The present invention relates generally to the methods and techniques for reducing the temperature variation of resistance of a vertical MOSFET devices.
For many years, manufacturers and developers of high performance power electronics have sought to improve power-handling density and manage device heat dissipation of discrete electronic components.
Vertical MOSFETs have an on-resistance (“RdsOn”) that increases monotonically and super-linearly with temperature. As the on-resistance increases, so does the power dissipated for a given drain current (Id) according to the power equation: Power=Id2×RdsOn. Power dissipation in turn causes the MOSFET junction temperature to increase, which further increases the on-resistance. If heat dissipation is sufficient, then the RdsOn will increase until thermal equilibrium is reached in the MOSFET. If heat dissipation system is insufficient, then the MOSFET will experience thermal runaway.
Reduction in RdsOn in modern vertical MOSFET devices has resulted in significant improvements in power supply efficiency. However, the RdsOn still increases with temperature. Systems incorporating these devices, especially systems that are operated at a variety of duty cycles and/or a variety of ambient temperatures, would benefit greatly from an RdsOn that demonstrates reduced variation with temperature.
The present disclosure is a field-effect device architecture that reduces the temperature variation of resistance. In particular, this disclosure provides a method and an apparatus for reducing the variation of RdsOn due to increasing temperature.
According to a preferred embodiment, a resistor having a negative temperature coefficient (“NTC”) is connected in series with a vertical MOSFET to obtain a more stable resistance variation with temperature. Also, variation of the device resistance with temperature is significantly reduced.
In a preferred embodiment, a MOSFET vertical field-effect device is constructed on an epitaxial Si wafer with an n+ doped base substrate.
In another embodiment, a MOSFET vertical field-effect device is constructed on a non-epitaxial Si wafer with an n− doped substrate.
The apparatus finds applicability in both n-channel and p-channel devices operating in either depletion or enhancement mode.
Vertical semiconductor devices are semiconductor constructs (for example MOSFETs, IGBTs and diodes) where the primary direction of current flow is vertical, that is, from top to bottom or bottom to top or both. Power discrete semiconductor devices are often built with such a vertical architecture.
“On-resistance” (RdsOn) is the resistance of a semiconductor device when it is biased in the “on-state” by applying voltages and/or currents to its electrodes. For example, a MOSFET has a gate electrode, a source electrode and a drain electrode with a drain-source voltage (Vds) applied between the drain electrode and source electrodes and a gate-source voltage (Vgs) applied between the gate and source electrodes. “On-state” means that current (Id) from the source electrode to the drain electrode is enabled by the gate-source voltage. For a power MOSFET, for example, RdsOn is defined as:
RdsOn=Id/Vds Eq. 1
Power MOSFETS including non-charge compensated vertical field effect devices and charge-compensated vertical field effect devices (e.g., super junction MOSFETS), like some other vertical semiconductor devices are positive temperature coefficient devices. In general, positive temperature coefficient devices have a device resistance which increases with increasing temperature.
Conversely, NTC devices have a resistance that decreases with increasing temperature. One example of an NTC device is an NTC resistor.
N+ source region 109 is adjacent the “p” type body regions. The p type body regions include p− body 140, “p+” body 141, and p+ body-contacting region 142. p+ body-contacting region 142 contacts source metal layer 108 which electrically shorts n+ source region 109 to p+ body-contacting region 142 to avoid accidental excitation of a parasitic bipolar junction transistor which is formed between the n+ source region, the p type body regions and the drain electrode 103. Source metal layer 108 is in further contact with a source electrode 102. The n− drift region 105 is below p-type body regions 140, 141, 142 and adjacent to n+ drain region 106.
Gate region 113 contacts an insulation oxide layer 112 adjacent n− drift region 105, p− body region 140, n+ source region 109 and insulation layer 111. Gate region 113 is filled with a gate material adjacent gate oxide layer 112. Gate region 113 is in electrical contact with gate electrode 101. Gate oxide layer 112 is also adjacent n− drift region 105. A gate material commonly used in MOSFET devices is polycrystalline silicon (polysilicon).
