Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
   The present document claims the benefit of U.S. Provisional Application No. 60/401,414, filed Aug. 5, 2002, the contents of which are incorporated by reference herein. 
   The present document is also related to the co-pending and commonly assigned patent application documents entitled “A Process for Fabricating Ultra-Low Contact Resistances In GaN Based Devices,” U.S. Ser. No. 60/401,415, and “GaN/AlGaN Heterostructure Field Effect Transistor with Dielectric Recessed Gate,” U.S. Ser. No. 10/214,422 which were filed on even date. The contents of these related applications are hereby incorporated by reference herein. 

   FIELD 
   The present invention relates to a new method for protecting a semiconductor device. More specifically, the present invention relates to a method for protecting the ohmic metal contacts and the channel of a device when the device is exposed to the high temperatures needed for alloying the ohmic metal contacts. 
   BACKGROUND 
   Semiconductor device fabrication that involves alloying ohmic metal contacts is a technique used for fabricating devices with low contact resistance in the ohmic metal contacts. However, temperatures in excess of 800° C. are typically necessary for alloying ohmic metal contacts for Group III-nitride material devices. However, exposure to such high temperatures creates problems within the channel of the device as well as with the ohmic metal contacts themselves. 
   Fabrication of low noise devices requires a narrow separation of the source and drain of the transistor. In gallium-nitride (GaN) technology and Group III-nitride technology, achieving a narrow separation between the source and drain becomes difficult due to the high temperature processing step of alloying the source and drain ohmic metal contacts. In general, the ohmic metal contacts have smooth edges, but when exposed to high temperatures, the edges become jagged. In addition, the high temperatures cause the edges of the ohmic metal contacts to move in an uncontrollable manner. These problems place a lower limit on the design of the source-drain separation. 
   Previously, attempts have been made at fabricating low resistance ohmic metal contacts. In one process, a substrate  5  is provided and a semiconductor layer  10  is deposited on the substrate  5 . Next, the source-drain regions are etched in the semiconductor layer  10  using chlorine plasma in a reactive ion etching system. The ohmic metal contacts  20  for the source and drain contact pads, as shown in  FIG. 1   a , are then deposited on the semiconductor layer  10 . The source-drain separation in this procedure is generally about 2 μm. Then, the ohmic metal contacts  20  are annealed for 30 seconds at 875° C. in a nitrogen ambient. This technique helps reduce the resistance of the ohmic metal contacts  20 . However, the process does not provide a method for protecting the structure of the ohmic metal contacts  20  from the high temperatures during the annealing process. After the ohmic metal contacts  20  are exposed to the high temperatures, as shown in  FIG. 1   b , the edges become jagged and the ohmic metal contacts  20  begin to migrate and creep towards one another in an uncontrollable manner. The problem with ohmic metal migration is that it places a lower limit on the design of the device. Typically, the ohmic metal contacts are deposited on the source and drain of a semiconductor device with a desired distance of about 1 micrometer between the source and drain. However, the source and drain may need to be moved further apart to account for the unpredictable migration of the ohmic metal contacts. As a result, it is not always possible to obtain a 1 micrometer separation between the source and drain. 
