Multilayer base heterojunction device

Abstract: This is a p-n junction device and the device comprises: a substrate 10 composed of a semiconductor material; a heavily doped n type sub-collector layer 14 over the substrate; a n type collector layer 16 over the sub-collector layer; a heavily doped p type first base layer 18, over the collector layer; a p type second base layer 20, substantially thinner than the first base layer, over the first base layer, with the second base layer being less heavily doped than the first base layer; and a n type emitter layer 24 over the second base layer, whereby, the second base layer serves as a diffusion barrier between the base and the emitter. Other devices and methods are also disclosed.

Description: FIELD OF THE INVENTION This invention relates to a semiconductor device as defined in the precharacterizing part of claim 1 and to a method as defined in the precharacterizing part of claim 12. BACKGROUND OF THE INVENTION Without limiting the scope of the invention, its background is described in connection with the diffusion of dopants in the base layer of a heterojunction bipolar transistor (HBT), as an example. Heretofore, in this field, it has been the object of device designers to develop HBTs to provide signal gain at microwave frequencies. A necessary consequence of this design goal is the formation of a structure that exhibits a low series base resistance. The speed of HBTs depends strongly on the device base resistance, which must be kept low to minimize resistive parasitics of the input. Self-aligned emitter-base contact fabrication techniques are often used to minimize the series base resistance by lowering the distance between these two contacts. The lowering of the base sheet resistance is, however, the most effective way to achieve a reduction in all components of the base resistance (series resistance, contact resistance, and access resistance). Low base sheet resistance in npn HBTs with base layers made from compound semiconductor materials, such as GaAs, has been achieved by heavily doping the base layer with Be or Zn. Base doping concentration in excess of 1x10 19 cm -3 is needed for microwave performance. Such heavily doped base layers, however, are not stable under high temperature growth or under high temperature and bias operating conditions. Degenerately doped base layers can act as diffusion sources under these type of stress conditions and p-type dopant can diffuse into the emitter and/or the collector layer irreversibly changing the device parameters. The presence of a heavily doped n-type layer close to the p-type doped layer also causes diffusion enhancement during layer growth at elevated temperatures (typical growth temperatures in MOCVD is 600 - 800°C). A semiconductor device of the kind as defined in the preamble of claim 1 is disclosed in IEEE Electron Device Letters, vol. 10, no. 7, pages 313-315 (1989). In particular, it shows an unintentionally doped GaAs layer having a thickness of 5 nm interposed between a 6x10 19 Be-doped GaInAs layer having a thickness of 30 nm and a 3x10 17 Si-doped AlGaAs layer having a thickness of 200 nm. This document is concerned with the issue of decreasing the emitter contact resistance. From Proceedings of "Gallium Arsenide and Related Compounds 1984", Biarritz, France, 1984, (Adam Hilger, Bristol, 1985), pages 599-604, it is known that introduction of 20 nm of undoped GaAs at an nAlGaAs/p + GaAs heterojunction provides a buffer against surface diffusion of Be, increasing the injection efficiency to that theoretically expected for a simple nAlGaAs/p + GaAs heterojunction diode. SUMMARY OF THE INVENTION The semiconductor device of the invention is provided with the features of the characterizing part of claim 1. Preferably, the device has a buffer layer over the substrate and under the sub-collector layer; a third base layer over the collector layer and under the first base layer, with the third base layer being less heavily doped than the first base layer, whereby the third base layer serves as a diffusion barrier between the base and the collector; a n type emitter stop layer over the second base layer and under the emitter layer, a grading layer over the emitter layer; a heavily doped n type first contact layer over the emitter layer or over a grading layer over the emitter layer; a n type second contact layer over the first contact layer, with the second contact layer being more heavily doped than the first contact layer; the first contact layer, second contact layer, first base layer, second base layer, sub-collector layer and collector layer are GaAs; and the emitter layer is AlGaAs. A method of forming the semiconductor device of the invention comprises the features defined in the characterizing part of claim 12. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1a-1b are cross-sectional views, at different processing stages, of a preferred embodiment of this invention; FIG. 2 is a more detailed view of a section of FIG. 1b; FIG. 3 is a doping profile of a preferred embodiment of this invention. Corresponding numerals and symbols in the different figures refer to corresponding parts unless otherwise indicated. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS In FIG. 1a, the layers of a preferred embodiment heterojunction bipolar transistor (HBT) are shown, which are formed epitaxially. The layers are subsequently etched and contact is made, to form the device shown in FIG. 1b. Fig. 2 shows more detail of a portion of FIG. 1b (layers 22-30). Refer to FIGS. 1a-1b and FIG. 2 in the following discussion of the preferred embodiment HBT. The preferred doping levels and thicknesses stated in the description below are approximate values only. The device is on a substrate 10 composed of a semi-insulating semiconductor material, such as undoped GaAs. A buffer layer 12, typically of undoped GaAs or AlGaAs, is epitaxially formed over the substrate 10. A sub-collector layer 14 of n+ GaAs is epitaxially formed over the buffer layer 12. The doping of the sub-collector layer 14 is preferably 2x10 18 cm -3 , and the thickness is preferably 1.0 µm. A collector layer 16 of n- to n type GaAs is epitaxially formed over the sub-collector layer 14. The doping of the collector layer 16 is preferably 2x10 16 cm -3 and the thickness is preferably 1.0 µm. The dopant preferably used for n type doping, in this device, is Si. The base region is formed over the collector layer 16 in two layers, with an optional third layer. The first base layer 18, of heavily (p++) doped p type GaAs material, typically doped 1-5x10 19 cm -3 , forms the bulk of the base of the transistor. The first base layer 18 is preferably 100 - 150 nm thick. This layer provides low sheet resistivity and low contact resistance. A thin, preferably 10 - 50 nm thick, second base layer 20, of p+ GaAs, is epitaxially formed over the first base layer 18 and serves as a diffusion barrier for the first base layer. The second base layer doping is lighter than the doping of the first base layer, preferably 1-2x10 18 cm -3 . The dopant preferably used for p type doping, in this device, is Zn. The thicknesses and doping concentrations of each layer is chosen considering the diffusion characteristics of each dopant. Generally, a layer of 10 - 50 nm is needed to effectively stop the diffusion of dopants to the p-n junctions. The concentration of dopant in these layers need to be low enough for minimal dopant outdiffusion (i.e. less than 5x10 18 cm -3 for Zn) while high enough to avoid significantly increased series resistance. The difference between the doping levels of these layers should also be minimized to avoid backdiffusion of minority carriers due to doping concentration profile induced reverse electrical field in the base. A third base layer, with the same doping and thickness as the second base layer 20, may be added between the collector layer 16 and the first base layer 18 to prevent diffusion into the collector during growth. An optional n to n+ GaAs emitter stop layer 22 can be epitaxially formed over the second base layer. This layer 22 may be doped at 1x10 18 cm -3 and 10 nm thick. The emitter stop layer 22 serves as a barrier between the emitter and the base of the device further isolating the Zn to the base layers, therefore keeping the emitter n type, as needed for proper device performance. The emitter layer 24, of n type AlGaAs (the wide bandgap of which provides the heterojunction effect), is epitaxially formed over the emitter stop layer 22 (or over layer 20, if layer 22 is not used), with a preferred doping of 2x10 17 cm -3 and a preferred thickness of 100 nm. A thin grading layer 26 is epitaxially formed over the emitter layer 24, in which the concentration of Al gradually diminishes (which provides a smooth bandgap transition from AlGaAs to GaAs). A first contact layer 28 is formed over the grading layer 26 of n+ GaAs. This layer's doping concentration and thickness are preferably 1x10 18 cm -3 and 100 nm, respectively. A second contact layer 30, more highly doped than the first contact layer 28 (which provides a suitable surface for deposition of emitter metallization), is epitaxially formed over the first contact layer 28. The second contact layer is n+ GaAs with preferable doping of 5x10 18 cm -3 and thickness of 150 nm. The first contact layer 28 is used as a spacer between the first base layer 18 and the second contact layer 30. The use of this layer lowers the built-in electric field at the emitter-base junction, which is responsible for diffusion enhancement during epitaxial layer growth. After epitaxial formation of the desired layers, the structure is anisotropically etched, preferably using a process such as reactive ion etching (RIE) in BCl 3 plasma, to form the desired structure, such as the one shown in FIG. 1b. At this point, contact formation may be done. The etching exposes the sub-collector layer 14 and the first base layer 18. If desired, the collector layer 16 may be left unetched on the sub-collector layer 14 and ion implantation