RdsOn=Rn+RCH+Ra+Rj+RD+RS Eq. 2
where RdsOn is the on-resistance, Rn, 151, is the resistance of n+ source region 109, and Rch 152 is the resistance of the channel formed in the p− portion of the p-type body region 140. Ra 153 is the surface resistance of the n− drift region which is modulated by the applied gate-source voltage. JFET region 130 is a portion of n− drift region 105 between the surfaces 132 of p type body (p− body) region 140. As a drain voltage is supplied, the depletion region expands outward from the junction at surfaces 132, which causes and increases the resistance 154 (Rd) due to constriction of the n− drift region between surfaces 132. Rj 154 is the resistance of the JFET region. RD 155 is the resistance between the JFET region 130 to the top of n+ drain region 106. RD is the resistance of the n-drift region and is the most dominant factor of RdsOn in high voltage MOSFETs. RS 156 is the resistance of the n+ drain region. In low voltage MOSFETs, where the breakdown voltage is below about 50V, RS also has a large effect on the on-resistance. Additional on-resistance can arise from a non-ideal contact between the various regions as well as from the electrode leads used to connect the device to the package.
RdsOn increases with temperature because the mobility of the holes and electrons decrease as the temperature rises. RdsOn of an n− channel power MOSFET device can be estimated with the following equation:
where T is a device temperature in Kelvin, β is a temperature coefficient and RdsOn(T) is the on-resistance at the device temperature T. The temperature coefficient is positive and commonly in the range of 2.0 to 2.5 for MOSFET devices.
N+ source region 209 is adjacent p type body regions. The p type body regions include p− body 240, p+ body 241 and p+ body contacting region 242. P+ body-contacting region 242 contacts source metal layer 208 which electrically shorts n+ source region 209 to p type body regions 240, 241, 242. Source electrode 202 is attached to source metal layer 208.
Gate region 213 is adjacent to gate oxide layer 212 which is adjacent n− drift region 205, p− body region 240, n+ source region 209 and insulation layer 211. Gate region 213 is in electrical contact with gate electrode 201. Gate oxide layer 212 is also adjacent n− drift region 205.
RdsOn=Rn+RCH+Ra++RD+RS+RNTC Eq. 4
where RdsOn is the on-resistance, Rn 251 is the resistance of n+ source region 209, Rch 252 is the resistance of the channel formed in the p− body region 240. JFET region 230 is a portion of n− drift region 205 between the surfaces 232 of p type body (p− body) region 240. As a drain voltage is supplied, the depletion region expands outward from the junction at surfaces 232, which creates and increases resistance (Rj) due to constriction of the n− drift region between surfaces 232. Rj 254 is the resistance of the JFET region. RD 255 is the n− drift region resistance between the JFET region 230 to the top of n+ drain region 206. Ra 253 is the surface resistance of the n− drift region which is modulated by the applied gate-source voltage. RS 256 is the resistance of the n+ drain region. RNTC 257 is the resistance of resistive layer 220 having a negative temperature coefficient which characterizes the decrease in resistance of RNTC 257 as temperature increases.
In a preferred embodiment of a vertical MOSFET device, a reduced variation of the RdsOn resistance with temperature is accomplished by adding an NTC resistor in series with the MOSFET.
In a preferred embodiment, the NTC resistor is provided by resistive layer 220 and is comprised of a thin film made of polysilicon (or amorphous silicon, deposited by sputtering for example) which is doped in-situ. In another embodiment, resistive layer 220 is a thin film comprised of a polysilicon (or amorphous silicon) which is doped by implantation and subsequently annealed, with the thickness of the polysilicon or amorphous silicon layer in a range of approximately 100 angstroms to approximately 4000 angstroms.
