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Porous silicon
500
450
400
Number of publications
350
300
250
200
150
100
50
0
56 66 76 86 96
Year
Figure 2-1 Number of publications per year regarding porous silicon since it was first
discovered
Although porous silicon was first discovered by Uhlir[1] in 1956, significant interest in this material is
more recent. Figure 2-1[2,3] illustrates this increasing interest by plotting the number of publications per
year on the subject of porous silicon since 1956. The small amount of interest shown in porous silicon
from the mid-1970’s and throughout the 1980’s relates almost exclusively to its use for device isolation
in integrated circuits[4,5]. The more noticeable interest shown from the start of this decade came with
the demonstration by Canham[6] of room temperature photoluminescence from this material. Since this
time the majority of research into porous silicon has focussed on observations of and explanations for
both photoluminescence and electroluminescence from this material, and its potential optoelectronic
applications.
The work described in this thesis uses p-type† porous silicon in the main. This chapter briefly reviews
the fabrication and structure of porous silicon this p-type silicon and possible applications of both n-
and p-type porous silicon.
The demonstration of photoluminescence from porous silicon stimulated research into the use of
porous silicon for optoelectronic circuits and forms around half of the literature currently available on
porous silicon. Several mechanisms have been proposed for this photoluminescence and a brief
review of both the observations and possible mechanisms is given in Appendix A. From a device point
of view it is electroluminescence rather than photoluminescence which is important, and this is
discussed in section 2.2.3 of this chapter.
†
Porous silicon fabricated from a p+ substrate is abbreviated to p+ porous silicon and likewise for
porous silicon fabricated from p–, n– and n+ substrates. Porous silicon fabricated from p-type
substrates or n-type substrates where the doping level is unspecified will be referred to p-type
porous silicon and n-type porous silicon respectively.
3
Porous Silicon
From pump
Cathode Electrode
Cell
_ +
O-ring
Silicon wafer
Metal contact
Porous silicon
To pump
Figure 2-2 Schematic diagram of two arrangements commonly used to fabricate porous silicon
(adapted from ref [15])
‡
The porosity of a layer can be determined by weighing the silicon substrate both before and after
anodisation (m1 and m2 respectively) and again after porous silicon layer has been removed (m3).
The porosity(P) and layer thickness(W) are then calculated by
P = (m1-m2)/(m1-m3) and W = (m1-m3)/(Sd)
where S is the surface area of the wafer which is anodised and d is the density of bulk silicon
4
Porous Silicon
300
19 -3
NA = 1x10 cm
17 -3
NA = 1x10 cm
100
0
0 100 200 300 400
Figure 2-3 Growth rate of porous silicon as a function of current density (Data taken from ref.
[16])
Good homogeneity within the porous silicon layers is obtained because the electrical contact to the
silicon substrate is made using the entire back surface of the wafer. This prevents lateral potential
variation across the wafer that would cause changes in the local current density. As discussed in
section 2.1.3 the porosity of a layer is partly determined by current density. Thus maintaining a
constant current density throughout the substrate allows constant porosity porous silicon to be
obtained, providing there are no local variations in the concentration of the hydrofluoric acid in the
electrolyte and that chemical leaching does not occur. The hydrofluoric acid concentration and
chemical leaching are also factors that determine the porosity of a porous silicon layer, as discussed
in section 2.1.3. Despite the nature of the anodic contact, however, hydrogen bubbles evolved during
the anodisation can cling to the surface of the wafer and cause variations in the local potential. For
this reason the electrolyte may be circulated during the anodisation to remove these bubbles. This is
particularly important in the double tank arrangement where the gas evolves during the cathodic
reaction[15] and can cause local variations in potential throughout the substrate.
Figure 2-3 illustrates how the growth rate of porous silicon depends upon the anodisation current
density for starting substrates that are both lightly and heavily doped. It is obvious from the graph that
the thickness of a porous silicon layer after a given time period depends upon the current density at
which it has been anodised. The thickness of a porous silicon layer is therefore uniform providing a
constant current density is maintained whilst any variation in the local current density across the wafer
would cause changes in the thickness of a layer across the wafer[6].
