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J. P. BANERJEE
Centre for Millimeterwave Semiconductor Devices and Systems
Institute of Radiophysics and Electronics
University of Calcutta, Kolkata 700009, INDIA.
Abstract:
A silicon (p+nn+) SDR IMPATT diode for Ka-band operation has been designed by using a double iterative DC
and Small signal simulation which involves simultaneous solution of Poissons equation and Carrier continuity
equation, satisfying appropriate boundary conditions in the depletion layer edges. Using the design parameters,
silicon epitaxial n/n+ wafers of appropriate thickness and resistivity of the epitaxial layer have been selected for
fabrication of (p+nn+) SDR IMPATT diode for Ka-band operation. The (p+nn+) SDR IMPATT diode has been
fabricated through diffusion technique. The optimized process steps of fabrication, starting from wafer cleaning
to packaging have been described in details. The DC V-I and RF characteristics of fabricated IMPATT diode
have been measured by using an integrated heat sink cum resonant cap waveguide cavity.
Keywords: Design, Fabrication, RF characterization, Small signal simulation, Silicon SDR IMPATT diode.
1.
Introduction
IMPact Avalanche Transit Time (IMPATT) devices have emerged as most powerful solid-state devices for
generation of high CW and pulsed power at millimeter wave frequencies [1], [2]. These devices provide high
oscillator output power with high DC to RF conversion efficiency in Silicon Monolithic Millimeter Wave
Integrated Circuits (SIMMWIC) [3]. The authors have designed a silicon (p+nn+) SDR IMPATT diode for Kaband operation by using double iterative DC and Small signal simulation methods which involve simultaneous
solution of Poissons and Carrier continuity equation with appropriate boundary conditions at the depletion
layer edges [4]. Based on the DC and Small Signal simulation the authors have appropriately selected silicon
epitaxial wafers with phosphorus and antimony as n and n+ dopants respectively. The substrate resistivity is
selected in the range of 0.0174 - 0.0185 ohm-cm and epitaxial resistivity in the range of 0.45-0.55 ohm-cm [5]
for fabrication of (p+nn+) SDR Ka- band IMPATT Diode.
The metallurgical junction of a silicon (p+nn+) SDR IMPATT diode can be grown by different techniques i.e. (i).
Diffusion (ii). Ion implantation (iii). Chemical vapor deposition and ( iv). Molecular Beam Epitaxy (MBE) . The
authors have chosen the diffusion route since it is the simplest method of fabrication of single drift diode, which
involves diffusion of p-type impurities in n/n+ epitaxial wafer [6]. The authors have used Boron as p-type dopant
since it can be diffused into silicon by solid source like Boron Nitride (BN), liquid source like Boron Tri
Bromide (BBr3) and gaseous source like Diborane (B2H6). The source BBr3 is highly volatile in nature and B2H6
is highly toxic, therefore solid source BN is chosen for easy handling of the doping source.
The major process steps adopted by the authors for fabrication of SDR IMPATT diodes are (i) wafer cleaning
(ii) Activation of Boron Nitride (BN) (iii) Stabilization of BN (iv) Pre-deposition of Boron (v) Drive in
Diffusion (vi) Low Temperature Oxidation (LTO) (vii) Cr-Au Metallization of p+ side (viii) Electroplating of
metalized p+ side (ix) Thinning of n+ side (x) CrAu Metallization of n+ side (xi) Photolithography (xii) Mesa
etching (xiii) Chip separation (xiv) Die/wire Bonding and packaging.
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For DC and RF characterization the diode is to be placed in a suitable microwave/mm wave cavity and mm
wave power is delivered by the device biased to break down [7]. The authors have used a resonant cap wave
guide mount [8] consisting of a resonant cap structure under which the diode is embedded and the two together
are mounted in a rectangular wave guide. The cap and the bottom surface of the wave guide form a localized
radial cavity around the diode. The mm wave signal generated by the diode is coupled to the main rectangular
wave guide cavity through the vertical open edges of the radial cavity.
2.
(3.a)
(3.b)
where g is the generation rate,
is the ionization rate and
is the velocity of charge carriers.
The above mentioned parameters are expressed in the following equations
(3.c)
(3.d)
(3.e)
where
From the above equations the fundamental time and space dependent differential equation involving the electric
field and the total current density under dynamic condition is given by
(4)
Where,
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n+
P+
To linearize the non-linear Eq. (4), we introduce a parameter H [10] mentioned above. Hence
(5)
where
= ac impedance.
and
(6a)
(6b)
from these two equations
(6c)
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at the left edge at
(n region)
(6d)
Considering
and separating the real and imaginary parts, the following second order
differential equations are obtained.
(7)
(8)
(9b)
Similarly at
(9c)
(9d)
The device negative resistance and reactance are obtained from the following
and
Conductance G =
(10.a)
Susceptance B
(10.b)
Quality factor
(11)
3.
