Source: http://www.google.com.tw/patents/US7645337
Timestamp: 2013-05-22 20:36:57
Document Index: 84069146

Matched Legal Cases: ['Application No. 60', 'art 1', 'art 1', 'in Fine', 'art1', 'art1']

�M�Q US7645337 - Systems and methods for creating crystallographic-orientation controlled ... - Google �M�Q�j�M �Ϥ� �a�� Play YouTube �s�D Gmail ���ݵw�� ��h »�i���M�Q�j�M | �������� | �n�J�i���M�Q�j�M�M�QIn accordance with one aspect, the present invention provides a method for providing polycrystalline films having a controlled microstructure as well as a crystallographic texture. The methods provide elongated grains or single-crystal islands of a specified crystallographic orientation. In particular,...http://www.google.com.tw/patents/US7645337?utm_source=gb-gplus-share�M�Q US7645337 - Systems and methods for creating crystallographic-orientation controlled poly-silicon films���}��US7645337 B2�X���������v�ӽЮѽs��10/994,205�o�G���2010�~1��12���ӽФ��2004�~11��18�� �u���v���2004�~11��18����L���}�M�Q��US20060102901US20090309104�o��HJames S. ImPaul Christian van der Wilt��M�Q�v�HThe Trustees Of Columbia University In The City Of New YorkTrustees Of Columbia University In The City Of New York, The ���M�Q������117/43117/46117/44117/37438/482117/45438/487117/904438/486��ڱM�Q������C30B13/00H01L21/20 �X�@����H01L21/2026H01L29/04C30B13/22H01L27/1285C30B29/605H01L27/1296 �ڬw������H01L21/20D2C30B29/60DC30B13/22�ѦҤ��m�M�Q�ޥ� (118)�D�M�Q�ޥ� (94)�Q�H�U�M�Q�ޥ� (3)�~���s�����M�Q�ӼЧ� ���M�Q�ӼЧ��M�Q����T�� �ڬw�M�Q��Systems and methods for creating crystallographic-orientation controlled poly-silicon filmsUS 7645337 B2�K�n In accordance with one aspect, the present invention provides a method for providing polycrystalline films having a controlled microstructure as well as a crystallographic texture. The methods provide elongated grains or single-crystal islands of a specified crystallographic orientation. In particular, a method of processing a film on a substrate includes generating a textured film having crystal grains oriented predominantly in one preferred crystallographic orientation; and then generating a microstructure using sequential lateral solidification crystallization that provides a location-controlled growth of the grains orientated in the preferred crystallographic orientation.
19. The method of claim 1, wherein laser-induced lateral crystallization is performed for a short distance such that no defects are formed in the microstructure or only defects are formed that do not alter said crystallographic orientation. ����
FIGS. 3A-3F illustrate the SLS process schematically. In an SLS process, an initially amorphous or polycrystalline film (for example, a continuous wave (CW)�Xprocessed Si film, an as-deposited film, or solid phase crystallized film) is irradiated by a very narrow laser beamlet. The beamlet is formed, for example, by passing a laser beam pulse through a slotted mask, which is projected onto the surface of the silicon film. The beamlet melts the amorphous silicon and, upon cooling, the amorphous silicon film recrystallizes to form one or more crystals. The crystals grow primarily inward from edges of the irradiated area toward the center. After an initial beamlet has crystallized a portion of the film, a second beamlet irradiates the film at a location less than the ��lateral growth length�� from the previous beamlet. In the newly irradiated film location, crystal grains grow laterally from the crystal seeds of the polycrystalline material formed in the previous step. As a result of this lateral growth, the crystals are of high quality along the direction of the advancing beamlet. The elongated crystal grains are generally perpendicular to the length of the narrow beamlet and are separated by grain boundaries that run approximately parallel to the long grain axes.
