This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2022-043924, filed on Mar. 18, 2022; the entire contents of which are incorporated herein by reference.
Embodiments relate to a semiconductor device and a method of manufacturing the same.
A semiconductor device used for power control or the like is required to reduce a leakage current and improve a breakdown voltage.
According to one embodiment, a semiconductor device includes a semiconductor part including a first semiconductor layer of a first conductivity type and a second semiconductor layer of a second conductivity type. The second semiconductor layer is provided in the first semiconductor layer. The semiconductor part includes first and second interfaces of the first semiconductor layer and the second semiconductor layer. The first interface intersects the second interface. The second semiconductor layer includes a plurality of sub-layers stacked in a direction orthogonal to the first interface. The second interface includes interfaces of the sub-layers of the second semiconductor layer and the first semiconductor layer. The second interface extending in a second direction inclined with respect to a first direction orthogonal to the first interface.
Embodiments will now be described with reference to the drawings. The same portions inside the drawings are marked with the same numerals; a detailed description is omitted as appropriate; and the different portions are described. The drawings are schematic or conceptual; and the relationships between the thicknesses and widths of portions, the proportions of sizes between portions, etc., are not necessarily the same as the actual values thereof. The dimensions and/or the proportions may be illustrated differently between the drawings, even in the case where the same portion is illustrated.
There are cases where the dispositions of the components are described using the directions of XYZ axes shown in the drawings. The X-axis, the Y-axis, and the Z-axis are orthogonal to each other. Hereinbelow, the directions of the X-axis, the Y-axis, and the Z-axis are described as an X-direction, a Y-direction, and a Z-direction. Also, there are cases where the Z-direction is described as upward and the direction opposite to the Z-direction is described as downward.
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Subsequently, an ion implantation mask HM1 is formed on the first semiconductor layer 11a, and a second-conductivity-type impurity such as aluminum (Al) is ion-implanted into the first semiconductor layer 11a through a first opening WP1 of the ion implantation mask HM1. Thereby, a second semiconductor layer 13a of the second conductivity type is formed in the first semiconductor layer 11a.
The second-conductivity-type impurity is implanted in a direction inclined with respect to an upper surface of the first semiconductor layer 11a. The implantation angle θ that is defined between an implantation direction and a direction perpendicular to the upper surface of the first semiconductor layer 11a is, for example, the same as the off-angle of the semiconductor substrate 10. Thereby, the second-conductivity-type impurity is ion-implanted in the [0001] direction, i.e., a direction perpendicular to a C-plane of the hexagonal crystal.
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Subsequently, an ion implantation mask HM2 is formed on the first semiconductor layer 11b, and a second-conductivity-type impurity such as aluminum (Al) is ion-implanted into the first semiconductor layer 11b through a second opening WP2 of the ion implantation mask HM2. The second-conductivity-type impurity is ion-implanted into the first semiconductor layer 11b at the same implantation angle θ as the implantation angle θ when the second-conductivity-type impurity is implanted into the first semiconductor layer 11a. Thereby, a second semiconductor layer 13b of the second conductivity type is formed in the first semiconductor layer 11b.
The ion implantation mask HM2 includes the second opening WP2 having the same width as a width of the first opening WP1 in the ion implantation mask HM1. The second opening WP2 is provided at a horizontal position displaced in a reverse direction of the implantation direction (e.g., a reverse direction of the X-direction) with respect to the horizontal position of the first opening WP1. Here, the horizontal position is a relative position in a horizontal direction along upper surfaces of the first semiconductor layer 11a and the second semiconductor layer 11b.
A displacement amount of the second opening WP2 in the horizontal direction with respect to the first opening WP1 is equal to, for example, a product of a layer thickness in the Z-direction of the first semiconductor layer 11b and a tangent of the implantation angle θ (see
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Subsequently, an ion implantation mask HM3 is formed on the first semiconductor layer 11c, and a second-conductivity-type impurity such as aluminum (Al) is ion-implanted into the first semiconductor layer 11c through a third opening WP3 of the ion implantation mask HM3. The second-conductivity-type impurity is ion-implanted into the first semiconductor layer 11c at the same implantation angle θ as the implantation angle θ when the second-conductivity-type impurities are implanted into the first semiconductor layers 11a and 11b. Thereby, a second semiconductor layer 13c of the second conductivity type is formed in the first semiconductor layer 11c.
