The present disclosure relates to a bipolar junction transistor with a modified structure for improved speed and breakdown voltage characteristics. In particular, it relates to a bipolar junction transistor with modified emitter and collector architectures and a charge control structure.
Bipolar junction transistors are used in different types of analog circuits. In particular, they are commonly used in analog amplifier circuits. The design and implementation of the analog circuit defines the required targets for the performance parameters, such as gain, speed and breakdown voltage (which defines the maximum useful operating voltage) of the bipolar junction transistor. Conventionally, optimizing the performance of the bipolar junction transistor is complex and is limited due to known trade-offs such as the trade-off between gain and Early voltage and the trade-off between speed and breakdown voltage as defined by the Johnson limit. Therefore, there is a need to modify the architecture of the transistor to at least expand the boundary imposed by these trade-offs on the performance of the transistor.
A bipolar junction transistor is provided with an emitter structure that is positioned above the upper surface of the base region. The thickness of the emitter and the interfacial oxide thickness between the emitter and the base is configured to optimise the gain for a given type of transistor. A method of fabricating PNP and NPN transistors on the same substrate using a complementary bipolar fabrication process is also provided. The method enables the emitter structure for the NPN transistor to be defined and optimised separately to that of the PNP transistor. This is achieved by using thermal processing for depositing the emitter layer for the NPN transistor and using epitaxial growth for depositing the emitter layer for the PNP transistor.
According to a first aspect of this disclosure, there is provided a bipolar junction transistor, comprising a collector; a base comprising an intrinsic base region and an extrinsic base region, the intrinsic base having an upper surface; and an emitter positioned above of the upper surface of the intrinsic base.
According to a second aspect of this disclosure, there is provided a method for fabricating an NPN and a PNP bipolar junction transistors on the same substrate, comprising: providing a wafer; forming collectors for an NPN and PNP transistors; forming a base and an emitter of the NPN transistor, the emitter being formed in a thermal furnace; forming a base and an emitter for a PNP transistor, the emitter being epitaxially grown; and forming emitter, collector and base contacts for the PNP and NPN transistors.
According to a third aspect of this disclosure, there is provided a method for fabricating a bipolar junction transistor, comprising: providing a wafer; forming a collector, forming an intrinsic base region and an extrinsic base region, the intrinsic base having a upper surface; and forming an emitter above of the upper surface of the intrinsic base; forming emitter, collector and base contacts.
Further features of the disclosure are defined in the appended claims.
The teachings of this disclosure will be discussed, by way of non-limiting examples, with reference to the accompanying drawings, in which:
The present disclosure provides a bipolar junction transistor with a modified structure for improved speed and breakdown voltage characteristics. In particular, it relates to a bipolar junction transistor with modified collector and emitter architectures and a charge control structure. In order to allow for better control of the dopant concentration profile in the collector region, the collector is grown as a multilayer collector with layers which are individually grown in separate epitaxial growth stages. For a PNP transistor, each layer, after it is grown, is doped in a dedicated implant stage. In this way, the thickness of each layer and the concentration of dopant in each layer can be better controlled to optimise the speed and breakdown voltage parameters for the bipolar junction transistor.
The disclosure also addresses the problem of the dependence of collector current on the collector-base voltage, also known as the Early effect. In use, the collector-base junction is reverse-biased resulting in a depletion or space-charge region that spreads across the base-collector interface into the bulk collector region below the base. The inventors have realised that the dependence of collector current on the collector-base voltage can be reduced by reducing the coupling of the charge from the space-charge region to the base and instead, coupling this charge to a charge control structure adjacent the space-charge region.
The emitter architecture can also be optimised to improve the performance of the bipolar junction transistor. In particular, the disclosure provides a single complementary fabrication process for PNP and NPN transistors, while providing separate emitter architectures to optimise the performance for a given type of transistor. The disclosure provides a process for optimising the thickness of the emitter and the thickness of the interfacial oxide between the emitter and the intrinsic base region for a given type of transistor to optimise the performance of the transistor. The fabrication process advantageously allows for flexibility in the design of the emitter architecture for a given type of transistor while still benefiting from the common processing advantages of a complementary bipolar fabrication process.
