /cm 3 or less. It has an O concentration and an Mg concentration of 0 pieces/cm 3 or more and 2 ⁇ 10 16 pieces/cm 3 or less. Furthermore, at least one of the C concentration and the Fe (iron) concentration in the second region of the first nitride semiconductor layer 410 is equal to the Si concentration, O 5 ⁇ 10 19 pieces/cm 3 or less, which is higher than both the concentration and the Mg concentration. Thereby, the insulation of the first nitride semiconductor layer can be improved.
- Second nitride semiconductor layer 420 is formed on main surface 410 a of first nitride semiconductor layer 410 .
- the second nitride semiconductor layer 420 is formed between the first nitride semiconductor layer 410 and the electron transit layer 430 .
- C or Fe is intentionally introduced into the second nitride semiconductor layer 420 .
- at least one of the C concentration and the Fe concentration in the second nitride semiconductor layer 420 is 5 ⁇ higher than the Si concentration, the O concentration, and the Mg concentration in the second nitride semiconductor layer 420. It is preferably 10 19 pieces/cm 3 or less.
- the second nitride semiconductor layer 420 includes a C-GaN layer 421 (an example of the main layer) and an intermediate layer 422 (an example of the intermediate layer).
- the C-GaN layer 421 is a GaN layer containing C (a GaN layer into which C is intentionally introduced). C plays a role in enhancing the insulating properties of GaN. Impurities other than C are not intentionally introduced into the C-GaN layer 421 during formation of the layer.
- the C-GaN layer 421 has a Si concentration of 0/cm 3 or more and 2 ⁇ 10 16 /cm 3 or less, an O concentration of 0/cm 3 or more and 2 ⁇ 10 16 /cm 3 or less, and 0 It has a Mg concentration of 2 ⁇ 10 16 pieces/cm 3 or more and 2 ⁇ 10 16 pieces/cm 3 or less.
- the C-GaN layer 421 includes a region in which the concentration of activated donor ions is 0/cm 3 or more and 2 ⁇ 10 14 /cm 3 or less.
- the main layer constituting the second nitride semiconductor layer 420 is not limited to the C-GaN layer 421, but is insulating or semi-insulating Al y Ga 1-y N (0 ⁇ y ⁇ 0. 1) as long as it consists of;
- the main layer constituting the second nitride semiconductor layer 420 has at least one of a C concentration higher than the C concentration of the electron transit layer 430 and an Fe concentration higher than the Fe concentration of the electron transit layer 430. is preferred.
- impurities other than the above-described C and Fe are not intentionally introduced into the main layer constituting the second nitride semiconductor layer 420 when the layer is formed.
- Intermediate layer 422 is formed in at least one of C-GaN layer 421 and on C-GaN layer 421 .
- the intermediate layer 422 is made of AlyGa1 -yN (0.5 ⁇ y ⁇ 1).
- Intermediate layer 422 is preferably made of AlN.
- the intermediate layer 422 may be one layer or more.
- the intermediate layer 422 is preferably two layers or less, more preferably one layer. Further, the intermediate layer 422 may be the uppermost layer among the layers constituting the second nitride semiconductor layer 420 and may be in contact with the electron transit layer 430 .
- the second nitride semiconductor layer 420 includes two intermediate layers 422a and 422b. Intermediate layers 422 a and 422 b are formed inside C—GaN layer 421 . Intermediate layers 422a and 422b divide the C-GaN layer 421 into three C-GaN layers 421a, 421b, and 421c.
- the C-GaN layer 421 a is the lowest layer among the layers forming the second nitride semiconductor layer 420 and is in contact with the first nitride semiconductor layer 410 .
- the intermediate layer 422a is in contact with the C--GaN layer 421a and is formed on the C--GaN layer 421a.
- the C-GaN layer 421b is in contact with the intermediate layer 422a and formed on the intermediate layer 422a.
- the intermediate layer 422b is in contact with the C-GaN layer 421b and is formed on the C-GaN layer 421b.
- the C-GaN layer 421c is in contact with the intermediate layer 422b and is formed on the intermediate layer 422b.
- the C-GaN layer 421 c is the uppermost layer among the layers forming the second nitride semiconductor layer 420 and is in contact with the electron transit layer 430 .
- the average carbon concentration in the depth direction at the center PT1 (FIG. 36) of the C-GaN layer 421 is 3 ⁇ 10 18 /cm 3 or more. It is 5 ⁇ 10 20 pieces/cm 3 or less, preferably 3 ⁇ 10 18 pieces/cm 3 or more and 2 ⁇ 10 19 pieces/cm 3 or less.
- each of the plurality of C-GaN layers may have the same average carbon concentration, or may have different average carbon concentrations. You may have Among the plurality of C-GaN layers, the uppermost C-GaN layer preferably has a C concentration higher than that of the electron transit layer 430 .
- each of the plurality of C-GaN layers has a thickness of, for example, 550 nm or more and 3000 nm or less, preferably 800 nm or more and 2500 nm. It has the following thickness:
- Each of the plurality of C-GaN layers may have the same thickness or different thicknesses.
- each of the two or more intermediate layers has the same thickness. They may have thicknesses different from each other.
- Each of the two or more intermediate layers preferably has a thickness of 10 nm or more and 30 nm or less.
- Each of the two or more intermediate layers is preferably formed with an interval of 0.5 ⁇ m or more and 10 ⁇ m or less.
- the second nitride semiconductor layer 420 is formed using the MOCVD method.
- the growth temperature of the GaN layer is set lower than the growth temperature of the GaN layer when C is not incorporated (specifically, C is not intentionally doped.
- the temperature is set to about 300° C. lower than the growth temperature of the GaN layer).
- C contained in the Ga source gas is taken into the GaN layer, and the GaN layer becomes a C--GaN layer.
- the growth temperature of the GaN layer is lowered, the quality of the C-GaN layer is degraded, and the in-plane uniformity of the C concentration of the C-GaN layer is degraded.
- the inventors of the present application have found a method of introducing a hydrocarbon as a C source gas (C precursor) together with a Ga source gas and an N source gas into a reaction chamber when forming a C-GaN layer.
- the incorporation of C into the GaN layer is promoted, so the GaN growth temperature is set to a high temperature (specifically, about 200° C. lower than the growth temperature of a GaN layer that is not intentionally C-doped).
- the C-GaN layer can be formed while setting the temperature.
- the quality of the C-GaN layer is improved, and the in-plane uniformity of the C concentration of the C-GaN layer is improved.
