Patent ID: 12261134

DETAILED DESCRIPTION

Integrated circuit components can be formed using gallium nitride (GaN) as a semiconductor material. For example, transistors, such as high electron mobility transistors (HEMTs), can be produced using GaN. HEMTs include a GaN layer coupled with another layer having a different bandgap and polarization field from the GaN layer. To illustrate, a GaN layer can be coupled with an AlGaN layer. An interface can be formed between the GaN layer and the AlGaN layer that has a relatively high electron mobility. The interface can be a two-dimensional electron gas (2DEG). When a voltage is applied to a portion of the AlGaN layer, movement of electrons can take place within the 2DEG.

GaN-based transistors can be used in power circuitry, such as high-power integrated circuits and power conversion integrated circuits. GaN-based transistors can also be used in monolithic microwave integrated circuits (MMICs). MMICs can include electronic components that operate at frequencies within the microwave range of electromagnetic radiation. For example, MMICs can include electronic components that operate at frequencies from about 300 megahertz (MHz) to about 300 gigahertz (GHz).

Typically, circuitry that includes GaN-based electronic components utilize gold (Au)-based materials to form the electrical contacts for the gate, source, and drain of GaN-based transistors. Additionally, Au-based materials are used in conventional processes to form connectors, interconnect devices, capacitor plates, and through substrate vias for integrated circuits that include GaN-based semiconductor devices. However, there are some drawbacks to the use of Au in the manufacturing of GaN-based semiconductors. For example, integrated circuits that include GaN-based semiconductors made from Au require processing equipment that is different from processing equipment used to make integrated circuits that include silicon-(Si) based semiconductor devices. That is, some of the processes used to make integrated circuits including Si-based semiconductor devices are different from the processes used to make integrated circuits including GaN-based semiconductor devices with components that include Au. Au can also cause defects in Si-based semiconductor devices. Thus, Au is typically not used in the manufacturing of front-end devices and interconnect devices that utilize Si-based production processes and any Au-based processing that does take place in relation to manufacturing Si-based semiconductor devices is performed in isolation from Si-based semiconductor device manufacturing processes. Accordingly, the use of Au to make GaN-based semiconductor devices causes the manufacturing of GaN-based semiconductor devices to be costly and inefficient relative to Si-based manufacturing processes.

Further, manufacturing GaN-based semiconductor devices using Au can limit the electronic components produced on a given wafer. To illustrate, GaN-based semiconductor devices produced using Au can be limited in the dimensions and characteristics of electronic components produced on a wafer, such as limited gate dimensions. Consequently, electronic components having different functionality are unable to be produced on an individual wafer in conventional GaN-based semiconductor devices that include Au electrical features. In one or more examples, conventional GaN-based semiconductor devices made using Au electrical features are unable to include both electrical features of transistors used in relatively high frequency applications (e.g., at least 3 gigahertz (GHz) or at least 5 GHz) and electrical features of transistors used in relatively high voltage applications (e.g., at least 30 V, at least 50 V, at least 80 V, or at least 100 V).

Implementations described herein are directed to manufacturing GaN-based semiconductor devices using Al-based materials. In example scenarios, the implementations described herein can be used to manufacture monolithic microwave integrated circuits with GaN-based semiconductor devices having electronic components that include Al-based metals. To illustrate, Al-based metals can be used to make electrical contacts for gates, sources, and drains of GaN-based transistors. Additionally, Al-based metals can be used to make connectors, interconnect devices, and capacitor plates of GaN-based semiconductor devices. The GaN-based semiconductor devices manufactured according to processes described herein can be produced without the use of Au-based metals. Thus, GaN-based semiconductor devices can be manufactured using equipment that is used to manufacture Si-based semiconductor devices and in facilities that produce Si-based semiconductor devices. In this way, the purchase of specialized equipment and/or the manufacturing of GaN-based semiconductor devices in isolation from Si-based semiconductor devices is unnecessary. Accordingly, by implementing the processes described herein, the production of GaN-based semiconductor devices can be streamlined and performed at a reduced cost in relation to the production of GaN-based semiconductor devices that include Au-based electronic components.

Further, the performance of GaN-based semiconductor devices that include Al-based electronic components can be improved with respect to GaN-based semiconductors made with Au-based electronic components. In particular, GaN-based semiconductor devices with Al-based electronic components can be manufactured using cleaning and rinsing processes that are more robust than those used in the production of Au-based electronic components. Consequently, the surfaces of the substrates to which the Al-based metals are bonded can be cleaner and have fewer contaminants. Thus, fewer defects and traps can be present in the GaN-based semiconductor devices described herein resulting in improved performance of electronic components of the GaN-based semiconductor devices. Also, implementations are described herein that reduce the gate length of transistors included in GaN-based semiconductor devices resulting in an increase of the speed of operation of the transistors included in GaN-based semiconductor devices.

FIG.1is a diagram depicting an example process100to manufacture monolithic microwave integrated circuits used in electronic devices. The process100can include providing a substrate102. The substrate102can be formed from a number of materials. For example, the substrate102can be formed from sapphire. In additional examples, the substrate102can be formed from silicon carbide (SiC). In further examples, the substrate102can be formed from Si. The substrate102can have a circular shape with a diameter from about 150 millimeters (mm) to about 300 mm. In illustrative examples, the substrate102can have a diameter from about 130 mm to about 170 mm, from about 180 mm to about 220 mm, or from about 140 mm to about 210 mm. Additionally, the substrate102can have an initial thickness from about 250 micrometers to about 800 micrometers. The thickness of the substrate102can be reduced through the process100to from about 80 mm to about 125 mm. In various examples, the substrate102can be referred to as a wafer and a number of integrated circuits can be manufactured using the substrate102. To illustrate, hundreds, up to thousands, and even up to millions of integrated circuits can be manufactured using the substrate102.

Electronic components of integrated circuits can be made in front-end device production104and back-end device production106. The front-end device production104can include the manufacturing of electronic components of integrated circuits, such as electrical contacts of transistors, capacitors, and connectors used to connect electronic components to one another. The back-end device production106can include the manufacturing of electronic components that couple the integrated circuits to packaging materials and/or printed circuit boards that can house or hold the integrated circuits. In illustrate examples, the process100can be used to make monolithic microwave integrated circuits108(MMICs) with the substrate102.

At least one of the front-end device production104or the back-end device production106can take place within a manufacturing facility that minimizes the amount of Au disposed on the substrate102. In one or more illustrative examples, at least one of the front-end device production104or the back-end device production106can be performed such that an amount of Au on the substrate after completion of at least one of the front-end device production104or the back-end device production106is no greater than about 100×1010Au atoms per cm2of the substrate102, no greater than about 50×1010Au atoms per cm2of the substrate102, no greater than about 25×1010Au atoms per cm2of the substrate102, no greater than about 10×1010Au atoms per cm2of the substrate102, no greater than about 5×1010Au atoms per cm2of the substrate102, no greater than about 1×1010Au atoms per cm2of the substrate102, or no greater than about 0.5×1010Au atoms per cm2of the substrate102. In addition, the substrate102can be free of Au atoms after completion of at least one of the front-end device production104or the back-end device production106.

In various implementations, one or more processes of the front-end device production104can take place in an environment that minimizes an amount of Au present, such that after the one or more processes of the front-end device production104take place, the substrate102has no greater than about 100×1010Au atoms per cm2of the substrate102, no greater than about 50×1010Au atoms per cm2of the substrate102, no greater than about 25×1010Au atoms per cm2of the substrate102, no greater than about 10×1010Au atoms per cm2of the substrate102, no greater than about 5×1010Au atoms per cm2of the substrate102, no greater than about 1×1010Au atoms per cm2of the substrate102, or no greater than about 0.5×1010Au atoms per cm2of the substrate102. Additionally, after the one or more processes of the front-end device production104take place in an environment that minimizes an amount of Au present, one or more processes of the back-end device production106can take place in an environment where Au-based electrical features are formed and the amount of Au present on a surface of the substrate102can be at least 150×1010Au atoms per cm2. In further implementations, after the one or more processes of the front-end device production104take place in an environment that minimizes an amount of Au present, one or more processes of the back-end device production106can take place in an environment where copper-(Cu) based electrical features are formed and the amount of Cu present on a surface of the substrate can be at least 0.04×1010Cu atoms per cm2. In one or more examples, after the one or more processes of the front-end device production104take place in an environment that minimizes the amount of Au and Cu present, one or more processes of the back-end device production106can take place in an environment where at least one of Cu-based electrical features or Au-based electrical features are formed.

A number of layers can be disposed upon the substrate102before front-end device production104takes place. For example, the substrate102can include an AlGaN/GaN layer that can be used to form electronic components on the substrate102. In illustrative examples, an AlGaN barrier layer can be formed on a GaN channel layer. The AlGaN barrier layer can cover at least a portion of the GaN channel layer. The AlGaN barrier layer and the GaN channel layer can be used to form gate regions, source regions, and drain regions of transistors. In some scenarios, at least one or more portions of the AlGaN layer can include a dopant. An interface between the AlGaN barrier layer and the GaN channel layer can create a channel for electrons to flow between a source region and a drain region of a transistor.

