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Patent US8222650 - Nitride semiconductor heterostructures and related methods - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsSemiconductor structures and devices based thereon include an aluminum nitride single-crystal substrate and at least one layer epitaxially grown thereover. The epitaxial layer may comprise at least one of AlN, GaN, InN, or any binary or tertiary alloy combination thereof, and have an average dislocation...http://www.google.com/patents/US8222650?utm_source=gb-gplus-sharePatent US8222650 - Nitride semiconductor heterostructures and related methodsAdvanced Patent SearchPublication numberUS8222650 B2Publication typeGrantApplication numberUS 12/617,150Publication dateJul 17, 2012Filing dateNov 12, 2009Priority dateDec 24, 2001Also published asUS7638346, US20090283028, US20100135349, WO2008042020A2, WO2008042020A3Publication number12617150, 617150, US 8222650 B2, US 8222650B2, US-B2-8222650, US8222650 B2, US8222650B2InventorsLeo J. Schowalter, Joseph A. Smart, Shiwen Liu, Kenneth E. Morgan, Robert T. Bondokov, Timothy J. Bettles, Glen A. SlackOriginal AssigneeCrystal Is, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (99), Non-Patent Citations (220), Referenced by (2), Classifications (16), Legal Events (1) External Links: USPTO, USPTO Assignment, EspacenetNitride semiconductor heterostructures and related methodsUS 8222650 B2Abstract Semiconductor structures and devices based thereon include an aluminum nitride single-crystal substrate and at least one layer epitaxially grown thereover. The epitaxial layer may comprise at least one of AlN, GaN, InN, or any binary or tertiary alloy combination thereof, and have an average dislocation density within the semiconductor heterostructure is less than about 106 cm−2.
RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 11/503,660, filed Aug. 14, 2006 now U.S. Pat. No. 7,638,346, which is a continuation-in-part of U.S. patent application Ser. No. 11/431,090, filed May 9, 2006, which is a continuation-in-part of U.S. patent application Ser. No. 10/910,162, filed Aug. 3, 2004 now abandoned, which is itself a continuation-in-part of U.S. patent application Ser. No. 10/324,998, filed Dec. 20, 2002, issued as U.S. Pat. No. 6,770,135 on Aug. 3, 2004, which claims the benefit of and priority to U.S. Provisional Application Ser. No. 60/344,672, filed Dec. 24, 2001. The entire disclosures of each of these applications are incorporated herein by reference.
ⅆ [ N ] ⅆ t = 2 γβ N 2 P N 2 - C N [ N ] 2 - B ( [ Al ] - K s [ N ] ) . ( 2 ) In these equations, the first term represents the addition of molecules from the vapor. It is assumed that all of the Al atoms stick but only a fraction y of the N2 molecules condense on the surface. The term βi represents the modified Hertz-Knudsen factor which is proportional to the square root of mass of the ith species (where i represents either Al or N2) divided by the temperature. The condensation coefficient in this model is not subscripted since we assume that it only applies to the N2 molecules.
( E L 2 P N 2 4 β Al 2 P s 3 - F AlN ) � ( β Al P Al - F AlN ) 2 = E L 3 . ( 4 ) Significantly, the only parameters appearing in this cubic equation are the Langmuir evaporation rate EL and the stoichiometric nitrogen pressure P. It is rather remarkable that, in the limit of very large B, of the five free parameters that appear in Eqs. (1) and (2), only two parameters are needed in Eq. (4) to determine the net flux at any nitrogen and aluminum partial pressure. Both of these parameters have been determined experimentally although there is substantial uncertainty in the Langmuir-evaporation rate as pointed out earlier.