- the C source gas includes methane, ethane, propane, butane, pentane, hexane, heptane, octane, ethylene, propylene, butene, pentene, hexene, heptene, octene, acetylene, propyne, butyne, pentyne, hexyne, Hydrocarbons such as heptine or octyne are used. Hydrocarbons containing double bonds or triple bonds are particularly preferred because they have high reactivity. As the C source gas, only one kind of hydrocarbon may be used, or two or more kinds of hydrocarbons may be used.
- the first nitride semiconductor layer 410 preferably has a thickness equal to or less than the thickness of the second nitride semiconductor layer 420 .
- a source gas containing an organic metal gas of Al and ammonia is introduced onto the substrate.
- the organic metal gas of Al reacts unnecessarily with ammonia to generate particles in the gas phase. Therefore, the flow rate of the raw material gas cannot be increased, and it takes a long time to form the nitride layer containing Al.
- the Al composition ratio of the first nitride semiconductor layer 410 is higher than the Al composition ratio of the main layer of the second nitride semiconductor layer 420 . Therefore, when the first nitride semiconductor layer 410 has a thickness equal to or less than the thickness of the second nitride semiconductor layer 420, the thickness of the first nitride semiconductor layer 410 and the second nitride semiconductor layer 420 is reduced. The time required for film formation can be shortened.
- a GaN layer (uid-GaN layer) that is a uid layer may be interposed between the first nitride semiconductor layer 410 and the second nitride semiconductor layer 420 .
- the second nitride semiconductor layer 420 may include layers other than the intermediate layer, or the intermediate layer may be omitted.
- the electron transit layer 430 is in contact with the second nitride semiconductor layer 420 and formed on the principal surface 420 a of the second nitride semiconductor layer 420 .
- the electron transit layer 430 is made of AlzGa1 -zN (0 ⁇ z ⁇ 0.1).
- the electron transit layer 430 is preferably a uid layer, and it is preferable that impurities for making the layer n-type, p-type, or semi-insulating are not intentionally introduced during formation of the layer.
- the Si concentration, O concentration, Mg concentration, C concentration, and Fe (iron) concentration of the electron transit layer 430 are all greater than 0 and 1 ⁇ 10 17 /cm 3 or less.
- the electron transit layer 430 has a Si concentration of 0/cm 3 or more and 1 ⁇ 10 16 /cm 3 or less, an O concentration of 0/cm 3 or more and 1 ⁇ 10 16 /cm 3 or less, and 0/cm 3 or more. Mg concentration of 1 ⁇ 10 16 pieces/cm 3 or less, C concentration of 0 pieces/cm 3 or more and 1 ⁇ 10 17 pieces/cm 3 or less, and Fe of 0 pieces/cm 3 or more and 1 ⁇ 10 17 pieces/cm 3 or less It is more preferable to have concentration. Electron transit layer 430 has a thickness of, for example, 0.3 ⁇ m or more and 5 ⁇ m or less. The electron transit layer 430 is formed using the MOCVD method.
- a region within 0.5 ⁇ m from the boundary with the barrier layer 440 in the electron transit layer 430 preferably has a C concentration of 0 or more and 1 ⁇ 10 17 /cm 3 or less.
- the region within 3 ⁇ m from the boundary with the barrier layer 440 in the electron transit layer 430 is 0 or more and 1 ⁇ 10 It preferably has a C concentration of 18 /cm 3 or less.
- the barrier layer 440 is formed on the main surface 430 a of the electron transit layer 430 .
- the barrier layer 440 is made of a nitride semiconductor having a bandgap wider than that of the electron transit layer 430 .
- the barrier layer 440 is made of, for example, a nitride semiconductor containing Al, such as a material represented by Al a Ga 1-a N (0 ⁇ a ⁇ 1).
- the barrier layer 440 is preferably made of Al a Ga 1-a N (0.17 ⁇ a ⁇ 0.27), and is more preferable than Al a Ga 1-a N (0.19 ⁇ a ⁇ 0.22). It is more preferable that Barrier layer 440 has a thickness of, for example, 10 nm or more and 50 nm or less.
- the barrier layer 440 preferably has a thickness of 25 nm or more and 34 nm or less, for example.
- barrier layer 440 is made of a material represented by Al a Ga 1-a N (0 ⁇ a ⁇ 1)
- the growth temperature for forming barrier layer 440 is, for example, 1000° C. or higher and 1100° C. or lower.
- Barrier layer 440 is formed using MOCVD.
- a spacer layer or the like may be interposed between the electron transit layer 430 and the barrier layer 440 .
- a cap layer or passivation layer may be formed over the barrier layer 440 .
- Source electrode 74 or drain electrode 84 and SiC layer 2 may be electrically connected via a conductive layer. This conductive layer may be formed inside a hole (via hole) extending from main surface 4 a of nitride semiconductor layer 4 to main surface 2 a of SiC layer 2 .
- the semiconductor device ND3 is manufactured by the following method.
- a semiconductor substrate NS2 is manufactured by a method substantially similar to that of the semiconductor substrate NS1 described in the first embodiment. However, when the nitride semiconductor layer 4 is formed on the main surface 2a of the SiC layer 2, the main surface 2a of the SiC layer 2 includes the first nitride semiconductor layer 410, the second nitride semiconductor layer 420, and the Layer 430 and barrier layer 440 are each deposited in that order.
- a source electrode 74 and a drain electrode 84 are formed on the main surface 4a of the nitride semiconductor layer 4 in the obtained semiconductor substrate NS2.
- Gate electrode 94 is formed on main surface 4 a of nitride semiconductor layer 4 .
- the semiconductor device ND3 is obtained by the above steps.
- the Si substrate 90 (FIG. 2) used in fabricating the semiconductor substrate is preferably fabricated by the Cz method (Czochralski method).
- Cz method a seed crystal of Si is gradually pulled up from molten Si in a quartz crucible into a predetermined atmosphere such as Ar. Si adhering to the seed crystal is cooled in the atmosphere and crystallized. Thus, a single crystal of Si is obtained.
- the Si substrate 90 when Si is crystallized, O contained in the quartz material forming the crucible is incorporated into the crystal. Therefore, the Si substrate 90 has a higher O concentration than the Si substrate manufactured by the Fz method.
- the Si substrate 90 has an O concentration of 3 ⁇ 10 17 /cm 3 or more and 3 ⁇ 10 18 /cm 3 or less. Since the Si substrate 90 has a high O concentration, it has a higher elastic limit than a Si substrate manufactured by the Fz (Float zone) method. The Si substrate 90 is easy to obtain a substrate of a large size (e.g., 8 inches in diameter) and is inexpensive compared to a SiC substrate or the like.
