The present disclosure is generally related to a circuit device and method of reducing peak current density.
In general, power switches may be used to provide a switched power supply to an inductive load. Inductive loads typically resist a change in current, such that when the power switch is deactivated, the inductive load may operate as a current source to drive current to the switch. If the power switch is a metal oxide semiconductor field effect transistor (MOSFET) device that is driving an inductive load, the MOSFET device may be controlled by a driver circuit coupled to a gate terminal of the MOSFET device. In a particular example, the driver circuit applies a gate voltage of approximately zero volts to a gate contact that is coupled to the gate terminal. However, the inductive load may continue to drive current onto a drain terminal of the MOSFET device.
Generally, during a MOSFET on-state to off-state transition, a displacement current is discharged from the drain terminal of the MOSFET device via a drain-to-gate capacitance and through the driver circuitry. However, a gate resistance of the gate terminal increases with a distance from the driver circuitry. Thus, at a remote end of gate terminal, a gate resistance is greater than at an end closest to the driver circuitry. Assuming a uniform drain-to-gate capacitance, this non-uniform gate resistance will lead to a non-uniform localized gate voltage. Gate terminal regions with higher resistance will sustain a higher voltage potential, forming increased localized charge in the active channel of a MOSFET device. Thus, the non-uniform gate resistance can result in a non-uniform channel current during a switching operation from an on-state to an off-state. In a particular embodiment, the non-uniform channel current can include localized current crowding. In this example, the current from the inductive load may continue to flow through the active portion of the MOSFET device during the on to off-state transition, with localized channel regions handling an increased current density.
In a particular embodiment, a gate contact may be provided at a first end of the gate terminal and the peak channel current density of the MOSFET device may be shifted toward a second end of the gate terminal. In another particular embodiment, two gate contacts may be provided at opposing ends of the gate terminal, and the peak channel current density of the MOSFET device is shifted away from the gate contacts toward a center of the gate terminal. In general, the current at the drain of the MOSFET device is unevenly distributed across a width of the drain, resulting in a peak channel current density at a small portion of the MOSFET device, which may cause overheating and snap-back effects and which may damage the MOSFET device.
In a particular embodiment, a method of forming a field effect transistor (FET) device having a reduced peak current density is disclosed. The method includes forming a field effect transistor (FET) device on a substrate. The FET device includes a drain terminal, a source terminal, a body terminal, and a gate terminal. The method further includes depositing a plurality of metal contacts along a width of a gate terminal of the FET device and forming a wire trace to contact each of the plurality of metal contacts to reduce a gate resistance along the width of the gate terminal.
In another particular embodiment, a circuit device includes a substrate and a field effect transistor (FET) device deposited on the substrate. The substrate includes an oxide layer having a plurality of thick oxide regions and a plurality of thin oxide regions. The FET device includes a drain terminal, a source terminal, a body terminal, and a gate terminal. The gate terminal includes a first portion that extends over a thick oxide region of the plurality of thick oxide regions and includes a second portion that extends over a thin oxide region of the plurality of thin oxide regions. The circuit device further includes a first plurality of drain contacts coupled to the drain terminal, a second plurality of source contacts coupled to the source terminal, a third plurality of source contacts coupled to the body terminal, and a fourth plurality of gate contacts coupled to the gate terminal along the first portion of the gate terminal.
In yet another embodiment, a circuit device includes a switching driver circuit, an inductive load, and a field effect transistor (FET) device. The FET device includes a drain terminal coupled to the inductive load. The FET device also includes a gate terminal coupled to the switching driver circuit and includes a source terminal. The gate terminal includes a plurality of contacts distributed along a width of the gate terminal to reduce a gate resistance across the width of the gate terminal. The plurality of contacts are adapted to reduce a peak current density of the FET device by distributing current across the width of the FET device when the switching driver circuit switches the FET device to an off state.
In general, the MOSFET device 102 has a device width that can be modeled as a series of MOSFET devices 110 arranged in parallel. The series of MOSFET devices 110 include a first MOSFET device 112, a second MOSFET device 114, a third MOSFET device 116, and a fourth MOSFET device 118. In a particular embodiment, the series of MOSFET devices 110 represent slices of the MOSFET device 102 at various locations along a width of the MOSFET device 102. It should be understood that the series of MOSFET devices 110 may be represented by any number of MOSFET devices arranged in parallel.