In various implementations, additional layers can be disposed between the substrate102and an AlGaN/GaN layer. For example, one or more nucleation layers can be disposed between the substrate102and an AlGaN/GaN layer. The one or more nucleation layers can include at least one of GaN, AlGaN, or AlN and can be used to grow the GaN channel layer and the AlGaN barrier layer. Additionally, one or more buffer layers can be disposed between the substrate102and an AlGaN/GaN layer. The one or more buffer layers can reduce the strain between the substrate102and an AlGaN/GaN layer that can arise due to differences in physical properties of the substrates, such as lattice constant and/or coefficient of thermal expansion, of the substrate102and the AlGaN/GaN layer.

Front-end device production104can include one or more first aluminum-based processes110. The one or more first aluminum-based processes110can utilize materials that include Al to produce features of electronic components of the MMICs108. For example, the one or more first aluminum-based processes110can include depositing one or more layers of one or more Al-based metals and forming one or more patterns with the one or more layers of the one or more Al-based metals that have been deposited. The one or more patterns formed using the one or more layers of the one or more Al-based metals can correspond to various electronic components that are included in MMICs108.

To illustrate, the one or more first aluminum-based processes110can include forming a gate electrical contact on a gate region of the AlGaN barrier layer. The gate electrical contact can include a TiN/Al material. The TiN/Al material can include at least one layer of TiN and at least one layer of Al. In illustrative examples, the gate electrical contact can form a Schottky Gate. The one or more aluminum-based processes110can also include forming a source electrical contact on a source region of the AlGaN barrier layer and a drain electrical contact on a drain region of the AlGaN barrier layer. A source electrical contact and a drain electrical contact can include a Ti/Al material. The Ti/Al material can include at least one layer of Ti and at least one layer of Al.

Additionally, the one or more first aluminum-based processes110can also include forming one or more capacitors. The plates for the one or more capacitors can include an Al-based metal and a dielectric material can be disposed between the plates of the one or more capacitors. In illustrative examples, a first plate of a capacitor can be formed on the AlGaN barrier layer using an Al-based metal. Subsequently, a dielectric material can be deposited over the AlGaN barrier layer and electrical features formed on the AlGaN barrier layer, such as impedance devices, connectors, electrical contacts of transistors, and the like. The dielectric material can include SiN, in some implementations. A second plate of a capacitor can be formed on the dielectric material layer using an Al-based metal in a location that corresponds with the location of the first plate of the capacitor. In this way, the dielectric material can be disposed between the two capacitor plates. An Al-based metal can include at least about 85% by weight Al, at least about 88% by weight Al, at least about 90% by weight Al, at least about 92% by weight Al, at least about 95% by weight Al, at least about 98% by weight Al, or at least about 99% by weight Al.

One or more connectors can also be formed as part of the one or more first Al-based processes110. The one or more connectors can electrically couple electronic components of a MMIC108. For example, the one or more connectors can couple one or more impedance devices, one or more capacitors, one or more gate electrical contacts, one or more drain electrical contacts, one or more source electrical contacts, or combinations thereof to one another. The one or more connectors can include metallic strips, wires, and/or balls. Additionally, the connectors can be formed from an Al-based metal.

The one or more first Al-based processes108can utilize Al-based metals to produce one or more vias of the MMICs108. The one or more vias can go through the substrate102and one or more of the layers disposed on the substrate102. To illustrate, the one or more vias can be disposed through the substrate102and a GaN channel layer and an AlGaN barrier layer disposed on the substrate102. The one or more vias can also be disposed through additional layers located between the substrate102and the AlGaN/GaN layer, such as one or more nucleation layers and/or one or more buffer layers. An Al-based metal can be used as a masking material to pattern the locations where the one or more vias are to be located. Additionally, an Al-based metal can be used to fill the one or more vias.

Further, the one or more first Al-based processes110can also include forming one or more inductors using one or more Al-based metals. The one or more inductors can be manufactured by producing a number of layers of the one or more Al-based metals in the form of coils. The one or more inductors can be formed on a dielectric layer. In implementations, the one or more inductors can be disposed within a dielectric material or enclosed by a dielectric material.

The one or more first Al-based processes110can be implemented to form gate electrical contacts having different gate lengths on the wafer102, where the wafer102can be comprised of SiC and have a diameter from about 130 mm to about 170 mm. For example, the one or more first Al-based processes110can be used to form first electronic components on the wafer102having a first gate length and second electronic components formed on the wafer102having a second gate length that is different from the first gate length. In one or more illustrative examples, the first gate length can be from about 100 nm to about 300 nm or from about 125 nm to about 200 nm. The second gate length can be from about 400 nm to about 1500 nm or from about 500 nm to about 1000 nm. In one or more examples, the first electronic components can operate at relatively high frequencies, such as at least 3 gigahertz (GHz). The second electronic components can operate at relatively higher voltages, such as at least 50 V.

The back-end device production106can include the manufacturing of electronic components that can couple the MMICs108to electrical contacts that are outside of the MMICs108. The back-end device production106can include one or more second aluminum-based processes112. In illustrative examples, the one or more second aluminum-based processes112can include using one or more Al-based metals to form one or more interconnect devices that can couple the MMICs108to electrical contacts of packaging substrates. The one or more second aluminum-based processes112can also include using one or more Al-based metals to form one or more interconnect devices that can couple the MMICs108to electrical contacts of printed circuit boards. In various examples, the one or more interconnect devices can be produced by stacking a number of layers of one or more Al-based metals disposed on successive layers of one or more dielectric materials. The one or more interconnect devices produced as part of the one or more second aluminum-based processes112can be thicker than conventional Au-based interconnect devices.

After the front-end device production104and back-end device production106have been implemented to produce the MMICs108on the substrate102, individual MMICs108can be obtained by cutting the substrate102to separate the MMICs108formed on the substrate102. One or more MMICs can then be placed into at least one electronic device114. In various scenarios an electronic device114can utilize one or more MMICs108in the communication of information between the electronic device114and one or more additional electronic devices.

FIG.2is a diagram depicting at least a portion of a cross-section of an example monolithic microwave integrated circuit (MIMIC)200with aluminum-based electrical features. The MMIC200can include a substrate202. The substrate202can be formed from various materials on which an AlGaN/GaN layer can be disposed. For example, the substrate202can be formed from and include a sapphire-containing material. In additional examples, the substrate202can be formed from and include an SiC-containing material. Further, the substrate202can be formed from and include a silicon-containing material.

A channel layer204can be disposed on the substrate202. The channel layer204can be formed from a GaN-containing material. The channel layer204can have a thickness from about 1 micrometer to about 15 micrometers, from about 2 micrometers to about 12 micrometers, or from about 3 micrometers to about 10 micrometers. Additionally, a barrier layer206can be formed on at least a portion of the channel layer204. The barrier layer206can be formed from an AlGaN-containing material. The barrier layer206can have a thickness from about 1 nanometer to about 50 nanometers, from about 5 nanometers to about 40 nanometers, or from about 10 nanometers to about 30 nanometers.

The channel layer204and the barrier layer206can, in at least some implementations, be formed using a chemical vapor deposition technique. At least one of the channel layer204or the barrier layer206can include one or more dopants. The one or more dopants can facilitate the transfer of electrons between a source region and a drain region of the MIMIC. In various implementations, the one or more dopants can modify physical characteristics of at least one of the channel layer204or the barrier layer206to minimize an amount of stress and/or strain between at least one of the channel layer204or the barrier layer206and the substrate202.

The MMIC200can also include a gate electrical contact208that is disposed over a gate region210. The gate region210can be part of at least one of the channel layer204or the barrier layer206. The gate region210can be at least substantially free of one or more dopants. In illustrative examples, the gate electrical contact208can be formed from a TiN/Al metal material. In these scenarios, the gate electrical contact208can include one or more TiN layers and one or more Al layers.

In addition, the MMIC200can include a first ohmic contact212. The first ohmic contact212can be a source electrical contact that is disposed over a source region214. The source region214can be part of at least one of the channel layer204or the barrier layer206. Further, the MMIC200can include a second ohmic contact216. The second ohmic contact216can be a drain electrical contact that is disposed over a drain region218. The drain region218can be part of at least one of the channel layer204or the barrier layer206. The source region214and the drain region218can individually include one or more dopants, such as n-type dopants or p-type dopants, to facilitate the transfer of electrons between the source region214and the drain region218. The first ohmic contact212and the second ohmic contact216can be formed from and include a Ti/Al material. In these situations, the first ohmic contact212and the second ohmic contact216can include one or more Ti layers and one or more Al layers. In illustrative examples, the gate electrical contact208, the first ohmic contact212, the second ohmic contact216, and the regions210,214,218can be part of a high electron mobility transistor (HEMT).