- Si substrate 90 is made of, for example, p + -type Si. Si substrate 90 may not be intentionally doped.
- the (111) plane is exposed on the upper surface of the Si substrate 90 .
- the upper surface of Si substrate 90 has an off angle of 0 or more and 1 degree or less, and more preferably has an off angle of 0.5 degree or less.
- Si substrate 90 preferably has a single crystal diamond structure.
- the Si substrate 90 contains B (boron) and has p-type conductivity
- the Si substrate 90 has a resistivity of, for example, 0.1 m ⁇ cm or more and 100 m ⁇ cm or less.
- the Si substrate 90 preferably has a resistivity of 0.5 m ⁇ cm or more and 20 m ⁇ cm or less, more preferably 1 m ⁇ cm or more and 5 m ⁇ cm or less.
- the Si substrate 90 has a diameter of about 50 mm (47 mm to 53 mm as an example) and a thickness of 270 ⁇ m or more and 1600 ⁇ m or less.
- Si substrate 90 has a diameter of about 50.8 mm (47.8 mm to 53.8 mm as an example) and a thickness of 270 ⁇ m or more and 1600 ⁇ m or less.
- the Si substrate 90 has a diameter of about 75 mm (72 mm to 78 mm as an example) and a thickness of 350 ⁇ m or more and 1600 ⁇ m or less.
- Si substrate 90 has a diameter of about 76.2 mm (73.2 mm to 79.2 mm as an example) and a thickness of 350 ⁇ m or more and 1600 ⁇ m or less.
- the Si substrate 90 has a diameter of about 100 mm (97 mm to 103 mm as an example) and a thickness of 500 ⁇ m or more and 1600 ⁇ m or less.
- the Si substrate 90 has a diameter of about 125 mm (122 mm to 128 mm as an example) and a thickness of 600 ⁇ m or more and 1600 ⁇ m or less.
- Si substrate 90 has a diameter of about 150 mm (147 mm to 153 mm as an example) and a thickness of 600 ⁇ m or more and 1600 ⁇ m or less.
- the Si substrate 90 has a diameter of about 200 mm (197 mm to 203 mm as an example) and a thickness of 700 ⁇ m or more and 2100 ⁇ m or less.
- the Si substrate 90 has a diameter of about 100 mm (99.5 mm to 100.5 mm as an example) and a thickness of 700 ⁇ m or more and 1100 ⁇ m or less.
- Si substrate 90 has a diameter of about 125 mm (124.5 mm to 125.5 mm as an example) and a thickness of 700 ⁇ m or more and 1100 ⁇ m or less.
- Si substrate 90 has a diameter of about 150 mm (149.8 mm to 150.2 mm as an example), and Si substrate 90 has a thickness of 900 ⁇ m or more and 1100 ⁇ m or less.
- the Si substrate 90 has a diameter of about 200 mm (199.8 mm to 200.2 mm as an example) and a thickness of 900 ⁇ m or more and 1600 ⁇ m or less.
- the Si substrate 90 may have n-type conductivity.
- the (100) plane or (110) plane may be exposed on the upper surface of the Si substrate 90 .
- FIG. 34 is a diagram showing distribution of the Al composition ratio inside the first nitride semiconductor layer 410 according to the fourth embodiment of the present invention.
- First nitride semiconductor layer 410 includes AlN layer 411 and AlGaN layer 415 .
- AlN layer 411 is formed on main surface 2 a of SiC layer 2 .
- the AlGaN layer 415 is formed on the main surface 411 a of the AlN layer 411 .
- the Al composition ratio inside the AlGaN layer 415 decreases from the bottom to the top.
- the AlGaN layer 415 includes an Al 0.75 Ga 0.25 N layer 412 (an AlGaN layer having an Al composition ratio of 0.75) and an Al 0.5 Ga 0.5 N layer 413 (an AlGaN layer having an Al composition ratio of 0.5). ) and an Al 0.25 Ga 0.75 N layer 414 (an AlGaN layer having an Al composition ratio of 0.25).
- the Al 0.75 Ga 0.25 N layer 412 is formed on the main surface 411 a of the AlN layer 411 .
- the Al 0.5 Ga 0.5 N layer 413 is formed on the main surface 412 a of the Al 0.75 Ga 0.25 N layer 412 .
- Al 0.25 Ga 0.75 N layer 414 is formed on main surface 413 a of Al 0.5 Ga 0.5 N layer 413 .
- Each of the AlN layer 411, the Al0.75Ga0.25N layer 412, and the Al0.5Ga0.5N layer 413 is a first nitride semiconductor made of AlxGa1 - xN ( 0.4 ⁇ x ⁇ 1). It corresponds to the first region of layer 410 .
- the Al 0.25 Ga 0.75 N layer 414 corresponds to the second region of the first nitride semiconductor layer 410 made of Al x Ga 1-x N (0.1 ⁇ x ⁇ 0.4).
- the Al composition ratio inside the first nitride semiconductor layer 410 is arbitrary.
- the bottom layer is preferably an AlN layer.
- the total thickness W of nitride semiconductor layer 4 is preferably 6 ⁇ m or more and 10 ⁇ m or less. More preferably, the thickness W is 7.5 ⁇ m or more and 8.5 ⁇ m or less.
- the thickness W is 6 ⁇ m or more, the substrate side direction viewed from the two-dimensional electron gas TE is thickly covered with an insulating or semi-insulating layer. As a result, high-frequency loss due to parasitic capacitance and parasitic resistance of the substrate can be suppressed, and high-frequency characteristics of the HEMT can be improved.
- the thickness W is 10 ⁇ m or less, it is possible to suppress the generation of cracks and the warp of the substrate due to the increase in the total thickness W of the nitride semiconductor layer 4 .
- the amount of warpage of the semiconductor substrate NS2 can be suppressed within a range of more than 0 and 50 ⁇ m or less.
- diamond substrate 1 and SiC layer 2 may be conductive, semi-insulating, or insulating.
- each of diamond substrate 1 and SiC layer 2 is preferably a semi-insulating substrate or an insulating substrate.
- the diamond substrate 1 preferably has a resistivity of 5 ⁇ 10 3 ⁇ cm or more and 1 ⁇ 10 16 ⁇ cm or less.
- the SiC layer 2 preferably has a resistivity of 1 ⁇ 10 3 ⁇ cm or more and 1 ⁇ 10 16 ⁇ cm or less.