As used herein, the terms “above”, “below”, “at a side of” and so on refer to components or regions as set out in the accompanying figures and are not intended to be limiting of real world devices.
The p-type collector 102 in
The intermediate layer 102b and the top layer 102c are individually grown in separate epitaxial growth stages as n-type epitaxial layers. Each of the buried, intermediate and top layer has a dedicated implant stage where it is implanted with a p-type dopant and has a corresponding dopant concentration profile which is partly determined by the thickness of the layer. The collector contact 110 is formed by extending a metal via 110a through an aperture in the insulating layers 108 to the upper surface of the collector, as shown in
In the embodiment of
As n-type epitaxial layers are used to form the intermediate and top layers of the collector, the multilayer collector stack can be used, without any ion implantations stages, for the formation of an n-type collector for a NPN transistor. That is, the n-type dopant concentration during the epitaxial growth of the n-type silicon layers for the multilayer collector can be optimised for a desired breakdown voltage of a NPN bipolar junction transistor. Therefore, the collectors for NPN and PNP bipolar junction transistors can be formed on a common silicon-on-oxide substrate, in a complementary fabrication process.
The base 103 of the PNP transistor 100 in
The emitter 104 of the PNP transistor in
The transistor 100 in
A method of fabricating a multilayer collector 102 will now be described with reference to
A trench structure 205, 206 is then formed adjacent the bulk collector region. This is followed by the formation of dielectric regions 207 using the conventional LOCOS process. These dielectric regions are formed such that there are portions of the upper surface of the collector, such as region 209 which is open between the dielectric regions. Open region 209 is used later in the fabrication process to define the intrinsic base region. A dielectric layer 210, preferably grown using the conventional TEOS process is deposited over other open regions such as 208 between the LOCOS defined dielectric regions. A portion of the dielectric layer over region 208 is removed later in the fabrication process to enable the formation of an electrical contact to the collector.
For a given thermal budget, the ratio of the thicknesses of the intermediate layer 202 of the collector to the top layer 203 of the collector can be adjusted to allow for the optimum merger of the dopant diffusivity rates to create an approximately uniform doping concentration profile as a function of depth in the multilayer collector. In practice, as seen in the example SIMS profile in
The thickness of the first p-type silicon layer 201a is adjusted to be 2.2 μm or greater to facilitate a high net boron content in this layer relative to the other layers of the collector. This allows connectivity to the sinker region to complete the current conduction path 116 in the bipolar transistor, as shown in
The next stage in the manufacturing process is to form the base and the emitter over the collector. This is shown in
In use, particularly in high-frequency applications, the parasitic capacitance between base and the collector of the bipolar junction transistor becomes significant. It is desirable to reduce this capacitance to improve the speed of the bipolar junction transistor. This capacitance is directly proportional to the base-collector junction area and therefore, it is desirable to reduce this area. One way of reducing the base-collector junction area is to push the edge or bird's beak 502a of the dielectric layer 502 further into the open area 503 which also defines the area of the intrinsic base 501a. This can be achieved by tuning the thickness of the dielectric layer during the LOCOS process—that is, due to the nature of the formation of the dielectric layer 502 and the bird's beak 502a in the LOCOS process, increasing the thickness of the dielectric layer increases the extent of the bird's beak 502a into the open area 503 resulting in a reduction or narrowing of the open area 503.
