Opto-Electronic Device and Method for its Manufacture

Abstract: In a monolithic OEIC in which an FET (Q1) and a light-­ emitting device (LD) are integrated, the light-emitting device (LD) has a first clad layer (14), an active layer (15), and a second clad layer (17) stacked on a substrate (11), the FET (Q1) has a channel layer (12) and source and drain layers (14₂, 14₃) with a high impurity concentration stacked on the sub­ strate (11), etching mask layers (15₂, 15₃) on the source and drain layers (14₂, 14₃), and a gate electrode (22) formed on a channel layer (12) between source and drain electrodes (21₁, 21₂) and the source and drain layers (14₂, 14₃), the first clad layer (14₁) of the light-emitting diode (LD) and the source and drain layers (14₂, 14₃) with a high impurity concentration of the FET (Q₁) are formed of the same semiconductor layer, and an active layer (15₁) of the light-emitting device (LD) and the etching mask layers (15₂, 15₃) fo the FET (Q1) are formed of the same semiconductor layer.

Description: The present invention relates to a field effect transistor having a structure useful for an opto-electronic integrated circuit device, an opto-electronic integrated circuit device including the field effect transistor, and a method of manufacturing the same. Generally, in manufacturing a field effect transistor (FET), the size of a gate region must be precisely controlled to satisfy its characteristics. For example, in a Schottky-gate FET (MESFET) using a compound semi-conductor, the gate length and channel thickness, in addition to the carrier concentration of a channel region, greatly affect the characteristics such as pinch-off voltage and transconductance. In one conventional MESFET structure, a recess is formed in a gate region of a semiconductor layer formed on a semi-insulating semiconductor substrate, and a gate electrode is buried in this recess (recessed gate structure). In order to obtain this MESFET, a semiconductor layer is grown on a substrate and is then selectively etchea to form a recess, and a gate electrode is buried in the recess. In order to obtain the desired characteristics in such a MESFET structure, the thickness of semiconductor layer in the recess region serving as a channel region and the width of the recess as a gate length must be precisely controlled. Pinch-off voltage Vp of an FET is generally given by the following equation: V p =  b - qN D A²/2εε₀ where  b is the barrier height of a Schottky junction; q, the electron charge; A, the channel thickness; N D , the carrier concentration of the channel region; ε, the relative dielectric constant; and ε₀, dielectric of vacuum. When an n-type InP layer with a carrier concentration of 1 × 10¹⁷/cm³ is used as a channel layer, in order to set the pinch-off voltage to be V p = -0.7 V, the channel thickness must be set at A = 0.128 µm, assuming that  b = 0.5 V and ε = 12.4. In order to restrict variations in V p within ±0.1 V, channel thickness A must be adjusted to be within a range of ±55 Å. It is difficult to restrict the variations in channel thickness within such a small range by the conventional method, which sets channel thickness A by controlling an etching depth, as described above. On the other hand, the gate length must be controlled to be a small value of, e.g., 1 µm to increase transconductance gm. It is also difficult to control the width of the recess, which determines the gate length, to be such a small value. Recently, an opto-electronic integrated circuit device (OEIC) obtained by integrating an electronic device and an optical device on a single substrate is attracting a great deal of attention. It is preferred to arrange electronic and optical devices as a monolithic IC in terms of simplification in an assembly process for improvement in reliability and yield. In addition, if the above devices are arranged as a monolithic IC, excessive wiring can be reduced, resulting in a reduction of parasitic inductance or parasitic capacitance. This is advantageous for a high speed operation. However, a conventional OEIC does not have an advantage as an IC because electronic and optical devices are merely formed on a single substrate by independent manufacturing processes. For example, in a semiconductor laser, an active layer width must be set to be about 1 µm to obtain a steady transverse mode control and a low threshold current value. Therefore, when the above-mentioned FET and the semiconductor laser are to be integrated on a single substrate, extreme precision is required as to the sizes for both the devices. It is difficult to form these devices on a single substrate by independent processes to obtain a required size precision for both the devices. This is because mask alignment is difficult, since