The ion implantation mask HM3 includes the third opening WP3 having the same width as the width of the second opening WP2 in the ion implantation mask HM2. The third opening WP3 is provided at a horizontal position displaced in the reverse direction of the implantation direction (e.g., the reverse direction of the X-direction) with respect to the horizontal position of the second opening WP2. A displacement amount of the third opening WP3 in the horizontal direction with respect to the second opening WP2 is equal to, for example, a product of a layer thickness in the Z-direction of the first semiconductor layer 11c and the tangent of the implantation angle θ. Thereby, the second semiconductor layers 13b and 13c are formed such that the side surfaces thereof are continuously connected. The ion implantation masks HM1 to HM3 each are, for example, a hard mask such as a silicon oxide film or a metal film, or a resin such as a resist.
Hereinafter, a stacked body of the first semiconductor layers 11a to 11c is described as the first semiconductor layer 11. Also, a stacked body of the second semiconductor layers 13a to 13c is described as the second semiconductor layer 13. It should be noted that the embodiment is not limited to the manufacturing method described above. For example, each stacked body of the first semiconductor layer 11 and the second semiconductor layer 13 may include four or more layers.
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Moreover, the embodiment is not limited to the example. The incident ion beam IB may be perpendicular to a crystal plane inclined clockwise in the M-plane by, for example, 17 degrees from the C-plane. In such a crystal plane and the C-plane, an atomic spacing becomes relatively wide, and so-called a channeling ion implantation can take place. Therefore, the ion-implanted second-conductivity-type impurity can be more widely distributed in the depth direction (e.g., Z-direction). That is, in the manufacturing method according to the embodiment, the number of epitaxial growth steps to obtain the second semiconductor layer 13 having a predetermined thickness can be reduced.
When the off-angle θ of the wafer is, for example, 4 degrees and the front surface 100F is inclined clockwise in the M-plane by 21 degrees, the incident ion beam IB enters in a channeling direction. Moreover, when the off-angle θ of the wafer 100 is −4 degrees and the front surface 100F is inclined clockwise in the M-plane by 13 degrees, the incident ion beam IB enters in the channeling direction. Thereby, it is possible to reduce the mask shielding effect due to the thicknesses of the ion implantation masks HM1 to HM3.
In the example, two step ion implantations are performed in each of the first semiconductor layers 11a to 11c. In each ion implantation, Al ions are implanted in a direction perpendicular to the C-plane. In
The first ion implantation is performed, for example, at room temperature under conditions of an implantation energy of 900 keV and an Al dose amount of 1×1013 cm−2. The second ion implantation is performed, for example, at room temperature under conditions of an implantation energy of 200 keV and an Al dose amount of 6×1012 cm−3. The embodiment is not limited to the example. For example, the high acceleration implantation may be performed at 600 to 1200 key, and the low acceleration implantation may be performed at 100 to 400 keV.
Also, in the first semiconductor layers 11b and 11c, the two step ion implantations are performed respectively under the above-described conditions. The Al distributions in the first semiconductor layers 11b and 11c each are the same distribution as the Al distribution introduced by the two step ion implantations. Moreover, the first semiconductor layers 11b and 11c each have a layer thickness (i.e., a thickness in the Z-direction) of, for example, 1.5 micrometers (μm).
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In the semiconductor device 1 shown in
The displacement amounts in the horizontal direction of the second semiconductor layers 13a to 13d reflect a relationship of horizontal positions of the first to third openings WP1 to WP3 included in the ion implantation masks HM1 to HM3 (see
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The second interface IF2 extends along, for example, a second plane PL2 inclined with respect to a first plane PL1 that is orthogonal to the first interface IF1. In other words, in the X-Z plane, the second interface IF2 extends in a second direction inclined with respect to a first direction orthogonal to the first interface IF1. An inclination angle of the second plane PL2 with respect to the first plane PL1 is equal to the implantation angle θ of the second-conductivity-type impurity. Moreover, a straight line connecting the center point 13BC of the first interface IF1 and the center point 13TC of a front surface 13TS opposite to the first interface IF1 is parallel to the second plane PL2.
