I. Field of the Invention
The present invention generally relates to the field of semiconductor devices and more particularly to bi-directional power switches.
2. Related Background Art
Power MOSFETs (metal-oxide-semiconductor field-effect transistor) are used to create monolithic bi-directional power switches (“BDS”). Bi-directional switches are used in many applications, such as in battery charging circuitry to permit controlling the discharging and charging of batteries. For instance, lithium-ion batteries should not continue to be charged after they are fully charged to prevent dangerous and catastrophic failures and fires.
Two types of bi-directional switches are currently available. The first type is exemplified by products such as Siliconix's Si8900EDB and International Rectifier's FlipFET. In these types of switches, the drains of two MOSFETs are connected together through a common silicon substrate as shown in
In both cases, current flow for these MOSFETs goes from the source to the drain via the substrate. When creating bi-directional switches, two vertical trench MOSFETS are used and connected via a common drain. The first type of bi-directional switch (e.g. Siliconix's Si8900EDB and International Rectifier's FlipFET) have higher RDSON (static drain-source on-resistance). This is because using vertical trench MOSFETs creates long current pathways from the source of the first MOSFET to the source of the second MOSFET. In particular, current first travels down vertically, then horizontally through the substrate then back up vertically. This causes the current to travel through high resistance structures resulting in, inter alia, high RDSON values. The second type has a lower RDSON but a high cost due to the additional copper package.
Accordingly, there is a need to provide bi-directional power switches with efficient current flow and without the need for costly packaging. There is also a need for bi-directional switches with improved (i.e., lower) on-resistance and monolithic structures.
According to an embodiment of the present invention, a lateral MOSFET bi-directional switch is disclosed. In accordance with one aspect of the present invention, a semiconductor device is disclosed with (a) a semiconductor substrate having an upper surface and a lower surface; (b) a first region of a first conductivity type in said semiconductor substrate and proximate to said upper surface; (c) a first source region and a second source region of a second conductivity type within said first region; (d) a drain region of a second conductivity type formed within said first region and proximate to said upper surface and between said first and second source regions; (e) a first source overlaying and connecting said first source region; (f) a second source overlaying and connecting said second source region; (g) a first gate above said upper surface and placed between said first source and said second source wherein said first gate overlays a portion of said first source region and said drain region; (h) a second gate above said upper surface and placed between said second source and said first gate wherein said second gate overlays a portion of said second source region and said drain region.
In accordance with another aspect of the present invention, a semiconductor device is disclosed with (a) a semiconductor substrate having an upper surface and a lower surface; (b) a first region of a first conductivity type in said semiconductor substrate and proximate to said upper surface; (c) a second region and a third region of a second conductivity type within said first well region; (d) a first source region of a first conductivity type within said second region and a second source region having a first conductivity type within said third region; (e) a first source overlaying and connecting said first source region; (f) a second source overlaying and connecting said second source region; (g) a first gate above said upper surface and placed between said first source and said second source wherein said first gate overlays a portion of said first source region and said second region; (h) a second gate above said upper surface and placed between said second source and said first gate wherein said second gate overlays a portion of said second source region and said third region.
In accordance with yet another aspect of the present invention, a semiconductor device is disclosed with (a) a semiconductor substrate having an upper surface and a lower surface; (b) a first region and a second region of a first conductivity type in said semiconductor substrate and proximate to said upper surface; (c) a first connecting region within said first region of a first conductivity type and a first source region within said first region of a second conductivity type; (d) a second connecting region within said second region of a first conductivity type and a second source region within said second region of a second conductivity type; (e) a first source overlaying and connecting said first source region; (f) a second source overlaying and connecting said second source region; (g) a first gate above said upper surface and placed between said first source and said second source wherein said first gate overlays a portion of said first source region and said first region; (h) a second gate above said upper surface and placed between said second source and said first gate wherein said second gate overlays a portion of said second source region and said second region.
In accordance with yet another aspect of the present invention, a semiconductor device is disclosed with (a) a semiconductor substrate having an upper surface and a lower surface; (b) a first region of a first conductivity type proximate to said upper surface; (c) a plurality of second regions of a second conductivity type within said first well region, each of said second region having a first source region of a first conductivity type within said second regions; (d) a plurality of third regions of a second conductivity type within said first region, each of said third region having a second source region of a first conductivity type within said third region; (e) a plurality of first sources overlaying and connecting said plurality of said first source regions; (f) a plurality of second sources overlaying and connecting said plurality of said second source regions; (g) a plurality of first gates above said upper surface wherein each first gate is placed between a first source and a second source and overlays a portion of said first source region and said second region; (h) a plurality of second gates above said upper surface wherein each second gate is placed between a second source and first gate and overlays a portion of said second source region and said third region.