   Another problem associated with the high temperatures needed for alloying ohmic metal contacts is that the electron mobility in the channel of transistors is severely reduced when the channel is exposed to high temperatures. Although the physical phenomenon causing the reduction in mobility is unknown, the problem has been experimentally determined. This problem ultimately slows down the speed of the device. In “GaN/AlGaN Heterostructure Field Effect Transistor with Dielectric Recessed Gate,” U.S. Ser. No. 10/214,422 a method for forming a gate recessed into a silicon-nitride (SiN) film is taught. The purpose of this technique is to lower the parasitic resistance of the gate. Using this technique, a substrate  40  is provided and a buffer layer  50  is deposited on the substrate  40 . Then, a first and second semiconductor layer  60 ,  70  are deposited. The first and second semiconductor layers will serve as the channel of the device. The first semiconductor layer  60  is typically GaN, and the second semiconductor layer is typically AlGaN. Finally, a dielectric layer  80 , typically SiN, is deposited on the second semiconductor layer  70 . A portion of the dielectric layer  80  and second semiconductor layer  70  is removed. Next, ohmic metal contacts  90 , as shown in  FIG. 2   a , are deposited and alloyed at about 875° C. After alloying, the dielectric layer  80  is recessed and a gate  95  is deposited as shown in  FIG. 2   b . As can be seen in  FIGS. 2   a  and  2   b , the ohmic metal contacts for the source and drain are still partly exposed. During subsequent high temperature processing the ohmic metal contacts  90  may creep towards each other. Furthermore, patterning a SiN dielectric layer  80  for gate  95  deposition is extremely difficult and unpractical after the SiN dielectric layer  80  has been exposed to the high alloying temperatures. The technique used to pattern the SiN dielectric layer  80  is likely to cause damage to the second semiconductor layer  70  underneath the gate  95 , thereby degrading the performance characteristics of the channel in the semiconductor device. 
   Therefore, there is a need for a method of fabricating a semiconductor device that can protect the ohmic metal contacts from high temperatures, resulting in the migration of the ohmic metal contacts. There is also a need for a method of fabricating a semiconductor device that can protect the channel and maintain the performance characteristics of the channel in the semiconductor device when the device is exposed to high temperatures. 
   SUMMARY 
   Accordingly, one aspect of the present invention provides a method and apparatus for fabricating a semiconductor device that prevents ohmic metal in the ohmic metal contacts from migrating and protects the channel when the ohmic metal contacts are alloyed. A substrate is provided whereon a plurality of layers of semiconductor material are deposited. The plurality of layers create a channel in the semiconductor device. An encapsulation layer is deposited on the plurality of layers. The encapsulation layer is used to protect the channel when the ohmic metal contacts are alloyed. Additionally, the encapsulation layer prevents the ohmic metal in the ohmic metal contacts from migrating during high temperature processing. After depositing the encapsulation layer, a portion of the encapsulation layer is removed to create an opening, wherein a gate metal is deposited. The encapsulation layer is further patterned and a portion of the encapsulation layer and plurality of layers are removed to create an opening wherein the ohmic metal contacts are deposited. As aforementioned, the encapsulation layer will protect the ohmic metal contacts by preventing movement when they are alloyed. 
   Another aspect of the present invention provides a method and apparatus for fabricating a semiconductor device which prevents ohmic metal in the ohmic metal contacts from migrating when protecting the channel is not of concern. A substrate is provided, using this method and apparatus, whereon a plurality of layers of semiconductor material are provided. A portion of the plurality of layers is removed to create openings wherein the ohmic metal contacts are deposited. An encapsulation layer is subsequently deposited on a portion of the ohmic metal contacts. The encapsulation layer will prevent the movement of the ohmic metal contacts when the ohmic metal contacts are alloyed. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
       FIG. 1   a  depicts a prior art device with deposited ohmic metal contacts. 
       FIG. 1   b  depicts the prior art device shown in  FIG. 1   a  after exposure to the high temperature. 
       FIG. 2   a  depicts a step in a prior art method for forming a GaN device. 
       FIG. 2   b  depicts a further processing step for the device shown in  FIG. 2   a.    
       FIG. 3   a  shows a substrate with the plurality of layers and the encapsulation layer. 
       FIG. 3   b  shows a substrate with the plurality of layers and the patterned encapsulation layer. 
       FIGS. 3   c  and  3   c - 1  show a further optional step of  3   b.    
       FIG. 3   d  shows  FIG. 3   b  with the photoresist layer removed. 
       FIG. 3   e  shows the refractory metal layer deposited in the opening. 
       FIG. 3   f  shows a photoresist layer deposited on the refractory metal layer. 
       FIG. 3   g  shows a portion of the refractory metal layer patterned and removed. 
       FIG. 3   h  shows a photoresist layer deposited on the refractory metal layer. 
       FIG. 3   i  shows a portion of the encapsulation layer and plurality of layers removed. 
       FIG. 3   j  shows the deposition of the ohmic metal contacts. 