Turning now to FIG. 2, the apparatus of the present invention, for example, a furnace, includes a heating source 6, such as a radio-frequency (�RF�) coil for inducing an electro-magnetic field within a growth chamber 2. This electro-magnetic field couples with a metallic susceptor, for example a push tube 3 located concentrically inside the coil and provokes heat generation thereon by the Joule effect. Although in a particular embodiment, susceptor/tube 3 is cylindrical, i.e., has a circular axial cross-section, as used herein, the terms �tube� or �tubular� also include tubes of non-circular axial cross-section. The relative position and dimension of the push tube with respect to the shielding elements and coil creates a thermal gradient along the walls of the susceptor 3, i.e., in the axial direction. A crucible 9 is movably disposed concentrically within tube 3, and includes the high-purity source material 11 at a proximal end thereof, e.g. polycrystalline AlN, and eventually, the growing AlN crystal 7 at the distal end (e.g., at tip 19) thereof.
Furthermore, by slicing or cutting the bulk AlN crystals of the present invention, crystalline AlN substrates of desired thickness�for example, about 500 μm or 350 μm�can be produced. These substrates can then be prepared, typically by polishing, for high-quality epitaxial growth of appropriate layers of AlN, GaN, InN and/or their binary and tertiary alloys to form UV LDs and high-efficiency UV LEDs. The aforementioned nitride layers can be described by the chemical formula AlXGayIn1-x-yN, where 0≦x≦1 and 0≦y≦1−x.
Example�260 nm Laser Diode Fabrication
FIG. 6 is a schematic cross-sectional view of a portion of a 260-nm laser diode fabricated using the method of the present invention. Initially, low defect density AlN substrate 40, which is prepared using the method discussed above, is polished by CMP. The polished substrate is then introduced into a conventional OMVPE system. The surface of the low defect density AlN substrate is cleaned to remove any oxide or other impurities on the crystal surface by heating the substrate at a temperature of 1150� C. for 20 min under ammonia plus nitrogen or hydrogen plus nitrogen flow prior to growth. An epitaxial layer 42 of AlN having a thickness of about 100 nm is then grown on the substrate to improve its surface quality before starting to grow the device layers. Next, an undoped AlXGa1-xN buffer layer 44 having a thickness of approximately 1 μm is grown atop the epitaxial AlN layer to relieve lattice mismatch through the formation of misfit dislocations. Formation of threading dislocations, which will continue to propagate through the device layers, is minimized by grading x from 1 to the final value of 0.5 (i.e. to 50% Al concentration). Onto the buffer layer, a 1-μm thick layer 46 of Si-doped AlXGa1-xN (x=0.5) is then grown to provide the n-type contact to the LD. A 50-nm thick layer 48 of Si-doped AlXGa1-xN (x=0.6) is then grown onto the Si-doped AlXGa1-xN (x=0.5) layer 46, followed by the growth of a 10-nm thick layer 50 of undoped AlXGa1-xN (x=0.5). Then, a 50-nm thick layer 52 of Mg-doped AlXGa1-xN (x=0.6) is grown onto the layer 50 followed by the growth of a 1-μm thick layer 54 of Mg-doped AlXGa1-xN (x=0.5). After the growth steps, the substrate 40 (now having epitaxial layers 42, 44, 46, 48, 50, 52 and 54 thereon) is slowly ramped down from the growth temperature of about 1100� C. and removed from the OMVPE system. In some embodiments, the top surface of epitaxial layer 54 is then coated with a metal contact layer 56 for the p-type semiconductor, and metal layer is coated with a photoresist (not shown), which is then developed. The photoresist is removed where the n-type metal contact 58 will be formed. The substrate, along with the epitaxial layers and the metal layer thereon, are then etched such that the semiconductor is removed down to the n-type layer 46, which will be used for the n-type metal contact 58. A second coating of photoresist (for lift off) (not shown) is deposited, which is then patterned and removed where the n-type contacts are desired. The n-type metallization is now complete, and the metal coating adjacent the second photoresist layer is removed to produce the desired wafer. Laser facets are achieved by cleaving the wafer. These facets may optionally be coated to protect them from damage. Wire bonding contacts (not shown) are made to the p-type and n-type metal layers and the laser diode is packaged appropriately. In other embodiments, the mesa etching and n-contact fabrication precedes p-type contact metallization due to the higher annealing temperature for the n-type contact (�900� C.) compared to the p-contact anneal at �600� C.