The MMIC200can include a first plate220and a second plate222of a capacitor. A dielectric material224can be disposed between the first plate220and the second plate222. The first plate220and the second plate222can be formed from and include an Al-based metal. That is, a substantial amount of the first plate220and the second plate222can include Al. The dielectric material224can be disposed over the channel layer204and the barrier layer206in addition to electrical features disposed on the channel layer204and/or the barrier layer206. The dielectric material224can include a SiN material.

The MMIC200can also include a first connector226coupled to the first ohmic contact212. The first connector226can be formed from an Al-based metal and can couple the first ohmic contact212to other electronic components of the MMIC200. Additionally, the MMIC200can include an impedance device228. The impedance device228can, in illustrative examples, include a resistor. The impedance device228can be formed from and include a material containing silicon and chromium (Cr). In the illustrative example ofFIG.2, the impedance device228can be coupled to the second ohmic contact216via a second connector230. The second connector230can be formed from an Al-based metal.

The impedance device228can also be coupled to an additional metallic device232via a third connector234. The additional metallic device232can be disposed on a second dielectric material layer236. The additional metallic device232can be an interconnect device, in some implementations. The additional metallic device232can also be an inductor. The additional metallic device232can be formed from an Al-based metal. In addition, the third connector234can be formed from an Al-based metal. The second dielectric material236can be different from the first dielectric material224. For example, the second dielectric material236can include a SiO2material or a Si2N3material. In further examples, the second dielectric material236can be a same dielectric material as the first dielectric material224.

The MMIC200can include a second additional metallic device238. In the illustrative example ofFIG.2the second additional metallic device238can be coupled to the second plate222of the capacitor by a fourth connector240. The second additional metallic device238can be disposed on the second dielectric material236. Additionally, the second additional metallic device238can include an interconnect device. The second additional metallic device238can also include an inductor, in various implementations. The second additional metallic device238can be formed from an Al-based metal. Further, the fourth connector240can be formed from an Al-based metal. Although not shown in the illustrative example ofFIG.2, the first additional metallic device232and the second additional metallic device238can be at least partially disposed in another layer of dielectric material. In these situations, the additional layer of dielectric material can include a same dielectric material as the second layer of dielectric material236or the additional layer of dielectric material can be different from the second layer of dielectric material236.

The MMIC200can also include a thru via242. The thru via242can pass through the substrate202, the channel layer204, and the barrier layer206. The thru via242can be at least partially filled. For example, the thru via242can be at least partially filled with an Al-based metal. In the illustrative example ofFIG.2, the thru via242is coupled to the first ohmic contact212. The thru via242can also be coupled to a metallic layer244. The metallic layer244can be used to couple the MMIC200to one or more devices or electronic components that are outside of the MMIC200. To illustrate, the metallic layer242can be used to couple the MMIC200to an integrated circuit package and/or to a printed circuit board. The metallic layer244can be formed from an Al-based material.

FIG.3is a diagram depicting an example process300to form electrical features on a substrate302having an AlGaN/GaN semiconductor layer. The substrate302can include an Si-containing substrate, a sapphire-containing substrate, or an SiC-containing substrate. The AlGaN/GaN semiconductor layer can be comprised of a GaN channel layer304and an Al/GaN barrier layer306. Although not shown in the illustrative example ofFIG.3, additional layers can be disposed between the substrate302and the GaN channel layer304, such as one or more nucleation layers or one and/or more buffer layers. Additionally, additional layers can be disposed between the GaN channel layer304and the AlGaN barrier layer306, such as one or more spacer layers and/or one or more interlayers.

The process300can include, at operation308, forming a gate contact310using a complementary metal oxide semiconductor (CMOS) compatible metal. For example, the gate contact can be formed from and include an Al-containing metal. In illustrative examples, the gate contact310can be formed from and include a TiN/Al material, such that that the gate contact310includes one or more layers of TiN and one or more layers of Al. The gate contact310can be deposited over a gate region of the AlGaN barrier layer306. The gate contact310can be formed by placing a mask layer on the AlGaN barrier layer306and patterning the mask layer to correspond to a design of the gate contact310. The mask layer can include one or more polymeric materials, in some implementations. For example, at least one mask layer can include a photoresist. In additional examples a mask layer can include a polymeric material utilized in a RELACS process. Additionally, the mask layer can include one or more dielectric materials. To illustrate, the mask layer can include SiN.

After the mask layer has been deposited on the AlGaN barrier layer306, the mask layer can be patterned. The mask layer can be patterned using a lithographic process, in some implementations. Parts of the mask layer can be removed according to the pattern. The parts of the mask layer can be removed using one or more chemical processes. The one or more chemical processes can include one or more etching processes, in various implementations. The metallic material used to form the gate contact310can be deposited within one or more of the regions remaining after portions of the mask layer have been removed. Further, after deposition of the metallic material used to form the gate contact, portions of the deposited metallic material can be removed using one or more etching processes.

After forming the gate contact310, one or more first processing operations312can be performed. The first processing operations312can be performed in preparation for the production of additional features on the AlGaN barrier layer306and/or the GaN channel layer304. The first processing operations312can include one or more operations to remove portions of the mask layer. For example, one or more operations removing photoresist from the AlGaN barrier layer306can be performed as part of the first processing operations312. Additionally, one or more cleaning operations and/or one or more rinsing operations can also take place as part of the first processing operations312.

At operation314, source and drain contacts can be formed. A source contact316can be formed by depositing a CMOS-compatible metal over a source region of the AlGaN barrier layer306. A drain contact318can be formed by depositing a CMOS-compatible metal over a drain region of the AlGaN barrier layer306. The CMOS-compatible metal can be an Al-containing metallic material. In illustrative examples, the CMOS-compatible metal can include a Ti/Al metal. The Ti/Al metal can include one or more layers of Ti and one or more layers of Al. Before depositing the CMOS-compatible metal to form the source contact316and the drain contact318, the AlGaN barrier layer306can be recess etched.

The source contact316and the drain contact318can be formed by placing one or more mask layers on the AlGaN barrier layer306and patterning the one or more mask layers to correspond to a design of the source contact316and the drain contact318. In various implementations, a mask layer used to form the source contact316and the drain contact318can be the same mask layer used to form the gate contact308. That is, a mask layer can be deposited and patterned to include a first portion that corresponds to the gate contact310, a second portion that corresponds to the source contact316, and a third portion that corresponds to the drain contact318. The one or more mask layers used to form the source contact316and the drain contact318can also be different than the mask layer used to form the gate contact310. For example, a first mask layer can be deposited and patterned to include a region that corresponds to the gate contact308and one or more additional mask layers can be deposited and patterned to include a region that corresponds to the source contact316and a region that corresponds to the drain contact318. The one or more mask layers used to form the source contact316and the drain contact318can include one or more polymeric materials. To illustrate, the one or more mask layers used to form the source contact316and the drain contact318can include a photoresist. Additionally, the one or more mask layers used to form the source contact316and the drain contact318can include one or more dielectric materials. In illustrative examples, the one or more mask layers used to form the source contact316and the drain contact318can include SiN.

The one or more mask layers used to form the source contact316and the drain contact318can be patterned by removing portions of the one or more mask layers according to a pattern. One or more lithographic processes can be used to pattern the one or more mask layers used to form the source contact316and the drain contact318. Additionally, one or more chemical processes can be used to pattern the one or more mask layers used to form the source contact316and the drain contact318. For example, one or more etching processes can be used to pattern the one or more mask layers used to form the source contact316and the drain contact318. Parts of the mask layer can be removed according to the pattern. The parts of the mask layer can be removed using one or more chemical processes. The one or more chemical processes can include one or more etching processes, in various implementations. The metallic material used to form the source contact316and the metallic material used to form the drain contact318can be deposited within one or more of the regions of the pattern formed after portions of the mask layer have been removed. Further, after deposition of the metallic material used to form the gate contact, portions of the deposited metallic material can be removed using one or more etching processes. The deposited metallic material used to form the source contact316and the drain contact318can also undergo one or more annealing processes during the formation of the source contact316and the drain contact318.

The process by which the gate contact308, the source contact316, and the drain contact318are formed is different from the conventional processes used to form gate contacts, source contacts, and drain contacts for GaN-based transistors. For example, conventional GaN-based transistors are made using a metal lift-off procedure. In contrast, the gate contact308, the source contact316, and the drain contact318are formed by depositing a metal material on the AlGaN barrier layer306and then etching the deposited metal material. The metal material can be deposited onto the AlGaN barrier layer306using an evaporation process. Additionally, the metal material used to form the gate contact308, the source contact316, and the drain contact318can be deposited onto the AlGaN barrier layer306using a sputtering process. Further, in various implementations, one or more cleaning processes can be performed before deposition of the metallic material to form the gate contact308, the source contact316, and the drain contact318on the AlGaN barrier layer306. The one or more cleaning processes can help to prepare the surface of the AlGaN barrier layer306in a way that increases adhesion of the metallic material to the AlGaN barrier layer306. Increased adhesion of the metallic material to the AlGaN barrier layer306can improve performance of MMICs produced according to the process300with respect to conventional processes used to manufacture GaN-based semiconductor devices.