- the substrate side direction viewed from the two-dimensional electron gas TE is thickly covered with an insulating or semi-insulating layer. As a result, high-frequency loss due to parasitic capacitance and parasitic resistance of the substrate can be suppressed, and high-frequency characteristics of the HEMT can be improved.
- the configuration of the semiconductor device ND3 in which the total thickness W of the nitride semiconductor layers 4 is 6 ⁇ m or more and 10 ⁇ m or less corresponds to the second configuration described above.
- the configuration of the semiconductor device ND3 in which the total thickness W of the nitride semiconductor layer 4 is 0.5 ⁇ m or more and less than 6 ⁇ m, and each of the diamond substrate 1 and the SiC layer 2 is a semi-insulating substrate or an insulating substrate is described above. corresponds to the third configuration.
- the Si substrate 90 is manufactured by the Cz method. Therefore, the Si substrate 90 has a high O concentration of 5 ⁇ 10 17 pieces/cm 3 or more and 1 ⁇ 10 19 pieces/cm 3 or less, and has a high elastic limit.
- the Si substrate 90 manufactured by the Cz method the first nitride semiconductor layer 410, the second nitride semiconductor layer 420, and the electron transit layer are formed with a total thickness W of 6 ⁇ m or more and 10 ⁇ m or less. Warping of the substrate caused by 430 can be suppressed.
- the SiC layer 2 between the Si substrate 90 and the first nitride semiconductor layer 410, the reaction between Ga contained in the layer formed on the Si substrate 90 and the Si of the Si substrate 90 The resulting meltback etching can be suppressed. Further, by forming the SiC layer 2 between the Si substrate 90 and the first nitride semiconductor layer 410, the SiC layer 2 serves as a buffer layer between the Si substrate 90 and the first nitride semiconductor layer 410. and can suppress the occurrence of cracks in the first nitride semiconductor layer 410 . As a result, a semiconductor substrate and a semiconductor device having high quality can be provided.
- the intermediate layer 422 in the second nitride semiconductor layer 420, by forming the intermediate layer 422 in at least one of the inside of the C-GaN layer 421 and on the C-GaN layer 421, Warpage of the Si substrate 90 can be suppressed, and cracks in the C-GaN layer 421 or the electron transit layer 430 on the intermediate layer 422 can be suppressed. This will be explained below.
- the base of the intermediate layer 422 is the C-GaN layer 421, and the layer formed on the intermediate layer 422 is also the C-GaN layer 421.
- the intermediate layer 422 is formed on the C--GaN layer 421, the base of the intermediate layer 422 is the C--GaN layer 421, and the layer formed on the intermediate layer 422 is the electron transit layer 430.
- the Al y Ga 1-y N (0.5 ⁇ y ⁇ 1) forming the intermediate layer 422 corresponds to the GaN forming the underlying C-GaN layer 421 (generally, the Al y Ga It is epitaxially grown on the C - GaN layer 421 in a mismatched state (slip state) with respect to the crystal of 1-yN (0 ⁇ y ⁇ 0.1).
- GaN forming the C-GaN layer 421 on the intermediate layer 422 or Al z Ga 1-z N (0 ⁇ z ⁇ 0.1) forming the electron transit layer 430 forms the underlying intermediate layer 422.
- GaN forming the C-GaN layer 421 on the intermediate layer 422 or Al z Ga 1-z N (0 ⁇ z ⁇ 0.1) forming the electron transit layer 430 is replaced by Al y It is epitaxially grown on the intermediate layer 422 so as to inherit the crystal structure of Ga 1-y N (0.5 ⁇ y ⁇ 1). Since the lattice constants of GaN and AlzGa1 -zN (0 ⁇ z ⁇ 0.1) are larger than those of AlyGa1 -yN (0.5 ⁇ y ⁇ 1), the intermediate layer 422 The lateral lattice constants in FIG.
- the C--GaN layer 421 or the electron transit layer 430 on the intermediate layer 422 contains compressive strain therein.
- C - The GaN layer 421 and the electron transit layer 430 receive stress from the underlying intermediate layer 422 .
- This stress causes the Si substrate 90 to warp and may cause cracks in the C-GaN layer 421 and the electron transit layer 430 .
- this stress is relieved by the compressive strain introduced into the C-GaN layer 421 on the intermediate layer 422 or the electron transit layer 430 during the formation of the C-GaN layer 421 and the electron transit layer 430 .
- warping of the Si substrate 90 can be suppressed, and cracks in the C-GaN layer 421 or the electron transit layer 430 can be suppressed.
- the semiconductor device ND3 also includes a C--GaN layer 421, an intermediate layer 422, and a first nitride semiconductor layer 410 having a dielectric breakdown voltage higher than that of GaN. As a result, the vertical withstand voltage of the semiconductor device ND3 can be improved.
- the lattice constant of Si and the AlzGa1 of the electron transit layer 430 The difference from the lattice constant of -zN (0 ⁇ z ⁇ 0.1) can be relaxed.
- the lattice constant of Al x Ga 1-x N (0.1 ⁇ x ⁇ 1) of the first nitride semiconductor layer 410 is the same as the lattice constant of Si and Al z Ga 1-z N (0 ⁇ z ⁇ 0.1 ) and the lattice constant of .
- the crystal quality of the electron transit layer 430 can be improved.
- the Si substrate 90 can be prevented from warping, and the C-GaN layer 421 and the electron transit layer 430 can be prevented from cracking.
- the semiconductor device ND3 includes the SiC layer 2 as a base layer for the electron transit layer 430.
- the lattice constant of SiC is closer to the lattice constant of Al z Ga 1-z N (0 ⁇ z ⁇ 0.1) of the electron transit layer 430 than the lattice constant of Si.
- the Si substrate 90 is warped.
- the effect of suppressing cracks in the C-GaN layer 421 and the electron transit layer 430, the effect of improving the withstand voltage of the semiconductor device ND3, and the crystal quality of the C-GaN layer 421 and the electron transit layer 430. can increase each of the effects of improving the
- the improvement in crystal quality of the electron transit layer 430 greatly contributes.
- the intermediate layer 422 in the second nitride semiconductor layer 420 improves efficiency. It is possible to effectively suppress the occurrence of warpage and the occurrence of cracks.
- the SiC layer 2 is present and the crystal quality of the C-GaN layer 421 is improved, the thickness of the C-GaN layer 421 and the electron transit layer 430 can be increased, so that the withstand voltage can be further improved. HEMT performance can also be improved.
