US 7,459,375 B2
Transfer method for forming a silicon-on-plastic wafer
Jer-Shen Maa, Vancouver, Wash. (US); Jong-Jan Lee, Camas, Wash. (US); Douglas J. Tweet, Camas, Wash. (US); and Sheng Teng Hsu, Camas, Wash. (US)
Assigned to Sharp Laboratories of America, Inc., Camas, Wash. (US)
Filed on Aug. 10, 2007, as Appl. No. 11/891,502.
Application 11/891502 is a division of application No. 10/913677, filed on Aug. 05, 2004, granted, now 7,279,400.
Prior Publication US 2007/0298588 A1, Dec. 27, 2007
Int. Cl. H01L 21/44 (2006.01)
U.S. Cl. 438—455  [438/458; 438/459; 438/475; 438/558; 257/E21.482; 257/E21.568] 18 Claims
OG exemplary drawing
 
1. A method of fabricating a silicon-on-plastic layer via layer transfer comprising:
preparing a silicon substrate;
depositing a layer of SiGe on the silicon substrate;
depositing a layer of insulator on the SiGe layer;
implanting hydrogen ions into the silicon substrate through the SiGe layer in a relaxation hydrogen implantation step;
annealing the silicon substrate and SiGe layer in a first annealing step to relax the SiGe layer; thereby forming a relaxed SiGe layer;
smoothing the relaxed SiGe layer;
depositing a layer of silicon on the relaxed SiGe layer;
implanting hydrogen ions in a splitting hydrogen implantation step to facilitate splitting of the wafer;
preparing a glass substrate;
bonding the glass substrate to the strained silicon layer to form a composite wafer;
splitting the composite wafer to provide a split wafer having, in seriatim, a glass substrate, a layer of strained silicon; a layer of relaxed SiGe; and silicon layer split from the silicon substrate;
dry etching the split wafer to remove the silicon layer split from the silicon substrate and a portion of the relaxed SiGe layer;
annealing the split wafer to increase the bond between the strained silicon and the glass substrate in a second annealing step;
selectively etching the split wafer to remove any remaining SiGe, thereby forming a strained silicon-on-glass wafer;
depositing a dielectric on the silicon side of the silicon-on-glass wafer;
preparing a plastic substrate;
applying adhesive and bonding the plastic to the silicon side of the silicon-on-glass wafer;
removing the glass from the glass side of the bonded, silicon-on-glass wafer to form a silicon-on-plastic wafer; and
completing a desired IC device on the silicon-on-glass wafer.