The first MOSFET device 112 includes a first drain-to-gate capacitance 132 and a first gate resistance 122. The second MOSFET device 114 includes a second drain-to-gate capacitance 134 and a second gate resistance 124. The third MOSFET device 116 includes a third drain-to-gate capacitance 136 and a third gate resistance 126. The fourth MOSFET device 118 includes a fourth drain-to-gate capacitance 138 and a fourth resistance 128. In a particular example, a drain current (ID) flows from the drain terminal 104 through the series of transistors 110 to the source terminal 108. The drain current (ID) is distributed such that the first MOSFET device 112 carries a first drain current (ID1), the second MOSFET device 114 carries a second drain current (ID2), the third MOSFET device 116 carries a third drain current (ID3), and a fourth MOSFET device 118 carries a fourth drain current (ID4). In a particular embodiment, a sum of the first, second, third, and fourth drain currents (ID1, ID2, ID3, and ID4, respectively) is equal to the drain current (ID).
Conventionally, switching a conventional MOSET device from an on-state to an off state caused the drain current (ID) to be distributed unevenly. In particular, the effective gate resistance increased along a width of the gate terminal. Accordingly, during a switch from an on state to an off state, the conventional MOSFET device can operate like a current divider circuit. In a particular embodiment, a portion of the MOSFET device is deactivated while other portions remain at least partially active. The turn off signal causes one portion of the MOSFET device to turn off more quickly than the other portion and the current is crowded to the other portion. In some instances, the drain current at the portion of the conventional MOSFET device that is furthest away from the gate contact can increase to a level that causes damage to the conventional MOSFET device 102.
Returning to
In a particular embodiment, by shorting/reducing the first, second, third, and fourth gate resistances 122, 124, 126, and 128 using the first, second, third, and fourth gate contacts 142, 144, 146, and 148, a peak current density of the circuit device 100 is reduced. Additionally, since the peak current density is reduced, the circuit device 100 may be operated at a higher operating voltage without destroying the MOSFET device 102 when it is switched from an on-state to an off-state.
In a particular embodiment, the drain terminal 214, the gate terminal 216, and the source/body terminal 218 correspond to the drain terminal 104, the gate terminal 106, and the source terminal 108 illustrated in
In a particular embodiment, the gate terminal 216 is deposited over a silicon oxide layer of the circuit substrate 201. The silicon oxide layer of the circuit substrate 201 has a variable thickness including thin oxide portions and thick oxide portions. The circuit substrate 201 includes a first thin oxide portion 234 of the silicon oxide layer that is associated with the drain portion 204 of the MOSFET device 202. The circuit substrate 201 further includes a second thin oxide portion 236 that is associated with the gate and source portions 206 and 208 of the MOSFET device 202. Additionally, the circuit substrate 201 includes a third thin oxide portion 239 that is associated with the body portion 209 of the MOSFET device 202. The gate terminal 216 extends over the second thin oxide portion 236 and over a relatively thick portion of the silicon oxide layer. In a particular embodiment, the plurality of gate contacts 226 is deposited over the thick portion of the silicon oxide layer. While the plurality of gate contacts 226 are illustrated as discrete gate contacts, it should be understood that the plurality of gate contacts may be a continuous contact that extends across the gate terminal 216 along an entire width (W) of the MOSFET device 202.
In general, the gate contact 226 can be deposited at the first gate portion 410 extending over the thick oxide portion 412 of the first oxide layer 354 because a photo-etch process that may be used to open a via from the top surface 380 to the gate terminal 216 does not penetrate through the thick oxide portion 412 to damage the underlying structure. In contrast, if the photo-etch process were performed to etch a via from the top surface 380 to the gate terminal over the second thin oxide region 236, the second thin oxide region 236 may be damaged, resulting in an electrical short circuit between the gate terminal 216 and the substrate 201. Further, other structural or physical damage may also result.