the layer structure of each device is different. Further, if these devices are formed in independent processes, many manufacturing processes are required as a whole, resulting in poor yield and high cost of an OEIC device. A device having a light-emitting element and a field effect transistor element, wherein the active (light emitting) and FET mask (gate patterning) layers are formed from different semiconductor layers is described in Electronic Letters, vol. 20, no. 15, July 1984 K. Kosahara et al, "Gigabit per second operation by monolithically integrated FiGaAsP/InP LD-FET". A conventional FET structure without an associated light emitting element is described in IEE Transactions on Electron Devices, vol. ED-31, no. 6, June 1984, 840, 841, C.L. Cheng et al, "A new self-aligned recessed-gate InP MESFET". It is now an object of the present invention to provide an FET having a structure useful for an OEIC and with superior characteristics. It is another object of the present invention to provide an OEIC device which integrates an FET and a light-emitting device in a compact size. It is still another object of the present invention to provide a method of manufacturing an OEIC device, capable of integrating an FET and a light-emitting device by a simple process that can produce their desired characteristics sufficiently. Thus, the present invention provides an opto-electronic integrated circuit device in which a light-emitting device and a field effect transistor are integrated on a semi-insulating substrate, wherein said light-emitting device includes a first clad layer, an active layer, and a second clad layer which are sequentially stacked above the semi-insulating semiconductor substrate, and said field effect transistor comprises a channel layer arranged on said substrate, heavily doped source and drain layers defining an opening therebetween on said channel, an etching mask formed on said source and drain layers, source and drain electrodes, and a gate electrode formed in said opening, wherein said first clad layer of said light-emitting device and said source and drain layers are formed of a single planar first semiconductor layer, and said active layer and said etching mask layer are formed of a second semiconductor layer. The present invention also provides a method of manufacturing an opto-electronic integrated circuit device having a light-emitting device and a field effect transistor integrated on a substrate, said method comprising the steps of growing a first semiconductor layer on the substrate, to serve as a channel layer of the field effect transistor; growing on said first semiconductor layer, a second semiconductor layer, being different in material from said first semiconductor layer and serving as an etching stopper layer; and growing on said second semiconductor layer, a third semiconductor layer different in material from said second semiconductor layer, and serving as a first clad layer of said light-emitting device and heavily doped source and drain layers; wherein the method further comprises the steps of: - growing a fourth semiconductor layer different in material from said third semiconductor layer; selectively etching said fourth semiconductor layer to define therein an active layer of said light-emitting device and respective etch mask regions above said source and drain layers and also defining the gate region of said field effect transistor; sequentially growing a fifth semiconductor layer serving as a second clad layer of said light-emitting device, and a sixth semiconductor layer serving as a cap layer, selectively etching said fifth and sixth semiconductor layers in a region thereof above where said field effect transistor is to be formed to cause the underlying portion of the etched fourth semiconductor layer to be exposed and whereby, substantially simultaneously, said field effect transistor is formed, to cause said third semiconductor layer to be etched with said etched fourth semiconductor layer being a mask, to define therein an opening at said gate region on said second semiconductor layer thereby forming spaced-apart source and drain layers in said third semiconductor layer, forming source and drain electrodes above said source and drain layers respectively; and forming a gate electrode (22) in said opening between said source and drain layers. Embodiments of the present invention will now be described in detail with reference to the following drawings, in which: Fig. 1 is a sectional view of an essential structure of an embodiment of an OEIC device according to the present invention; Fig. 2 is an equivalent circuit diagram of the OEIC; Figs. 3A to 3F are sectional views of manufacturing steps of the device in Fig. 1; and Fig. 4 is a sectional view of