One or more second processing operations320can be performed after the source contact316and the drain contact318are formed on the AlGaN barrier layer306. The one or more second processing operations320can be performed in preparation for the production of additional features on the AlGaN barrier layer306and/or the GaN channel layer304. The one or more second processing operations320can include one or more operations to remove portions of one or more mask layers used to form the source contact316and the drain contact318. For example, one or more operations removing photoresist and/or dielectric material from the AlGaN barrier layer306can be performed as part of the one or more second processing operations320. Additionally, one or more cleaning operations and/or one or more rinsing operations can also take place as part of the one or more second processing operations320.

At operation322a first layer of Al-based features can be formed. For example, a first Al-based feature324can be formed and a second Al-based feature326can be formed. The first Al-based feature324and the second Al-based feature326can be formed from and include an Al-based metal. The Al-based metal can include at least 85% by weight Al. The first Al-based feature324and the second Al-based feature326can be formed by depositing an amount of an Al-based metal onto the AlGaN barrier layer306. The first Al-based feature324and the second Al-based feature326can be formed by depositing the Al-based metal on to the AlGaN barrier layer306according to a pattern. The pattern can be formed by one or more masking layers. The one or more masking layers can comprise a polymeric material, such as a photoresist. Additionally, the one or more masking layers can comprise a dielectric material, such as SiN. The pattern used to make the first Al-based feature324and the second Al-based feature326can be produced by removing portions of the one or more masking layers according to the pattern. Portions of the one or more masking layers can be removed to produce a pattern through one or more chemical processes, such as one or more photolithography processes. Additionally, portions of the one or more masking layers can be removed to produce a pattern through one or more etching processes.

In illustrative examples, at least one of the first Al-based feature324or the second Al-based feature326can be connectors that couple electronic components of an integrated circuit to one another. For example, the first Al-based feature324can be a connector that couples the source contact316to one or more additional electronic components of an integrated circuit. Additionally, the second Al-based feature326can be a connector that couples the drain contact318to one or more additional electronic components of an integrated circuit. Further, at least a portion of at least one of the first Al-based feature324or the second Al-based feature326can be a plate of a capacitor.

Although the illustrative example ofFIG.3shows the first Al-based feature324and the second Al-based feature326disposed on the AlGaN barrier layer306, in additional implementations, at least a first portion of the first Al-based feature324can be disposed on the AlGaN barrier layer306and a second portion of the first Al-based feature324can be disposed on another layer, such as the GaN channel layer304. Also, at least a portion of the second Al-based feature326can be disposed on the AlGaN barrier layer306and a second portion of the second Al-based feature326can be disposed on another layer, such as the GaN channel layer304.

Additional electronic components, not shown in the illustrative example ofFIG.3, can be formed on the AlGaN barrier layer306and/or the GaN channel layer304. For example, one or more impedance devices can be formed on at least one of the AlGaN barrier layer306and/or the GaN channel layer304. In illustrative examples, the one or more impedance devices can include one or more thin film resistors. The one or more thin film resistors can include a ceramic base with a metallic material disposed on the ceramic base. The metallic material can include an amount of Ni and an amount of Cr. The one or more impedance devices can be coupled to the AlGaN barrier layer306and/or the GaN channel layer304using one or more suitable techniques. In various implementations, the one or more impedance devices can be coupled to the AlGaN barrier layer306and/or the GaN channel layer304using an adhesive.

One or more third processing operations328can be performed, at operation328, after the first Al-based features are formed. The one or more third processing operations328can be performed in preparation for depositing additional layers on the AlGaN barrier layer306and/or the GaN channel layer304and/or for forming additional electronic components. The one or more third processing operations328can include one or more operations to remove portions of one or more mask layers used to form the first Al-based feature324and the second Al-based feature326. For example, one or more operations removing photoresist and/or dielectric material from the GaN channel layer304and/or from the AlGaN barrier layer306can be performed as part of the one or more third processing operations328. Additionally, one or more cleaning operations and/or one or more rinsing operations can also take place as part of the one or more third processing operations328.

At operation330, a dielectric layer332can be formed. The dielectric layer332can be formed over at least a portion of the GaN channel layer304. The dielectric layer332can also be formed over at least a portion of the AlGaN barrier layer306. Additionally, the dielectric layer332can be formed over electronic components disposed on the GaN channel layer304and/or the AlGaN barrier layer306. For example, the dielectric layer332can be disposed over at least a portion of the gate contact308, at least a portion of the source contact316, at least a portion of the drain contact318, at least a portion of the first Al-based feature324, and/or over at least a portion of the second Al-based feature326.

The dielectric layer332can be formed using one or more deposition techniques. For example, the dielectric layer332can be formed using one or more chemical vapor deposition techniques. Additionally, the dielectric layer332can be formed using one or more atomic deposition techniques. The dielectric layer332can also be patterned by using one or more chemical processes and/or one or more mechanical processes. To illustrate, the dielectric layer332can be patterned using one or more chemical mechanical polishing (CMP) techniques. The dielectric layer332can include a SiO2material. Additionally, the dielectric layer332can include a Si2N3material. Further, the dielectric layer332can include a SiN material.

Although the illustrative example ofFIG.3shows the dielectric layer332as being directly disposed over the GaN channel layer304; the AlGaN barrier layer306; the contacts308,316,318; and the Al-based features324,326, in additional implementations, one or more intermediate dielectric layers can be disposed between the dielectric layer332and one or more of the features304,306,308,316,318,324,326. In illustrative examples, an intermediate dielectric layer comprised of SiN can be disposed between the dielectric layer332and one or more of the features304,306,308,316,318,324,326.

One or more fourth processing operations334can be performed after the dielectric layer332is formed at operation330. The one or more fourth processing operations334can be performed in preparation for the formation of additional electronic components on the dielectric layer332. One or more cleaning operations and/or one or more rinsing operations can take place as part of the one or more fourth processing operations334.

Second Al-based features can be formed at operation336. The second Al-based features can include a third Al-based feature338, a fourth Al-based feature340, and a fifth Al-based feature342. The third Al-based feature338, the fourth Al-based feature340, and the fifth Al-based feature342can be formed from and include an Al-based metal. The Al-based metal can comprise at least 85% by weight Al. The third Al-based feature338, the fourth Al-based feature340, and the fifth Al-based feature342can be formed by depositing an amount of an Al-based metal onto the dielectric layer332. At least one of the third Al-based feature338, the fourth Al-based feature340, or the fifth Al-based feature342can be produced by depositing the Al-based metal according to a pattern formed by the dielectric layer332. In additional implementations, the Al-based metal can be deposited according to a pattern formed by one or more masking layers. The one or more masking layers can comprise a polymeric material, such as a photoresist. The pattern used to make at least one of the third Al-based feature338, the fourth Al-based feature340, or the fifth Al-based feature342can be produced by removing portions of the one or more masking layers according to the pattern. Portions of the one or more masking layers can be removed to produce a pattern through one or more chemical processes, such as one or more photolithography processes. Additionally, portions of the one or more masking layers can be removed to produce a pattern through one or more etching processes.

In illustrative examples, at least one of the third Al-based feature338, the fourth Al-based feature340, or the fifth Al-based feature342can be connectors that couple electronic components of an integrated circuit to one another. In addition, at least a portion of at least one of the third Al-based feature338, the fourth Al-based feature340, or the fifth Al-based feature342can be a plate of a capacitor. Further, at least a portion of at least one of the third Al-based feature338, the fourth Al-based feature340, or the fifth Al-based feature342can be an inductor. In additional examples, at least a portion of at least one of the third Al-based feature338, the fourth Al-based feature340, or the fifth Al-based feature342can comprise at least a portion of an interconnect device.

One or more fifth processing operations344can be performed after the second Al-based features are formed at operation336. The one or more fifth processing operations344can be performed in preparation for depositing additional layers on the dielectric layer332and/or for forming additional electronic components. The one or more fifth processing operations344can include one or more operations to remove portions of one or more mask layers used to form the Al-based features338,340,342. For example, one or more operations removing photoresist and/or dielectric material from the dielectric layer332can be performed as part of the one or more fifth processing operations344. Additionally, one or more cleaning operations and/or one or more rinsing operations can also take place as part of the one or more fifth processing operations344.