- the second nitride semiconductor layer 420 is one or more intermediate layers 422 formed inside the C-GaN layer 421 and/or on the C-GaN layer 421. , AlyGa1 -yN (0.5 ⁇ y ⁇ 1).
- the C-GaN layer 421 has at least one of a C concentration higher than that of the electron transit layer 430 and an Fe concentration higher than that of the electron transit layer 430 . As a result, it is possible to suppress the occurrence of warpage and cracks while increasing the insulating properties of the nitride semiconductor layer.
- the amount of warpage can be 0 or more and 50 ⁇ m or less.
- the top surface of the semiconductor substrate NS2 can be free of traces of meltback etching.
- the C-GaN layer 421 can be formed while setting the growth temperature of GaN to a high temperature. Since the growth temperature of GaN is high, the quality of the C-GaN layer 421 is improved.
- FIG. 35 is a diagram schematically showing two-dimensional growth of GaN forming the C-GaN layer 421.
- FIG. FIG. 35(a) shows growth when the growth temperature of GaN is low
- FIG. 36(b) shows growth when the growth temperature of GaN is high.
- the two-dimensional growth of GaN is promoted, and defects such as pits existing in the lower layer of C-GaN layer 421 are removed.
- DF is covered by C-GaN layer 421 .
- the defect density of the C-GaN layer 421 can be reduced, and a situation can be avoided in which the defect DF penetrates the semiconductor substrate in the vertical direction and the breakdown voltage of the semiconductor substrate is significantly lowered.
- FIG. 36 is a plan view showing the configuration of the semiconductor substrate NS2 according to the fourth embodiment of the present invention.
- the planar shape of semiconductor substrate NS2 is arbitrary.
- the diameter of the semiconductor substrate NS2 is 6 inches or more.
- the center of the semiconductor substrate NS2 is defined as the center PT1
- the position 71.2 mm away from the center PT1 is defined as the edge PT2. .
- the in-plane uniformity of the film thickness of the C-GaN layer 421 is improved, and the in-plane uniformity of the C concentration of the C-GaN layer 421 is improved.
- the vertical intrinsic breakdown voltage value of the semiconductor substrate NS2 is improved, and the defect density of the C-GaN layer 421 is reduced. As a result, the in-plane uniformity of the vertical current-voltage characteristics can be improved.
- the carbon concentration at the central position in the depth direction (vertical direction in FIG. 34) at the center PT1 of the C-GaN layer 421 is defined as concentration C1
- the central position in the depth direction at the edge PT2 of the C-GaN layer 421 is
- the carbon concentration in is C2
- the concentration error ⁇ C represented by ⁇ C (%)
- ⁇ 100/C1 is 0 or more and 50% or less, preferably 0 or more and 33% or less. be.
- the film thickness error ⁇ W is greater than 0 and less than or equal to 8%, preferably greater than 0 and less than or equal to 4%.
- Each of the semiconductor devices ND1, ND2, and ND3 in the second to fourth embodiments has a device (specifically, transistor TR1, TR2, TR3, or TR4, or diode DD1) instead of the manufacturing method described above. ) is formed, the silicon substrate 91 is removed, and the diamond substrate 1 and the SiC layer 2 are bonded.
- a modification of the manufacturing method of the semiconductor device ND3 according to the fourth embodiment shown in FIG. 33 will be described below.
- 37 to 41 are cross-sectional views showing a modification of the manufacturing method of the semiconductor device ND3 according to the fourth embodiment of the present invention.
- a Si substrate 90 is prepared with reference to FIG.
- a SiC layer 2 having a 3C-type crystal structure is formed on a main surface 90 a of a Si substrate 90 .
- nitride semiconductor layer 4 is formed on main surface 2 a of SiC layer 2 . Thereby, the semiconductor substrate SB is manufactured.
- a device is fabricated on the semiconductor substrate SB with reference to FIG.
- source electrode 74, drain electrode 84, and gate electrode 94 on main surface 4a of nitride semiconductor layer 4, transistor TR4, which is a device included in semiconductor device ND3, is manufactured.
- Si substrate 90 is selectively etched to remove the entire Si substrate 90 (in FIG. 35, the removed Si substrate 90 is indicated by a dashed line). ing). After removing Si substrate 90, main surface 2b of SiC layer 2 is exposed.
- main surface 2b of SiC layer 2 and main surface 1a of diamond substrate 1 are bonded as indicated by arrow AW3.
- a bonding layer 3 is formed between the principal surface 1a of the diamond substrate 1 and the principal surface 2b of the SiC layer 2 by bonding.
- a semiconductor device ND3 is thus obtained.
- the manufacturing method of this modified example other than the above is the same as the manufacturing method of the semiconductor device ND3 in the third embodiment, so the description thereof will not be repeated.
- the heat conductive layer may be made of polycrystalline SiC (poly SiC) instead of diamond.
- Polycrystalline SiC has a high thermal conductivity like diamond. Therefore, when the heat conductive layer is made of polycrystalline SiC, the thermal resistance of the semiconductor device can be improved as in the case where the heat conductive layer is made of diamond.
- the inventors of the present application conducted the following simulation to confirm the effects of the present application.
- the inventors of the present application produced samples 1 to 5 each having the structure ST1 or ST2, and calculated the relationship between the gate-drain distance LDG and the breakdown voltage of each of the samples 1 to 5.
- FIG. 42 is a diagram showing structures ST1 and ST2 in the first embodiment of the present invention.
- structure ST1 is a structure that models semiconductor device ND1.
- the structure ST1 comprises a conductive substrate 1001 corresponding to the SiC layer 2, a nitride semiconductor layer 1002, a source electrode 1003, a drain electrode 1004, a gate electrode 1005 and a conductive layer 1006.
- a nitride semiconductor layer 1002 having a thickness D is formed on a conductive substrate 1001 .
- a source electrode 1003, a drain electrode 1004 and a gate electrode 1005 are formed on the nitride semiconductor layer 1002 with a space therebetween.
- Conductive layer 1006 is formed inside nitride semiconductor layer 1002 and electrically connects source electrode 1003 and conductive substrate 1001 .
- structure ST2 has the same structure as structure ST1 except that conductive layer 1006 is not provided.
- source electrode 1003 and conductive substrate 1001 are not electrically connected.
- Sample 1 (Invention Example): Sample 1 has structure ST1 and has a thickness D of 2 ⁇ m.
- Sample 2 (example of the present invention): Sample 2 has structure ST1 and has a thickness D of 4 ⁇ m.
- Sample 3 (Invention Example): Sample 3 has structure ST1 and has a thickness D of 6 ⁇ m.
