IP Library Granted Patent US 9,716,164
Granted Patent B2
US 9,716,164 · App. 14/430,513 · Granted Jul 25, 2017

Methods of forming III-V semiconductor structures using multiple substrates, and semiconductor devices fabricated using such methods

Inventor: Mariam Sadaka (Austin, TX)
Assignee: SOITEC
H01L29/7787H01L21/0254H01L21/02425H01L21/6835H01L21/76256H01L23/36H01L29/201H01L29/2003H01L29/205H01L29/66462H01L29/7781H01L29/7788H01L24/16H01L24/29H01L24/32H01L24/73H01L29/4175H01L2221/6834H01L2221/68327H01L2224/0401H01L2224/05025H01L2224/131H01L2224/16237H01L2224/293H01L2224/2929H01L2224/29147H01L2224/29184H01L2224/32245H01L2224/73253H01L2224/81191H01L2224/81203H01L2224/81815H01L2224/83851H01L2224/83895H01L2924/1461
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Quick Facts
Patent No.
US 9,716,164
App. No.
14/430,513
Granted
Jul 25, 2017
Kind
B2
Abstract

Methods of forming semiconductor devices include epitaxially growing a III-V base layer over a first substrate in a first deposition chamber. The III-V base layer is transferred from the first substrate to a second substrate, and at least one III-V device layer is epitaxially grown on the III-V base layer in a second deposition chamber separate from the first deposition chamber while the III-V base layer is disposed on the second substrate. The first substrate exhibits an average coefficient of thermal expansion (CTE) closer to an average CTE exhibited by the III-V base layer than an average CTE exhibited by the second substrate. Semiconductor devices may be fabricated using such methods.

Claims (22)

1. A method of forming a semiconductor device, comprising:

epitaxially growing a III-V base layer over a surface of a first substrate in a first deposition chamber, the first substrate comprising metallic molybdenum or a metallic molybdenum alloy, the first substrate exhibiting a first average CTE, the III-V base layer comprising a III-V semiconductor material exhibiting a second average CTE within about 10% or less of the first average CTE;

transferring the III-V base layer from the surface of the first substrate to a surface of a second substrate;

after transferring the III-V base layer to the second substrate, epitaxially growing a first III-V device layer and on an exposed surface of the III-V base layer in a second deposition chamber separate from the first deposition chamber, and epitaxially growing a second III-V device layer on the first III-V device layer in the second deposition chamber while the III-V base layer is disposed on the second substrate, the first III-V device layer having first material composition, the second III-V device layer having a second material composition differing from the first material composition so as to define an electron channel of at least one transistor proximate a heterojunction between the first III-V device layer and the second III-V device layer;

providing a first source contact and a second source contact of the at least one transistor in electrical contact with the second III-V device layer and in electrical communication with the electron channel;

providing a gate structure of the at least one transistor proximate the electron channel between the first source contact and the second source contact;

temporarily bonding a carrier substrate over the first source contact, the second source contact, and the gate structure;

removing second substrate from the III-V base layer and exposing a surface of the III-V base layer;

providing a layer of conductive material over at least a portion of the exposed surface of the III-V base layer, the layer of conductive material defining a drain contact of the at least one transistor; and

providing a dielectric material over the drain contact on a side thereof opposite the III-V base layer;

wherein the at least one transistor comprises a vertical high electron mobility transistor.

2. The method of claim 1 , further comprising configuring the at least one transistor to comprise a pseudomorphic high electron mobility transistor.

3. The method of claim 1 , wherein epitaxially growing the III-V base layer over the surface of the first substrate comprises epitaxially growing a polar III-V semiconductor material over the surface of the first substrate, and wherein growing the first III-V device layer on the exposed surface of the III-V base layer comprises growing the first III-V device layer on a Group V face of the polar III-V semiconductor material.

4. The method of claim 1 , further comprising:

selecting the III-V base layer to comprise a first binary III-V semiconductor material and selecting the first binary III-V semiconductor material to comprise GaN;

selecting the first III-V device layer to comprise a ternary III-V semiconductor material and selecting the ternary III-V semiconductor material to comprise AlGaN; and

selecting the second III-V device layer to comprise a second binary III-V semiconductor material and selecting the second binary III-V semiconductor material to comprise GaN.

5. The method of claim 1 , further comprising:

selecting the first material composition of the first III-V device layer to exhibit a first energy bandgap; and

selecting the second material composition of the second III-V device layer to exhibit a second energy bandgap differing from the first energy bandgap, a conduction band in an energy band structure within the first III-V device layer and the second III-V device layer extending below a Fermi energy level proximate the heterojunction such that a two-dimensional electron gas is defined in at least one of the first III-V device layer and the second III-V device layer proximate the heterojunction.

6. The method of claim 1 , further comprising selecting the second substrate to comprise a second substrate material exhibiting a third average CTE differing from the first average CTE.

7. The method of claim 6 , further comprising selecting the second substrate material to comprise silicon.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 23, 2015
From: SADAKA, MARIAM
To: SOITEC
Reel/Frame 035234/0673 →
Continuity (2)
Provisional Application 61704860 · Sep 24, 2012
Related Publication 20150255591A1 · Sep 10, 2015