The authors have carried out DC and Small signal simulation to design a Ka-band (p+nn+) SDR IMPATT diode.
The current density and junction temperature have been taken to be 9107 A/m2 and 2250C respectively. The
realistic field and temperature dependence of carrier ionization rates and the drift velocities [11], [12] at 2250 C
and the effect of mobile space charge have been considered in the simulation. The admittance plot has been
optimized to get the peak negative conductance at around 36.5 GHz of Ka-band. Fig.3 to Fig.5 shows the electric
field E(x) profile, normalized current density
the admittance (G-B) plot of Ka-band (p+nn+) SDR IMPATT diode with peak frequency at 36.5 GHz.
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6x107
Epilayer resistivity = 0.50 ohm-cm
1.0
Temp = 2250 C
0.5
0.0
0.0
-0.5
-0.5
-1.0
-1.0
p n
0
2x107
0.5
P(x)=(J -J )/J
3x107
4x107
1.0
5x107
1x107
-1.6x10-6
-1.4x10-6 -1.2x10-6
-1.0x10-6
-8.0x10-7 -6.0x10-7
-4.0x10-7
-2.0x10-7
0
0.0
-1.6x10-6
-1.4x10-6
-1.2x10-6
-1.0x10-6
-8.0x10-7
-6.0x10-7
-4.0x10-7
0.0
-2.0x10-7
x [meter]
x [meter]
3.0x1022
20
Epilayer resistivity = 0.50 ohm-cm
Current density = 9x107 Amp/m2
Temp = 2250 C
42 GHz
Susceptance(B)x106 in mho/m2
2.5x1022
2.0x1022
1.5x1022
40 GHz
15
38 GHz
37 GHz
36.5 GHz
36 GHz
35 GHz
10
34 GHz
32 GHz
5
30 GHz
28 GHz
Temp = 2250 C
26.5 GHz
1.0x1022
-1.6x10-6 -1.4x10-6 -1.2x10-6 -1.0x10-6 -8.0x10-7 -6.0x10-7 -4.0x10-7 -2.0x10-7
0
0.0
2.0x10-7
x [meter]
-4.5
-4.0
-3.5
-3.0
-2.5
-2.0
Conductance(G)x106 in mho/m2
-1.5
-1.0
Wafer Characteristics:
Type /dopant
Wafer Diameter
Substrate Thickness
Substrate Resistivity
Crystal orientation
Epitaxial Thickness
Epitaxial Resistivity
Type/dopant
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: N/Phosphorus
: 7.57 - 7.67 cm
: 381 25 (micron)
: 0.0174 - 0.0185 (ohm-cm)
: <111>
: 3.6-4.4 micron
: 0.45-0.55 ohm-cm
: N/Antimony
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4.1 Wafer cleaning
Wafer cleaning is a very important step in mm wave device fabrication process because of the variety of organic
and inorganic contaminants of unknown origin, which are present on the semiconductor surface, which
deteriorate the performance of the device [13].
a) Wafer is kept in a clean beaker containing DI water having 18 M resistivity which is then placed inside an
ultrasonic cleaner for 2- 4 minutes. This cleaning removes contaminating additives from the wafer surface
through acoustic streaming [14-15].
b) The wafer is then transferred to a beaker containing hot (80-850C) trichloro-ethelyene (TCE) for 10 to 15
minutes to remove the organic particles like air born bacteria, grease and wax from the surface of the wafer.
c) Trichloro - ethelyene (TCE) is removed by acetone.
d) The wafer is then rinsed thoroughly by running in DI water to remove acetone.
e) The wafer is then transferred to a beaker containing solution of NH4OH : H2O2 : H2O in ratio of 10:20:70
and heated to 80-850C for 10 to 15 minutes to remove heavy metallic impurities [16].
f) The wafer is rinsed with running DI water.
g) The wafer is immersed in a beaker containing solution of HCL: H2O2 : H2O in the ratio of 10:20:70 and
heated to 80-850C for 10-15 minutes to remove light metallic impurities.
h) It is then rinsed thoroughly in running DI water.
i) To make the mirror like hydrophobic surface, the wafer is dipped into a solution containing H2O : HF ::
90:10 for 1-2 minutes.
j) The wafer is finally rinsed by running DI water. Then N2 gas blower is used to dry up the wafer.
4.2 Activation of Boron Nitride (BN)
a) The starting wafer was n/n+ type and p+n junction was formed by boron diffusion. For this purpose, solid
source of boron, viz, Boron Nitride (BN) cakes having same diameter as that of silicon wafer was used.
b) The BN wafer is placed on a quartz boat and is very slowly pushed to the uniform temperature zone of the
furnace, shown in Fig.7. The BN wafer is activated in Oxygen ambient at 9750 C in the furnace for 20 25
minutes with 2-3 lit/minute flow rate of oxygen. During activation, a skin of B2O3 is formed on the surface
of BN wafer according to the following reaction: 4BN+3O2=2B2O3+2N2.