In accordance with yet another aspect of the present invention a semiconductor device is disclosed having a plurality of first sources and a plurality of second sources wherein current flows from a first source to an associated second source. The semiconductor device have the first sources dispersed among the second sources. The semiconductor devide may also have current paths from different first sources to associated second sources that are substantially similar.
a is a cross sectional view of one cell of a bi-directional switch in accordance with an embodiment of the present invention.
b is a top view one embodiment of
c is a cross sectional view of one cell of a bi-directional switch in accordance with an embodiment of the present invention.
a is a top view of solder bumps of an exemplary device without access to the drain.
b is a top view of solder bumps of an exemplary device with access to the drain.
It will be appreciated that for simplicity and clarity of illustration, elements illustrated in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements are exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals have been repeated among the figures to indicate corresponding or analogous elements.
The preferred embodiment of the present invention uses conventional CMOS fabrication processes to fabricate a semiconductor device embodying the present invention to reduce the costs of production. In accordance with one aspect of the present invention, however, only one type of MOSFETs (either an n-channel or p-channel MOSFET) is made on the die. Since the device of the present invention only consists of parallel n-channel or p-channel transistors, the problem of latch-up is avoided.
In one embodiment, multiple bi-directional switches are fabricated on a single monolithic chip and connected in parallel. Preferably, these bi-directional switches are interconnected by runners that are short and wide. These interconnections are disclosed in more detail in U.S. patent application Ser. No. 10/601,121 filed Jun. 19, 2003 and U.S. Provisional Application 60/416,942 filed Oct. 8, 2002, both incorporated herein by reference in their entirety.
Referring now to
Source 340 is placed over region 320, drain 350 is placed over region 330, and gate 360 is placed, with an insulating layer (e.g. SiO2), between source 340 and drain 350. In this embodiment gate 360 overlays that portion of P-well 312 that is proximate to the surface under gate 360. Gate 360 also partially extends over those sections of regions 320 and 330 having the N majority carrier concentrations.
In operation, when gate 360 is biased, an n-channel forms under gate 360 thereby permitting current to flow between source 340 and drain 350 via region 320, the n-channel under gate 360 (not shown) and region 330.
The MOSFET shown in
The MOSFET of
Source 460 is placed over region 440 and drain 470 is placed over region 450. Gate 480 is placed, with an insulating layer (e.g. SiO2), between source 460 and drain 470. Gate 480 overlays a portion of region 440, a portion of p-well 430 that extends to the surface under gate 480, a portion of N-well 420 which also extends to the surface under gate 480, and a portion of region 450.
In operation, when gate 480 is biased, an n-channel forms under gate 480 in p-well 430 that extends under gate 480 thereby permitting current to flow between source 460 and drain 470 via region 440, the n-channel (not shown) formed under gate 480 in p-well 430, N-well 420 and region 450.
The MOSFET shown in
a shows one cell of a MOSFET bi-directional switch using two of the MOSFET shown in
Sources 460a and 460b are placed over regions 440a and 440b, respectively. Drain 470 is placed over region 450. Gate 480a is placed, with an insulating layer (e.g. SiO2), between source 460a and a drain 470. Gate 480a overlays a portion of region 440a, a portion of p-well 430a that extends to the surface under gate 480a, a portion of N-well 420 which also extends to the surface under gate 480a, and a portion of region 450. Gate 480b is placed, with an insulating layer (e.g. SiO2), between source 460b and drain 470. Gate 480b overlays a portion of region 440b, a portion of p-well 430b that extends to the surface under gate 480b, a portion of N-well 420 which also extends to the surface under gate 480b, and a portion of region 450. Use of drain 470 is optional.
In operation, when gates 480a and 480b are properly biased for bi-directional use, an n-channel forms under gate 480a in p-well 430a that extends under gate 480a and under gate 480b in p-well 430b that extends under gate 480b. This permits current to flow between source 460a and source 460b via region 440a, the n-channel (not shown) formed under gate 480a in p-well 430a, N-well 420 and region 450, the n-channel (not shown) formed under gate 480b in p-well 430b, and region 440b.
In another embodiment of
b shows an exemplary top view of one embodiment of the bi-directional switch cell of
c shows one cell of a MOSFET bi-directional switch using two of the MOSFET shown in
Sources 340a and 340b are placed over regions 320a and 320b, respectively. Drain 350 is placed over region 330. Gate 360a is placed, with an insulating layer (e.g. SiO2), between source 340a and drain 350. Gate 360a overlays aportion of region 320a, a portion of P-well 312 that extends to the surface under gate 360a, and a portion of region 330. Gate 360b is placed, with an insulating layer (e.g. SiO2), between source 340b and drain 350. Gate 360b overlays a portion of region 320b, a portion of P-well 312 that extends to the surface under gate 360b, and a portion of region 330. Use of drain 350 is optional.