       FIG. 3   k  shows the deposition of the gate metal layer. 
       FIG. 4   a  shows a substrate with the plurality of layers of semiconductor material 
       FIG. 4   b  shows the photoresist on the second layer, and a portion of the second layer removed. 
       FIG. 4   c  shows the deposition of the ohmic metal contacts. 
       FIG. 4   d  shows the encapsulation layer deposited on the ohmic metal contacts. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. 
   First Embodiment 
   A method and apparatus for protecting the ohmic metal contacts and channel of a semiconductor device according to a first embodiment of the present invention is described with reference to  FIGS. 3   a - 3   k . Referring to  FIG. 3   a , a substrate  101 , preferably comprised of silicon carbide (SiC), is provided. Next, a first layer  102 , preferably comprised of GaN and preferably fabricated using molecular beam epitaxy, is deposited on the substrate  101 . A second layer  103 , preferably comprised of AlGaN and fabricated using molecular beam epitaxy, is deposited on the second layer  102 . An interface  105  is created between the first layer  102  and the second layer  103 . The interface  105  serves as the channel of the semiconductor device. An encapsulation layer  104 , preferably comprised of SiN, is deposited on the surface of the second layer  103 . The encapsulation layer  104  has a thickness typically in the range of 50-200 nanometers, but is preferably 100 nanometers thick. 
   Next, as shown in  FIGS. 3   b - 3   c ,  3   c - 1 , and  3   d , a first opening  108  for a gate structure is formed. First, a first layer of photoresist  106 , preferably electron-sensitive photoresist, is deposited on the exposed SiN layer  104  as shown in  FIG. 3   b . Electron beam lithography is used to pattern and remove at least a portion of the electron-sensitive photoresist layer  106  and the encapsulation layer  104 , thereby creating the first opening  108 , as shown in  FIG. 3   b , which exposes the surface of the second layer  103 . Optionally, as shown in  FIG. 3   c  and in even greater detail in  FIG. 3   c - 1 , a portion of the second layer  103  may also be removed using reactive ion etching. The removal of a portion of the encapsulation layer  104 , leaves two separate encapsulation layers  104   a ,  104   b . The first opening  108  exposes a portion of the second layer  103  and is created by the separation of the encapsulation layers  104   a ,  104   b . After the first opening  108  is created, the remaining portion of the electron-sensitive photoresist layer  106  is removed, as shown in  FIG. 3   d , using techniques known in the art. 
   Next, as shown in  FIG. 3   e , a refractory metal layer  110 , preferably comprised of molybdenum (Mo), tungsten (W), or tungsten silicide, is deposited on the surface of the remaining encapsulation layers  104   a ,  104   b  and in the first opening  108 . The refractory metal layer  110  typically has a thickness in the range of 100-400 nanometers, but is preferably 100 nanometers thick. Optionally, a thin layer of platinum (Pt) or titanium (Ti) (not shown) may be applied over the refractory metal layer  110  to help promote the adhesion of a gold layer, which is discussed later. 
   The refractory metal layer  110 , which is deposited in the first opening  108  makes direct contact with the surface of the second layer  103 . The portion of the refractory metal layer  110  deposited on the encapsulation layers  104   a ,  104   b  extends partially over the edge of the encapsulation layers  104   a ,  104   b  to make contact with the refractory metal layer  110  deposited in the first opening  108 . The partial extension over the edge creates a second opening  112  directly above the portion of the refractory metal contacting the second layer  103 . This refractory metal layer  110  will eventually become the gate of the device. 
   As shown in  FIG. 3   f , a second layer of photoresist  114 , preferably for optical photolithography, is deposited on a portion of the refractory metal layer  110  and in the second opening  112 . The portion of the refractory metal layer  110  not covered by the photolithography photoresist  114  is removed, as shown in  FIG. 3   g , using techniques known in the art, such as a CF 4  dry etch. After the desired portion of the refractory metal layer  110  has been removed, the optical photolithography photoresist  114  is removed using techniques known in the art. 