an essential structure of another embodiment of an OEIC device accoroing to the present invention. Fig. 1 shows an essential structure of an OEIC device. Laser diode LD and MESFET-Q₁ are integrated on semi-insulating InP substrate 11. Laser LD and MESFET-Q₁ are a part of an optical switching circuit arranged as a monolithic IC, as shown in Fig. 2. In Fig. 2, reference symbols Q₁ and Q₂ denote a MESFET constituting a differential switching circuit; Q3, a current source MESFET; LD, a laser diode; and R, a load resistor. A suitable DC bias can be applied to laser LD through terminal B. This optical switching circuit is used for ON/OFF control of laser LD by a high speed operation of MESFET-Q₁ and Q₂. In order to obtain the high speed operation, the optical switching circuit is preferred to be arranged as a monolithic IC. Laser diode LD has a double heterojunction structure including n-type InP clad layer 14₁ (first clad layer), undoped GaInAsP active layer 15₁, and p-type InP clad layer 17 formed on (100) semi-insulating InP substrate 11. MESFET-Q₁ includes channel layer 12 formed on substrate 11, drain and source layers 14₂ and 14₃ of an n-type InP layer with a high impurity concentration, drain and source electrodes 21₁ and 21₂, and gate electrode 22. Etching mask layers 15₂ and 15₃ are formed on at least portions of layers 14₂ and 14₃. Clad layer 14₁ of laser LD and source, drain layers 14₂, 14₃ of MESFET-Q₁ are formed of common n-type InP layer 14. Active layer 15₁ of laser diode LD and etching mask layers 15₂ and 15₃ of MESFET-Q₁ are formed of common GaInAsP layer 15. Laser diode LD and MESFET-Q₁ are isolated by insulating layer 19. Electrode 20 is formed on p-type clad layer 17 of laser diode LD through p⁺- type GaInPaP cap layer 18. The steps of manufacturing the OEIC will be described with reference to Figs. 3A to 3F. As shown in Fig. 3A, n-type InP layer 12 (first semiconductor layer), serving as the channel layer of MESFET-Q1, is grown to a predetermined thickness on semi-insulating InP substrate 11. Then, n-type GaInAsP layer 13 (second semiconductor layer), serving as an etching stopper for preventing a change in thickness of the channel layer during the following etching process, is grown to about 0.2 µm. Subsequently, n-type InP layer 14 (third semiconductor layer), serving as n-type clad layer of laser diode LD and as source and drain layers with a high impurity concentration of MESFET-Q₁, is grown on the resultant structure. n-type InP layer 14 has a carrier concentration of 1 × 10¹⁸/cm³ and a thickness of about 2 µm. Undoped GaInAsP layer 15 (fourth semiconductor layer), serving as the active layer of laser diode LD and as the etching mask layer of the source and drain regions of MESFET-Q₁, is grown on the resultant structure. In this laser diode LD, actually, fourth semiconductor layer 15 includes a GaInAsP layer serving as an optical waveguide layer, in additional to the active layer, with a band gap wider than that of the active layer. The thickness of GaInAsP layer 15 is about 0.3 µm. P-type InP layer 16, having a carrier concentration of about 1 × 10¹⁸/cm³, is grown to a suitable thickness to protect the active layer. The above description is the first stage of a crystal growth process. In this embodiment, a low pressure MOCVD method was used in consideration of controlability of film thickness. Trimethyl indium (TMI) and phosphine (PH₃) were used as materials to grow the InP layer. TMI, trimethyl gallium (TMG), PH₃, and arsine (AsH₃) were used as materials to grow the GaInAsP layer. Hydrogen selenide (H₂Se) was used as a doping gas of an n-type impurity. In every case, hydrogen (H₂) was used as a carrier gas. As shown in Fig. 3B, InP layer 16 and GaInAsP layer 15 therebelow are selectively etched to form a mesa for localizing active layer 15₁ of laser LD, and to form etching mask layers 15₂ and 15₃ of MESFET-Q₁ simultaneously. Etching mask layers 15₂ and 15₃ are used as masks in a process of forming the recess of the gate region. The etching process is performed using a photo-resist as a mask, but an SiO₂ film may be inserted between InP layer 15 and the photoresist. Since lithography is performed on a completely flat surface, the active region of the laser diode LD and a size of the channel region of the MESFET-Q1 can be set with high precision. When the SiO₂ film is used, the film must be removed before the next process. Next, a second stage of the crystal growth process will be described. In this process, as shown in Fig. 3C, p-type InP layer 17 (fifth semiconductor layer), serving as the p-type clad layer having a carrier concentration of 1 × 10¹⁸/cm³ and a thickness of 1 to 4 µm, and subsequently p⁺-type GaInAsP layer 18 (sixth semiconductor layer), serving as the cap