Group-III Nitride Substrate Carbon Gradient for Defect Control

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Solution Overview

Problem

Current substrate manufacturing methods for group-III nitride crystals, which involve mixing impurities like oxygen and silicon to reduce resistance, lead to lattice constant changes and propagation of dislocation defects and cracking during device layer formation.

Innovation Solution

A method involving a group-III nitride substrate with controlled carbon and oxygen concentrations, where the carbon concentration is higher at the front surface than the inner layer, and oxygen concentration is lower at the front surface, is used to generate a group-III nitride crystal by reacting a group-III element oxide with nitrogen and carbon-containing gases, with varying concentrations throughout the growth process to suppress defects and cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If impurities such as oxygen and silicon are mixed into the group-III nitride crystal to reduce resistance, then the electrical conductivity is improved, but the lattice constant changes and causes propagation of dislocation defects and cracking

Engineering Contradiction:
Improveelectrical conductivityVSAvoidlattice constant control
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating a non-uniform carbon concentration distribution within the crystal structure. The carbon concentration is set to be higher in specific regions (such as near interfaces or in buffer layers) and lower in other regions, allowing local resistance reduction without causing uniform lattice constant changes throughout the entire crystal. This spatially differentiated impurity distribution enables electrical conductivity improvement in specific areas while maintaining overall lattice constant control and preventing widespread dislocation defects and cracking.

Inventive Principle:
Principle #3Local quality

2Reliability

If the carbon concentration is increased to reduce resistance, then the electrical conductivity is improved, but the lattice constant changes which may cause dislocation defects and cracking

Engineering Contradiction:
Improveelectrical conductivityVSAvoiddislocation defects and cracking
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter changes by precisely controlling the carbon concentration parameter within specific numerical ranges and gradients. Rather than simply increasing carbon concentration uniformly, the invention optimizes the carbon concentration parameter to fall within a window that provides sufficient electrical conductivity improvement while remaining below the threshold that would cause excessive lattice constant changes. The carbon concentration is controlled to be within specific ranges (e.g., 1×10^17 to 1×10^20 atoms/cm³ in certain regions) to achieve the desired balance between conductivity enhancement and defect prevention.

Inventive Principle:
Principle #35Parameter changes

3Productivity

If the group-III element oxide gas is supplied at high concentration during early to middle stage of growth, then the crystal growth rate is improved, but the carbon incorporation may increase which affects lattice constant

Engineering Contradiction:
Improvecrystal growth rateVSAvoidlattice constant control
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by implementing time-dependent control of gas supply concentrations during the crystal growth process. The carbon element-containing gas concentration is dynamically adjusted based on the growth stage: higher concentrations are supplied during early to middle growth stages to maintain adequate growth rate, while the concentration is reduced or optimized during later stages to prevent excessive carbon incorporation that would alter the lattice constant. This dynamic, stage-specific gas supply strategy enables the system to adaptively balance growth rate and lattice constant control throughout the growth process.

Inventive Principle:
Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces substrate resistance and controls the lattice constant, preventing dislocation defects and cracking during device layer formation, while maintaining high electrical conductivity and crystallinity.

Implementation Method 1

reacting the group-III element oxide gas with the nitrogen-containing gas in an atmosphere of the carbon element-containing gas to generate a group-III nitride crystal

Methodology Applied
Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Implementation Method 2

reacting an oxide of a group-III element with a reducing gas, or reacting a metal of the group-III element with an oxidizing gas to generate a group-III element oxide gas

Methodology Applied
Scientific EffectRedox reactions: Redox Reactions

Data Source

PatentUS11396716B2Group-III nitride substrate containing carbon at a surface region thereof
Publication Date: 2022.07.26 PANASONIC HOLDINGS CORP
  • US11396716B2 patent drawing
  • US11396716B2 patent drawing
  • US11396716B2 patent drawing

AI summary

A group-III nitride substrate includes: a base material part of a group-III nitride including a front surface, a back surface, and an inner layer between the front surface and the back surface, wherein the carbon concentration of the front surface of the base material part is higher than the carbon concentration of the inner layer.