Formation of silicon on plasma synthesized aluminum nitride structure by ion cutting

The application of silicon-on-insulator (SOI) substrates to high-power integrated circuits is hampered by self-heating effects due to the poor thermal conductivity of the buried SiO2 layer. We propose to replace the buried SiO2 layer in SOI with a plasma synthesized AlN thin film to mitigate the self-heating penalty. The AlN films synthesized on silicon by metal plasma immersion ion implantation and deposition exhibit outstanding surface topography and excellent insulating characteristics. Using a modified direct bonding process in conjunction with hydrogen-induced layer transfer, a silicon-on-AlN structure has been successfully fabricated. Cross-sectional high-resolution transmission electron microscopy, x-ray photoelectron spectroscopy, and spreading resistance profiling results reveal a uniform buried AlN layer beneath a single crystal Si overlayer. The interfaces between the top Si layer, buried AlN layer, and Si substrate are smooth and sharp. Moreover, the use of relatively thick buried AlN layer bodes well for SOI wafers in high voltage and high power applications.