The doping level of the polysilicon or amorphous silicon thin film is preferably in the range of about 1 e17 atoms/cm3 to about 1 e21 atoms/cm3. These values can vary by as much as ±5%. The dopants in the polysilicon or amorphous silicon thin film are from the group of elements consisting of arsenic, phosphorus, boron or any combination of these elements required to achieve a desired resistance value for the resistive layer at a base temperature (such as 25° C.) and a desired negative temperature coefficient of resistance value.
In another embodiment, resistive layer 220 is a metalized resistive thin film made of silicon-chromium. The silicon percentage of the silicon-chromium film is preferably in the range of about 40% to about 80%. These values can vary by as much as ±5%. The thickness of the silicon-chromium film is in the range of approximately 25 angstroms to approximately 2000 angstroms as required to achieve the desired sheet resistance value for the resistive layer at a base temperature (such as 25° C.) and the desired negative temperature coefficient of resistance value. These values can vary by as much as +10%.
In another embodiment, resistive layer 220 is a metalized resistive thin film made of silicon-nickel. The silicon percentage of the silicon-nickel film is preferably in the range of about 40% to about 80%. The thickness of the silicon-nickel film is in the range of approximately 25 angstroms to approximately 2000 angstroms as required to achieve the desired sheet resistance value for the resistive layer at a base temperature (such as 25° C.) and the desired negative temperature coefficient of resistance value. These values can vary by ±10%.
Referring to
At step 406, a backgrind is conducted on the second side to reduce wafer thickness.
At step 407, an NTC resistive thin film is grown or deposited on the n+ substrate. For example, the NTC resistive thin film can be made of polysilicon deposited or grown on the second side, or amorphous silicon deposited by sputtering or other methods. The NTC resistive thin film may be doped in-situ.
At step 408, depending upon whether the NTC resistive thin film was doped in-situ and whether such doping is sufficient to achieve the desired negative temperature coefficient characteristics. The NTC resistive thin film may be further doped by implantation to give it a desired negative temperature coefficient of resistance. At step 409, the NTC resistive thin film is annealed (by laser or RF annealing for example).
At step 410, apply a metal layer to the NTC resistive thin film to create the drain connection.
Referring to
Referring to
At step 429, a vertical field effect device is constructed on the first side. At step 431, backgrind is conducted on the second side. At step 432, an n+ drain region is implanted on the second side. At step 433, the n+ drain region is annealed. At step 435, an NTC resistive thin film is grown or deposited on the second side, wherein the resistive film may be doped in-situ. At step 436, depending upon whether the NTC resistive thin film was doped in-situ and whether such doping is sufficient to achieve the desired negative temperature coefficient characteristic. The NTC resistive film may be further doped by implantation. At step 438, the NTC resistive thin film is annealed. At step 439, the second side is metalized to create the drain connection.
Referring to
At step 443, a vertical field effect device is constructed on the first side. At step 444, backgrind is conducted on the second side.
At step 445, an n+ drain region is implanted on the second side. At step 446, the n+ drain region is annealed. At step 447, an NTC resistive thin film is grown or deposited on the second side. At step 448, the NTC resistive thin film is doped through implantation to achieve the desired negative temperature coefficient characteristic. At step 449, the NTC resistive thin film is annealed. At step 450, the second side is metalized to create the drain connection.
Referring to
At step 456, a vertical field effect device is constructed on the first side. At step 457, backgrind is conducted on the second side. At step 458, an n+ drain region is implanted on the second side. At step 460, an NTC resistive thin film is grown or deposited on the second side, wherein the thin film may be doped in-situ. At step 461, depending on whether the resistive thin film is doped in-situ and whether such doping is sufficient to achieve the desired negative temperature coefficient characteristic, the NTC resistive thin film may be further doped by implantation. At step 462, the n+ drain region and the NTC resistive thin film are annealed together. At step 464, the second side is metalized to create the drain connection.