At operation346, an additional dielectric layer348can be formed. The additional dielectric layer348can be formed over at least a portion of the dielectric layer332. The additional dielectric layer348can also be formed over at least a portion of the third Al-based feature338, the fourth Al-based feature340, and/or the fifth Al-based feature342. The additional dielectric layer348can be formed using one or more deposition techniques. For example, the additional dielectric layer348can be formed using one or more chemical vapor deposition techniques. Additionally, the additional dielectric layer348can be formed using one or more atomic deposition techniques. The additional dielectric layer348can also be patterned by using one or more chemical processes and/or one or more mechanical processes. To illustrate, the additional dielectric layer348can be patterned using one or more chemical mechanical polishing (CMP) techniques. The additional dielectric layer348can comprise a same material as the dielectric layer332. Also, the additional dielectric layer348can comprise a different material than the dielectric layer332. The additional dielectric layer348can include a SiO2material. Further, the additional dielectric layer348can include a Si2N3material. The additional dielectric layer348can also include a SiN material.

In various implementations, additional operations can be performed to produce a GaN-based integrated circuit that includes the features disposed on the substrate302. For example, interconnect devices can be produced or portions of interconnect devices, such as the third electrical feature338and/or the fifth electrical feature342in some examples, produced according to the process300can be enlarged. Additionally, vias can be produced within the substrate302. An example process for producing through substrate vias will be described in more detail with respect toFIG.4and an example process to produce relatively thick interconnect devices will be described in more detail with respect toFIG.5.

FIG.4is a diagram of an example process400to produce through substrate vias in a substrate402having an AlGaN/GaN semiconductor layer. The substrate402can include an Si-containing substrate, a sapphire-containing substrate, or an SiC-containing substrate. The AlGaN/GaN semiconductor layer can be comprised of a GaN channel layer404and an Al/GaN barrier layer406. Although not shown in the illustrative example ofFIG.4, additional layers can be disposed between the substrate402and the GaN channel layer404, such as one or more nucleation layers and/or one or more buffer layers. Additionally, additional layers can be disposed between the GaN channel layer404and the AlGaN barrier layer406, such as one or more spacer layers and/or one or more interlayers. A gate contact408, a source contact410, and a drain contact412can be located on the AlGaN barrier layer406. The gate contact408can be formed from and include a TiN/Al metallic material. The source contact410and the drain contact412can, individually, be formed from and include a Ti/Al metallic material. The representation shown in the illustrative example ofFIG.4of the substrate402and the features disposed on the substrate402can correspond to a cross-section of at least a portion of the substrate402and at least a portion of the features disposed on the substrate402.

At operation414, an Al-based mask layer416can be deposited on the substrate402. The Al-based mask layer416can be deposited on a surface of the substrate402that is opposite and substantially parallel with respect to an additional surface of the substrate402on which the Al-based mask layer416is disposed. Before depositing the Al-based mask layer416onto the substrate402, the surface of the substrate402can be subjected to one or more cleaning operations and/or one or more rinsing operations to prepare the surface for the Al-based mask layer416. Further, although the illustrative example ofFIG.4shows a group of features disposed on the substrate402and on the AlGaN/GaN semiconductor layer, other features not shown can also be disposed on at least one of the substrate402, the GaN channel layer404, and the AlGaN barrier layer406.

The Al-based masked layer416can be deposited onto the substrate402using an evaporation process. Additionally, the Al-based masked layer416can be deposited onto the substrate402using a sputtering process. Although not shown in the illustrative example ofFIG.4, one or more additional layers can be disposed between the Al-based mask layer416and the substrate402. For example, one or more additional barrier layers can be disposed between the Al-based mask layer416and the substrate402. In illustrative examples, a barrier layer disposed between the Al-based mask layer416and the substrate402can include a dielectric material.

The Al-based mask layer416can be patterned at operation418. The patterning of the Al-based mask layer416can include etching portions of the Al-based mask layer416according to a pattern. For example, an opening420can be etched into the Al-based mask layer416. The opening420can be etched into the Al-based mask layer416by one or more reactive ion etching processes. The opening420can also be etched into the Al-based mask layer416by one or more plasma etching processes.

A through substrate via424can be produced at operation422. Producing the through substrate via424can include removing portions of the substrate402, portions of the GaN channel layer404, and portions of the AlGaN barrier layer406according to the pattern formed into the Al-based masked layer416. For example, the through substrate via424can be formed in the substrate402, the GaN channel layer404, and the AlGaN barrier layer406at a location that corresponds to the location of the opening420in the Al-based mask layer416. One or more chemical processes can be used to etch the substrate402, the GaN channel layer404, and the AlGaN barrier layer406. For example, one or more plasma etch processes can be used to produce the through substrate via424. In additional examples, the through substrate via424can be produced using one or more laser drilling operations.

After the through substrate via424has been produced, at operation426, the through substrate via424can be at least partially filled. The through substrate via424can be at least partially filled with a metallic material428. To illustrate, the metallic material428can be an Al-based metal. In the illustrative example ofFIG.4, the metallic material428included in the through substrate via424can form a connection between the source contact410and other connectors and/or electronic components coupled to an integrated circuit that includes the substrate402and the features located on the substrate402.

FIG.5is an example process500to produce Al-based interconnect devices for MMICs having an AlGaN/GaN semiconductor layer. One or more Al-based interconnect devices can be formed on a layer502. The layer502can include a substrate used to produce GaN-based semiconductor devices. For example, the layer502can include a GaN channel layer. In additional examples, the layer502can include an AlGaN barrier layer. In further examples, the layer502can include a layer of dielectric material.

A first dielectric layer504can be disposed on the layer502. The first dielectric layer504can include a SiN-containing dielectric layer. The first dielectric layer504can also include a SiO2-containing dielectric layer. Additionally, the first dielectric layer504can include a Si2N3-containing dielectric layer. The first dielectric layer504can be formed using one or more deposition techniques. For example, the first dielectric layer504can be formed using one or more chemical vapor deposition techniques. Additionally, the first dielectric layer504can be formed using one or more atomic deposition techniques. Further, one or more chemical processes and/or one or more mechanical processes can be applied to the first dielectric layer504. To illustrate, the first dielectric layer504can be patterned using one or more chemical mechanical polishing (CMP) techniques.

The first dielectric layer504can have a thickness506of at least about 1 micrometer, at least about 2 micrometers, at least about 3 micrometers, or at least about 4 micrometers. Further, the first dielectric layer506can have a thickness506no greater than about 10 micrometers, no greater than about 8 micrometers, no greater than about 6 micrometers, or no greater than about 5 micrometers. In illustrative examples, the first dielectric layer504can have a thickness506from about 1 micrometer to about 10 micrometers or from about 2 micrometers to about 5 micrometers.

The first dielectric layer504can enclose at least a portion of an electrical feature508. The electrical feature508can include a source contact, a drain contact, a gate contact, an impedance device, a capacitor plate, a connector, or one or more combinations thereof. The electrical feature508can be coupled to a connector510. At least a portion of the connector510is enclosed by the first dielectric layer504. The electrical feature508can include an amount of Al. Additionally, the connector510can include an amount of Al. In illustrative examples, the connector510can include an Al-based metal.

At operation512, an Al-based metal can be deposited onto the first dielectric layer504and a second dielectric layer516can be deposited. The Al-based metal deposited onto the first dielectric layer504can be used to form a first interconnect device portion514. The first interconnect device portion514can be formed by depositing a first amount of the Al-based metal onto the first dielectric layer504. The first amount of the Al-based metal can be deposited onto the first dielectric layer504using an evaporation process or a sputtering process. Additionally, the first amount of the Al-based metal can be deposited onto the first dielectric layer504in a location that corresponds with the location of the connector510.

The first amount of the Al-based metal deposited onto the first dielectric layer504can be patterned to form the first interconnect device portion514. The first amount of the Al-based metal can be patterned using one or more mask layers. The one or more mask layers can be deposited onto the first dielectric layer504and formed according to a pattern. The pattern of the one or more mask layers can be formed using one or more photolithography processes. The pattern of the one or more mask layers can also be formed using one or more etching processes. The pattern of the one or more mask layers can include an opening that corresponds to the shape and size of the first interconnect device portion514and the Al-based metal can be deposited into the opening. The one or more mask layers can include a polymeric material, such as a photoresist. Additionally, the one or more mask layers can include a dielectric material. In illustrative examples, the one or more mask layers can include the second dielectric layer516.

In additional implementations, the first amount of the Al-based metal can be deposited onto the first dielectric layer504and etched to conform to a shape and size of the first interconnect device portion514. The second dielectric layer516can then be deposited over the first interconnect device portion514and over the first dielectric layer504.

The second dielectric layer516can have a thickness518. The thickness518can be different from the thickness506of the first dielectric layer504. In illustrative examples, the second dielectric layer516can have a thickness518from about 2 micrometers to about 12 micrometers, from about 2.5 micrometers to about 8 micrometers, or from about 3 micrometers to about 6 micrometers. Additionally, the first interconnect device portion514can have a thickness from about 2 micrometers to about 6 micrometers.

At operation520, an opening522can be formed in the second dielectric layer516. The opening522can be formed in the second dielectric layer516using one or more etching operations. Additionally, the opening522can be formed in the second dielectric layer516using one or more chemical mechanical polishing operations.