The process of sequential lateral solidification (SLS) generally includes generating a plurality of laser beam pulses; directing the plurality of laser beam pulses through a mask to generate a plurality of patterned laser beams; irradiating a portion of a selected region of a film with one of the plurality of patterned beams, the beam having an intensity that is sufficient to melt throughout its entire thickness the irradiated portion of the film, wherein the irradiated portion of the film laterally crystallizes upon cooling. The process includes repositioning the film to irradiate a subsequent portion of the selected region with patterned beams, such that the subsequent position overlaps with the previously irradiated portion permitting the further lateral growth of the crystal grains. In one embodiment, successive portions of the selected region are irradiated such that the film is substantially completely crystallized in a single traversal of the patterned beams over the selected region of the film. By ��completely crystallized�� it is meant that the selected region of the film possesses the desired microstructure and crystal orientation, so that no further laser scanning of the region is required. The mask includes a dot-patterned mask and has opaque array patterns which include at least one of dot-shaped areas, hexagonal-shaped areas and rectangular shaped areas.
At its most basic, hybrid SLS is a two-step process as illustrated in FIG. 4. In the first step 42, a textured precursor is produced or provided. A textured film contains grains having predominantly the same crystallographic orientation in at least a single direction; however, they are randomly located on the surface and are of no particular size (microstructure). More specifically, if one crystallographic axis of most crystallites in a thin polycrystalline film points preferentially in a given direction, we refer to the microstructure as having a one-axial texture. For the embodiments described herein, the preferential direction of the one-axial texture is a direction normal to the surface of the crystallites. Thus, ��texture�� refers to a one-axial surface texture of the grains as used herein. The degree of texture can vary depending upon the particular application. For example, a higher degree of texture is preferable for a thin film transistor (TFT) being used for a driver circuit as opposed to a TFT that is used for a switch circuit.
In the second step 44 of the hybrid SLS process, SLS is performed. The lateral crystallization results in ��location-controlled growth�� of grain boundaries and elongated crystals of a desired crystallographic orientation. Location-controlled growth referred to herein is defined as the controlled location of grains and grain boundaries using particular beam patterns and masks such as, for example, dot-patterned masks.
As described briefly herein before, sequential lateral solidification (��SLS��) is a crystallization process that provides elongated grains or single-crystal islands of a crystallized material in predefined locations on a film. However, SLS is not able to fully define the crystallographic orientation of those grains. In an SLS process growth begins with existing grains as it is epitaxial growth and, thus, the process cannot provide for growth in a preferred orientation. Epitaxial growth is referred to as the growth of the crystals of one material on the crystal face of another material, such that the crystalline grains of both materials have the same structural orientation. Sequential lateral solidification produces large grained structures through small-scale translation of a thin film between sequential pulses emitted by a pulsed laser. As the film absorbs the energy of each pulse, a small area of the film melts completely and recrystallizes laterally from the solidus/melt interface to form a crystalline region. By ��lateral crystal growth�� or ��lateral crystallization,�� as those terms are used herein, it is meant a growth technique in which a region of a film is melted to the film/surface interface and in which recrystallization occurs in a crystallization front moving laterally across the substrate surface.
Seed Selection through Ion Channeling (SSIC) can be used to provide (110) texture in crystalline films. Non-textured (or mildly (110)-textured) as-deposited poly-silicon (Si) films can be converted into strongly (110) textured films by silicon ��self implantation�� at a specific dose close to the complete amorphization threshold followed by solid-phase crystallization. Due to the effect of ion channeling along the <110> directions in Si grains, only those grains that have this direction parallel to the direction of the implantation survive. When the implantation is perpendicular to the surface of the Si film, this means that <110> surface oriented grains survive. During the subsequent recrystallization, a large-grain <110> oriented poly-Si film is obtained.
Surface-Energy-Driven Grain Growth (SEDGG) can be used to generate (111) texture in crystalline film. SEDGG is a particular secondary grain growth mechanism and is commonly also called surface-energy-driven secondary grain growth (SEDSGG). Primary, or normal, grain growth is observed upon heating (>1000�X C.) of a material and is driven by a reduction of the grain boundary area. In the case of thin films, this process is halted when the grain diameter reaches values comparable to the film thickness. Beyond that point, secondary, or abnormal, grain growth can occur. This process is driven by free energy anisotropies at the surface and the interface of the secondary grains. Since the magnitude of the surface free energy is almost certainly larger than that of the Si�XSiO2 interface free energy, it is expected that minimization thereof dominates the process. The energy of a free surface of Si is minimized with (111) texture and indeed it is observed that secondary grains are predominantly <111>.