The electrical contact to silicon substrates with low doping levels can be improved by a high dose
back implant. A metal evaporation is also necessary for these substrates when they are to be
anodised in the single tank cell of Figure 2-2a. This is unnecessary for anodisation in the double tank
because the contact is electrolytic and not metallic. An advantage of the double tank arrangement is
that it avoids a potential source of contamination of the porous silicon in any subsequent thermal and
chemical processing[15]. Substrates with high doping levels require neither a back implant nor a metal
evaporation for either arrangement.
The choice of electrolyte is determined by the necessity for the electro-active species required for the
anodisation to be efficiently transported to the porous silicon - silicon interface where the anodisation
process primarily occurs. The hydrophobic[17] and organophillic[15] nature of porous silicon means that
ethanol is a more suitable carrier than water, hence its use in the electrolyte. It can be seen from
Figure 2-4, however, that roughness is still observed at the porous silicon – silicon interface. In the
work described in Chapter 6 it will be seen that similar roughness also occurs at the interface between
porous silicon layers of different porosity. The amplitude of this roughness does decrease with
increasing porosity. In one example[18] increasing the porosity from 65% to 85% caused the amplitude
of the roughness to be reduced from 6nm to 3nm. It is thought that this reduction is a result of the
increasing pore widths associated with increasing porosity allowing easier access of the electrolyte to
the pore tips. Ethanol also acts as a surfactant agent and assists in removing hydrogen bubbles from
the surface(s) of the silicon substrate.
5
Porous Silicon
Porous Silicon
Silicon
Figure 2-4 Interface between porous silicon and silicon substrate. The porous silicon layer has
a thickness of 5µm and a porosity of 56%.
The electrolyte used for the fabrication of the porous silicon described in chapter 6 of this thesis
consisted of a 1:1:2 ratio of HF, water and ethanol. Water forms part of the electrolyte merely because
the hydrofluoric acid was supplied in a 50% aqueous form. Details of the electrolytes used for the
porous silicon described in chapter 5 and section 6.4 are given in those sections.
6
Porous Silicon
H H
1. In the absence of electron holes, a hydrogen saturated
silicon surface is virtually free from attack by flouride ions
Si
in the HF based electrolyte. The induced polarisation
between the hydrogen and silicon atoms is low because
Si Si
the electron affinity of hydrogen is about that of silicon.
F
H H
2. If a hole reaches the surface, nucleophillic attack on an
Si Si-H bond by a fluoride ion can occur and a Si-F bond is
formed.
Si Si
H
F H 3. The Si-F bond causes a polarisation effect allowing a
F
second fluorine ion to attack and replace the remaining
Si
hydrogen bond. Two hydrogen atoms can then combine,
injecting an electron into the substrate.
Si Si
H2
4. The polarisation induced by the Si-F bonds reduces the
F F
F F electron density of the remaining Si-Si backbonds making
Si them susceptible to attack by the HF in a manner such
H+ H+ that the remaining silicon surface atoms are bonded to the
hydrogen atoms.
Si Si
F F
Figure 2-5 Suggested mechanism for the electrochemical dissolution of silicon (after ref [23])
7
Porous Silicon
- +
HF
electrolyte
Si
HF Si
Electrolyte
+
H
Porous silicon
HF electrolyte Silicon
Figure 2-6 Band diagram of the silicon - porous silicon interface where the radius of a silicon
branch is small enough to exhibit quantum confinement (adapted from ref [24])
90
80
Porosity (%)
70
60
19 -3
50 NA = 1x10 cm
17 -3
NA = 1x10 cm
40
0 100 200 300 400
Current density (mA/cm2)
Figure 2-7 Porosity - current density curve for p– and p+ porous silicon (taken from ref. [16])
2.1.3 Porosity
The factors that determine the porosity of a porous silicon layer include the substrate doping,
anodisation current density and the HF concentration and pH value of the anodising electrolyte. The
relationship between porosity and current density is shown in Figure 2-7 for the porous silicon used for
the fabrication of optoelectronic components described in chapter 6. This graph shows how the
porosity of a layer increases with increasing current density and decreasing substrate doping[22]. The
porosity also increases with decreasing HF concentrations and increasing pH values of the electrolyte.