layer, are grown. This crystal growth process is also performed by the low-pressure MOCVD method. Note that the film thickness need not be strictly controlled in this process, so that liquid-phase epitaxy (LPE) may be used. The recess formed in Fig. 3B is so small as 0.3 to 0.4 µm. Therefore, a substantially flat surface can be obtained through the second stage of the crystal growth process. All the crystal growth is ended in this second stage of the crystal growth process. Note that when a distributed feedback (DFB) laser diode is used, a process of forming a diffraction grating by two-beam interference or the like is added after growth of InP layer 14 or GaInAsP layer 15. In the former case, three crystal growth processes are required. However, in the latter case, since an optical waveguide layer is formed on the active layer , InP layer 16, for protecting the active layer, is not required, and the number of crystal growth processes is not increased. Thereafter, as shown in Fig. 3D, proton-ion implantation is performed around the device region of the laser diode to form insulating layer 19. Layer 19 is formed in order to concentrate the injected current, to improve response characteristic of the laser diode by reducing a junction area, and to electrically isolate elements. For this purpose, insulating layer 19 is formed to reach n-type InP layer 14 and at both sides of stripe-like active layer 15₁ at a distance of about 2 µm. Note that this proton-ion implantation is performed using an Au mask (not shown). This Au mask can be obtained with high dimensional precision because photolithography is performed on a flat surface. Thereafter, as shown in Fig. 3E, anode electrode 20 of laser diode LD is formed by deposition and alloying of an Au/AuZn/Au film. Then, after unnecessary GaInAsP layer 18 is removed, using electrode 20 as a mask, an InP etching process is performed by a hydrochloric acid solution. If this etching process time is long enough, after p-type InP layer 17 on the MESFET region is completely removed, n-type InP layer 14 on the gate region is selectively etched because etching mask layers 15₂ and 15₃, formed of the GaInAsP layer, protective source and drain regions. n-type InP layer 12, serving as the channel layer, is not etched, because GaInAsP layer 13 serves as an etching stopper. Thus, drain and source layers 14₂ and 14₃, formed of n-type InP layer 14, are isolated. An isolating groove between layers 14₂ and 14₃ has a substantially vertical end face, although its lower portion is slightly widened. As a result, the gate length defined by layers 15₂ and 15₃ can be obtained. Thereafter, as shown in Fig. 3F, drain and source electrodes 21₁ and 21₂ are formed. In this embodiment, the drain and source electrodes 21₁ and 21₂ are formed on etching mask layers 15₂ and 15₃. The region of the etching mask layers 15₂ and 15₃, on which the drain and source electrodes 21₁ and 21₂ are formed, may be removed so that drain and source electrodes 21₁ and 21₂ directly contact layers 14₂ ano 14₃. Then, GaInAsP layer 13, used as an etching stopper of the gate region, is etched to expose n-type InP layer 12. An Au film is deposited on exposed InP layer 12 to form gate electrode 22. Drain and source layers 14₂ and 14₃ are formed to have a reverse mesa shape. Therefore, the Au film is not deposited on the end faces, and gate electrode 22 is automatically buried between drain and source layers 14₂ and 14₃. Thus, according to the above embodiment, a monolithic OEIC device including a laser diode and a MESFET is formed. The laser diode and the MESFET have two semiconductor layers in common, resulting in a reduced number of manufacturing processes. Another reason for a reduced number of manufacturing processes is that the process of isolating source and drain layers is very simple. Since p-type InP layer 17, serving as a p-type clad layer of the laser diode, is an unnecessary layer on the MESFET region, it is to be removed to isolate the source and drain layers. According to the embodiment, by etching the InP layer using GaInAsP layers 15₂ and 15₃ on the source and drain regions and GaInAsP layer 13 on the channel layer as an etching mask and an etching stopper, respectively, the unnecessary p-type InP layer in the MESFET region is removed, and subsequently the crain and source layers of an n-type InP layer are isolated. In addition, since etching mask layers 15₂ and 15₃ are patterned simultaneously with the patterning of active layer 15₁, additional mask formation is not required in this process of isolating the source and drain layers. In this embodiment, since crystal growth is performed with a reduced number of processes and on a flat surface, process control becomes easy. Therefore, good crystals can be