In operation, when gates 360a and 360b are properly biased for bi-directional use, an n-channel forms under gate 360a in the portion of P-well 312 that extends under gate 360a and under gate 360b in the portion of P-well 312 that is extends under gate 360b. This permits current to flow between source 340a and source 340b via region 320a, the n-channel (not shown) formed under gate 360a in P-well 312, region 330, the n-channel (not shown) formed under gate 360b in P-well 312, and region 320b.
Source 670a is placed over P+ region 640a and the portion of region 650a having the N+ majority carrier concentrations. Source 670b is placed over P+ region 640b and the portion of region 650b having the N+ majority carrier concentration. The P+ regions allow the sources to contact their respective P-wells. Region 660 of n conductivity type (N majority carrier concentration) is formed in substrate 610. Gate 680a is placed, with an insulating layer (eg. SiO2), between source 670a and gate 680b and overlays a portion of region 650a, P-well 620a and region 660. Gate 680b is placed, with an insulating layer (e.g. SiO2), between source 670b and gate 680a and overlays a portion of region 650b, P-well 620b and region 660. Region 660 is essentially a common drain—access to the drain is optional.
In another embodiment of
In operation, when gates 680a and 680b are properly biased for bi-directional use, an n-channel forms under gate 680a in that portion of P-well 620a that extends under gate 680a, and an n-channel forms under gate 680b in that portion of P-well 620b that extends under gate 680b. This permits current to flow between source 670a and source 670b via region 650a, the n-channel (not shown) formed under gate 680a in P-well 620a, region 660, the n-channel (not shown) formed under gate 680b in P-well 620b, and region 650b.
Referring to
If the battery has sufficient energy to drive the device, control circuit 130 biases gate G1 relative to source S1 and gate G2 relative to source S2. This permits current to flow from the battery through the bi-directional switch to the device.
If the battery has insufficient energy to drive the device, for instance, if the voltage is too low, control circuit 130 removes the bias from gate G1 thereby stopping current from flowing from S1 and isolating the battery from the rest of the device. This helps prevent the device from operating on too low a voltage which could cause malfunctions, and also prevents the battery from draining itself too low which can cause damage to the battery. Gate G1 may also be closed in situations where the device is being run from the charger to prevent using the battery during such operation.
If the battery is being charged, control circuit 130 biases gate G1 relative to source S1 and gate G2 relative to source S2. This permits current to flow from the charger through the bi-directional switch to the battery.
If the battery is fully charged, control circuit 130 closes gate G2 to prevent overcharging the battery, which could cause a catastrophic failure or a fire for certain types of batteries such as lithium ion batteries.
Table 1 compares the characteristics of certain prior art devices against bi-directional switches formed with the embodiment shown in
1. A specific RDSON of 30 mΩ mm2 is assumed.
2. The die sizes for LateralDiscrete are limited by the maximum current allowed for each bump rather than RDSON requirement. A 0.5 mm pitch is assumed for solder bumps and seven (7) source bumps are used for a peak pulse current of 10 A (same as IR).
As can be seen, the present invention provides a smaller on-resistance for a given die size. It also allows the use of devices that provide access to the drain or devices with no access to the drain.
In accordance with another aspect of the present invention multiple cells are used to create a bi-directional switch able to handle large current flows with reduced on-resistance by interleaving multiple sources and gates. This design improves the on-resistance by reducing the current path, which reduces the on resistance, and also by connecting the cells in parallel, which connects the resistance in parallel which also dramatically reduces the resistance. An exemplary embodiment is shown in
With reference to
In embodiments using multiple cells (and interleaved sources and gates), multiple layers (preferably metal) are used to interconnect sources S1 together, interconnect sources S2, interconnect gates G1, interconnect gates G2, and to interconnect drains if used. The performance of these interconnections can be improved using the novel interconnections disclosed in U.S. patent application Ser. No. 10/601,121.
It should be apparent to those skilled in the art that the foregoing are illustrative only and not limiting, having been presented by way of example only. All the features disclosed in this description may be replaced by alternative features serving the same purpose, and equivalents or similar purpose, unless expressly stated otherwise. For instance, one skilled in the art can reverse the conductivity types shown in these embodiments as needed and without departing from the spirit or scope of the invention. Using
This application claims the benefit of U.S. Provisional Application 60/444,943, filed Feb. 4, 2003 and U.S. Provisional Application 60/501,192, filed Sep. 8, 2003, each of which are hereby incorporated by reference in its entirety.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US04/03051 | 2/4/2004 | WO | 7/14/2005 |
Number | Date | Country | |
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60444932 | Feb 2003 | US | |
60501192 | Sep 2003 | US |