8
Porous Silicon
c
Figure 2-8 Microstructure of porous silicon - a) Cross section of p– porous silicon (photograph
taken from ref. [20]), b) Cross section of p+ porous silicon (photograph supplied by
Berger [27]), c) Planar view of p+ porous silicon (photograph supplied by Loni [28])
The relationship between porosity and pH values is caused by chemical dissolution of the porous
silicon branches by OH– ions present in the electrolyte. The dissolution rate increases with increasing
levels of the OH– ions in the electrolyte and therefore increasing pH values. This chemical dissolution
continues for as long as the porous silicon remains in contact with the electrolyte, increasing the
porosity of a layer even after the anodisation process is completed. The dissolution rate is partially
dependent upon the surface area available for reaction, a measurement that can be determined by
gas adsorption isotherms[14]. The surface area density, defined as the surface area of the silicon
branches forming the porous silicon, varies from 200m2/cm3 for porous silicon formed from p+ silicon
(ρ = 0.01Ωcm) to 600m2/cm3 for p– silicon (ρ = 1Ωcm)[14,15], though it decreases with increasing
porosity above 50%[15].
The effect of chemical dissolution on a porous silicon skeleton is to reduce the diameter of the
individual silicon branches. At higher porosities, already thin branches may disappear weakening the
remaining structure. Drying such layers can cause cracking or complete disintegration of the branches
due to capillary tensions that occur on the branch surface at the liquid - vapour phase of drying. These
forces can be avoided by supercritical drying. The use of such a technique has enabled layers of up to
97% porosity to be fabricated[29].
2.1.4 Microstructure.
The width and orientation of the branches and pores that form a porous silicon skeleton change as the
level of doping in the original substrate is altered. Figure 2-8 shows SEM and TEM photographs of
both p– and p+ porous silicon. As can be seen from Figure 2-8a porous silicon fabricated from lightly
doped p-type substrates consist of a highly inter-connected network of fine silicon branches. These
branches are typically less than 5nm wide and separated by pores of similar dimensions[30]. Figure 2-
9
Porous Silicon
8b and Figure 2-8c illustrate how porous silicon fabricated from more heavily doped p-type substrates
produces layers with wider pores and silicon branches which run parallel to each other. The widths of
the pores and branches of the p+ porous silicon typically have widths of 10 – 25nm though widths up
to 100nm have been reported[31]. These wider pores explain the lower density of the surface area[31] of
p+ porous silicon reported in the previous section. Figure 2-8c shows how the silicon branches of
these heavily doped layers have many small ‘buds’ that are not constrained to any plane[32]. It has
been noted that the distribution of the pore widths and the average pore width both increase with
increasing current density and decreasing HF concentrations in the electrolyte[14].
The method is based on the oxidation of porous silicon to isolate pre-defined islands of crystalline
silicon from the bulk silicon substrate. Providing the porosity of the porous silicon was sufficiently high,
the expansion of the silicon branches would fill the pores and not increase the thickness of the layer
causing the silicon islands to warp. The ideal porosity was estimated to be near 56%[36]. Figure 2-10
illustrates the methods used to implement the FIPOS process. This was achieved by either the
preferential anodisation to isolate predefined islands of silicon[5,39] or the epitaxial growth of silicon on
a porous silicon layer that retains the monocrystalline character of the bulk substrate[37].