A dielectric layer, preferably an oxide layer 504 of a predetermined thickness, is then deposited, directly over the SiGe layer 501, as shown in
The dielectric layer 504 is selectively etched to expose the intrinsic base region 501a and a thin dielectric layer 505, preferably an oxide layer, thinner than the dielectric layer 504, is grown over the intrinsic base region 501a as shown in
A polysilicon layer 507 is then deposited as shown as shown in
The total distance 705 and 703b, that is the distance between the crystalline-polycrystalline transition of the SiGe layer and an edge of the emitter 704, can also be optimised for a desired speed of the bipolar junction transistor. For a PNP transistor, this distance is 0.55 μm or less. For an NPN transistor, this distance is 0.4 μm or less.
PNP and NPN transistors can be fabricated in a complementary bipolar fabrication process, that is, both type of devices can be fabricated on a single substrate. The inventors have realised that even in a complementary fabrication process, the characteristics of the emitter can be customised for optimum performance for a given type of transistor.
A method of fabricating PNP and NPN transistors with emitter region customised for each transistor type will now be described with reference to
The collector 802 for the PNP transistor can be a multilayer collector and can be fabricated using the process as described earlier in
After the deposition of the SiGe layer 801, a portion of the layer 801 is then selectively doped with a p-type dopant to form the intrinsic base 801a and the extrinsic base 801b regions for the NPN transistor, as shown in
A dielectric layer, preferably an oxide layer 806 is then blanket deposited across the wafer, over the semiconductor layer 801, as shown in
A polysilicon layer 809 is then thermally grown across the wafer, over the dielectric layer 806 and the spacer regions 807a and 807b, as shown in
A portion of the layer 801 is then selectively doped with an n-type dopant to form the intrinsic base 801c and the extrinsic base 801d regions for the PNP transistor, as shown in
A dielectric layer, preferably an oxide layer 810 is then blanket deposited across the wafer, over the semiconductor layer 801 and over the emitter structure 809 for the NPN transistor, as shown in
A polysilicon layer 813 is then epitaxially grown across the wafer, over the dielectric layer 809 and the spacer regions 810a, 810b as shown in
The height of the emitter can be configured to be at least 300 nm for a PNP bipolar junction transistor. The thickness of an IFO layer (not shown), formed as a result of the epitaxial growth of the polysilicon layer 813 over the intrinsic base region 801c, can be optimized to be approximately 500 pm for a PNP bipolar junction transistor.
The complementary bipolar fabrication process described above enables the emitter structure for the NPN transistor to be defined separately to that of the PNP transistor. As mentioned before, the thickness of the interfacial oxide layer and the height of the emitter can be configured to optimise the performance, in particular, the gain, for a given type of transistor. In the process described above, the emitter layer for the NPN transistor is grown in a thermal furnace as opposed to the epitaxially grown emitter layer for the PNP transistor.
The inventors have realised that for an NPN transistor, the interfacial oxide thickness needs to be minimised to reduce emitter resistance and noise. The minimisation of interfacial oxide growth is achieved by growing the polysilicon emitter layer for the NPN transistor in a thermal furnace.
The inventors have also realised that the average grain size for the polysilicon crystals in the emitter can be used to optimise the gain for a given type of transistor. That is, the grain size of the polysilicon crystals in the emitter can be used to control parameters such as carrier lifetime and the recombination rate of injected carriers from the base to the emitter. Taking into account these parameters, the inventors have realised that the average grain size of the polysilicon crystals in the emitter for the NPN transistor has to be smaller than the average grain size of the polysilicon crystals in the emitter for the PNP transistor. The growth of the polysilicon emitter in a thermal furnace produces a smaller average grain size for the polysilicon crystals in the emitter for the NPN transistor when compared to the epitaxially grown emitter for the PNP transistor. For the NPN transistor, a smaller average grain size for the polysilicon crystals advantageously decreases the gradient of carriers injected from the base transistor and thereby decreases the injected base current.
