Method and apparatus for controlled dopant incorporation and activation in a chemical vapor deposition system
First Claim
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1. A chemical vapor deposition system comprising:
- a chemical vapor deposition reactor including;
a chamber;
a rotatable wafer carrier adapted to receive at least one wafer and rotate at a predetermined rotation speed during epitaxial growth;
at least one wafer mounted to the rotatable wafer carrier within the chamber;
a viewport defined in a wall of the chamber; and
a gas injection system configured to deliver a gas mixture towards the at least one wafer;
a UV light source configured to generate a UV light beam, the UV light source operably coupled to the viewport;
a rastering subsystem in communication with the UV light source and adapted to control the UV light beam through the viewport towards the at least one wafer to produce a raster pattern on a semiconductor layer formed on the at least one wafer mounted within chamber such that, during epitaxial growth, in response to the predetermined rotation speed the UV light beam is configured to be incident upon a plurality of regions of the semiconductor layer such that point defects in such regions are dissociated.
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Abstract
Embodiments include systems and methods for producing semiconductor wafers having reduced quantities of point defects. These systems and methods include a tunable ultraviolet (UV) light source, which is controlled to produce a raster of a UV light beam across a surface of a semiconductor wafer during epitaxial growth to dissociate point defects in the semiconductor wafer. In various embodiments, the tunable UV light source is configured external to a Metal Organic Chemical Vapor Deposition (MOCVD) chamber and controlled such that the UV light beam is directed though a window defined in a wall of the MOCVD chamber.
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Citations
30 Claims
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1. A chemical vapor deposition system comprising:
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a chemical vapor deposition reactor including; a chamber; a rotatable wafer carrier adapted to receive at least one wafer and rotate at a predetermined rotation speed during epitaxial growth; at least one wafer mounted to the rotatable wafer carrier within the chamber; a viewport defined in a wall of the chamber; and a gas injection system configured to deliver a gas mixture towards the at least one wafer; a UV light source configured to generate a UV light beam, the UV light source operably coupled to the viewport; a rastering subsystem in communication with the UV light source and adapted to control the UV light beam through the viewport towards the at least one wafer to produce a raster pattern on a semiconductor layer formed on the at least one wafer mounted within chamber such that, during epitaxial growth, in response to the predetermined rotation speed the UV light beam is configured to be incident upon a plurality of regions of the semiconductor layer such that point defects in such regions are dissociated. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A semiconductor processing system configured for epitaxial growth of one or more device layers on at least one wafer, the system comprising:
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a single vacuum chamber comprising a plurality of processing chambers, each of the plurality of processing chambers having a top portion and a bottom portion, the single vacuum chamber having; a cover containing the top portion of each of the plurality of processing chambers, each top portion having at least a gas injection system configured to deliver a gas mixture, and at least one of metrology instruments, thermal and other non-deposition treating systems, and testing systems, a viewport defined in the cover, and a UV light source configured to generate a UV light beam, the UV light source operably coupled to the viewport and in communication with a rastering subsystem; and a base comprising a carousel rotatably mounted within the base, the carousel containing the bottom portion of each of the plurality of processing chambers, each bottom portion adapted to receive at least one wafer rotatably mounted therein and rotate at a predetermined rotation speed during epitaxial growth from the gas mixture, wherein when the top portion and the bottom portion of each of the plurality of processing chambers are engaged by closing the cover on the base, each of the plurality of processing chambers are sealed off from each other processing chamber, and wherein the rastering subsystem is in communication with the UV light source and adapted to control the UV light beam through the viewport towards the at least one wafer during epitaxial growth to produce a raster pattern on a semiconductor layer formed on the at least one wafer mounted within chamber in response to the predetermined rotation speed such that the UV light beam is configured to be incident upon a plurality of regions of the semiconductor layer such that point defects in such regions are dissociated.
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13. A method for epitaxial growth of at least one semiconductor layer comprising:
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positioning at least one wafer within a chamber defined within a chemical vapor deposition reactor, the chemical vapor deposition system comprising; a rotatable wafer carrier adapted to receive the at least one wafer; a viewport defined in a wall of the chamber;
a gas injection system configured to deliver a gas mixture towards the at least one wafer;a UV light source configured to generate a UV light beam, the UV light source operably coupled to the viewport; and a rastering subsystem in communication with the UV light source and adapted to control the UV light beam through the viewport towards the at least one wafer; and
rotating the rotatable wafer carrier at a predetermined rotation speed during epitaxial growth of the at least one wafer;applying a gas mixture within the chamber to cause the at least one semiconductor layer to grow epitaxially on the at least one wafer; and
selectively directing a UV light beam through a rastering system to produce a raster pattern on the at least one semiconductor layer, the UV light beam selectively tuned to the at least one semiconductor layer and the gas mixture during the rotating of the rotatable wafer carrier and in response to the predetermined rotation speed such that the UV light beam is configured to be incident upon a plurality of regions of the semiconductor layer so as to dissociate point defects in the at least one semiconductor layer. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A semiconductor device made by the process of:
- positioning at least one wafer within a chamber defined within a chemical vapor deposition reactor including;
a rotatable wafer carrier adapted to receive the at least one wafer and rotate at a predetermined rotation speed during epitaxial growth;
a viewport defined in a wall of the chamber;
a gas injection system configured to deliver a gas mixture towards the at least one wafer;a UV light source configured to generate a UV light beam, the UV light source operably coupled to a viewport; and
a rastering subsystem in communication with the UV light source;applying a gas mixture within the chamber wherein application of the gas mixture causes one or more semiconductor layers to grow epitaxially on the wafer; and while applying the gas mixture, using a rastering system adapted to control the UV light beam to selectively direct a UV light beam through the viewport towards the at least one wafer during epitaxial growth to produce a raster pattern on the one or more semiconductor layers thereof in response to the predetermined rotation speed such that the UV light beam is configured to be incident upon a plurality of regions of the semiconductor layer, the UV light beam selectively tuned to the one or more semiconductor layers and the gas mixture so as to dissociate point defects in the one or more semiconductor layers. - View Dependent Claims (26, 27, 28, 29, 30)
- positioning at least one wafer within a chamber defined within a chemical vapor deposition reactor including;
Specification