obtained, resulting in superior device characteristics. Further, according to the present invention, since photolithograpny is performed on a flat surface, micro sizes, i.e., the active layer width of the laser diode and the gate length of the MESFET can be precisely controlled. A structural parameter can be automatically set by the combination of materials of the semiconductor layers. More specifically, in forming the channel region of the MESFET, the gate length can be controlled by the etching mask layer on the source and drain regions. Changes in the channel layer thickness can be prevented by the etching stopper on the channel layer. Thus, the gate length and the thickness of the channel layer of the MESFET, which is present together with the laser diode, can be automatically and precisely controlled. As a result, an OEIC device having superior characteristics can be obtained with a good yield. The present invention is not limited to the above embodiment. For example, GaInAsP layers are used as the etching stopper layer on the channel layer and the etching mask layer of the source and drain regions of the MESFET, and as the active layer and the cap layer of the laser diode in this embodiment, but GaInAs layers may be used as these semiconductor layers. As a combination of semiconductor materials for constituting the heterojunotion, AℓGaAS/GaAs or AℓInAS/GaInAs, in addition to GaInAsP/InP, may be used. The FET is not limited to the MESFET with a Schottky gate structure, but may be a MISFET or a HEMT. The present invention can be applied to the case in which a light-emitting diode, in addition to the laser diode, is used as a light-emitting device. For example, Fig. 4 shows an embodiment using an AℓInAs/GaInAs HEMT instead of an InP MESFET. Instead of InP layer 12 and GaInAsP layer 13 in the preceding embodiment, n⁻-type GaInAs layer 24 epitaxially grown on semi-insulating substrate 11 and n⁺-type AℓInAs layer 25 epitaxially grown thereon are formed. Two-dimensional electron gas (2DEG) 26 is formed at the interface of layers 24 and 25. By changing a concentration of 2DEG 26 by applying a voltage to gate electrode 22 on n+-AℓInAs layer 25, the drain current can be controlled. GaInAsP layers 27₁ and 28₁ of laser diode LD constitute an optical waveguide layer and an active layer, respectively, ana GaInAsP layers 27₂, 27₃, 28₂, and 28₃ of the HEMT region serve as etching mask layers. In this embodiment, the laser diode is of a mushroom type. The width of a groove of a region in which electrode 22 of the HEMT is formed and the widths of the active layer and InP buried regions 30₁ and 30₂ on both sides thereof are defined simultaneously by a PEP process in which the substrate is flat before p-type InP layer is grown, and by the subsequent selective etching process of InGaAsP layers 27 and 28. InGaAsP layers 27 and 28, outside p-type InP buried regions 30₁ and 30₂ of the laser diode, are removed by the selective side etching process. Widths of regions 30₁ and 30₂ can be controlled to about 0.5 to 1 µm respectively. Therefore, conductive and capacitive leakage currents outside the active layer can be reduced, so that linear characteristics with a high-speed response time can be obtained.

Claims: An opto-electronic integrated circuit device in which a light-emitting device (LD) and a field effect transistor (Q1) are integrated on a semi-insulating substrate (11), wherein said light-emitting device includes a first clad layer (14₁), an active layer (15₁; 28₁), and a second clad layer (17) which are sequentially stacked above the semi-insulating semiconductor substrate (11), and said field effect transistor comprises a channel layer (12; 24) arranged on said substrate (11), heavily doped source and drain layers (14₂, 14₃) defining an opening therebetween on said channel, an etching mask (15₂, 15₃; 28₂, 28₃) formed on said source and drain layers (14₂, 14₃), source and drain electrodes (21₁, 21₂), and a gate electrode (22) formed in said opening, characterised in that said first clad layer (14₁) of said light-emitting device and said source and drain layers (14₂, 14₃) are formed of a single planar first semiconductor layer (14), and said active layer (15₁; 28₁) and said etching mask layer (15₂, 15₃; 28₂, 28₃) are formed of a second semiconductor layer (15). A device according to claim 1, characterised in that said gate electrode (22) is formed on said channel layer (12). A device according to claim 2, characterized in that said semi-insulating semiconductor substrate (11) is an InP substrate, said channel layer (12) of said field effect transistor is an n-type InP layer formed on the entire surface of said substrate (11), said source and drain layers (14₂, 14₃) of said field effect transistor and said first