may be used to contact the sub-collector layer 14 through the collector layer 16. The emitter contact 34, and the collector contacts 36 are preferably formed of layered AuGe/Ni/Au at thicknesses of 50 nm, 14 nm, and 400 nm, respectively. The base contacts 32 are preferably layered Ti/Pt/Au at thicknesses of 50 nm, 25 nm, and 150 nm, respectively. In Table 1, below, the preferred ranges for both doping and thicknesses of the different layers of the device may be found. The preferred values may be found in the discussion above. A graphical representation of the typical doping levels of the device is shown in FIG. 3, and may be used for further clarification. The described preferred embodiment of the present invention has the advantage that an HBT can be formed with low base resistance, and therefore high operating frequency, by the use of the heavily Zinc doped first base layer 18. If not for the inclusion of the less heavily doped second base layer 20, Zinc diffusion into the emitter 24, driven by heat dissipated by the device and the forward biased base-emitter p-n junction, would degrade the device performance irreversibly over its operating lifetime, producing unstable and unpredictable device performance. A preferred embodiment has been described in detail hereinabove. It is to be understood that the scope of the invention also comprehends embodiments different from those described, yet within the scope of the claims. For example, while the p type dopant is referred to as Zn, it could also be materials such as C, Be, Mg, or Mn, and the n type dopant, while preferably silicon, could be a material such as S, or Se. Similarly, the AlGaAs emitter could be any appropriate wide bandgap material such as InGaP and the GaAs could be replaced with a material such as InGaAs or InP. The second base layer 20 can be used in relation to any two semiconductor layers where it is desired to control the diffusion of dopants from one layer into the other, for example, in any p-n junction device (such as diodes, transistors, lasers, etc). Words of inclusion are to be interpreted as nonexhaustive in considering the scope of the invention. While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. LAYER TYPICAL DOPING RANGES (cm -3 ) TYPICAL THICKNESS RANGES (µm) SUB-COLLECTOR 14 1-4 x 10 18 0.5 - 1.5 COLLECTOR 16 2-10 x 10 16 0.3 - 3.0 FIRST BASE 18 1-7 x 10 19 0.05 - 0.15 SECOND BASE 20 1-2 x 10 18 0.01 - 0.05 EMITTER STOP 22 5-10 x 10 17 0.006 - 0.015 EMITTER 24 1-10 x 10 17 0.05 - 0.2 GRADING 26 3-10 x 10 17 0.03 - 0.06 FIRST CONTACT 28 1-3 x 10 18 0.1 - 0.2 SECOND CONTACT 30 3-6 x 10 18 0.1 - 0.2

Claims: A semiconductor device comprising: a substrate (10) of semiconductor material; a first layer of semiconductor material having a dopant impurity of a heavy concentration of one conductivity type disposed over said substrate (10), said first layer defining a sub-collector layer (14); a second layer of semiconductor material having a dopant impurity of said one conductivity type and of lesser concentration than the dopant impurity of said first semiconductor layer defining said sub-collector layer (14) and disposed over said first semiconductor layer, said second semiconductor layer of said one conductivity type defining a collector layer (16); a third semiconductor layer disposed over said second semiconductor layer defining said collector layer (16) and having a dopant impurity of heavy concentration of the other conductivity type, said third semiconductor layer of the other conductivity type defining a first base layer (18); a fourth semiconductor layer disposed over said third semiconductor layer defining said first base layer (18), said fourth semiconductor layer being substantially thinner in thickness than said third semiconductor layer; and a fifth semiconductor layer having a dopant impurity of said one conductivity type and disposed over said fourth semiconductor layer, said fifth semiconductor layer of said one conductivity type defining an emitter layer (24); said fourth semiconductor layer providing a diffusion barrier between said third semiconductor layer of said other conductivity type defining said first base layer (18) and said fifth semiconductor layer of said one conductivity type defining said emitter layer (24); characterized in that said fourth semiconductor layer is formed by a doped second base layer (20) having a dopant impurity of said other conductivity type, said second base layer having a reduced concentration of dopant impurity of said other conductivity type as compared to the concentration of said dopant impurity of said other conductivity type of said first base layer (18); and that said fourth semiconductor layer has a thickness of 10 to 50 nm. The device of claim 1, characterized in that said device is a p-n junction device, and that said one conductivity type comprises n type and said other conductivity type comprises p type. The device of claim 2, characterized in that said device has a buffer layer (12) over said substrate (10) and