   The next step is the formation of ohmic metal contacts  118  for the device (shown in  FIGS. 3   j  and  3   k ). As shown in  FIG. 3   h , a third layer of photoresist  116 , preferably for photolithography, is deposited to cover all the exposed refractory metal layer  110  and a portion of the encapsulation layers  104   a ,  104   b . The area of encapsulation layers  104   a ,  104   b , that remain exposed will be removed to create regions where the ohmic metal contacts  118  will be deposited. In this embodiment, the spacing between the ohmic metal contacts  118  is as low as 1 micrometer apart. Techniques known in the art, such as reactive ion etching using CF 4  or Cl gas, are used to etch away the exposed portion of the encapsulation layers  104   a ,  104   b , as well as a portion of the second layer  103  as shown in  FIG. 3   i.    
   Ohmic metal contacts  118 , preferably comprising a combination of titanium (Ti), aluminum (Al), nickel (Ni), and gold (Au), are deposited on the second layer  103 , as shown in  FIG. 3   j  in the regions where a portion of the encapsulation layer  104   a ,  104   b , and second layer  103  were removed. Next, the third layer of photoresist  116  is removed using techniques known in the art. If any ohmic metal was deposited on the third layer of photoresist  116  during deposition of the ohmic metal contacts  118 , that ohmic metal will be removed when the third layer of photoresist  116  is removed. After the ohmic metal contacts  118  are deposited, the device is heated to temperatures in excess of 800° C., in order to alloy the ohmic metal contacts  118 . The encapsulation layers  104   a ,  104   b  form a dam to prevent the flow or migration of ohmic metal during the high temperature alloying process. Furthermore, the remaining encapsulation layers  104   a ,  104   b  protects the interface  105  against a reduction in electron mobility during the alloying. 
   After alloying the ohmic metal contacts  118 , a gate contact  120 , preferably comprising gold, is deposited on the remaining refractory metal layer  110  and in the second opening  112 , as shown in  FIG. 3   k . The gate contact  120  helps to reduce the resistance of the gate of the transistor. 
   Second Embodiment 
   A method and apparatus for protecting the ohmic metal contacts of a semiconductor device according to a second embodiment will now be described and is shown in  FIGS. 4   a - 4   d . In this second embodiment, a substrate  201 , preferably comprising silicon-carbide (SiC), is provided. The first layer  202 , preferably comprising GaN, and the second layer  203 , preferably comprising AlGaN, are deposited on the substrate  201  as shown in  FIG. 4   a . Next, a layer of photoresist  224 , preferably for optical lithography, is deposited on the second layer  203 . The photoresist layer  224  is patterned and a portion of the second layer  203  is removed as shown in  FIG. 4   b , using techniques known in the art such as RIE with CF 4  or Cl 2  gas. 
   Next, ohmic metal contacts  218  are deposited on the first layer  202 , as shown in  FIG. 4   c . The ohmic metal contacts  218  have first surfaces  219  and first edges  223 . After the ohmic metal contacts  218  are deposited, an encapsulation layer  204 , preferably comprising SiN, is deposited on a portion of the first surfaces  219  of the ohmic metal contacts  218  in a manner as to cover the first edges  223  of the ohmic metal contacts, as shown in  FIG. 4   d . The SiN layer  204  may be in the range of 50-200 nanometers, but is preferably about 100 nanometers thick. It is preferable to deposit the least amount of the SiN layer  204  on the first surfaces  219  of the ohmic metal contacts  218 , as shown in  FIG. 4   d . The ohmic metal contacts  218  are preferably comprised of a combination of titanium (Ti), aluminum (Al), nickel (Ni), and gold (Au). After the ohmic metal contacts  218  have been deposited, the ohmic metal contacts  218  are alloyed at preferably 850° C. for approximately 30 seconds to reduce their resistance. 
   The encapsulation layer on the first edges  223  of the ohmic metal contacts  218  will help prevent the first edges  223  of the ohmic metal contacts  118  from becoming rough or moving while exposed to the high temperatures needed to alloy the ohmic metal contacts  218 . 
   Let it be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the spirit of the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances which fall within the scope of the appended claims.

Technology Category: 5