Semiconductor Etching for Electrode Defect Repair

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Solution Overview

Problem

The challenge in performing an electric characteristic test on power semiconductor chips lies in setting appropriate current or voltage application conditions due to unpredictable electrode pattern defects or deficiencies, which require significant effort and time to control.

Innovation Solution

A method involving selective etching with a higher etching ratio for semiconductor materials than electrode films is used to remove regions below pattern defective parts, allowing for controlled thickness adjustments and easier test condition setting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a current or voltage application condition is set in accordance with the size or degree of electrode pattern defect or electrode deficiency, then the non-defective item is not damaged by the test, but a great amount of effort and time is required to set the test condition

Engineering Contradiction:
Improvequality assuranceVSAvoidtest setup time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by performing etching to remove the semiconductor layer below defective electrode regions before the electric characteristic test. This advance preparation creates a controlled test structure where the degree of layer removal can be precisely managed, eliminating the need for time-consuming test condition adjustments based on defect size. The etching step establishes a predetermined test configuration that simplifies subsequent testing while maintaining reliability.

Inventive Principle:
Principle #10Preliminary action

2Ease of operation

If the semiconductor layer below defective parts is removed to control thickness, then test condition setting becomes easier, but an additional etching process is required

Engineering Contradiction:
Improvetest condition settingVSAvoidmanufacturing process
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The patent merges the test preparation step with the existing manufacturing process by integrating the etching operation into the production flow. The etching process that removes the semiconductor layer below defective electrodes is combined with other manufacturing steps, such as performing the etching before or during electrode formation. This integration ensures that test preparation is automatically completed as part of normal manufacturing, adding minimal complexity while significantly easing test condition setting.

Inventive Principle:
Principle #5Merging (Combining)

3Reliability

If electrode pattern defect or electrode deficiency occurs, then quality cannot be ensured without extensive testing, but extensive testing increases time and effort requirements

Engineering Contradiction:
Improvequality assuranceVSAvoidtest efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent converts the harmful effect of electrode pattern defects and deficiencies into a beneficial outcome by using the defective regions as targets for selective etching. Instead of treating defects as problems that require extensive testing to detect, the method uses the defects to identify where semiconductor layer removal is needed. This transforms quality assurance from a detection-oriented process into a preventive process, where the etching step proactively addresses potential test failures before they occur, thereby improving both reliability and productivity.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 enables efficient control of semiconductor layer thicknesses below defects, simplifying the setting of test conditions and facilitating the electric characteristic test.

Implementation Method 1

a first etching having a higher selected ratio with respect to a semiconductor material of the first semiconductor layer than a material of the first electrode film over the first electrode film

Methodology Applied
Scientific EffectEtching:

Data Source

PatentUS10811511B2Method of manufacturing semiconductor device
Publication Date: 2020.10.20 MITSUBISHI ELECTRIC CORP
  • US10811511B2 patent drawing
  • US10811511B2 patent drawing
  • US10811511B2 patent drawing

AI summary

It is an object of the present invention to easily perform an electric characteristic test for ensuring quality of a semiconductor device on an electrode pattern defect or deficiency. A method of manufacturing a semiconductor device according to the present invention performs, a first etching having a higher selected ratio with respect to a semiconductor material of a first semiconductor layer than a material of a first electrode film over the first electrode film, and removes a region in the first semiconductor layer below a pattern defective part or a deficiency part of the first electrode film at least partially to form an electrode film in the pattern defective part or the deficiency part of the first electrode film.