20 min
O2
4.3 Stabilization
After activation, oxygen is shut off and nitrogen is passed into the furnace with a flow rate of 2-3 lit/minute for
20 minutes at temperature of 9750C , shown in Fig. 8.
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20 min
Fig.8. Stabilization
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11000C
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Table : 1
The Process Parameters for Chromium and Gold deposition by Electron Beam evaporation technique
Metal
Chromium (Cr)
Gold (Au)
Vacuum
(mm of Hg)
3.410-5
2.010-5
E-Beam Voltage
(KV)
5.4 - 5.5
5.4 - 5.5
E-Beam Current
(mA)
100
100
Substrate
Temperature(0C)
2200C
2800C
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4.11 Photolithography
An array of circular dots are reproduced on silicon wafer by using ultraviolet source and photo resist. The dotlike image is formed with a dark field mask. The wafer is coated with negative photo-resist by keeping the
wafer on spinner by using vacuum. The spinning speed is set at 2000 rpm and timer is set at 2 minutes so that
the thickness of the photo-resist is neither too thin nor too thick. Pre-baking is done in a baking furnace at a
temperature of 700C for duration of 30 minutes. This is followed by exposing the photo-resist coated wafer with
UV source for 2 minutes in a Mask aligner. Post baking is done at a temperature of 800C for duration of 30
minutes. Then the wafer is dipped in a developer.
4.12 Mesa etching
After photolithography process, first gold (Au) and then (Cr) chromium is removed from n+ side of the silicon
wafer by using selective chemicals. After removing metalized layers, the wafer was dipped into mesa etching
solution of HF, HNO3 and CH3COOH for 20 minutes and an array of mesa chips with appropriate diameter of
50 micron is obtained, shown in Fig.18 and photographs of array of mesa chips in Fig.19. All the chips are now
ready for bonding and packaging.
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5.
For DC and RF characterization of IMPATT diode, the diode is placed in a proper microwave / mm wave cavity
to get oscillation and RF power. The diode having device admittance (GD + jBD) is mounted in a microwave /
mm wave cavity .The device is biased to breakdown and connected to load having admittance (GL + j BL). The
condition for stable oscillation is fulfilled when the magnitude of the negative conductance of the device equals
the magnitude of the positive conductance of the load, i.e.
GD = GL
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and the magnitude of the capacitive susceptance of the device equals the magnitude of the inductive susceptance
of the load.
BD = BL
The authors have used a resonant cap cavity [8], in which the device is placed between the broad lower face of
a mm wave guide and the bottom face of a circular metal disc called resonant cap, schematically shown Fig.24.
The bias is given by a constant current power supply through a low pass mm wave filter connected with the top
surface of the resonant cap. The low pass type filter prevents high frequency oscillations from coupling with
the power supply when dc or low frequency bias current can pass through the filter and the diode. Considerable
heat is generated in the diode junction where large current is flowing at breakdown. Therefore an integral heat
sink cum wave guide cavity is used whose photograph is shown in Fig.25. The cap and the bottom surface of the
wave guide form a localized radial cavity around the diode. The mm wave signal generated by the diode is
coupled to the main rectangular wave guide cavity through the vertical open edges of the radial cavity.
DC Bias
Ampere meter
IMPATT Oscillator
Isolator
Attenuator
Voltmeter
Power meter
Directional coupler
10 dB
Spectrum Analyzer
Directional coupler
10 dB
Frequency counter
Fig.26 shows a block diagram of a Ka-band measurement test set up used for DC and RF characterization of
IMPATT diode. Fig. 27 shows the DC V-I characteristic of the fabricated IMPATT diode. It is seen from the
graph that the diode has a soft break down in the range of 25 -31 volt. A maximum current up to 85 mA is
pushed through the device. Fig. 28 and Fig. 29 shows the plot of DC bias current vs output power and frequency
respectively. Fig. 30 shows a typical Ka-band spectrum (34.891 GHz) of the fabricated diode. A power output of
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14. 65 mW has been achieved at a frequency of 35.70 GHz with a bias current of 85 mA and break down
voltage of 31 volt.
