Single crystal SiC and a method of producing the same

Abstract: The single crystal SiC according to the invention is produced in the following manner. Two complexes M in each of which a polycrystalline film 2 of β-SiC (or α-SiC) is grown on the surface of a single crystal α-SiC substrate 1 by thermochemical deposition, and the surface 2a of the polycrystalline film 2 is ground so that the smoothness has surface roughness of 200 angstroms RMS or smaller, preferably 100 to 50 angstroms RMS are subjected to a heat treatment under a state where the complexes are closely fixed to each other via their ground surfaces 2a', at a high temperature of 2,000°C or higher and in an atmosphere of a saturated SiC vapor pressure, whereby the polycrystalline films 2 of the complexes M are recrystallized to grow a single crystal which is integrated with the single crystal α-SiC substrates 1. Large-size single crystal SiC in which impurities, micropipe defects, and the like do not remain, and which has high quality can be produced with high productivity.

Description: Background of the Invention 1. Field of the Invention The present invention relates to single crystal SiC and a method of producing the same, and more particularly to single crystal SiC which is used as a semiconductor substrate wafer for a light-emitting diode, an X-ray optical device such as a monochromatic sorter, a high-temperature semiconductor electronic element, and a power device, and also to a method of producing the single crystal SiC. 2. Description of the Prior Art SiC (silicon carbide) is superior in heat resistance and mechanical strength, and also has good resistance to radiation. In addition, it is easy to perform the valence control of-electrons and holes by doping an impurity. Moreover, SiC has a wide band gap (for example, single crystal 6H-SiC has a band gap of about 3.0 eV, and single crystal 4H-SiC has a band gap of 3.26 eV). Therefore, it is possible to realize a large capacity, a high frequency, a high dielectric strength, and a high resistance to environments which cannot be realized by existing semiconductor materials such as Si (silicon) and GaAs (gallium arsenide). For these reasons, single crystal SiC receives attention and is expected as a semiconductor material for a next-generation power device. As a method of growing (producing) single crystal SiC of this type, employed are the Achison method and the sublimation and recrystallization method which are generally known as an industrial method of producing an SiC abrasive material. In the Achison method, a seed crystal substrate is heated from the outer circumference by using a high frequency electrode, so as to generate many nuclei in a center portion of the seed crystal substrate, whereby a plurality of spiral crystal growths are developed with being centered at the center portion of the seed crystal substrate. In the sublimation and recrystallization method, powder SiC produced by the Achison method is used as a raw material, and a crystal is grown on a single crystal nucleus. In the Achison method of the above-described conventional production methods, however, a single crystal is grown slowly over a long time period, so that the crystal growth rate is as low as about 1 mm/hr. In addition, a large number of crystal nuclei are generated in an initial growth stage, and they propagate to an upper portion of the crystal as the crystal growth advances. Thus, it is difficult to singly obtain a large-size single crystal. In the sublimation and recrystallization method, a highspeed growth of about 1 mm/hr is adopted mainly for an economical reason (production cost), so that impurities and pin holes which have a diameter of several microns and which pass through the crystal in the growing direction are likely to remain at about 100 to 1,000/cm 2 in a growing crystal. Such pin holes are called micropipe defects and cause a leakage current when a semiconductor device is fabricated. Accordingly, there exists a problem in that single crystal SiC having sufficiently good quality cannot be obtained. In the Achison method and the sublimation and recrystallization method, moreover, it is very difficult in a technical point of view to maintain cleanness of the atmosphere in the vicinity of a growing crystal, thereby producing a problem in that the quality is impaired also by contamination from the outside in the vicinity of a single crystal. These problems block a practical use of single crystal SiC which has superior characteristics as compared with other existing semiconductor materials such as Si and GaAs as described above. Summary of the Invention The