Metal-Induced Lateral Crystallization (MILC) can be used to provide crystalline films having (110) texture. In metal-induced crystallization, metal, the most popular being nickel (Ni), is brought in contact with the Si film and subsequent heating causes the film to crystallize rapidly. When the Ni�XSi contacting is done only locally (for example, by having a windowed buffer layer between the Si and metal films), a laterally crystallized poly-Si film is obtained with a lower Ni residue and with a high degree of (110) texture.
In this process, NiSi2 precipitates are formed by Ni diffusion through the Si film. NiSi2 has a cubic lattice and the lattice mismatch with c-Si is only 0.4%. Due to this small mismatch, a few nm of c-Si will grow after which the Ni migrates/diffuses to its surface and the process is repeated. As the process continues, long needle-like crystals are formed and high degree of crystallization can be reached if some additional solid-phase crystallization is allowed to happen sideways from these needle-like crystals. Growth on the NiSi2 precipitates occurs on a single {111} plane only and as such it is one dimensional. Occasionally, however, a different {111} plane is chosen and the needle-like crystal makes a 109�X or 71�X turn. This process can be sustained when the needles remain in the plane of the film (i.e., they do not hit surface of interface) and this can be achieved when the surface orientation of the grains is <110>.
Partial Melting ZMR can be used to provide crystalline films having (100) texture. Zone-melting recrystallization (ZMR) of Si films results in the formation of large grained polycrystalline Si films having a preferential <100> surface orientation of the crystals. An embodiment of the present invention uses these orientated polycrystalline films as a precursor for crystallization using SLS. The embodiment includes the use of oriented seed grains to promote the formation of large directionally grown oriented crystals. Thus, ZMR of polycrystalline films is used to obtain (100) textured large-grain poly-Si films. Growth of long (100) textured grains starts on grains formed in the ��transition region�� between the unmelted and the completely melted areas of the film. This is the regime of partial melting (i.e., coexistence of solid and liquid), which only exists in radiatively heated Si films as a result of a significant increase in reflectivity of Si upon melting (a semiconductor-metal transition). In this partial melting regime, <100> grains have been observed to dominate, a phenomenon that is linked to a crystallographic anisotropy in the SiO2�XSi interfacial energy.
The above results have typically been obtained at scanning velocities of a few mm/s to less than 1 mm/s. For higher velocities (i.e., for ��rapid-ZMR��), (100) textured growth is no longer stable and a random orientation is obtained. It is observed that the crystallographic orientation of laterally growing grains ��rolls off�� into random orientations. The ��transition region��, however, exhibits a strong (100) texture, even though the degree decreases with increasing velocity. One way to maximize the degree of texture in partial melting rapid-ZMR is to create a precursor with a maximized number of seeds for <100> growth. One way to do so includes depositing a (100)-textured poly-Si films. It may also work to precrystallize the Si film into very small-grain material that, provided orientation is random, ensures a high density of texture (100) grains, for example, through complete-melting crystallization (CMC) to create nucleated grains.
Zone melt irradiation using a continuous laser produces silicon films having <100> orientation as described by M. W. Geis et. al., ��Zone-Melting recrystallization of Si films with a moveable-strip-heater oven��, J. Electro-Chem. Soc. 129, 2812 (1982), the entire teachings of which are incorporated hereby by reference. FIG. 9A illustrates an image of a crystallized film of the (100) textured precursor after partial melting using rapid ZMR using a CW-laser as described herein before. (100) textured are preferred for electronics as it leads to a maximum quality Si/SiO2 interface in terms of the number of interface states.
SLS can be used to generate crystalline films having (110) texture. The hybrid SLS process in certain embodiments can use an SLS process in the first step of generating a textured precursor. The SLS process used in the first step is a texture inducing SLS process. Analysis of directional poly-Si obtained through excimer-laser based SLS (see FIG. 5A) show that depending on the details of the process (film thickness, step size, pulse duration), either (100) or (110) texture is obtained in the direction of the scan. For the surface orientation of the grains, this results in a limitation to a certain range of orientations compatible with these in-plane orientations (for example, (111) surface texture is physically impossible when there is a (100) in-plane texture). The in-plane texture gets developed rather rapidly, as observed from the mild texture for 2-shot SLS. Due to ��roll-off�� of the orientation, however, it may not get much stronger when grains are extended, even for long-scan directional SLS.