- Sample 4 (Invention Example): Sample 4 has structure ST1 and has a thickness D of 8 ⁇ m.
- Sample 5 (comparative example): Sample 5 has structure ST2.
- FIG. 43 is a diagram showing the relationship between the gate-drain distance LDG and the breakdown voltage of each of the samples 1 to 5 in the first embodiment of the present invention.
- samples 1 to 4 in which the source electrode and the conductive substrate are electrically connected, have a higher gate-drain gap than sample 5, in which the source electrode and the conductive substrate are not electrically connected.
- the rate of increase in breakdown voltage increased as the distance LGD increased. It should be noted that the withstand voltage of each of the samples 1 to 4 reaches the upper limit value at the predetermined distance LGD because the insulating state of the nitride semiconductor layer 1002 between the gate electrode 1005 and the drain electrode 1004 is broken. , the insulating state of the nitride semiconductor layer 1002 between the drain electrode 1004 and the conductive substrate 1001 is destroyed.
- the breakdown voltage of the structure ST1 is expressed by the following equation (1), the distance LGD between the gate and the drain and the nitride semiconductor layer is described to depend on the smaller of the thickness D of the
- Breakdown voltage (V) Min (100 (V/ ⁇ m) x LGD ( ⁇ m), 150 (V/ ⁇ m) x D ( ⁇ m)) (1)
- the inventors of the present application fabricated each of samples 6 to 8 having structure ST3 or structure ST4, and calculated the thermal resistance of each of samples 6 to 8.
- FIG. 44 is a diagram showing structures ST3 and ST4 in the second embodiment of the present invention.
- structure ST3 is a structure that models the semiconductor device ND1.
- Structure ST3 comprises substrate 1011 , SiC layer 1012 , nitride semiconductor layer 1013 , source electrode 1014 , drain electrode 1015 and gate electrode 1016 .
- SiC layer 1012 and nitride semiconductor layer 1013 are stacked in this order on substrate 1011 .
- a source electrode 1014, a drain electrode 1015 and a gate electrode 1016 are formed on the nitride semiconductor layer 1013 with a space therebetween.
- the nitride semiconductor layer 1013 has a thickness D of 6 ⁇ m.
- structure ST4 is a model of the structure of Non-Patent Document 1.
- Structure ST4 has the same structure as structure ST3 except that it does not include SiC layer 1012 .
- Sample 6 (example of the present invention): Sample 6 has structure ST3.
- the substrate 1011 is made of diamond with a thickness of 300 ⁇ m.
- the SiC layer 2 has a thickness of 1 ⁇ m and a 3C-type crystal structure.
- Sample 7 has structure ST3.
- the substrate 1011 is made of Si with a thickness of 300 ⁇ m.
- the SiC layer 2 has a thickness of 1 ⁇ m and a 3C-type crystal structure.
- Sample 8 has structure ST4.
- the substrate 1011 is an SOI substrate and includes a Si substrate, a SiO2 layer and a Si layer. Each of the Si substrate, SiO2 layer and Si layer is laminated in this order.
- the Si substrate has a thickness of 300 ⁇ m.
- the upper surface of the Si substrate has a plane orientation of (100).
- the SiO 2 layer has a thickness of 1 ⁇ m.
- the Si layer has a thickness of 3.5 ⁇ m.
- the upper surface of the Si substrate has a plane orientation of (111).
- Region RG has a rectangular shape when structures ST3 and ST4 are viewed from above.
- the region RG is within 2 ⁇ m from the end of the gate electrode 1016 on the side of the drain electrode 1015 toward the drain electrode 1015 and has a gate width of 100 ⁇ m (the length of the gate electrode 1016 in the direction perpendicular to the bare surface). is the area of
- FIG. 45 is a graph showing the overall thermal resistance of each of Samples 6-8 in the second example of the present invention.
- FIG. 46 is a table showing the thermal resistance of each of the multiple layers constituting each of Samples 6 to 8 in the second example of the present invention and the overall thermal resistance.
- the thermal resistance of sample 6 is 78.20 (K/W)
- the thermal resistance of sample 7 is 132.96 (K/W)
- the thermal resistance of sample 8 is It was 403.51 (K/W).
- the thermal resistance of sample 6 was very small compared to the thermal resistance of samples 7 and 8.
- the thermal resistance of Si forming the substrate 1011 is higher than that of diamond, so the thermal resistance is higher than that of Sample 6.
- the thermal resistance increased significantly over samples 6 and 7 because the thermal resistance of the SiO 2 layer in substrate 1011 was very high.
- the inventors calculated the relationship between the thermal resistance of each of Samples 6 and 8 and the thickness D of the nitride semiconductor layer 1013 .
- FIG. 47 is a diagram showing the relationship between the thermal resistance of each of Samples 6 and 8 and the thickness D of nitride semiconductor layer 1013 in the second example of the present invention.
- the thermal resistance of sample 6 gradually increased as the thickness D of nitride semiconductor layer 1013 increased.
- the thermal resistance of Sample 8 sharply decreased as the thickness D of the nitride semiconductor layer 1013 increased.
- the inventors of the present application prepared each of samples 9 to 11 by the following method in order to examine the relationship between the heat treatment and the structure of the bonding layer 3.
- Sample 9 (Invention Example): The main surface of the diamond substrate and the main surface of the 3C-type SiC layer were bonded using the surface activation bonding method. No heat treatment was performed on the resulting structure after bonding.
- Sample 10 (Invention Example): The main surface of the diamond substrate and the main surface of the 3C-type SiC layer were bonded using the surface activation bonding method. The resulting structure was heat treated at a temperature of 600° C. after bonding.
- Sample 11 (example of the present invention): The main surface of the diamond substrate and the main surface of the 3C-type SiC layer were bonded using the surface activation bonding method. The resulting structure was heat treated at a temperature of 1000° C. after bonding.
- the inventors of the present application used a TEM (Transmission Electron Microscope) to observe the cross section of the bonding layer formed at the boundary between the main surface of the diamond substrate and the main surface of the SiC layer for each of Samples 9 to 11. .
- the bonding layer was observed from each of the [001] direction, which is the crystal zone axis of diamond, and the [ ⁇ 101] direction, which is the crystal zone axis of SiC.
- An FFT (Fast Fourier transform) pattern was obtained by image processing a part of the TEM image. JEM-2200FS manufactured by JEOL Ltd. was used as the TEM.
- the acceleration voltage during observation was set to 200 kV.
- EDS Electronic Dispersive X-ray Spectroscopy
- JEM-ARM200F manufactured by JEOL Ltd. was used as the EDS device.