invention has been conducted in view of the above-mentioned circumstances. It is an object of the invention to provide large-size single crystal SiC in which impurities, micropipe defects, and the like do not remain, in which contamination from the outside is suppressed to a minimum level, and which has high quality, and a method of producing single crystal SiC which is large and has high quality, and which can expedite the practical use of SiC as a semiconductor material. In order to attain the above-mentioned object, the essential features of the method of producing single crystal SiC of the invention are defined in claim 1. Preferred embodiments of the invention are defined in the dependent claims 2 and 3. The fact that the surfaces of the polycrystalline films are smoothly ground and the smooth surfaces are closely fixed to each other suppresses contamination,which is caused by adhesion of suspended substances and the like in the vicinity to the surfaces of the polycrystalline films, to a minimum level. Moreover, even when the ambient atmosphere is varied during the heat treatment, a phenomenon that the variation of the ambient atmosphere causes a surface portion of the polycrystalline films to be decomposed to disappear, or crystals depositing onto the vicinity to adhere to the surfaces of the polycrystalline films can be suppressed to a minimum level. Therefore, impurities, micropipe defects, and the like do not substantially remain. Furthermore, contamination from the outside, and an effect of the variation of the ambient atmosphere during the heat treatment can be suppressed to a minimum level so that large-size single crystal SiC which stably has very high quality is obtained with high productivity. Thus, it is possible to attain the effect of expediting the practical use of single crystal SiC which is superior in a large capacity, a high frequency, a high dielectric strength, and a high resistance to environments to existing semiconductor materials such as Si (silicon) and GaAs (gallium arsenide) and which is expected as a semiconductor material for a power device. Other objects and effects of the invention will be clarified in embodiments which will be described below. Brief Description of the Drawings Fig. 1 is a schematic view showing a state where a first step (a step of growing a film by thermochemical deposition) of the method of producing single crystal SiC according to the invention is ended; Fig. 2 is a schematic view showing a state where a second step (a step of grinding the surface of the grown film) of the production method is ended; Fig. 3 is a schematic view showing a state before a third step (a step of heat treatment) of the production method; and Fig. 4 is a schematic view showing a state where the third step (the step of heat treatment) of the production method is ended. Preferred Embodiments of the Invention Hereinafter, an embodiment of the invention will be described with reference to the drawings. Figs. 1 to 4 are schematic views illustrating the method of producing single crystal SiC according to the invention, in the sequence of production steps. In Fig. 1, 1 denotes a single crystal hexagonal α-SiC substrate (6H type or 4H type). The single crystal α-SiC substrate 1 is produced by the sublimation and recrystallization method or the Achison method. A polycrystalline cubic β-SiC film 2 is grown by thermochemical deposition in the range of 1,300 to 1,900°C so as to form an end portion 2e over the whole periphery of the side face of the single crystal α-SiC substrate 1. Immediately after the film growth, as shown in Fig. 1, the surface 2a of the polycrystalline β-SiC film 2 is in a rough face state where small irregularities are scattered. The surface 2a of the polycrystalline β-SiC film 2 in the rough surface state is ground so that the smoothness has surface roughness of 200 angstroms RMS or smaller, preferably 100 to 50 angstroms RMS, thereby producing a complex M. As shown in Fig. 2, the complex M has the polycrystalline β-SiC film 2 which has a clean ground surface 2a' without irregularities, and a thickness t that is uniform over the whole area. Next, as shown in Fig. 3, two thus configured complexes M are closely fixed to each other via the smooth clean ground surfaces 2a' of the polycrystalline β-SiC films 2 so that crystal orientations of the single crystal α-SiC substrates 1 of the complexes M are directed to the same direction. Thereafter, a heat treatment is performed in which the whole of the two complexes M which are closely fixed to each other as described above is held for several hours in the atmosphere of a saturated SiC