In use, the emitter-base junction of the transistor is forward biased whereas the collector-base junction is reversed biased. A common problem in conventional bipolar junction transistors is the dependence of collector current on collector-base voltage, also known as the Early effect. Applying a reverse-bias voltage across the collector-base junction results in a depletion region that spreads across the base-collector interface, into the bulk collector region below the base. The depletion region comprises ionised acceptor atoms in the collector. The charge as a result of the ionised acceptor atoms in the collector is balanced by an equal but opposite charge of ionised donor atoms in the base to balance the net electric field. As the collector voltage is increased, the width of the depletion region increases which in turn reduces the effective width of the base. A reduction in the effective base width results in an increase in collector current due to an increase in diffusion current through the base. It is desirable to reduce this modulation of base-width and hence the dependency of collector current on the collector voltage.
One way of solving this problem is to reduce the coupling of the charge of the ionised acceptor atoms to the base and instead couple this charge to a charge control structure adjacent the collector-base space charge region. This reduces the amount of ionised donor atoms in the base to balance the net electric field, thereby reducing the modulation of base-width with the collector voltage.
In some embodiments, the charge control structure may comprise only the lateral field plate 1002. In some embodiments, the charge control structure may comprise only the trench structure 1001 or 1201.
Example 1 is a bipolar junction transistor, comprising: a collector; a base; an emitter; and a charge control structure configured to control, in use, a charge distribution in the collector to control the breakdown voltage of the transistor, wherein the charge control structure comprises: a first field plate, extending laterally over, and insulated from, an upper surface of the collector; and a second field plate, extending vertically adjacent, and insulated from, a side of the collector.
Example 2 is bipolar junction transistor according to Example 1, wherein the first field plate extends from the base towards a collector contact.
Example 3 is a bipolar junction transistor according to Example 2, wherein the collector contact is positioned towards a first side of the transistor, and the base is positioned towards a second side of the transistor, opposite the first side.
Example 4 is a bipolar junction transistor according to Example 3, wherein the base has a base contact, and the emitter has an emitter contact, positioned between the collector contact and the base contact, the lateral length of the first field plate being greater than the lateral distance between the emitter and base contacts.
Example 5 is a bipolar junction transistor according to Example 4, wherein the lateral distance between the emitter and base contacts is measured from the centre points of those contacts.
Example 6 is a bipolar junction transistor according to Example 4, wherein the lateral length of the first field plate is at least three quarters of the lateral distance between the emitter and collector contacts.
Example 7 is a bipolar junction transistor according to Example 6, wherein the lateral distance between the emitter and collector contacts is measured from the centre points of those contacts.
Example 8 is a bipolar junction transistor according to any of Examples 1-7 wherein the first field plate is insulated from the collector by a first dielectric layer, positioned between the upper surface of the collector and the first field plate.
Example 9 is a bipolar junction transistor according to any of Examples 1-8, wherein the first field plate is a layer of doped semiconductor material.
Example 10 is a bipolar junction transistor according to any of Examples 1-9, wherein the transistor has a trench structure adjacent a side of the collector, and the second field plate forms part of the trench structure.
Example 11 is a bipolar junction transistor according to any of Examples 1-10 wherein the second field plate is conductive and is coupled to a field plate contact, such that the potential at the second field plate can be controlled.
Example 12 is a bipolar junction transistor according to Example 10 or Example 11, wherein the trench structure is a double-trench, each trench being separated from the other by the second field plate.
Example 13 is a bipolar junction transistor according to Example 12, wherein the double-trench comprises a first trench, positioned between the collector and the second field plate, the first trench comprising a doped semiconductor dielectrically isolated from the collector and the second field plate.
Example 14 is a bipolar junction transistor according to Example 10 or Example 11, wherein the trench structure comprises a doped semiconductor dielectrically isolated from the collector.
Example 15 is a bipolar junction transistor according to Example 14, wherein the trench is horizontally aligned with and positioned beneath the base contact.