under said sub-collector layer (14). The device of claim 2, characterized in that said device has a third base layer over said collector layer (16) and under said first base layer (18), with said third base layer being less heavily doped than said first base layer (18), whereby said third base layer serves as a diffusion barrier between said base and said collector. The device of claim 2, characterized in that said device has a n type emitter stop layer (22) over said second base layer (20) and under said emitter layer (24). The device of claim 2, characterized in that said device has a grading layer (26) over said emitter layer (24). The device of claim 2, characterized in that said device has a heavily doped n type first contact layer (28) over said emitter layer (24) or over a grading layer (26) over said emitter layer (24). The device of claim 7, characterized in that said device has a n type second contact layer (30) over said first contact layer (28), with said second contact layer (30) being more heavily doped than said first contact layer (28). The device of claim 8, characterized in that said first contact layer (28), second contact layer (30), first base layer (18), second base layer (20), sub-collector layer (14) and collector layer (16) are GaAs. The device of claim 2, characterized in that said emitter layer (24) is AlGaAs. The device of claim 2, characterized in that said device is a heterojunction bipolar transistor. A method of forming a semiconductor device as defined in claim 1 comprising: forming a first layer of semiconductor material having a heavy concentration of a dopant of one conductivity type as a sub-collector layer (14) over a substrate (10) of semiconductor material; forming a second semiconductor layer having a dopant impurity of said one conductivity type over said sub-collector layer (14) of said one conductivity type as a collector layer (16); forming a third semiconductor layer having a dopant impurity of the other conductivity type at a high concentration as a first base layer (18) of the other conductivity type over the collector layer (16) of said one conductivity type; forming a fourth semiconductor layer of substantially reduced thickness as compared to said third semiconductor layer of said other conductivity type defining said first base layer (18) over said first base layer (18) of said other conductivity type; forming a fifth semiconductor layer having a dopant impurity of said one conductivity type over said fourth semiconductor layer, said fifth semiconductor layer defining an emitter layer (24), such that said fourth semiconductor layer serves as a diffusion barrier between said third semiconductor layer of said other conductivity type defining said first base layer (18) and said fifth semiconductor layer of said one conductivity type defining said emitter layer (24); characterized in that said fourth semiconductor layer is formed as a second base layer (20) with a dopant impurity of said other conductivity type at a reduced concentration as compared to the dopant impurity of said other conductivity type in said first base layer (18); and that said fourth semiconductor layer has a thickness of 10 to 50 nm. The method of claim 12, characterized in that said semiconductor device is a p-n junction device, and that said one conductivity type comprises n type and said other conductivity type comprises p type. The method of claim 13, characterized in that a buffer layer (12) is formed over said substrate (10) and under said sub-collector layer (14). The method of claim 13, characterized in that a third base layer is formed over said collector layer (16) and under said first base layer (18), with said third base layer being less heavily doped than said first base layer (18), whereby said third base layer serves as a diffusion barrier between said base and said collector. The method of claim 13, characterized in that a n type emitter stop layer (22) is formed over said second base layer (20) and under said emitter layer (24). The method of claim 13, characterized in that a grading layer (26) is formed over said emitter layer (24). The method of claim 13, characterized in that a heavily doped n type first contact layer (28) is formed over said emitter layer (24) or over a grading layer (26) over said emitter layer (24). The method of claim 18, characterized in that a n type second contact layer (30) is formed over said first contact layer (28), with said second contact layer (30) being more heavily doped than said first contact layer (28). The method of claim 19, characterized in that said first contact layer (28), second contact layer (30), first base layer (18), second base layer (20), sub-collector layer (14) and collector layer (16) are GaAs. The method of claim 13, characterized in that said emitter layer (24) is AlGaAs.

Inventors: BAYRAKTAROGLU BURHAN, BAYRAKTAROGLU, BURHAN
Applicants: TEXAS INSTRUMENTS INC, TEXAS INSTRUMENTS INCORPORATED
Application year: 1992
Main classification: H01L29
IPC codes: H01L21, H01L29