- the acceleration voltage was set to 200 kV and the magnification was set to 1000000.0.
- the emission current was set to 100 ⁇ A and the probe current was set to 10.0 nA.
- a square area of 39.07 nm ⁇ 39.07 nm was set as the mapping range.
- the pixel size was set to 0.15 nm x 0.15 nm.
- FIGS. 48 to 50 is a TEM image of the cross section of the bonding layer of each of samples 9 to 11 in the third example of the present invention.
- FIG. 51 is a diagram showing the atomic density distribution along the distance in the depth direction from the surface of the SiC layer of each of samples 9 to 11 in the third example of the present invention.
- FIGS. 48(a), 49(a), and 50(a) are diagrams of the bonding layer viewed from the [001] direction, which is the crystal zone axis of diamond.
- FIGS. 48(b), 49(b), and 50(b) are diagrams of the bonding layer viewed from the [ ⁇ 101] direction, which is the crystal zone axis of SiC.
- 48(a), 48(b), 49(a), 49(b), 50(a), and 50(b) the upper left photograph C2 is 48(b), 49(a), 49(b), 50(a), and 50(b), respectively.
- FIG. 51(a) is a diagram showing the atomic density distribution of sample 9.
- FIG. 51(b) is a diagram showing the atomic density distribution of the sample 10.
- FIG. 51(c) is a diagram showing the atomic density distribution of the sample 11.
- FIG. 51(a) is a diagram showing the atomic density distribution of sample 9.
- FIG. 51(b) is a diagram showing the atomic density distribution of
- the FFT pattern of sample 9 did not show clear bright spots indicating the presence of crystals.
- the inside of the bonding layer of Sample 9 was mainly composed of Si and C. From these results, it can be seen that when heat treatment was not performed after bonding, no crystal grains existed inside the bonding layer, and an amorphous layer containing Si and C as main components existed.
- the FFT pattern of sample 10 did not show clear bright spots indicating the presence of crystals.
- the inside of the bonding layer of sample 10 was mainly composed of Si and C. From these results, it was found that when heat treatment was performed at a temperature of 600° C. after bonding, no crystal grains existed inside the bonding layer, and Si and C were the main constituents, similarly to the case where heat treatment was not performed after bonding. It can be seen that there is an amorphous layer as a component.
- the FFT pattern of sample 11 showed clear bright spots indicating the presence of crystals. These distinct bright spots were aligned along various directions on the order of nanometers. No bright spots (unclear bright spots) indicating the presence of an amorphous layer appeared.
- the inside of the bonding layer of Sample 11 was mainly composed of Si and C. From these results, when heat treatment is performed at a temperature of 1000° C. after bonding, there is no amorphous layer inside the bonding layer, and polycrystalline grains mainly composed of Si and C are present. I understand.
- the decreasing concentration region is a region where the carbon concentration of C monotonically decreases from the thermally conductive layer (diamond substrate in this case) toward the SiC layer.
- the reduced concentration region had a thickness of 4.5 nm or greater.
- the present disclosure provides a semiconductor substrate, a semiconductor device, a method for manufacturing a semiconductor substrate, and a method for manufacturing a semiconductor device that can improve heat dissipation.
- INDUSTRIAL APPLICABILITY According to the present disclosure, an energy saving effect can be obtained by improving the power energy conversion efficiency of a semiconductor device, which can contribute to achievement of sustainable development goals.
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Abstract
Description
1a,1b ダイヤモンド基板の主面
2,21~23,1012 SiC(炭化ケイ素)層(炭化ケイ素層の一例)
2a,2b,21a,22a,23a SiC層の主面
3,31~33 接合層(接合層の一例)
3a,3b アモルファス層(第1および第2のアモルファス層の一例)