Example 16 is a method of manufacturing a bipolar junction transistor, comprising: providing a wafer; forming a collector region; forming a vertical field plate, extending vertically adjacent, and insulated from, a side of the collector region; forming a base region; forming a horizontal field plate extending laterally over, and insulated from, an upper surface of the collector region; forming an emitter region; and forming contacts for each of the collector, base and emitter regions, wherein the vertical and horizontal field plates form a charge control structure configured to control, in use, a charge distribution in the collector to control the breakdown voltage of the transistor.
Example 17 is a method according to Example 16, further comprising forming a trench structure around the collector region, wherein the trench structure includes the vertical field plate.
Example 18 is a method according to Examples 16 or 17, wherein the collector region is epitaxially grown, and the method further comprises: forming a dielectric layer over the collector region, the dielectric layer insulating the horizontal field plate from the collector region; forming an opening in the dielectric layer; and depositing a layer of semiconductor over the dielectric layer and doping the layer of semiconductor to form the base region and the horizontal field plate.
Example 19 is a method according to Examples 16, 17 or 18, wherein the wafer is a silicon-on-oxide wafer.
Example 20 is a bipolar junction transistor, comprising: a collector on a buried oxide layer of a silicon-on-oxide substrate, wherein the collector comprises a collector sink close to a first dielectrically isolated trench on a first side of the transistor; a dielectric layer recessed into the upper surface of the collector, wherein the dielectric layer comprises a plurality of openings; an emitter and a base proximal to a second dielectrically isolated trench on a second side of the transistor opposite to the first side, wherein the emitter is positioned over a crystalline intrinsic region of the base; a first field plate structure extending laterally over the dielectric layer towards the collector sink; an emitter, a base and a collector contact, wherein the base contact connects to an extrinsic polycrystalline portion of the base, such that the base contact is aligned with and positioned over the second dielectrically isolated trench.
Example 21 is a bipolar junction transistor comprising a bipolar junction transistor, comprising: an emitter; a base; and a collector; wherein the collector comprises a plurality of individually grown epitaxial layers, each layer having a respective dopant implant such that each layer has a respective dopant profile.
Example 22 is a bipolar junction transistor according to any of claims 1-15, wherein the collector comprises a plurality of individually grown epitaxial layers, each layer having a respective dopant implant such that each layer has a respective dopant profile.
Example 23 is a bipolar junction transistor according to Example 21 or Example 22 wherein the dopant profiles are at least partially determined by the thickness of each layer.
Example 24 is a bipolar junction transistor according to Example 23, wherein the dopant profiles are dopant concentration profiles.
Example 25 is a bipolar junction transistor according to Example 24, wherein the respective dopant concentration profile for each layer is different to that of the other layers.
Example 26 is a bipolar junction transistor according to any of Examples 21-25, wherein each layer has a thickness that is different to that of the other layers.
Example 27 is a bipolar junction transistor according to any of Examples 21-26, wherein the collector has three individually grown epitaxial layers, including a buried layer, an intermediate layer and a top layer.
Example 28 is a bipolar junction transistor according to Example 27, wherein the intermediate layer is thicker than the top layer.
Example 29 is a bipolar junction transistor according to any of Examples 21-28, wherein each layer has a maximum dopant concentration and the maximum dopant concentration for the buried layer is higher than the maximum dopant concentrations of the other layers.
Example 30 is a bipolar junction transistor according to any of Examples 21-29, wherein the transistor is a PNP transistor and the dopant is P-type.
Example 31 is a bipolar junction transistor according to Example 30, wherein the plurality of layers are silicon layers, and the dopant is boron.
Example 32 is a bipolar junction transistor according to any of Examples 21-31, wherein the collector has an overall dopant concentration profile having an overall maximum dopant concentration, and the thickness of the buried layer is configured to limit the overall maximum dopant concentration.
Example 33 is a bipolar junction transistor according to Example 32, wherein the collector is made from silicon, the dopant is boron and the overall maximum dopant concentration is less than or equal to 1E18 cm−3.