Further, the process500can include, at operation524, depositing a second amount of the Al-based material and a third dielectric layer526. The second amount of the Al-based metal can be deposited in the opening522and on top of the second dielectric layer516to form a second interconnect device portion528. The second amount of the Al-based metal can be deposited into the opening522and onto the second dielectric layer516using an evaporation process or a sputtering process.

The second amount of the Al-based metal deposited onto the second dielectric layer516can be patterned to form the second interconnect device portion528. The opening522can define a first, lower part530of the second interconnect device portion528and a second, upper part532of the second interconnect device portion528can be formed using one or more mask layers. In implementations, the lower part530can also be referred to herein as a “connecting portion” between the first interconnect device portion514and the second interconnect device portion528. The one or more mask layers can be deposited onto the second dielectric layer516and formed according to a pattern. The pattern of the one or more mask layers can be formed using one or more photolithography processes. The pattern of the one or more mask layers can also be formed using one or more etching processes. The pattern of the one or more mask layers can include an opening that corresponds to the shape and size of the second, upper part second interconnect device portion532and the Al-based metal can be deposited into the opening. The one or more mask layers can include a polymeric material, such as photoresist. Additionally, the one or more mask layers can include a dielectric material. In illustrative examples, the one or more mask layers can include the third dielectric layer526.

In additional implementations, the second amount of the Al-based metal can be deposited onto the second dielectric layer516and etched to conform to a shape and size of the second interconnect device portion528. The third dielectric layer526can then be deposited over the second interconnect device portion528and over the second dielectric layer516. The third dielectric layer526can have a thickness534. In illustrative examples, the third dielectric layer526can have a thickness534from about 2 micrometers to about 12 micrometers, from about 2.5 micrometers to about 8 micrometers, or from about 3 micrometers to about 6 micrometers. Additionally, the second interconnect device portion528can have a thickness from about 2 micrometers to about 6 micrometers.

By implementing the process500, interconnect devices that are formed from and include Al-based metals can be produced that are different from the Au-based interconnect devices made using conventional GaN-based semiconductor processing. Additionally, the process500can be used to produce interconnect devices that are thicker than interconnect devices that are produced using Au-based metals with respect to conventional GaN-based semiconductor processing.

FIG.6is an example process600to produce a gate electrical contact for a substrate602having an AlGaN/GaN semiconductor layer using a reduced enhancement of lithography by assist of chemical shrink (RELACS) technique. The illustrative example ofFIG.6can represent a cross-section of at least a portion of a substrate602and at least a portion of an AlGaN/GaN semiconductor layer on which a RELACS technique is being performed. The AlGaN/GaN semiconductor layer can include a GaN channel layer604and an AlGaN barrier layer606. Additionally, a layer of photoresist608can be disposed on the AlGaN barrier layer606.

The process600can include operation610of patterning and forming an opening in the layer of photoresist608. A location of the opening612can be patterned using one or more photolithography operations. The opening612can be formed by removing a portion of the layer of photoresist608according to the pattern. The portion of the layer of the photoresist608corresponding to the opening612can be removed using one or more chemical etching operations. The opening612can have a length614. The length614of the opening612can be from about 175 nm to about 500 nm or from about 200 nm to about 400 nm.

At operation616, a layer of RELACS material618can be deposited into the opening612and over a remaining portion of the layer of photoresist608. The layer of RELACS material618can include a polymeric material. In addition, at operation620, the layer of RELACS material618can be cured. The RELACS material618can be cured by exposing the RELACS material618to heat. The RELACS material618can also be cured by exposing the RELACS material618to a range of wavelengths of electromagnetic radiation. Components of the RELACS material618can interact with components included in the layer of photoresist608to harden and form a cured RELACS layer622that comprises at least a portion of the RELACS material618. In illustrative examples, portions of the RELACS layer622and portions of the layer of photoresist608can undergo a crosslinking reaction to form the cured RELACS layer622.

Further, at operation624, an opening626can be formed by removing the portion of the layer of RELACS material618that is not cured. The opening626can be formed by applying one or more chemical processes to remove the portion of the layer of RELACS material618that is not cured. In addition, one or more mask layers can be used to remove the portion of the RELACS material618that is not cured. The opening626can have a length628that is less than the length614. The length628can be from about 50 nm to about 150 nm. The length628can correspond to a gate length of a gate electrical contact.

A gate electrical contact630can be formed at operation632. The gate electrical contact630can be formed by depositing a metallic material into the opening626and onto the cured RELACS layer622. The gate electrical contact630can be formed by applying one or more etching processes to the metallic material deposited into the opening626and onto the cured RELACS layer622. The gate electrical contact630can also be formed by applying one or more annealing processes to the metallic material deposited into the opening626and onto the cured RELACS layer622. In illustrative examples, the gate metallic contact630can be formed from and include a TiN/Al material having one or more layers of TiN and one or more layers of Al.

FIG.7is a flow diagram depicting operations of an example process700to produce electrical features of a monolithic microwave integrated circuit having an AlGaN/GaN semiconductor layer. The process700can include, at operation702, providing a substrate having an AlGaN/GaN semiconductor layer. For example, a GaN-based channel layer disposed on a surface of the substrate. In addition, an AlGaN-based barrier layer can be disposed on at least a portion of the GaN-based channel layer. In illustrative examples, the substrate can be trimmed from an initial thickness to a modified thickness. The initial thickness can be from about 250 micrometers to about 500 micrometers and the modified thickness can be from about 100 micrometers to about 200 micrometers. Further, the substrate can comprise a silicon-containing substrate, a silicon carbide-containing substrate, or a sapphire-containing substrate.

At operation704, electrical contacts can be formed for one or more gate regions, one or more source regions, and one or more drain regions of one or more transistors of a monolithic microwave integrated circuit. The one or more gate regions, one or more source regions, and one or more drain regions can be included in the AlGaN barrier layer. The electrical contacts can be formed by depositing one or more metal layers onto the portions of the AlGaN barrier layer that correspond to the one or more gate regions, the one or more source regions, and the one or more drain regions. The one or more metal layers can be deposited according to a pattern that corresponds with the locations of the one or more gate regions, the one or more drain regions, and the one or more source regions. The pattern can be formed using one or more mask layers. In addition, one or more photolithography processes and one or more etching processes can be used to produce one or more patterned metal layers that includes electrical contacts for the one or more gate regions, the one or more drain regions, and the one or more source regions of the one or more transistors of the monolithic microwave integrated circuit. Electrical contacts for the one or more gate regions can be formed from and include an aluminum-containing metal. For example, the one or more gate electrical contacts can be formed from and include a TiN/Al metallic material. Further, electrical contacts for the one or more drain regions and the one or more source regions can include an aluminum-containing metal. To illustrate, the one or more drain electrical contacts and the one or more source electrical contacts can be formed from and include a Ti/Al metallic material.

Additionally, aluminum-based electronic components of the monolithic microwave integrated circuit can be formed at operation706. The aluminum-based electronic components can be formed from and include metals having at least about 85% by weight aluminum, at least about 95% by weight aluminum, and higher amounts of aluminum. Forming the electronic components of the monolithic microwave integrated circuit can include, at operation708, producing one or more connectors. The one or more connectors can electrically connect electronic components included in the monolithic microwave integrated circuit. For example, the one or more connectors can couple the one or more gate electrical contacts to other electronic components of the monolithic microwave integrated circuit. The one or more connectors can also couple the one or more drain electrical contacts to additional electronic components of the monolithic microwave integrated circuit. Further, the one or more connectors can couple the one source electrical contacts to additional electronic components of the monolithic microwave integrated circuit. The one or more connectors can couple capacitors to electronic components of the monolithic microwave integrated circuit. In specific examples, the one or more connectors can couple capacitors to electrical contacts of transistors of the monolithic microwave integrated circuit. The one or more connectors can also couple impedance devices to electronic components of the monolithic microwave integrated circuit. In illustrative examples, the one or more connectors can couple impedance devices to electrical contacts of transistors of the monolithic microwave integrated circuit.

Forming the aluminum-based electronic components of the monolithic microwave integrated circuit can also include, at operation710, producing one or more interconnect devices. The one or more interconnect devices can couple the monolithic microwave integrated circuit to packaging materials and/or to printed circuit boards. In addition, the one or more interconnect devices can be coupled to additional electronic components of the monolithic microwave integrated circuit using the one or more connectors. For example, an interconnect device of the one or more interconnect devices can be coupled to a capacitor using a connector of the one or more connectors. Further, an interconnect device of the one or more interconnect devices can be coupled to an impedance device using a connector of the one or more connectors.

