The
fully depleted silicon-on-insulator (FD-SOI) wafer is the core
material of the FD-SOI technology used for manufacturing the applications
with ultralow energy consumption for internet of things, artificial
intelligence, automotive, and wearable devices. Ion-cut process is
the main technology to fabricate FD-SOI wafers. After ion cutting,
the silicon layer transferred on the insulator includes a spongelike
damaged layer. Therefore, it must contain a thinning buffer layer
with a thickness more than 150 nm to remove the damaged layer by a
polishing step. The requirement of the additional buffer layer makes
the direct fabrication of a less than 100 nm thick SOI layer from
the as-split status impossible. Here, we develop a process based on
solid-phase epitaxial growth (SPEG) technique, abandoning the polishing
step, and thus achieve a one-step fabrication of FD-SOI substrate.
First, inducing amorphization of an SOI layer via blistering supersaturated
hydrogen ions through microwaving fully consumes the possible stable
defect clusters. Next, using SPEG technique catalyzed by surrounding
hydrogen ions restores the amorphized SOI layer to the initial crystalline
structure. To approach the purpose, a silicon (Si)-clad layer deposited
on the oxidized surface was used. The Si-clad layer has two functions
promoting the success of SPEG processing. It acts as a filter to prevent
co-implanted impurities in the silicon layer to avoid the occurrence
of crystal segregation during recrystallization. It also serves as
a sacrificial layer to bring the split location close to the implant
peak causing the hydrogen concentration in the entire SOI layer in
supersaturation. When amorphizing this layer, an undamaged crystalline
layer is retained at the interface of the SiO2/Si as a
seed layer to promote the regrowth of a perfect SOI layer in a argon-annealing
step. By integrating with the ion-shower implantation used in flat-panel
display manufacturing, the technology can fabricate the next generation
of larger SOI wafers without the need to upgrade the ion implanter.