An etched grooved GaN-based permeable-base transistor structure is disclosed, along with a method for fabrication of same.
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11. A method for fabricating an etched grooved GaN-based permeable-base transistor device, comprising:
opening a window for helium implantation on a hydride vapor phase epitaxy (HVPE) grown n+ GaN quasi-substrate layer, using optical lithography;
implanting helium with an implant depth of about approximately 2 μm on the n+ n+ GaN quasi-substrate layer over the window for helium implantation, so as to provide an insulating layer for contact pads of the device;
opening a window for collector fingers using E-beam lithography;
depositing an ohmic metallization layer over the window for the collector fingers;
lifting-off ohmic metallization, thereby forming the collector fingers;
opening a window for a self-aligned base recess using optical lithography;
etching to recess a base layer to an n− GaN quasi-substrate layer grown on the n+ GaN quasi-substrate layer, wherein the etching is performed with a ramp down in chuck bias voltage; depositing conformal silicon nitride for passivation of the recessed base layer;
directionally etching to remove silicon nitride on planes parallel to the n+ GaN quasi-substrate layer;
depositing a base metallization layer; and
lifting-off base metallization, thereby forming a base contact pad.
1. A method for fabricating an etched grooved GaN-based permeable-base transistor device, comprising:
opening a window for helium implantation on a hydride vapor phase epitaxy (HVPE) grown n+ GaN quasi-substrate layer, using optical lithography;
implanting helium on the n+ n+ GaN quasi-substrate layer over the window for helium implantation, so as to provide an approximately 2 μm thick insulating layer for contact pads of the device;
opening a window for collector fingers using E-beam lithography;
depositing an ohmic metallization layer over the window for the collector fingers;
lifting-off ohmic metallization, thereby forming the collector fingers;
opening a window for a self-aligned base recess using optical lithography;
etching to recess a base layer to an n− GaN quasi-substrate layer grown on the n+ GaN quasi-substrate layer, wherein the etching is performed with a ramp down in chuck bias voltage wherein said ramp down is from a high chuck bias voltage to a low chuck bias voltage;
opening a window for a collector contact pad, using optical lithography;
depositing a high quality silicon nitride layer over the window for a collector contact pad, the high quality silicon nitride layer being about approximately 1000–2000 Å thick, and deposited over the window for helium implantation via plasma enhanced chemical vapor deposition (PECVD); and
lifting-off or wet chemical etching the high quality silicon nitride layer, thereby forming a silicon nitride collector contact pad.
0. 2. The method of
3. The method of
opening a window for Ti metallization of the collector contact pad using optical lithography;
depositing Ti over the window for Ti metallization of the collector contact pad; and
lifting-off Ti metallization, thereby forming a Ti collector contact pad.
4. The method of
opening a window for a second Ti metallization of the collector contact pad using optical lithography;
depositing Ti over the window for the second Ti metallization of the collector contact pad; and
lifting-off second Ti metallization, thereby forming a Ti cap over the collector contact pad.
5. The method of
6. The method of
opening an emitter etch/contact window using optical lithography;
etching an emitter recess to the n+ GaN quasi-substrate layer;
depositing an emitter ohmic metallization layer over the etched emitter recess; and
lifting-off emitter ohmic metallization, thereby forming an emitter contact pad.
7. The method of
8. The method of
9. The method of
10. The method of
12. The method of
13. The method of
0. 14. The method of
15. The method of
16. The method of
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This application Genii GenII system. Other such systems can be used here as well. Seamless epitaxy of GaN via MBE on GaN quasi-substrates can be achieved by growing the epilayers in group III-rich conditions. These base and emitter layers replicate the underlying GaN quasi-substrate layer without renucleation. The base and collector layers are doped with silicon (Si) to carrier concentrations of 5×1016 and 5×1018, respectively.
When the PBT is in ON condition, the majority carriers flow from emitter (held at ground potential) to collector (biased at positive potential). Under normal operation, the Schottky barrier is reverse-biased by a negative base-to-emitter voltage. A voltage dependent depletion region forms beneath the Schottky barrier. This constricts the effective area of the n-channel (reducing the depletion region on either side of the emitter finger), causing the channel to open and the collector current to vary with applied base bias.