The second interface IF2 includes a direction along the first interface IF1. The second interface IF2 includes a direction, for example, orthogonal to the X-direction, i.e., the Y-direction. Moreover, the second interface IF2 includes a direction inclined by the implantation angle θ with respect to a direction orthogonal to the first interface IF1, i.e., the Z-direction.
In the semiconductor device 2 shown in
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In contrast, in the semiconductor device 1 according to the embodiment, the second interface IF2 between the first semiconductor layer 11 and the second semiconductor layer 13 is flat and extends along the second plane PL2. Therefore, in the semiconductor device 1, it is possible to prevent the leakage current due to the steps in the second interface IF2 and to prevent the breakdown voltage from decreasing.
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In the semiconductor device 3, the steps (see
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The semiconductor part SP is provided between the first electrode 20 and the second electrode 30. The first electrode 20 is provided on a back surface of the semiconductor part SP. The second electrode 30 is provided on a front surface of the semiconductor part SP.
The control electrode 40 is provided inside a trench GT. The trench GT is provided on the front surface side of the semiconductor part SP. That is, the semiconductor device 3 has a trench gate structure. The control electrode 40 is provided between the first electrode 20 and the second electrode 30. The control electrode 40 is electrically insulated from the semiconductor part SP by a first insulating film 43. Also, the control electrode 40 is electrically insulated from the second electrode 30 by a second insulating film 45. The first insulating film 43 is, for example, a gate insulating film. The second insulating film 45 is, for example, an interlayer insulating film.
The semiconductor part SP includes the first semiconductor layer 11, the second semiconductor layer 13, a third semiconductor layer 15 of the second conductivity type, a fourth semiconductor layer 17 of the first conductivity type, a fifth semiconductor layer 19 of the second conductivity type, and a sixth semiconductor layer 21 of the first conductivity type.
The first semiconductor layer 11 extends between the first electrode 20 and the second electrode 30. Multiple second semiconductor layers 13 are provided in the first semiconductor layer 11 and are arranged in the Y-direction. The first semiconductor layer 11 and the second semiconductor layers 13 provide the so-called Si structure. In the example, the control electrode 40 is provided between each of the second semiconductor layers 13 and the second electrode 30.
The third semiconductor layer 15 is provided between the first semiconductor layer 11 and the second electrode 30. The third semiconductor layer 15 is provided between two adjacent control electrodes 40 and faces the control electrodes 40 via the first insulating film 43.
The fourth semiconductor layer 17 is partially provided on the third semiconductor layer 15 between the third semiconductor layer 15 and the second electrode 30. The fourth semiconductor layer 17 is in contact with the first insulating film 43.
The fifth semiconductor layer 19 is partially provided on the third semiconductor layer 15 between the third semiconductor layer 15 and the second electrode 30. The fourth semiconductor layer 17 and the fifth semiconductor layer 19 are arranged on the third semiconductor layer 15.
The second electrode 30 is connected to the fourth semiconductor layer 17 and the fifth semiconductor layer 19 at the front surface side of the semiconductor part SR The second electrode 30 contacts the fourth semiconductor layer 17 and the fifth semiconductor layer 19 with, for example, an ohmic connection.
The sixth semiconductor layer 21 is provided between the first semiconductor layer 11 and the first electrode 20. The sixth semiconductor layer 21 is formed by, for example, thinning the semiconductor substrate 10 to be a prescribed thickness. The semiconductor substrate 10 is thinned by, for example, grinding the back surface thereof. The first electrode 20 is connected to the sixth semiconductor layer 21 with, for example, an ohmic connection.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the invention.
Number | Date | Country | Kind |
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2022-043924 | Mar 2022 | JP | national |