The PSE 502 includes a transformer 514 that is coupled to wires 518 and 520 and to the Ethernet cable 512. The wires 518 and 520 are selectively coupled to a power source 516 via a power switch 517. The switch 517 may be a field effect transistor (FET) device, such as the MOSFET devices illustrated in
The powered device 504 includes an interface 525, such as an Ethernet connector (i.e., an RJ-45 Ethernet connector), that couples the Ethernet cable 512 to a transformer 522. The transformer 522 is coupled to the diode bridge 506 via first and second input terminals 524 and 526. The diode bridge 506 receives a signal via the first and second input terminals 524 and 526 and rectifies the signal to provide a positive power supply (Vpos) to a first terminal 528 and to provide a negative power supply (Vneg) to a second terminal 530. The powered device 504 also includes Power over Ethernet (PoE) controller, hot swap, and switching regulator circuitry 532 that is coupled to the first and second terminals 528 and 530 to receive a power supply and to provide a regulated power supply to a first supply terminal 534 and to a second supply terminal 536, which are coupled to an output load 538. In a particular embodiment, the PoE controller, hot swap, and switching regulator circuitry 532 includes a field effect transistor (FET) device, such as the MOSFET devices illustrated in
In a particular embodiment, the PoE controller, hot swap, and switching regulator circuitry 532 includes a logic circuit that is adapted to switch the controller, hot swap, and switching regulator circuitry 532 to an off state. The controller, hot swap, and switching regulator circuitry 532 includes a metal oxide semiconductor field effect transistor (MOSFET) device having a gate terminal coupled to a wire trace via a plurality of contacts that are deposited along a width of the gate terminal. In a particular embodiment, the plurality of contacts are disposed along substantially an entire width of the gate terminal, reducing a peak current density by reducing/shorting a gate resistance associated with the MOSFET device to distribute a discharge current across the entire width of the MOSFET device when the MOSFET device switches from an on state to an off state.
In a particular embodiment, the plurality of gate contacts distributed across a width of the gate terminal of the MOSFET device, as described with respect to
In a particular embodiment, the drain current is shifted or crowded away from the driver circuit (i.e., away from the gate contact) along the gate terminal until a large portion of the drain current flows through a current channel associated with a relatively small portion of the conventional MOSFET device. While the conventional MOSFET device is switched off, the conventional MOSFET device may continue to conduct current. In this condition, the high current through a small area of the conventional MOSFET device can damage the device. Further, as the drain voltage rises and the drain current increases at a portion of the conventional MOSFET device, the current flow through the current channel can increase, which may destroy at least a portion of the conventional MOSFET device. In a particular embodiment, the current may increase due to impact ionization, snapback effects, other electrical phenomena, or any combination thereof. In a particular embodiment, the term impact ionization refers to an electrical phenomenon in which the increasing drain current coupled with the drain voltage induces creation of additional charge carriers, which can create current that flows into the oxide layer and which can be trapped in the oxide layer, adversely impacting the transistor operation. In a particular instance, the impact ionization can result in an avalanche breakdown that results in an undesired current gain at the current channel. In a particular instance, the impact ionization can result in an increase in body or substrate current which may contribute to the turn-on of the parasitic bipolar junction transistor (BJT) formed by the MOSFET source, body and drain regions. This BJT turn-on may lead to snapback, where the MOSFET drain voltage collapses while the drain terminal current increases.
In a particular embodiment, the gate terminal includes a polysilicon deposit that has a first portion that extends over a thick oxide layer and has a second portion that extends over a relatively thin oxide layer. The metal contacts are deposited along the width of the polysilicon deposit over the first portion.
Although the present specification describes components and functions that may be implemented in particular embodiments with reference to particular standards and protocols, the disclosed embodiments are not limited to such standards and protocols. For example, standards for Power over Ethernet and other power and data transmission techniques (such as broadband Internet over power lines) represent examples of the state of the art. Such standards are periodically superseded by updated equivalents having essentially the same functions. For example, the PoE standard may be superseded by a PoE plus standard that, among other modifications, allows for transmission of higher voltages to powered devices that support such voltages. Accordingly, replacement standards and protocols having the same or similar functions as those disclosed herein are considered equivalents thereof.
The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be reduced. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.
The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true spirit and scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.
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