6. Conclusion
In this paper the design of a SDR Ka-band IMPATT diode and then fabrication process steps following the
diffusion technique are described in details followed by measurement of DC and RF characterization of
developed IMPATT diode. A silicon (p+nn+) SDR IMPATT diode for Ka-band operation has been designed by
using double iterative DC and Small signal simulation methods which involve simultaneous solution of
Poissons equation and Carrier continuity equation under appropriate boundary conditions. The computation
starts from the field maximum point in the depletion layers and proceeds towards the depletion layer edges. The
current density and junction temperature have been taken to be 9107 A/m2 and 2250C respectively. The realistic
field and temperature dependence of carrier ionization rates and the drift velocities at 2250 C and the effect of
mobile space charge have been considered in the simulation. The design has been optimized to get the peak
negative conductance at 36.5 GHz. Based on the DC and Small signal simulation, the authors have selected the
thickness and resistivity of silicon epitaxial n/n+ wafers for fabrication of a (p+nn+) SDR Ka-band IMPATT
Diode through diffusion route . The optimized process flow chart for realization of Ka-band SDR IMPATT is
shown below.
A resonant cap cavity has been used for DC and RF characterization of the fabricated diode. A power output of
14. 65 mW at a frequency of 35.70 GHz has been achieved at a bias current of 85 mA with break down voltage
of 31 volt. It is observed that the frequency of operation of the fabricated diode closely matches with the design
frequency. The power and frequency can be optimized by thinning the substrate in the range of 5 -10 micron so
as to minimize the effects of series resistance. To get the maximum output power at the desired frequency the
operating dc bias current is in the range of 150 - 200 mA without the problem of thermal burnout of the device.
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Wafer cleaning
Activation of Boron
Nitride (BN)
Stabilization
Low Temperature
Oxidation
Drive in Diffusion
Pre-deposition of
Boron
Cr-Au Metallization
of p+ side
Electroplating of
metalized p+ side
Thinning of n+ side
Mesa etching
Photolithography
CrAu Metallization
of n+ side
Chip separation
Die/wire Bonding
and packaging
RF characterization
Acknowledgement
The first author is thankful to Shri. S.K. Ray, DS & Director, Research Centre Imarat, Hyderabad, Shri. R. Das,
Director, RF Systems, Dr. V.G. Borkar, Head, Antenna & Components Group and Shri. J.V. Prasad, Head,
MMW Seekers & Sensors Division for their consistent support and encouragement for carrying out the research
work.
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[15]
[16]
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Wolf, Helmut F., Silicon Semiconductor Data, Signetics Corporation, Pergamon Press, First Edition 1969.
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Sons, 1976.
Gibbons, G., Avalanche diode microwave oscillators, Oxford University Press, Oxford 1973, Ch.4, pp. 45-65.
Pal, Tapas Kumar., A Tunable Millimeter wave (Ka-Band) IMPATT Source Using an Integrated Heat Sink cum Waveguide mount,
Patent no. 221758, INDIA, 15.02.2001.
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(Dublin, Republic of Ireland: Bolle Press), p. 494, 1985.
Gummel, H. K. and Blue, J. L., A small signal theory of avalanche noise in IMPATT diodes, IEEE Trans. Electron Devices, vol.
ED-14, pp.569-580.1967.
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Authors
Shri Tapas Kumar Pal, born in October, 1976 at Kolkata, obtained his M.Sc degree in Physics with
specialization in Microwaves from University of Calcutta in 1999. He has worked as a Senior
Research Fellow and Senior Scientist at Centre of Advanced Study in Radiophysics & Electronics,
University of Calcutta for a period of 2.5 years from Feb 2000 onwards. Later he worked as an
Examiner of Patents & Designs at Patent Office, Kolkata till July 2005. Presently he is working as a Scientist
D at Research Centre Imarat, DRDO, Hyderabad. He is currently engaged in development of MMW Seekers
and Sensors. His special interests are Design and Development of MMW IMPATT Diodes, Oscillators and
Amplifiers and their computer simulations. He has also been pursuing Ph.D (Tech) Degree at Institute of
Radiophysics & Electronics, University of Calcutta, on Millimeter wave IMPATT Diodes and Oscillators. He
is a Life Member of IETE and Member of IEEE.
Dr J. P. Banerjee obtained B.Sc. (Hons.) and M.Sc. in Physics and Ph.D. in Radio Physics and
Electronics from the University of Calcutta. He is presently a full Professor in the Institute of
Radio Physics and Electronics, C.U. He is the recipient of Indian National Science Academy
Award and Griffith Memorial Prize in Science of the Calcutta University in 1986. He is the
principal co-author of more than 125 research papers in international journals in the fields of Semiconductor
Science and Technology, Microwave and Millimeter wave avalanche transit time devices and Avalanche Photodetectors. He has authored a text book on solid state electronic devices published by Vikas Publishing Ltd, New
Delhi, India. He is a fellow of IETE, Senior Member of IEEE, a life member of the Society of EMI and EMC
and Semiconductor Society, India. He served as a referee for various National and International technical
journals. Presently he is also serving as the Director of a collaborative research centre entitled Centre of
Millimeter wave Semiconductor Devices and systems in the University of Calcutta.
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