In a PBT, the base bias induces a potential barrier under the collector. Near pinch-off, electrons that are injected from the emitter are accelerated by the collector bias, and pass across the potential barrier. At higher collector biases, the thermionic emission current rises exponentially with applied collector bias eventually becoming space charge limited, resulting in a triode mode device operation, where the collector current does not saturate at high collector voltages.
When a negative bias is applied to the collector, the depletion region expands and current flow through the channel is restricted. This will ultimately result in pinch off of the channel, and turn off of the PBT. Pinch off can be approximated using the equation:
where q is the charge of an electron, a is the channel thickness (or, in the case of a PBT, half the width of 1 finger), ∈(r) is the relative permittivity of the material, and ∈(0) is the permittivity of vacuum.
Fabrication Methodology
The GaN PBT, because it is based on vertical transport, has three distinctly doped layers versus the two of lateral transistor devices for the metal contacts and the device itself to perform optimally. The material structure to be employed in the GaN PBT, in accordance with one embodiment of the present invention, is shown in
Due to the lattice mismatch of GaN grown on sapphire or SiC, the bottom n+ layer is deposited thick (e.g., n+5×1018 cm−3, HVPE) to keep the vertical threading dislocations minimal The layer structure is chosen because the heavily doped regions will be used for ohmic contacts and the lightly doped region will be used for a Schottky contact to adequately pinch off for a given range of high frequency operation. The desired blocking voltage of the transistor determines the thick n-region. The final structure will look similar to that shown in
Note that a full PBT will have a plurality of the collector fingers, and is this particular case. Only three are shown in
When referring to example embodiments of the PBT process described herein, the following views shall be discussed and are illustrated in
This is a seven-mask process flow that is the baseline for all of the subsequent versions. Various modifications and details not included in this version will be apparent in light of this disclosure.
This particular embodiment begins with the HVPE growth of 10 μm of heavily doped (e.g., 2×1018 cm−3 to 5×1018 cm−3) n-GaN followed by 2 μm of MBE grown, lightly doped (e.g., 2×1016 cm−3 to 5×1016 cm−3) n-GaN and 0.3 μm of MBE grown, highly doped (e.g., 2×1018 cm−3 to 5×1018 cm−3) n-GaN. The silicon nitride deposition (to be discussed in turn) is to passivate the sidewalls of the collector fingers to prevent shorting of the base to the collector if metal accidentally deposits on the sidewalls.
The mask levels for this example process are shown here in Table 1:
TABLE 1
Level 1
He implant mask
Level 2
Nitride isolation pad
Level 3
Collector ohmic pad mask
Level 4
E-beam lithography of collector fingers for liftoff
Level 5
Base recess and metallization
Level 6
Emitter and device isolation etch, emitter ohmic
Level 7
Microwave test pad metal deposition
The process flow will now be discussed in steps, and with reference to the
Step 1: Perform RCA wafer clean. The purpose of the RCA wafer clean is to remove organic contaminants (e.g., dust particles, grease or silica gel) from the wafer surface, as well as any oxide layer that may have built up, and any ionic or heavy metal contaminants.
Step 2: Open windows for helium (He) implantation using optical lithography. Due to the fact that the PBT is a “normally-on” device, the semiconductor material is conducting by default. Thus, an insulating layer is used to isolate the pads from the device. In this particular embodiment, the insulating layer is provided with He implantation.
Step 3: Perform He2+ implantation at about 250 keV, 1.35 μm isolation depth (determined from a TRIM calculation).
Step 4: Strip the photo resist mask. The resulting structure after stripping is shown in
Step 5: Open windows for thin, high quality silicon nitride pad (SiNx), about 1000–2000 Å thick, using optical lithography.
Step 5a: Perform deposition of high quality SiNx pad, 1000–2000 Å thick. This SiNx layer serves as the second electrical isolation for the collector and base contact pads.
Step 5b: Perform lift-off of high quality silicon nitride pad, 1000–2000 Å thick.
Step 6: Open windows for Ti metal pad using optical lithography.
Step 6a: Perform Ti metallization.
Step 6b: Perform lift-off of Ti metallization.
Step 7: Perform E-beam lithography of collector fingers and for self-aligned base recess and metallization.
