Method of forming an epitaxial layer on a crystalline substrate

Claim 2

An improved method of forming an epitaxial layer of crystalline semi-conductive material on a crystalline substrate, said method comprising: (a) contacting and wetting a clean selected crystalline substrate with a controlled thickness of selected molten melt to form a sandwich, said melt comprising a saturated solution of selected semi-conductive materials capable of forming desired semi-conductive junctions with said substrate, said contacting and wetting being carried out while shielding said sandwich from contamination; (b) maintaining said shielding while subjecting said sandwich to heat treatment comprising controlled progressive lowering of temperature of said sandwich while maintaining said melt molten and said substrate cooler than said melt until deposition of the desired epitaxial layer on said substrate is effected; and (c) recovering the semi-conductive product.

Claim 3

The improved method of claim 1 wherein said product comprises a light-emitting diode wherein said epitaxial layer is a heteroepitaxial layer and wherein said shielding includes a protective enclosure filled with an inert gas and enclosing said sandwich.

Claim 4

The improved method of claim 2 wherein said substrate comprises GaAs and wherein said heteroepitaxial layer comprises Ga x Al 1 -x As.

Claim 5

The improved method of claim 2 wherein said substrate comprises GaAs and wherein said heteroepitaxial layer comprises GaAs x P 1 -x .

Claim 6

The improved method of claim 2 wherein said substrate comprises GaP and said heteroepitaxial layer comprises In x Ga 1 -x P.

Claim 7

The improved method of claim 2 wherein said substrate comprises GaP and said heteroepitaxial layer comprises Ga x Al 1 -x P.

Claim 8

The improved method of claim 2 wherein said substrate comprises GaAs and said heteroepitaxial layer comprises In x Ga 1 -x P.

Claim 9

The improved method of claim 1 wherein said epitaxial layer is heteroepitaxial, and wherein said progressive temperature lowering is at a rate sufficient to prevent melt inhomogenization and is effected by passing said sandwich through an elongated treating zone having a plurality of successive heating sub-zones forming a temperature gradient from one end of said zone to the opposite end thereof.

Claim 10

The improved method of claim 8 wherein said substrate comprises a relatively thin wafer, wherein said melt is disposed generally parallel to the main axis of said wafer and wherein said sandwich is passed through said zone progressively from the hotter end to the cooler end of said zone with said main axis generally perpendicular to the main axis of said zone and the direction of said passage through said zone whereby improved formation of said layer is effected.

Claim 11

The improved method of claim 9 wherein said sandwich is passed through said zone at a heat change rate of about 0.1°- 10° C./minute.

Claim 12

The improved method of claim 10 wherein the temperature gradient within said sandwich is about 1°- 6° C./cm (thickness of said sandwich perpendicular to said main axis).

Claim 13

The improved method of claim 10 wherein said melt has a thickness of about 0.2- 2 mm. in said sandwich.

Claim 14

The improved method of claim 12 wherein a spaced plurality of said sandwiches are simultaneously passed through said zone.

Claim 15

The improved method of claim 1 wherein said substrate is covered and wetted by said melt on opposite sides of extended surface area and wherein the melt on each said side has said thickness of about 0.2- 2 mm.

Claim 16

The improved method of claim 1 wherein said sandwich is disposed in a holder fitted within a crucible to form a tool which limits said thickness of said melt, protects said sandwich and progressively moves said sandwich through said zone.

Claim 17

The improved method of claim 15 wherein a plurality of said sandwiches are supported in spaced relation within said tool during said passage through said zone.

Claim 18

The improved method of claim 1 wherein said epitaxial layer is heteroepitaxial, wherein said substrate is prewetted before treating it with said melt in said zone, and wherein said prewetting is effected by contacting the surface of said substrate with material selected from the group consisting of a major component of said melt and said melt, at a temperature lower than that of said zone.

Claim 19

The improved method of claim 17 wherein said substrate surface is prewetted with said major component which comprises the solvent of said melt.

Claim 20

The improved method of claim 17 wherein said substrate surface is prewetted with said melt.

Claim 21

The improved method of claim 17 wherein said product is a light-emitting diode, wherein said sandwich is disposed in a holder fitted within a crucible to form a tool which is in turn shielded by hydrogen and disposed for movement along the length of an elongated oven having a plurality of progressively cooler heating zones from one end to the other, wherein the dimensions of said holder limit the thickness of said melt on said substrate to about 0.2- 2 mm. per substrate surface, wherein said substrate is a flat thin wafer with its main axis perpendicular to the direction of movement of said tool from the hotter to the cooler end of said oven during said treating, and wherein the rate of movement of said sandwich is such as to produce a heat change rate in said sandwich of about 0.1°- 10° C./minute and a temperature gradient in said sandwich of about 1°- 6° C./cm. sandwich thickness perpendicular to said main axis, so as to produce an essentially perfect epitaxial liquid layer regrowth with essentially perfect impurity distribution, due to melt limitation, for desired heterojunctions.