Example 34 is a bipolar junction transistor according to any of claims 27-33, wherein the buried layer is a p-type layer, the intermediate layer is an n-type layer overlying the p-type buried layer, and the top layer is an n-type layer overlying the intermediate layer.
Example 35 is a bipolar junction transistor according to any of claims 27-34, wherein a ratio of a thickness of the intermediate layer to a thickness of the top layer is configured to optimise dopant diffusivity rates to create a desired dopant profile across the epitaxial layers for a given thermal budget.
Example 36 is a bipolar junction transistor according to Example 35, wherein the ratio of a thickness of the intermediate layer to a thickness of the top layer is 4.5:3.3.
Example 37 is a method of manufacturing a collector of a bipolar junction transistor, comprising: providing a first layer of silicon; implanting the first layer of silicon with a first concentration of dopant; forming a second layer of silicon over the first layer; implanting the second layer of silicon with a second concentration of dopant; exposing the collector to a specified thermal budget such that each layer has a respective dopant profile.
Example 38 is a method according to Example 37, further comprising, before exposing the collector to a specified thermal budget, providing a third layer of silicon over the second layer and implanting the third layer of silicon with a third concentration of dopant.
Example 39 is a method according to Example 38, wherein the second silicon layer is epitaxially grown over the first silicon layer and the third layer is epitaxially grown over the second silicon layer.
Example 40 is a method according to any of claims 37 to 39, wherein the first layer is provided as part of a silicon on oxide wafer and wherein the first layer has a starting thickness of at least 2.2 μm.
Example 41 is a PNP bipolar junction transistor, comprising: a collector, the collector having: a buried layer, an intermediate layer and a top layer, at least the intermediate and top layers being individually grown epitaxial layers, each layer having a respective dopant implant profile; wherein: the intermediate layer is thicker than the top layer; and the dopant is boron; a base, positioned over a portion of the collector; and an emitter, positioned over the base.
Example 42 is a bipolar junction transistor according to any of Examples 1-15, wherein the transistor is a PNP bipolar junction transistor and the collector comprises, a buried layer, an intermediate layer and a top layer, at least the intermediate and top layers being individually grown epitaxial layers, each layer having a respective dopant implant profile; wherein: the intermediate layer is thicker than the top layer; and the dopant is boron; the base being positioned over a portion of the collector; and the emitter, positioned over the base.
Example 43 is a bipolar junction transistor according to example 20, wherein the transistor is a PNP bipolar junction transistor and the collector comprises, a buried layer, an intermediate layer and a top layer, at least the intermediate and top layers being individually grown epitaxial layers, each layer having a respective dopant implant profile; wherein: the intermediate layer is thicker than the top layer; and the dopant is boron; the base being positioned over a portion of the collector; and the emitter, positioned over the base.
Example 44 is a bipolar junction transistor according to Example 20, wherein the collector comprises a plurality of individually grown epitaxial layers, each layer having a respective dopant implant such that each layer has a respective dopant profile.
Example 45 is a bipolar junction transistor according to Example 44, wherein the collector further comprises features relating to the collector in any of claims 23-36.
Example 46 is a bipolar junction transistor comprising: a collector; a base comprising an intrinsic base region and an extrinsic base region, the intrinsic base having an upper surface; and an emitter positioned above of the upper surface of the intrinsic base.
Example 47 is a bipolar junction transistor according to any of Examples 1-15, 21-36, 41, 42 wherein, the base comprises an intrinsic base region and an extrinsic base region, the intrinsic base having an upper surface; and the emitter positioned above of the upper surface of the intrinsic base
Example 48 is a bipolar junction transistor according to Example 20, 43-45 wherein the base further comprises an extrinsic base region, the intrinsic base having an upper surface; and the emitter positioned above of the upper surface of the intrinsic base.
Although this invention has been described in terms of certain embodiments, the embodiments can be combined to provide further embodiments. In addition, certain features shown in the context of one embodiment can be incorporated into other embodiments as well.
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