Referring to
At step 483, a polysilicon or amorphous silicon NTC resistive film is grown or deposited on the n− substrate. At step 485, an n+ drain region is implanted through the NTC film. One advantage to implanting the n+ drain region through the NTC film is that the effective thickness of the NTC film will be set by the depth of the n+ drain implant. This will result in a very uniform across the wafer effective NTC film thickness due to the precise depth control of the n+ ion implant. At step 486, depending on whether the NTC film is doped in-situ and whether such doping is sufficient to achieve the desired negative temperature coefficient characteristic, the NTC resistive film may be further doped by implantation. At step 487, the NTC drain region and the NTC film are annealed together. At step 489, the second side is metalized to create the drain connection.
Referring to
At step 528, a material is selected and further specified for the resistive thin film based on the temperature dependence curve and based on physical compatibility with the semiconductor substrate including a temperature expansion coefficient. The material can include dopants with specified doping levels. At step 530, a sheet resistance for the resistive thin film is determined for the material.
At step 532, a set of desired processing properties is determined for creating the resistive thin film. The set of desired processing properties include the desired composition, doping type and level, and thickness of the resistive thin film, which is determined by dividing the specified resistance at 25° C. by the sheet resistance. At step 533, a vertical field device is constructed on the first side of a wafer.
At step 534, the resistive thin film is grown or deposited and processed according to the material properties, the processing properties and the desired composition, doping type and level, and thickness on the side of the wafer.
At step 536, the thin film is doped in-situ or by implantation. At step 538, the thin film is annealed, if required.
In a preferred embodiment of the method, the material of the resistive thin film is selected from the group of materials including polysilicon, amorphous silicon, silicon-chromium, silicon-nickel or a combination of these materials. In another embodiment, a different material can be selected provided the material and processing properties can be derived to achieve a negative temperature coefficient of resistance.
In a first embodiment, polysilicon or amorphous silicon is selected as the material for the resistive thin film and the polysilicon is doped in-situ. In a second preferred embodiment, polysilicon or amorphous silicon is selected as the material for the resistive thin film and the polysilicon or amorphous silicon is doped by implantation and subsequently annealed. In the first embodiment and the second embodiment, the doping level of the polysilicon or amorphous silicon thin film is selected to be in the range of 1 e 17 atoms/cm3 to 1 e21 atoms/cm3 and the dopants in the polysilicon or amorphous silicon thin film are selected from the group of elements consisting of arsenic, phosphorus, boron or any combination of these elements required to achieve a desired resistance value for the resistive layer at the base temperature (25° C.) and the desired temperature dependence curve.
In a third embodiment, silicon-chromium is selected as the material of the resistive thin film. The silicon percentage of the silicon-chromium film is chosen in the range of 40% to 80% and the thin film is grown with a thickness in the range of approximately 25 A to approximately 2000 A as required to achieve the desired sheet resistance value for the resistive layer at the base temperature (such as 25° C.) and the desired temperature dependence curve.
In a fourth embodiment, silicon-nickel is selected as the material of the resistive thin film. The silicon percentage of the silicon-nickel film is chosen in the range of 40% to 80% and the thin film is grown with a thickness in the range of approximately 25 A to approximately 2000 A as required to achieve the specified resistance value for the resistive layer at the base temperature (such as 25° C.) and the desired temperature dependence curve.
The embodiments presented in this disclosure are intended to provide implementable examples of the present invention, but are not intended to limit the present invention. For example, other materials besides Si can be used as a base semiconductor material. Various ranges of doping levels for the n+ regions, n-columns, p-columns and p-type body can be employed as required.
This application claims priority benefit from U.S. Provisional Application No. 61/778,698 filed Mar. 13, 2013. The patent application identified above is incorporated here by reference in its entirety to provide continuity of disclosure.
Number | Date | Country | |
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61778698 | Mar 2013 | US |