Referring to FIGS. 7-8, in some embodiments, an apparatus 70 for self-seeded growth of single-crystal AlN boules includes a crucible 72 having a conical crucible portion 74, such as the one disclosed in U.S. Pat. No. 6,719,842 (�the '842 patent�), incorporated herein by reference, consisting essentially of tungsten and fabricated by a CVD process. Multiple grain layers within the wall of the conical portion can be obtained by interrupting the tungsten deposition several times before the final wall thickness was obtained. Other crucible materials can be used such as tungsten-rhenium (W�Re) alloys; rhenium (Re); tantalum monocarbide (TaC); a mixture of Ta2C and TaC; a mixture of Ta2C, TaC and Ta; tantalum nitride (Ta2N); a mixture of Ta and Ta2N; hafnium nitride (HfN); a mixture of Hf and HfN; a mixture of tungsten and tantalum (W�Ta); tungsten (W); and combinations thereof. In certain versions of these embodiments, a tip 75 of the conical portion has a narrow angle, for example, about 15�. The apparatus further includes a source base crucible portion 76, having an AlN source 77, for example, consisting essentially of high-purity AlN ceramic disposed therein. In various embodiments, the source base crucible is fabricated from tungsten and is prepared from a high-density, powder metallurgy cylinder hollowed out by electric discharge machining. Thus fabricated, the base crucible portion includes a plurality of grains arranged in multiple layers within the wall of the crucible.
From simple calculations where the strain energy in the pseudomorphic layer is balanced against the extra energy involved in creating dislocations, the critical layer thickness for different lattice mismatches (which, in this case, is controlled by the percentage of GaN in the epitaxial layer) can be calculated. (See, for example, Matthews and Blakeslee in the J. Crystal Growth 27, 118 (1974), and U.S. Pat. No. 4,088,515). The AlGaN supply layers (�60% Al) can be 40 nm thick and remain pseudomorphic. At 50%, the critical thickness goes down to 30 nm. The critical thickness of pure GaN is estimated to be 12.5 nm with respect to AlN. In reality, slightly thicker pseudomorphic layers can typically be grown because the formation of strain-relieving misfit dislocations is kinetically hindered. In addition, putting one or more additional AlN epitaxial layers at the top of the device structure as a buffer may also help stabilize the pseudomorphic layers with low dislocation densities.
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Growth, (Jan. 25, 2006) vol. 287, No. 2, pp. 372-375.Referenced byCiting PatentFiling datePublication dateApplicantTitleUS8742440 *Feb 17, 2011Jun 3, 2014Sharp Kabushiki KaishaNitride semiconductor light-emitting element and method for producing sameUS20120319080 *Feb 17, 2011Dec 20, 2012Mayuko FudetaNitride semiconductor light-emitting element and method for producing same* Cited by examinerClassifications U.S. Classification257/79, 257/E33.008International ClassificationH01L27/15Cooperative ClassificationH01S5/32341, H01L21/02458, H01L21/0254, H01L21/02389, H01L33/0075, H01L21/0251, H01S2301/173, H01S2304/04European ClassificationH01L21/02K4C1B1, H01L21/02K4B1B1, H01L21/02K4B5L7, H01L21/02K4A1B1, H01L33/00G3CLegal EventsDateCodeEventDescriptionDec 10, 2009ASAssignmentFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SCHOWALTER, LEO J.;SMART, JOSEPH A.;LIU, SHIWEN AND OTHERS;SIGNED BETWEEN 20060918 AND 20060920;REEL/FRAME:23636/326Owner name: CRYSTAL IS, INC.,NEW YORKFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SCHOWALTER, LEO J.;SMART, JOSEPH A.;LIU, SHIWEN;AND OTHERS;SIGNING DATES FROM 20060918 TO 20060920;REEL/FRAME:023636/0326Owner name: CRYSTAL IS, INC., NEW YORKRotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google