The original FIPOS method suggested by Imai was the preferential anodisation of a p-type bulk silicon
substrate over implanted islands of n– silicon[5]. The current density - voltage characteristics of
different substrates vary, as shown in Figure 2-10[15]. Limiting the potential during anodisation
facilitates the preferential anodisation of p+ substrate over p– substrates, n+ substrates over n– or p-
type substrates and p-type substrates over n– substrates.
The original structures that were fabricated displayed the advantages of SOI and FIPOS devices
already mentioned. Unfortunately devices fabricated in this manner required thick porous silicon layers
in order to fabricate silicon islands of moderate widths. This was caused by the rate of pore formation
being uniform in all directions giving rise to a layer of at least half the island width[5]. The layer
thickness was reduced by either ion implantation or epitaxial growth to define the layers that would
form the porous silicon[39]. The silicon islands were then formed by the epitaxial growth and etching of
an additional silicon layer. Another problem was that of wafer warpage that was resolved by
implementing the FIPOS method in an n/n+/n structure[38]. This also removed the remaining problems
of non-uniform porous silicon layers, and the thin wisp of silicon that remained under the silicon island
where the anodisation fronts met[39].
10
Silicon substrate
Preferential anodisation Growth of silicon on porous silicon
Implantation to define silicon islands Etch to define islands Epitaxial growth of silicon layer
11
Anodisation to form porous silicon Anodisation to form porous silicon Etch to define islands
140
80
60 n+
40
20
n-
0
-0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
Potential (volts)
Figure 2-10 Current density - potential graph for p+, p–, n+ and n– silicon substrates (taken from
ref [15])
2.2.2 Micromachining
The techniques employed for dielectric isolation using porous silicon can also be used for
micromachining applications. Micromachining is used to fabricate small-scale mechanical devices that
are integrated with conventional microelectronics. Examples of micromachined devices include
motors, cantilevers and a wide variety of sensors that are designed to sense temperature, IR and UV
radiation, fluid flow or gas flow. Many of these structures are fabricated on free-standing membranes,
structures that can be easily fabricated using porous silicon.
Conventional micromachining methods to form free-standing membranes include anisotropically
etching[42] the rear of a substrate. This is a well established technology whose main drawback it the
need for double sided lithography. The use of double sided lithography is avoided when surface
micromachining technology[42] is used. Instead an easily etchable sacrificial layer is deposited on to
the substrate surface followed by a second layer that will form the membrane. A second layer is then
deposited that, after defining the micromachined device and removing the sacrificial layer, forms the
free-standing membrane. The drawback of this method is the limited distance that can be obtained
between the membrane and substrate. The limiting factor is defined by the maximum thickness
obtainable for the sacrificial layer and is typically limited to several microns. Although this distance
may be sufficient for applications such as micromotors, applications such as sensing often require
thickness for the sacrificial layer to be several tens of microns to reduce heat transfer to the substrate.
Porous silicon provides a good alternative to both methods described above. It is formed without the
use of double-sided lithography and can be fabricated to thicknesses of several tens of microns. The
fabricated layers, regardless of thickness, are then easily removed using a weak potassium hydroxide
solution or even photoresist developing solution. Additionally, unlike anisotropic etching the geometry
of the porous silicon layers is not limited to certain planes and so they can be formed locally on a
wafer with controlled undercutting.
A variety of devices have been demonstrated using this fabrication method including cantilever
beams[40], bolometers for thermal measurements[41], flow channels and wires[42]. Bridges[42] have been
shown to be stable under heat treatment and gas flow though not, unfortunately, to being dropped on
the floor! It has recently been suggested[41] that the porous silicon may not need to be removed in all
applications as was originally demonstrated over a decade ago for flow sensors[43]. The low thermal
conductivity of p- porous silicon means that the porous silicon may provide sufficient thermal isolation
from the substrate. This removes the need for removing the porous silicon to provide an air gap,
providing an almost identical thermal isolation function whilst improving the mechanical robustness of
the device.
12
Porous Silicon
13
Porous Silicon
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Porous Silicon
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17