The one or more interconnect devices can be produced using multiple layers of dielectric material. In illustrative examples, the one or more interconnect devices can be produced by stacking aluminum-based metal regions on top of one another by patterning dielectric layers that are disposed on top of one another. For example, after one layer of a first metal region of an interconnect device is formed, a dielectric layer can be deposited over the first metal region and patterned in such a way as to be the support for an additional layer of a second metal region of the interconnect device. The dielectric layers can be formed from and include SiN, SiO2, or Si2N3.

Additionally, forming aluminum-based components of the monolithic microwave integrated circuit can include, at operation712, producing one or more inductors. The one or more inductors can be coupled to electronic components of the monolithic microwave integrated circuit using one or more connectors. The one or more inductors can be produced by depositing and patterning one or more layers of aluminum-based metals. In illustrative implementations, the one or more inductors can be produced using techniques similar to those used to produce the one or more interconnect devices. That is, the one or more inductors can be produced by stacking metal layers using dielectric layers as support for the respective metal layers.

At operation714, one or more through substrate vias can be formed. The one or more through substrate vias can include respective pathways that pass through the substrate and at least a portion of the AlGaN/GaN semiconductor layer. The one or more through substrate vias can couple electronic components of the monolithic microwave integrated circuit with an aluminum-based mask layer disposed on an underside of the substrate. The mask layer can be used to form a pattern that corresponds to respective locations of the through substrate vias. The mask layer can also couple the monolithic microwave integrated circuit to packaging materials and/or to printed circuit boards. In illustrative examples, the through substrate vias can be at least partially filled with a metallic material. For example, the through substrate vias can be at least partially filled with an aluminum-based metal.

Each of the non-limiting aspects or examples described herein may stand on its own or may be combined in various permutations or combinations with one or more of the other examples.

A numbered non-limiting list of aspects of the present subject matter is presented below.

Aspect 1. A process to form an aluminum (Al) based gallium nitride (GaN) monolithic microwave integrated circuit comprises: providing a substrate having: a barrier layer that includes an AlGaN material and includes a drain region, a source region, and a gate region; and a channel layer disposed between a surface of the substrate and the barrier layer, the channel layer including a GaN material; depositing a gate electrical contact layer on the gate region of the barrier layer, the gate electrical contact layer including a first metallic material that includes Al; forming a gate electrical contact with the first metallic material of the gate electrical contact layer; depositing a source and drain electrical contact layer on the drain region and the source region of the barrier layer, the source and drain electrical contact layer including a second metallic material that includes Al; and forming a source electrical contact and a drain electrical contact using the second metallic material of the source and drain electrical contact layer.

Aspect 2. The process of aspect 1, comprises: depositing a first amount of an Al-based metal over at least a first portion of the barrier layer; forming a first electrical feature from the first amount of the Al-based metal; depositing a second amount of the Al-based metal over at least a second portion of the barrier layer; and forming a second electrical feature from the second amount of the Al-based metal.

Aspect 3. The process of aspect 2, comprises: applying a mask layer to the first amount of the Al-based metal; forming the mask layer into a pattern; and removing a portion of the first amount of the Al-based metal according to at least a portion of the pattern to form the first electrical feature.

Aspect 4. The process of aspect 3, wherein the portion of the first amount of the Al-based metal is removed using one or more etching processes.

Aspect 5. The process of any one of aspects 1-4, wherein the substrate includes silicon carbide (SiC) and has a diameter from about 140 mm to about 210 mm.

Aspect 6. The process of aspect 5, wherein a surface of the substrate has no greater than 1×1010atoms per cm2.

Aspect 7. The process of aspect 2, comprises: depositing an amount of a dielectric material over the first electrical feature and over the second electrical feature; depositing a third amount of the Al-based metal over a portion of the dielectric material that is aligned with the first electrical feature; and forming a third electrical feature from the third amount of the Al-based metal; and wherein the first electrical feature is a first plate of a capacitor and the third electrical feature is a second plate of the capacitor with a portion of the dielectric material disposed between the first plate and the second plate.

Aspect 8. The process of aspect 7, comprises: removing a portion of the dielectric material to form a pathway to the source electrical contact, the pathway being free of the dielectric material; depositing a fourth amount of the Al-based metal over an additional portion of the dielectric material and into the pathway; and forming a connector from the fourth amount of the Al-based metal, the connector being coupled to the source electrical contact.

Aspect 9. The process of aspect 2, comprises: depositing an amount of an impedance device metal onto at least one of a portion of the barrier layer or a portion of the carrier layer; and forming an impedance device from the amount of the impedance device metal; and wherein: the second amount of the Al-based metal is deposited over at least a portion of the impedance device; and the second electrical feature is a connector between the impedance device and an additional electronic component.

Aspect 10. The process of any one of aspects 1-9, wherein the first metallic material includes at least one layer of Al and at least one layer of titanium nitride (TiN) and the second metallic material includes at least one layer of Al and at least one layer of titanium (Ti).

Aspect 11. The process of aspect 1, comprises: forming a mask layer including the Al-based metal on an additional surface of the substrate, the additional surface of the substrate being at least substantially parallel with respect to the surface of the substrate; forming the mask layer into a pattern; removing a portion of the mask layer, a portion of the substrate, a portion of the channel layer, and a portion of the barrier layer according to the pattern to form a via through the mask layer, the substrate, the channel layer, and the barrier layer; and depositing an amount of the Al-based metal to at least partially fill the via.

Aspect 12. A process to form an aluminum (Al) based gallium nitride (GaN) monolithic microwave integrated circuit comprises: providing a substrate having: a barrier layer that includes an AlGaN material and includes a drain region, a source region, and a gate region; and a channel layer disposed between a surface of the substrate and the barrier layer, the channel layer including a GaN material; forming a patterned layer of a first polymeric material onto the barrier layer, wherein the patterned layer includes a first opening in the first polymeric material, the first opening has a first length, and the first polymeric material is photosensitive; forming a layer of a second polymeric material on the patterned layer and within a portion of the first opening to form a second opening, the second opening having a second length that is less than the first length and corresponding to a shape of a gate electrical contact; depositing a gate electrical contact layer onto at least a portion of the patterned layer and within the second opening, the gate electrical contact layer including a metallic material that includes Al; and forming a gate electrical contact using the gate electrical contact layer.

Aspect 13. The process of aspect 12, wherein the substrate includes a sapphire-containing substrate, a silicon carbide-(SiC) containing substrate, or a silicon-(Si) containing substrate.

Aspect 14. The process of aspect 12 or aspect 13, wherein the first length is at least about 0.30 micrometers and the second length is from at least about 0.10 micrometers to no greater than about 0.25 micrometers.

Aspect 15. The process of any one of aspects 12-14, wherein the second polymeric material includes at least one component that reacts with the first polymeric material in response to exposure to at least one of a range of wavelengths of electromagnetic radiation or a range of temperatures.

Aspect 16. The process of any one of aspects 12-15, comprises: depositing a source and drain electrical contact layer on the drain region and the source region of the barrier layer, the source and drain electrical contact layer including an additional metallic material that includes Al; and forming a source electrical contact and a drain electrical contact using the additional metallic material of the source and drain electrical contact layer.

Aspect 17. The process of aspect 16, comprises: reducing an initial thickness of the substrate by removing an amount of the substrate to produce a modified substrate having a modified thickness; forming a layer of an Al-based metal on an additional surface of the modified substrate, the additional surface of the modified substrate being at least substantially parallel with respect to the surface of the substrate; applying a mask layer to the layer of the Al-based metal; forming the mask layer into a pattern; removing a portion of the layer of the Al-based metal, a portion of the modified substrate, a portion of the channel layer, and a portion of the barrier layer according to the pattern to form a via through the layer of the Al-based metal, the modified substrate, the channel layer, and the barrier layer; and depositing an amount of the Al-based metal to at least partially fill the via.

Aspect 18. The process of aspect 17, wherein the initial thickness of the substrate is from about 250 micrometers to about 500 micrometers and the modified thickness of the substrate is from about 100 micrometers to about 200 micrometers.

Aspect 19. A process to form an aluminum (Al) based gallium nitride (GaN) monolithic microwave integrated circuit comprises: providing a substrate having: a barrier layer that includes an AlGaN material and includes a drain region, a source region, and a gate region; and a channel layer disposed between a surface of the substrate and the barrier layer, the channel layer including a GaN material; forming a gate electrical contact on the gate region of the barrier layer using a first metallic material that includes Al; forming a source electrical contact on the source region of the barrier layer and a drain electrical contact on the drain region of the barrier layer using a second metallic material that includes Al, the second metallic material being different from the first metallic material; depositing a first dielectric material layer over the gate electrical contact, the source electrical contact, the drain electrical contact, and over at least one of exposed portions of the barrier layer or exposed portions of the channel layer; forming a pattern of first Al-based metal regions on the first dielectric material layer; depositing a second dielectric material layer over the pattern of first Al-based metal regions and over the first dielectric material layer; removing a portion of the second dielectric material layer according to a second pattern to produce a cavity that exposes a portion of a first Al-based metal region; depositing an amount of the Al-based metal into the cavity such that the amount of the Al-based metal fills the cavity to produce a connecting portion of the Al-based metal in the cavity and an excess portion of the amount of the Al-based metal overflows onto the second dielectric material layer; and forming a second Al-based metal region on the second dielectric material layer using the excess portion of the amount of the Al-based metal, the second Al-based metal region being coupled to the first Al-based metal region by the connecting portion.