3c,3d SiO2(酸化ケイ素)層
3e 多結晶層
3f 濃度減少領域
4,41~43,1002,1013 窒化物半導体層(窒化物半導体層の一例)
4a,41b,42b,43b 窒化物半導体層の主面
6,12,61~63,121~123 層間絶縁層
6a,12a,121b,122b,123b 層間絶縁層の主面
10 カソード電極(第2の電極の一例)
11 アノード電極(第1の電極の一例)
41a,42a,43a,121a,122a,123a ビアホール
51,52,131~134,151,152,1006 導電層(導電層の一例)
71~74,1003,1014 ソース電極(第1の電極およびソース電極の一例)
81~84,1004,1015 ドレイン電極(第2の電極およびドレイン電極の一例)
90 Si(ケイ素)基板
90a Si基板の主面
91~94,1005,1016 ゲート電極(ゲート電極の一例)
95,96 支持基板
141,142 絶縁層
141a,142a 絶縁層の主面
161,162 溝
410 第1の窒化物半導体層(第1の窒化物半導体層の一例)
410a 第1の窒化物半導体層の主面
411 AlN(窒化アルミニウム)層
411a AlN層の主面
412~415 AlGaN(窒化アルミニウムガリウム)層
412a,413a,414a AlGaN層の主面
420 第2の窒化物半導体層(第2の窒化物半導体層の一例)
420a 第2の窒化物半導体層の主面
421,421a,421b,421c C(炭素)-GaN(窒化ガリウム)層
422,422a,422b 中間層
430 電子走行層(電子走行層の一例)
430a 電子走行層の主面
440 障壁層(障壁層の一例)
1001 導電性基板
1011 基板
ND1~ND3 半導体デバイス(半導体デバイスの一例)
NS1,NS2 半導体基板(半導体基板の一例)
ST1~ST4 構造
TE 2次元電子ガス
TR1~TR4 トランジスタ
e1,e2 電子
Claims (20)
- ダイヤモンドまたは多結晶炭化ケイ素よりなる熱伝導層と、
前記熱伝導層の一方の主面側に形成され、3C型の結晶構造を有する炭化ケイ素層と、
前記熱伝導層と前記炭化ケイ素層との間に形成された接合層と、
前記炭化ケイ素層の一方の主面に形成された窒化物半導体層とを備えた、半導体基板。 - 前記炭化ケイ素層と前記窒化物半導体層とは互いに接触しており、かつ前記炭化ケイ素層と前記窒化物半導体層との間にはアモルファス層が存在しない、請求項1に記載の半導体基板。
- 前記熱伝導層はダイヤモンドよりなり、
前記接合層は、
前記熱伝導層の前記一方の主面に形成された、炭素を主成分とする第1のアモルファス層と、
前記第1のアモルファス層と前記炭化ケイ素層との間に形成された、炭素およびケイ素を主成分とする第2のアモルファス層とを含む、請求項1に記載の半導体基板。 - 前記炭化ケイ素層は単結晶であり、
前記熱伝導層はダイヤモンドよりなり、
前記接合層は、少なくとも炭化ケイ素の多結晶粒を含む、請求項1に記載の半導体基板。 - 前記熱伝導層はダイヤモンドよりなり、
前記接合層は、炭素原子密度の濃度減少領域を含み、
前記炭素原子密度の濃度減少領域中の炭素原子密度は、前記熱伝導層から前記炭化ケイ素層に向かって単調減少し、
前記炭素原子密度の濃度減少領域の厚さは2nm以上である、請求項1に記載の半導体基板。 - 前記接合層は、酸化ケイ素を含む、請求項1に記載の半導体基板。
- 前記炭化ケイ素層は、0.1μm以上5μm以下の厚さを有する、請求項1に記載の半導体基板。
- 前記炭化ケイ素層の前記一方の主面は、(1,1,1)、(-1,-1,-1)、または(1,0,0)の面方位を有する、請求項1に記載の半導体基板。
- 前記熱伝導層はダイヤモンドからなり、
前記熱伝導層は、5×103Ω・cm以上1×1016Ω・cm以下の抵抗率を有する、請求項1に記載の半導体基板。 - 前記炭化ケイ素層は、1×1015個/cm3以上1×1021個/cm3以下の電子濃度を有する、請求項9に記載の半導体基板。
- 前記窒化物半導体層は、
前記炭化ケイ素層の前記一方の主面側に形成された第1の窒化物半導体層であって、絶縁性または半絶縁性の層を含み、AlxGa1-xN(0.1≦x≦1)よりなる第1の窒化物半導体層と、
前記第1の窒化物半導体層の一方の主面側に形成された第2の窒化物半導体層であって、絶縁性または半絶縁性のAlyGa1-yN(0≦y<0.1)よりなる主層を含む第2の窒化物半導体層と、
前記第2の窒化物半導体層の一方の主面側に形成され、AlzGa1-zN(0≦z<0.1)よりなる電子走行層と、
前記電子走行層の一方の主面側に形成され、前記電子走行層のバンドギャップよりも広いバンドギャップを有する障壁層とを含み、
前記窒化物半導体層の厚さは、6μm以上10μm以下である、請求項1に記載の半導体基板。 - 前記熱伝導層はダイヤモンドよりなり、
前記窒化物半導体層は、0.5μm以上6μm未満の厚さを有し、
前記熱伝導層は、5×103Ω・cm以上1×1016Ω・cm以下の抵抗率を有し、
前記炭化ケイ素層は、1×103Ω・cm以上1×1016Ω・cm以下の抵抗率を有する、請求項1に記載の半導体基板。 - 請求項1~12のいずれかに記載の半導体基板と、
前記炭化ケイ素層の前記一方の主面側に形成された第1および第2の電極とを備え、
前記第1の電極と前記炭化ケイ素層とが電気的に接続された、半導体デバイス。 - 前記窒化物半導体層は、前記窒化物半導体層の一方の主面から前記炭化ケイ素層に達するビアホールを含み、
前記第1の電極は前記窒化物半導体層の前記一方の主面に形成され、
前記第1の電極と前記炭化ケイ素層とを電気的に接続する導電体層であって、前記ビアホール内に形成された導電体層をさらに備えた、請求項13に記載の半導体デバイス。 - 前記炭化ケイ素層、前記窒化物半導体層、ならびに前記第1および第2の電極の各々は複数であり、
複数の前記炭化ケイ素層の各々は、前記熱伝導層の前記一方の主面側に形成され、かつ互いに絶縁されており、
複数の前記窒化物半導体層の各々は、前記複数の炭化ケイ素層の各々の前記一方の主面に形成され、
複数の前記第1の電極および複数の第2の電極の各々は、前記複数の炭化ケイ素層の各々の前記一方の主面側に形成される、請求項13に記載の半導体デバイス。 - 請求項1~12のいずれかに記載の半導体基板と、
前記窒化物半導体層の一方の主面に形成されたソース電極およびゲート電極と、
前記炭化ケイ素層の一方の主面に形成されたドレイン電極とを備えた、半導体デバイス。 - ケイ素基板の一方の主面に、3C型の結晶構造を有する炭化ケイ素層を形成する工程と、
前記炭化ケイ素層の一方の主面に窒化物半導体層を形成する工程と、
前記ケイ素基板を前記炭化ケイ素層から除去する工程と、
前記炭化ケイ素層の他方の主面と、ダイヤモンドまたは多結晶炭化ケイ素よりなる熱伝導層の一方の主面とを接合する工程とを備えた、半導体基板の製造方法。 - 前記炭化ケイ素層を形成する工程は、
前記ケイ素基板の前記一方の主面を炭化することにより、第1の炭化ケイ素層を形成する工程と、
前記第1の炭化ケイ素層の一方の主面に炭化ケイ素を結晶成長させることにより、第2の炭化ケイ素層を形成する工程とを含む、請求項17に記載の半導体基板の製造方法。 - 請求項17に記載の半導体基板の製造方法により、半導体基板を製造する工程と、
前記炭化ケイ素層の前記一方の主面側に第1および第2の電極を形成する工程と、
前記第1の電極と前記炭化ケイ素層とを電気的に接続する工程とを備えた、半導体デバイスの製造方法。 - ケイ素基板の一方の主面に、3C型の結晶構造を有する炭化ケイ素層を形成する工程と、
前記炭化ケイ素層の一方の主面に窒化物半導体層を形成することで、半導体基板を作製する工程と、
前記半導体基板にデバイスを作製する工程と、
前記デバイスを作製する工程の後で、前記ケイ素基板を除去することで前記炭化ケイ素層の他方の主面を露出する工程と、
前記炭化ケイ素層の前記他方の主面を露出する工程の後で、前記炭化ケイ素層の前記他方の主面と、ダイヤモンドまたは多結晶炭化ケイ素よりなる熱伝導層の一方の主面とを接合する工程とを備えた、半導体デバイスの製造方法。
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2022
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CN116666199A (zh) * | 2023-08-02 | 2023-08-29 | 中国科学院微电子研究所 | 一种基于临时载体的SiC/金刚石复合衬底制造方法 |
CN116666199B (zh) * | 2023-08-02 | 2023-10-03 | 中国科学院微电子研究所 | 一种基于临时载体的SiC/金刚石复合衬底制造方法 |
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