vapor pressure and at a temperature in the range of 2,000°C, preferably 2,200 to 2,400°C. In accordance with the crystal growth of the single crystal α-SiC substrates 1 of the complexes M, each of the polycrystalline cubic β-SiC films 2 is recrystallized, so that, as shown in Fig. 4, the polycrystalline β-SiC films 2 are formed into single crystal portions 2' which are oriented in the same direction as the crystal orientations of the single crystal α-SiC substrates 1. The single crystal portions 2' are integrated with single crystals 1' of the substrates 1, with the result that a single crystal 5 which is large or namely thick is grown. After the heat treatment, as apparent from Fig. 4, the interface which clearly exists between the ground surfaces 2a' of the polycrystalline β-SiC films 2 before the heat treatment is fused and integrated so as to disappear. As described above, the two complexes M in each of which the surface 2a of the polycrystalline cubic β-SiC film 2 that is grown on the single crystal α-SiC substrate 1 by thermochemical decomposition is mirror-polished so that the smoothness has surface roughness of 2x10 1 nm (200 angstroms) RMS or smaller, preferably 1x10 1 to 0,5x10 1 nm (100 to 50 angstroms) RMS are heat-treated while crystal orientations of the single crystal α-SiC substrates 1 of the complexes are directed to the same direction, and the smooth ground surfaces 2a' are closely fixed to each other. Therefore, contamination which is caused by adhesion of suspended substances and the like in the vicinity to the surfaces 2a' of the polycrystalline β-SiC films 2 can be suppressed to a minimum level. Even when variation of the ambient atmosphere, for example, variation of the saturated SiC vapor pressure during the heat treatment occurs, moreover, also a phenomenon that the variation of the ambient atmosphere causes portions of surfaces 2a' of the polycrystalline β-SiC films 2 to be decomposed to disappear, or crystals depositing onto the vicinity to adhere to the surfaces 2a' of the polycrystalline β-SiC films 2 can be suppressed to a minimum level. Therefore, remainings of impurities, micropipe defects, and the like, contamination from the outside, and formation of grain boundaries in the interface of the complexes M are prevented from occurring. As a result, large-size single crystal SiC which stably has very high quality is obtained with high productivity. In the embodiment described above, as the polycrystalline films, the polycrystalline β-SiC films 2 are used. Alternatively, complexes in each of which a polycrystalline hexagonal (6H) α-SiC substrate of a high impurity (10 14 atm/cm 3 or less) is grown on the surface of the single crystal α-SiC substrate 1 may be heat-treated. In the alternative, it is possible to obtain large-size single crystal SiC with higher productivity as compared with the above-described case where the polycrystalline β-SiC films 2 are used.

Claims: A method of producing single crystal SiC, wherein two complexes are produced respectively by growing a polycrystalline film of β-SiC or α-SiC on a surface of a single crystal α-SiC substrate by thermochemical deposition, the surface of said polycrystalline films of said two complexes are ground so that smoothness has surface roughness of 2x10 1 nm (200 angstroms) RMS or smaller, said two complexes are piled via surface of said polycrystalline films so that crystal orientations of said single crystal α-SiC substrates of said complexes are directed to the same direction and where said smooth surfaces are closely fixed to each other, said two piled complexes are then heat-treated at a high temperature in a range of 2000°C, preferably 2200 to 2400°C, whereby said polycrystalline films of said complexes are recrystallized to grow a single crystal which is integrated with said single crystal α-SiC substrates of said complexes. A method of producing single crystal SiC according to claim 1, wherein the surfaces of said polycrystalline films of said two complexes are ground so that smoothness has surface roughness of 1x10 1 to 0,5x10 1 nm (100 to 50 angstroms) RMS or smaller. A method of producing single crystal SiC according to claims 1 or 2, wherein said heat treatment is performed at an atmosphere of a saturated SiC vapor pressure or the vicinity.

Inventors: HIRAMOTO MASANOBU, TANINO KICHIYA, HIRAMOTO, MASANOBU, TANINO, KICHIYA, Hiramoto, Masanobu c/o Nippon Pillar Pack.Co.,Ltd., Tanino, Kichiya c/o Nippon Pillar Packing Co.,Ltd.
Applicants: NISSIN ELECTRIC CO LTD, NISSIN ELECTRIC CO., LTD.
Application year: 1998
Main classification: C30B29
IPC codes: C30B33, C30B25, C30B29, C30B1