Step 7a: Perform ohmic metallization of collector. Prior to metallization, a 1 minute HCl:DI H20 (1:1) dip is used for removing contaminants on the semiconductor surface. Although not mentioned in other steps, this can beneficially be used for all metal depositions on semiconductor material.
Step 7b: Perform lift-off of ohmic metallization of collector.
Step 8: Open windows for a Ti cap in collector pad region using optical lithography.
Step 8a: Deposit thin Ti cap in collector pad region again to prevent collector metal fingers from peeling upward and losing contact to the pad.
Step 8b: Perform lift-off of the thin Ti cap in collector region.
Step 9: Open windows for the base recess/metallization (collector lines are part of mask) using optical lithography.
Step 9a: Perform a high density plasma etch to recess the base layer to n− layer (e.g., about 0.5 μm).
Step 9b: Perform conformal SiNx deposition for spacer and sidewall passivation. This layer prevents shorting between the base and collector if metal accidentally deposits on the finger sidewalls.
Step 9c: Perform directional etch to remove SiNx on parallel surfaces.
Step 9d: Perform base metallization (Pt/Ni).
Step 9e: Perform lift-off of base metallization (Pt/Ni).
Note that a post Schottky deposition anneal is used to alloy the ohmic contacts. This is because the Schottky metal is deposited before the emitter ohmic metal. A low temperature anneal does not substantially alter the forward bias behavior of the Schottky contacts, but decreases the reverse leakage current. Further note that the Schottky contacts are the contacts in the base region). In one particular embodiment, an anneal for about 60 seconds at 500° C. is used to maintain low reverse current leakage while providing low contact resistance.
Step 10: Open emitter etch/contact window using optical lithography.
Step 10a: Etch emitter recess to bottom, HVPE n+ GaN quasi-substrate layer (e.g., about 2.5 μm).
Step 10b: Perform emitter ohmic metallization.
Step 10c: Perform lift-off of emitter ohmic metallization. FIG. 3aa shows the resulting structure after the emitter ohmic metallization of this step.
Step 11: Open windows for RF test pad metallization using optical lithography. FIG. 3bb shows the resulting structure after the optical lithography of this step.
Step 11a: Deposit RF test pad metal. FIG. 3cc shows the resulting structure after the deposition of test pad metal of this step. In one particular embodiment, this metal includes an adhesion layer (e.g., titanium or nickel) and a thick gold (Au) capping layer, since Au is a good microwave conductor and prevents oxidation.
Step 11b: Perform lift-off RF test pad metal. FIG. 3dd shows the resulting and final structure after the RF test pads liftoff of this step.
Variations on Fabrication Methodology
A first variation on the PBT fabrication methodology deals with the deposition of the SiNx in step 5. In more detail, a conformal deposition of SiNx over the entire wafer followed by photo resist patterning and wet chemistry etch to remove the SiNx from the unwanted areas may be more desirable, since SiNx is sometimes difficult to remove via liftoff. In this case, the SiNx is about 1000 Å thick, and the wet chemical etch will provide a shallow slope on the sidewalls which will ensure metal continuity from the collector fingers to the contact pad. In addition, the metal pad on top of the collector region can be altered to Ni/Pt because of the new Schottky metal on the collector fingers.
The electron beam lithography can also be changed, to provide a second variation. In particular, instead of opening up windows for the fingers and depositing metal as previously described in steps 7 through 7b, a large window can be opened. For example,
Following base recess, all steps would be similar to those previously discussed until step 9d, where the Schottky metal deposited would be the metal for both the base region and collector fingers. The Schottky metal would be feasible as the collector metal because of ballistic electrons that could pass the potential barrier. In addition, the Ti capping layer on the collector contact in steps 8 through 8b can be omitted, in this particular variation.
In a third variation of the fabrication process, a “0” level Ti/Pt layer can be used. In more detail, note that the first layer (step 3) is a He implantation, which requires alignment for further steps in the process. In particular, implanted He areas are not distinguishable under optical alignment For this reason, a “0” level mask for subsequent optical and electron beam alignment was added. The metal to be used for enabling optical alignment is titanium (Ti) followed by platinum (Pt). In one such embodiment, this “0” level mask is a Ti/Pt layer of about 200–500/1500 Å, respectively. These metals are chosen because of Ti's good adhesion to GaN and Pt is a good alignment metal for e-beam writers (because it is high Z). Crosses for optical alignment and squares for e-beam alignment are thus provided.