clad layer (14₁) of said light-emitting device are n-type InP layers formed on said channel layer (12), said etching mask layer (15₂, 15₃) of said field effect transistor and said active layer (15₁) of said light-emitting device are GaInAsP layers or GaInAs layers formed on said n-type InP layer, and said second clad layer (17) of said light-emitting device is a p-type InP layer. A device according to claim 2, characterized in that said field effect transistor is a Schottky gate field effect transistor in which a Schottky barrier is formed between said gate electrode (22) and said channel layer (12). A device according to claim 1, characterized in that said light-emitting device is a laser diode having a double heterojunction structure. A method of manufacturing an opto-electronic integrated circuit device having a light-emitting device (LD) and a field effect transistor (Q1) integrated on a substrate, said method comprising the steps of growing a first semiconductor layer (12; 24)) on the substrate, to serve as a channel layer of the field effect transistor; growing on said first semiconductor layer (12; 24), a second semiconductor layer (13; 25), being different in material from said first semiconductor layer (12; 24) and serving as an etching stopper layer; and growing on said second semiconductor layer (13; 25), a third semiconductor layer (14) different in material from said second semiconductor layer (13; 25), and serving as a first clad layer (14₁) of said light-emitting device and heavily doped source and drain layers (14₂, 14₃); characterized in that the method further comprises the steps of:- growing a fourth semiconductor layer (15; 28) different in material from said third semiconductor layer (14); selectively etching said fourth semiconductor layer (15; 28) to define therein an active layer (15₁; 28₁) of said light-emitting device and respective etch mask regions (15₂, 15₃; 28₂, 23₃) above said source and drain layers (14₂, 14₃) and also defining the gate region of said field effect transistor; sequentially growing a fifth semiconductor layer (17) serving as a second clad layer of said light-emitting device, and a sixth semiconductor layer (18) serving as a cap layer, selectively etching said fifth and sixth semiconductor layers (17, 18) in a region thereof above where said field effect transistor (Q₁) is to be formed to cause the underlying portion of the etched fourth semiconductor layer (15₂, 15₃; 28₂, 28₃) to be exposed and whereby, substantially simultaneously, said field effect transistor is formed, to cause said third semiconductor layer (14) to be etched with said etched fourth semiconductor layer (15₂, 15₃; 28₂, 28₃) being a mask, to define therein an opening at said gate region on said second semiconductor layer (13) thereby forming spaced-apart source and drain layers (14₂, 14₃) in said third semiconductor layer (14), forming source and drain electrodes (21₁, 21₂) above said source and drain layers (14₂, 14₃) respectively; and forming a gate electrode (22) in said opening between said source and drain layers (14₂, 14₃). A method according to claim 6 characterised in that it further comprises the step of selectively etching said second semiconductor layer (13) so that a portion of said second semiconductor layer (13) disposed in the opening is removed before forming said gate electrode (22). A method according to claim 7, characterized in that said semi-insulating semiconductor substrate (11) is an InP substrate, said first semiconductor layer (12) is an n-type InP layer, said second semiconductor layer (13) is a GaInAsP layer or a GaInAs layer, said third semiconductor layer (14) is an n-type InP layer, said fourth semiconductor layer (15) is a GaInAsP layer or a GaInAs layer, said fifth semiconductor layer (14) is a p-type InP layer, and said sixth semiconductor layer (18) is a p-type GaInAsP layer or a GaInAs layer. A method according to claim 7, characterized in that said field effect transistor is a Schottky gate field effect transistor in which a Schottky barrier is formed between said gate electrode (22) and said channel layer. 7 A method according to claim 7, characterized in that said light-emitting device is a laser diode having a double heterojunction structure.

Inventors: HIRAYAMA YUZO C O PATENT DIVIS, KINOSHITA JUN ICHI C O PATENT, MORINAGA MOTOYASU C O PATENT D, NAKAMURA MASARU C O PATENT DIV, SUZUKI NOBUO C O PATENT DIVISI, HIRAYAMA, YUZO C/O PATENT DIVISION, KINOSHITA, JUN'ICHI C/O PATENT DIVISION, MORINAGA, MOTOYASU C/O PATENT DIVISION, NAKAMURA, MASARU C/O PATENT DIVISION, SUZUKI, NOBUO C/O PATENT DIVISION
Applicants: TOSHIBA KK, KABUSHIKI KAISHA TOSHIBA
Application year: 1987
Main classification: H01L29
IPC codes: H01S5, H01L21, H01L33, H01L29, H01L27