Aspect 20. The process of aspect 19, wherein the first Al-based metal region, the second Al-based metal region, and the connecting portion comprise at least a portion of an interconnect device coupled to an electronic component disposed on the barrier layer or disposed on the channel layer.

Aspect 21. The process of aspect 19 or aspect 20, wherein the first Al-based metal region, the second Al-based metal region, and the connecting portion comprise at least a portion of an inductor.

Aspect 22. The process of any one of aspects 19-21, wherein: a thickness of the first Al-based metal region, the second Al-based metal region, and the connecting portion taken together is at least about 6 micrometers; and the first dielectric material layer and the second dielectric material layer comprise at least one of silicon oxide (SiO2) or disilicon trinitride (Si2N3).

Aspect 23. The process of any one of aspects 19-22, comprises depositing at least one additional dielectric material layer onto the second dielectric material layer such that the second Al-based metal region is covered by the at least one additional dielectric material layer.

Aspect 24. A device having an aluminum (Al) based gallium nitride (GaN) monolithic microwave integrated circuit comprises: a substrate having: a barrier layer disposed on the substrate, the barrier region including an AlGaN material and including a drain region, a source region, and a gate region; and a channel layer disposed between a surface of the substrate and the barrier layer, the channel layer including a GaN material; a gate electrical contact disposed on the gate region of the barrier layer, the gate electrical contact including a first metallic material that includes Al; a source electrical contact disposed on the source region of the barrier layer, the source electrical contact including a second metallic material that includes Al; and a drain electrical contact disposed on the drain region of the barrier layer, the drain electrical contact including the second metallic material that includes Al.

Aspect 25. The device of aspect 24, comprising a capacitor including a first plate, a second plate, and a dielectric material disposed between the first plate and the second plate, wherein: at least a portion of the first plate is disposed on at least one of the carrier layer or the barrier layer disposed on a portion of the barrier layer; the second plate is disposed on the dielectric material; and the first plate and the second plate include an Al-based metal.

Aspect 26. The device of aspect 24, wherein a portion of the first plate is disposed over and in contact with the source electrical contact.

Aspect 27. The device of aspect 25, wherein: the dielectric material is part of a dielectric material layer that is disposed over at least a portion of the barrier layer, at least a portion of the channel layer, and electrical features disposed on at least one of the barrier layer or the channel layer; the Al-based metal includes at least 95% Al by weight; and the dielectric material layer includes silicon dioxide (SiO2) or disilicon trinitride (Si2N3).

Aspect 28. The device of aspect 27, comprising: a connector coupled to the source electrical contact, the connector including a first portion that passes through the dielectric material layer and a second portion that is disposed on the dielectric material layer, the connector including the Al-based metal.

Aspect 29. The device of any one of aspects 24-28, comprising: an impedance device disposed on at least one of the channel layer or the barrier layer; and a connector coupled to the impedance device and the drain electrical contact, the connector including an Al-based metal.

Aspect 30. The device of any one of aspects 24-29, comprising: a via that passes through the substrate and at least one of the channel layer or the barrier layer, the via being filed at least partially with an Al-based metal and the via is coupled with an electrical feature disposed on at least one of the barrier layer or the carrier layer.

Aspect 31. The device of aspect 30, wherein the via is coupled with the source electrical contact.

Aspect 32. The device of any one of aspects 24-31, wherein the first metallic material includes at least one layer of Al and at least one layer of titanium nitride (TiN) and the second metallic material includes at least one layer of Al and at least one layer of titanium (Ti).

Aspect 33. The device of any one of aspects 24-33, wherein at least a portion of the gate electrical contact has a length from about 100 nm to about 300 nm.

Aspect 34. The device of aspect 33, wherein: the substrate includes silicon carbide (SiC); and the device includes an additional gate electrical contact disposed on an additional gate region of the barrier layer, the additional gate electrical contact including the first metallic material and at least a portion of a length of the additional gate electrical contact is from about 500 nm to about 1000 nm.

Aspect 35. The device of any one of aspects 24-34, wherein: the substrate is a sapphire-containing substrate, a silicon carbide-(SiC) containing substrate, or a silicon-(Si) containing substrate; and a thickness of the substrate is no greater than about 200 micrometers.

Aspect 36. The device of any one of aspects 24-35, wherein the surface of the substrate that the channel layer and the barrier layer are disposed over is a first surface of the substrate and the substrate includes a second surface that is at least substantially parallel to the first surface; and the device comprises an Al-based metal layer that is disposed on the second surface.

Aspect 37. A device having an aluminum (Al) based gallium nitride (GaN) monolithic microwave integrated circuit comprises: a substrate having: a barrier layer disposed on the substrate, the barrier region including an AlGaN material and including a drain region, a source region, and a gate region; and a channel layer disposed between a surface of the substrate and the barrier layer, the channel layer including a GaN material; a plurality of dielectric layers disposed over the channel layer and the barrier layer; a first portion of an interconnect device disposed within a first dielectric layer of the plurality of dielectric layers, the first portion of the interconnect device including an Al-based metal; and a second portion of an interconnect device coupled to the first portion of the interconnect device and disposed within a second dielectric layer of the plurality of dielectric layers, the second portion of the interconnect device including the Al-based metal.

Aspect 38. The device of aspect 37, comprising: a gate electrical contact disposed on the gate region of the barrier layer, the gate electrical contact including a first metallic material that includes Al; a source electrical contact disposed on the source region of the barrier layer, the source electrical contact including a second metallic material that includes Al; and a drain electrical contact disposed on the drain region of the barrier layer, the drain electrical contact including the second metallic material that includes Al.

Aspect 39. The device of aspect 38, wherein the interconnect device is coupled to the source electrical contact by a connector disposed in a third dielectric layer of the plurality of dielectric layers.

Aspect 40. The device of any one of aspects 37-39, comprising an impedance device disposed on at least one of the channel layer or the barrier layer, and wherein the interconnect device is coupled to the impedance device by a connector disposed in a third dielectric layer of the plurality of dielectric layers.

Aspect 41. The device of any one of aspects 37-40, wherein a thickness of the first portion of the interconnect device together with the second portion of the interconnect device is at least 3.5 micrometers.

Aspect 42. The device of any one of aspects 37-41, comprising: a first portion of an inductor device disposed within a dielectric layer of the plurality of dielectric layers, the first portion of the inductor device including the Al-based metal; and a second portion of the inductor device coupled to the first portion of the inductor device and disposed within an additional dielectric layer of the plurality of dielectric layers, the second portion of the inductor device including the Al-based metal.

Aspect 43. The device of any one of aspects 37-42, wherein a first part of the first portion of the interconnect device has a first length and a second part of the first portion of the interconnect device has a second length that is less than the first length, the second part of the first portion of the interconnect device being adjacent to the second portion of the interconnect device.

Aspect 44. The device of any one of aspects 37-43, comprising a via that passes through the substrate and at least one of the channel layer or the barrier layer, the via being filed at least partially with an Al-based metal and the via is coupled with an electrical feature disposed on at least one of the barrier layer or the channel layer.

Aspect 45. A process to form a gallium nitride (GaN) monolithic microwave integrated circuit comprises: providing a substrate including silicon carbide (SiC), the substrate having: a diameter from about 140 mm to about 210 mm; a barrier layer that includes an AlGaN material and includes a drain region, a source region, and a gate region; and a channel layer disposed between a surface of the substrate and the barrier layer, the channel layer including a GaN material; and producing one or more electrical features on the barrier layer in an environment such that, after production of the one or more electrical features, a surface of the substrate has no greater than about 1×1010gold (Au) atoms per cm2.

Aspect 46. The process of aspect 45, comprising: depositing a gate electrical contact layer on the gate region of the barrier layer, the gate electrical contact layer including a first metallic material; forming a gate electrical contact with the first metallic material of the gate electrical contact layer; depositing a source and drain electrical contact layer on the drain region and the source region of the barrier layer, the source and drain electrical contact layer including a second metallic material; and forming a source electrical contact and a drain electrical contact using the second metallic material of the source and drain electrical contact layer.

Aspect 47. The process of aspect 46, wherein the first metallic material includes aluminum (Al) and the second metallic material includes Al.

Aspect 48. The process of aspect 46 or aspect 47, comprising: etching a portion of the gate electrical contact layer according to a first pattern to form the gate electrical contact; and etching one or more portions of the source and drain electrical contact layer according to a second pattern to form the drain electrical contact and the source electrical contact.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These implementations are also referred to herein as “examples.” Such examples may include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments may be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments may be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.