The thick Pt was found to work best for this e-beam writing system. Also, it was found that the He2+ implantation given in step 3 would penetrate the photo resist about 3.50 μm based on a TRIM calculation of Rp+ΔRp (the ion range and range straggling). This shows that a thick resist, such as AZ4620, is needed. In addition, the SiNx etch can be done via a wet chemistry of NH4F, which will leave a shallow slope on the nitride walls due to the slow etching and isotropy characteristic of wet chemistry etches. The e-beam photo resist, PMMA, is not intended to be a dry etch mask and for this reason, cannot be used as previously given in step 7. For this reason, only the collector fingers shall be opened.
In one such particular embodiment for high power operation, 20 fingers could be used. These fingers shall be 40–200 μm long and varying width (0.15–0.3 μm). The metal on top of these fingers can be, for example, Schottky, Ni/Pt/Ni (200/500/500 Å), where the final Ni layer is used as an etch mask since it was found to withstand a chlorine etch well. This is followed by the base etch similar to step 9. The settings of this etch shall be ICP, ˜0.43 μm in depth using pure Cl2 chemistry, 400 W ICP power, and 200 eV ion energies. The low bias voltage is used to provide a slow and accurate etch depth. The structure resulting from the base etch following collector metal deposition (with photo resist) is shown in
A base metal deposition as given in step 9b isolates the base metal from the GaN material on the sides of the collector fingers so an additional etching after the SiNx deposition is needed to expose the sidewalls of the collector fingers, and to allow better base metal contact and, therefore, better base voltage control of the collector current resulting in higher transconductance in the device. This deposited SiNx is, for instance, less than 500 Å via PECVD. This thickness is decreased since the minimum base region width is 1500 Å and 1000 Å of SiNx on both sides would completely close the base region. This additional etch is a two-stage etch.
First, a CH4—O2 mix is used via RIE to directionally remove the SiNx since Cl2 has a much faster etch rate on GaN than on SiNx. Following SiNx removal, an ICP base etch for collector finger contact will be used to etch the GaN 0.07 μm as shown in
A fourth variation of the fabrication process includes the initial deposition of Ti/Al/Pt alignment markers. The addition of Al is to create an ohmic contact at the first layer for ohmic circular transmission line measurement (CTLM) and Schottky diode test structures that will be employed since the e-beam writer cannot write large areas during definition of the collector regions (otherwise, the first ohmic deposition). The addition of Al will not affect the e-beam alignment with the thick Pt (e.g., 1500 Å) deposited. He implantation under both base and collector contact pads is used due to the high conductivity of the material. This is shown in
The first SiNx deposition is similar to previous versions with the exception that it is now included under the base contact pad (as well as the collector pad) as shown in
Collector fingers were also changed from Schottky to ohmic since collector and base metals were no longer to be deposited simultaneously. The new metal scheme is Ti/Ni (100/400 Å). Process tests support the use of a thicker Ni layer and removal of the Al layer and are the reason for this increase in thickness. This thin metal is the maximum thickness allowed with the thin (e.g., 1500 Å) e-beam resist needed for fine features (e.g., 0.15 μm). Following this metal liftoff, SiNx is deposited (as previously described with the two stage etch).
After the base metallization, the emitter is etched. This requires a thick resist of, for instance, AZ4620 of about 4 μm. Dimensions of the emitter etch are given in
A fifth variation of the fabrication process includes a modification to the silicon nitride pad deposited in steps 5, 5a, and 5b. In this alternative embodiment, the SiNx pad is square such that, the He implanted region will extend out to the collector fingers, and no SiN will be under the fingers. This will reduce the difference in height between the fingers in the collector pad region (e.g., view 3 of
Probing of the various CTLM test structures shows ohmic metal contacts which have specific contact resistivity, ρc, of about 3×10−6Ω·cm2, which is an indication of the excellent contact quality.
The DC characteristic curve of a device with 1:1 finger pitch is shown in
The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
Bellotti, Enrico, Moustakas, Theodore D., Eddy, Jr., Charles R., Chu, Kanin, Gunter, Liberty L.
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