Etch stop layer system
First Claim
1. A monocrystalline etch-stop layer system for use on a monocrystalline Si substrate, said system comprising a substantially relaxed graded layer of Si1-xGex, and a uniform etch-stop layer of substantially relaxed Si1-yGey.
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Abstract
A SiGe monocrystalline etch-stop material system on a monocrystalline silicon substrate. The etch-stop material system can vary in exact composition, but is a doped or undoped Si1-xGex alloy with x generally between 0.2 and 0.5. Across its thickness, the etch-stop material itself is uniform in composition. The etch stop is used for micromachining by aqueous anisotropic etchants of silicon such as potassium hydroxide, sodium hydroxide, lithium hydroxide, ethylenediamine/pyrocatechol/pyrazine (EDP), TMAH, and hydrazine. These solutions generally etch any silicon containing less than 7×1019 cm−3 of boron or undoped Si1-xGex alloys with x less than approximately 18. Alloying silicon with moderate concentrations of germanium leads to excellent etch selectivities, i.e., differences in etch rate versus pure undoped silicon. This is attributed to the change in energy band structure by the addition of germanium. Furthermore, the nondegenerate doping in the Si1-xGex alloy should not affect the etch-stop behavior. The etch-stop of the invention includes the use of a graded-composition buffer between the silicon substrate and the SiGe etch-stop material. Nominally, the buffer has a linearly-changing composition with respect to thickness, from pure silicon at the substrate/buffer interface to a composition of germanium, and dopant if also present, at the buffer/etch-stop interface which can still be etched at an appreciable rate. Here, there is a strategic jump in germanium and concentration from the buffer side of the interface to the etch-stop material, such that the etch-stop layer is considerably more resistant to the etchant. This process and layer structure allows for an entire range of new materials for microelectronics. The etch-stop capabilities introduce new novel processes and structures such as relaxed SiGe alloys on Si, SiO2, and SiO2/Si. Such materials are useful for future strained Si MOSFET devices and circuits.
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Citations
229 Claims
- 1. A monocrystalline etch-stop layer system for use on a monocrystalline Si substrate, said system comprising a substantially relaxed graded layer of Si1-xGex, and a uniform etch-stop layer of substantially relaxed Si1-yGey.
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33. A monocrystalline etch-stop layer system for use on a monocrystalline Si substrate, said system comprising a substantially relaxed graded layer of Si1-xGexa uniform etch-stop layer of substantially relaxed Si1-yGey;
- and a strained Si1-zGez layer.
- View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56)
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57. A monocrystalline etch-stop layer system for use on a monocrystalline Si substrate, comprising a substantially relaxed graded layer of Si1-xGex;
- a uniform etch-stop layer of substantially relaxed Si1-yGey;
a second etch-stop layer of strained Si1-zGez; and
a substantially relaxed Si1-wGew layer. - View Dependent Claims (58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79)
- a uniform etch-stop layer of substantially relaxed Si1-yGey;
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80. A method of integrating a device or layer comprising:
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depositing a substantially relaxed graded layer of Si1-xGex;
on a Si substrate;
depositing a uniform etch-stop layer of substantially relaxed Si1-yGey on said graded buffer; and
etching portions of said substrate and said graded buffer in order to release said etch-stop layer. - View Dependent Claims (81, 82, 83, 84, 85, 86, 87, 88)
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89. A method of integrating a device or layer comprising:
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depositing a substantially relaxed graded layer of Si1-xGex on a Si substrate;
depositing a uniform first etch-stop layer of substantially relaxed Si1-yGey on said graded buffer;
depositing a second etch-stop layer of strained Si1-xGex;
depositing a substantially relaxed Si1-wGew layer;
etching portions of said substrate and said graded buffer in order to release said first etch-stop layer; and
etching portions of said residual graded buffer in order to release the second etch-stop Si1-zGez layer. - View Dependent Claims (90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111)
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112. (New) A semiconductor structure comprising:
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a layer structure including a uniform etch-stop layer, wherein said uniform etch-stop layer has a relative etch rate which is less than approximately the relative etch rate of Si doped with 7×
1019 boron atoms/cm3. - View Dependent Claims (113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134)
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135. (New) A semiconductor structure, comprising:
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a layer structure including a strained Si1-zGez layer, and a handle wafer comprising an insulator, the layer structure being bonded to the handle wafer, wherein 0<
z<
1. - View Dependent Claims (136, 137, 138, 139, 140, 141, 142, 143)
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144. (New) A semiconductor structure, comprising:
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a layer structure including;
a uniform etch-stop layer; and
a strained layer disposed over the uniform etch-stop layer, and an insulator layer disposed over the layer structure, wherein the uniform etch-stop layer has a relative etch rate which is less than approximately the relative etch rate of Si doped with 7×
1019 boron atoms/cm3. - View Dependent Claims (145, 146)
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147. (New) A semiconductor structure, comprising:
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an etch-stop layer; and
a substantially relaxed layer disposed over the etch-stop layer. - View Dependent Claims (148, 149, 150)
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151. (New) A semiconductor structure, comprising:
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a first uniform etch-stop layer;
a second etch-stop layer disposed over the uniform etch-stop layer; and
a substantially relaxed layer disposed over the second etch-stop layer, wherein the first uniform etch-stop layer has a relative etch rate which is less than approximately the relative etch rate of Si doped with 7×
1019 boron atoms/cm3. - View Dependent Claims (152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162)
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163. (New) A method for forming a semiconductor structure, the method comprising:
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forming a uniform etch-stop layer;
providing a handle wafer; and
bonding the uniform etch-stop layer to the handle wafer, wherein said uniform etch-stop layer has a relative etch rate which is less than approximately the relative etch rate of Si doped with 7×
1019 boron atoms/cm3. - View Dependent Claims (164, 165, 166, 167, 168, 169, 170)
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171. (New) A method for forming a semiconductor structure, the method comprising:
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providing a first substrate; and
forming a layer structure over the first substrate by;
forming a uniform etch-stop layer over the first substrate; and
forming a strained layer over the uniform etch-stop layer, wherein the uniform etch-stop layer has a relative etch rate which is less than approximately the relative etch rate of Si doped with 7×
1019 boron atoms/cm3. - View Dependent Claims (172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182)
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183. (New) A method for forming a semiconductor structure, the method comprising:
forming a layer structure by forming a strained Si1-zGez layer, and bonding the layer structure to a handle wafer comprising an insulator, wherein 0≦
z<
1.- View Dependent Claims (184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197)
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198. (New) A method for forming a semiconductor structure, the method comprising:
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forming a strained etch-stop layer; and
forming a substantially relaxed Si1-wGew layer over the etch-stop layer. - View Dependent Claims (199, 200)
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201. (New) A method for forming a semiconductor structure, the method comprising:
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forming a first uniform etch-stop layer;
forming a second etch-stop layer over the uniform etch-stop layer; and
forming a substantially relaxed layer over the second etch-stop layer, wherein the first uniform etch-stop layer has a relative etch rate which is less than approximately the relative etch rate of Si doped with 7×
1019 boron atoms/cm3. - View Dependent Claims (202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219, 220, 221, 222, 223, 224, 225, 226, 227, 228)
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229. (New) A method for forming a semiconductor structure, the method comprising:
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providing a first substrate;
forming a layer structure on the first substrate by;
forming a substantially relaxed graded layer on the first substrate; and
forming a uniform etch-stop layer on the graded layer; and
releasing the etch-stop layer by removing at least a portion of the substrate and at least a portion of the graded layer,
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Specification