Droplet migration doping using carrier droplets

Claim 1

In the method of moving a melt of metal-rich semiconductor material through a solid body of silicon semiconductor material by thermal gradient zone melting processing comprising the steps of a. selecting a body of single crystal semiconductor material so that the body has a first type conductivity, a selected resistivity, and at least one major surface having a preferred planar crystal structure orientation which is one selected from the group consisting of (100), (110) and (111), the vertical axis of the body being substantially aligned with a first axis of the crystal structure; b. preparing the surface having the preferred planar crystal structure orientation to accommodate one or more physical configurations of a layer of metal thereon; c. vapor depositing a layer of metal on the selected surface of the body of semiconductor material; d. heating the body and the metal deposit to a temperature sufficient to form a melt of metal-rich material on the surface of the body; e. establishing a unidirectional temperature gradient along substantially the vertical axis of the body and the first axis of the crystal structure; f. migrating the metal-rich melt through the body along the unidirectional temperature gradient to divide the body into a plurality of regions of first type conductivity and to form at least one array of regions of recrystallized material of the body having solid solubility of the vapor deposited metal therein, the metal including at least one dopant impurity material therein to impart a predetermined second type conductivity and a selected level of resistivity thereto; the improvement in the method of processing which includes vapor depositing a layer of metal which comprises a first material which includes at least a first metal which improves physical properties of the melt such as the penetration of the melt, when formed, into the surface of the body, increases stability of the migration of the melt through the body, and increases the rate of melt migration through the body, the at least one first metal is one selected from the group consisting of aluminum, gallium, indium and magnesium, and a second material which includes at least a second metal which imparts to the recrystallized region predetermined electrical characteristics of conductivity type, level of resistivity, and control of lifetime and the like, and the temperature gradient zone melting is practiced at a temperature greater than the temperature at which intermetallic compounds are formed by the material of the semiconductor body and the at least one first metal.