One method to obtain a particular (100) texture includes a particular SLS process to create a certain in-plane texture twice, perpendicular with respect to each other. The details of this process are described in U.S. Patent Application No. 60/503,419, J. S. Im, entitled ��Method and system for producing crystalline thin films with a uniform crystalline orientation,�� the entire teachings of which are incorporated herein by reference. This can lead to formation of surface oriented material: if the orientation is controlled in both x and y directions, the orientation in the z direction per definition is controlled as well.
SLS can be used to generate crystalline films having (111) texture. Analysis of SLS using a pulsed solid-state laser (frequency-doubled Nd:YVO4), are described by M. Nerding et. al., in, ��Tailoring texture in laser crystallization of silicon thin-films on glass,�� Solid State Phenom. 93, 173 (2003), the entire contents of which are incorporated herein by reference. Although fundamentally the same process as with an excimer laser, there are some differences that can influence the orientation of the grains. The most prominent of these is the wavelength (532 nm), but it is possible that the spatial profile (Gaussian) and the pulse duration (20 ns) also play a role in the process. When SiNx buffer layers are used, however, a strong (111) surface orientation is obtained for a film thickness of at least approximately 150 nm.
Proper epitaxy, however, requires both high-quality (i.e., defect free) as well as a uniformly oriented material. High quality can be achieved with the sequential lateral solidification (SLS) method, most importantly, with processes that can be used to create location-controlled single-crystal islands. In particular, the embodiments described herein of the hybrid SLS process are useful in the thin film transistor (TFT) industry as they leverage epitaxial growth, provide for TFT uniformity though anisotropy of performance level both through mobility and through interfacial defect density and TFT uniformity through quality of the material. Details of the effects of uniformity of TFTs, being field effect devices, are described by T. Sato, Y. Takeishi, H. Hara and Y. Okamoto, ��Mobility anisotropy of electrons in inversion layers on oxidized silicon surfaces,�� in Physical Review B (Solid State) 4, 1950 (1971) and by M. H. White and J. R. Cricchi, ��Characterization of thin-oxide MNOS memory transistors,�� in IEEE Trans. Electron Devices ED-19, 1280 (1972), the entire teachings of both are incorporated herein by reference.
The experimental conditions for the embodiment [(111) texture, SLS (150 nm Si)] include scanning a 500��500 �gm2 with a 4 �gm between-pulse translation leading to 125 pulses per unit area, performed with the SLS system described with respect to FIG. 5A. A commercially available ELA system can be used in an alternate embodiment and fewer pulses per unit area may be sufficient to reach the desired degree of texture. For the second step of SLS processing, a 4-shot dot�XSLS system using ˜1.8 �gm large shadow regions placed in an 8 �gm square grid is used.
FIGS. 8A and 8B illustrate an image of a crystallized film for mapping of the crystallographic orientation resulting from the hybrid SLS process for <100> islands after creation of the textured precursor (FIG. 8A) using the aforementioned ELA process, and after the SLS process (FIG. 8B), respectively, in accordance with an embodiment of the invention. Data for the images in FIGS. 8A and 8B are collected using the electron back scatter diffraction method for mapping of the crystallographic orientation. FIG. 8A shows a map and its corresponding inverse pole figure (IPF) (FIG. 8A-1) of a film after step one of the process carried out using the multiple-pulse ELA at an energy density slightly higher than that commonly used in manufacturing of TFTs. FIG. 8B and its corresponding IPF (FIG. 8B-1) shows the image after performance of the dot-SLS process. The experimental conditions for this embodiment include the use of a frequency-doubled (532 nm) Nd: YV04 continuous wave laser shaped in a thin beam (100s �gm long, ˜10 or tens of �gm wide) scanned at 1 cm/s. FIG. 8B uses a 3.3 cm/s scan followed by 4-shot dot-SLS process using the system described in FIG. 5A.
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