Structure and method for semiconductor power devices

A semiconductor device includes a semiconductor-on-insulator region on a substrate. The semiconductor-on-insulator region includes a first semiconductor region overlying a dielectric region. The device includes an MOS transistor and a bipolar transistor. The MOS transistor has a drain region, a body region, and a source region in the first semiconductor region. The MOS transistor also includes a gate. The device also includes a second semiconductor region overlying the substrate and adjacent to the drain region, and a third semiconductor region overlying the substrate and adjacent to the second semiconductor region. The bipolar transistor includes has the drain region of the MOS transistor as an emitter, the second semiconductor region as a base, and the third semiconductor region as a collector. Accordingly, the drain of the MOS transistor also functions as the emitter of the bipolar transistor. Additionally, the gate and the base are coupled by a resistive element.

BACKGROUND OF THE INVENTION

The present invention relates in general to semiconductor power devices. More particularly, the invention provides structures and methods for a high voltage laterally diffused metal oxide semiconductor (LDMOS) device.

High voltage LDMOS transistors are finding increasingly broad applications in modern electronics, such as portable consumer electronics, power management circuits, automotive electronics, disk drives, display devices, RF communication circuits, and wireless base station circuits, etc. In these applications, the performance of an LDMOS transistor is usually measured by its on-resistance, switching speed, and breakdown voltage.

FIG. 1is a cross-sectional view of a conventional high voltage LDMOS transistor100. An n−-type well region12is formed on an n-type substrate10. A p−-type body region13is formed in n−-type well region12. An n+-type source region15and an n-type lightly doped source region16are formed in p−-type body region13. An n-type lightly doped drain region18is formed in n−-type well region12.

A gate insulating layer20extends over n−-type well region12and a surface portion of p-type body region13. A gate conductive layer21extends over gate insulating layer20. A source electrode23is in contact with n+-type source region15and p-type body region13. An n+-type sinker region20connects the n-type lightly doped drain region18with the n+-type substrate10, which is used as a drain electrode.

Upon applying a reverse bias across the drain-source electrodes, a depletion region extends out from the junction between p-type body region13and n-type well region12, as shown by the arrow32. High electric fields tend to build up in the depletion region, and breakdown occurs when the electric fields exceed certain limitations. When device100is turned on, the current flows from the drain region10through the sinker region and channel region to the source electrode23. This current path often introduces a high on-resistance Rdson. Additionally, the charges in the well region and the body region can limit the switching speed of the device, when a gate voltage is applied to turn on and off the device.

Even though conventional LDMOS devices, such as device100inFIG. 1, are satisfactory in certain applications, they suffer from many limitations. These limitations include low breakdown voltage, high on-resistance, and excess gate charges that impact device switching speed.

Thus, there is a need for improved LDMOS device structures and cost-effective manufacturing methods that offer reduced on-resistance, higher breakdown voltage, and lower gate charges.

BRIEF SUMMARY OF THE INVENTION

In accordance with embodiments of the present invention, a composite semiconductor device includes an MOS transistor built in an SOI layer combined with a bipolar transistor. The drain of the MOS transistor also forms the emitter of the bipolar transistor, and the base of the bipolar transistor is coupled to the gate of the MOS transistor by a resistive element. In an embodiment, the MOS transistor is an LDMOS built in SOI for power applications. Depending on the embodiment, the composite device can provide reduced on-resistance, higher breakdown voltage, and lower gate charges. In one embodiment, part of the bipolar transistor is built in a vertical semiconductor region connecting a front side semiconductor layer of the SOI with a back side substrate. Additionally, a method for forming the composite device is provided.

According to a specific embodiment, a semiconductor device includes a semiconductor-on-insulator (SOI) region on a substrate. The semiconductor-on-insulator region includes a first semiconductor region overlying a dielectric region. The device includes an MOS transistor and a bipolar transistor. The MOS transistor has a drain region, a body region, and a source region in the first semiconductor region. The MOS transistor further includes a gate. The device also includes a second semiconductor region overlying the substrate and adjacent to the drain region, and a third semiconductor region overlying the substrate and adjacent to the second semiconductor region. The bipolar transistor includes the drain region of the MOS transistor as an emitter, the second semiconductor region as a base, and the third semiconductor region as a collector. Additionally, the gate and the base are coupled by a resistive element.

In an embodiment, the MOS transistor is an LDMOS built using an SOI layer, and the LDMOS is combined with the bipolar transistor to form a an SOI lateral diffused bipolar MOS (LDBiMOS) device. In a specific embodiment, part of the bipolar transistor is built in a vertical semiconductor region connecting a front side semiconductor layer of the SOI with a back side substrate.

In a specific embodiment, the MOS transistor is an NMOS transistor and the bipolar transistor is an NPN bipolar transistor. In another embodiment, the MOS transistor is a PMOS transistor and the bipolar transistor is a PNP bipolar transistor.

In accordance with another embodiment of the present invention, a method for forming a semiconductor device includes providing a semiconductor-on-insulator layer on a semiconductor substrate of a first conductivity type. The semiconductor-on-insulator layer includes a semiconductor layer overlying a dielectric layer. The method includes forming a void in the semiconductor-on-insulator layer to expose a portion of the substrate, and then forming a first semiconductor region to fill the void. That is, the first semiconductor region provides a region of semiconductor material that is in contact with both the semiconductor layer and the substrate. The method also includes forming an MOS transistor and a bipolar transistor. The MOS transistor includes a drain region, a source region, and a body region in the semiconductor layer. The MOS transistor also has a gate which is separated from the body region by a gate dielectric. The bipolar transistor includes the drain region as an emitter, an upper portion of the first semiconductor region as a base, and a lower portion of the first semiconductor region as a collector. Then a resistive element is formed overlying the semiconductor substrate and is coupled to the base and to the gate.

In an embodiment, three electrodes are formed for the semiconductor device: a first electrode coupled to the source region, a second electrode coupled to the substrate, and a third electrode coupled to the base which is also coupled to the gate through the resistive element.

In a specific embodiment the void is formed by removing a portion of the first semiconductor layer and a portion of the underlying dielectric layer. In an embodiment, the first semiconductor region is epitaxially grown to fill the void in the semiconductor-on-insulator layer.

In another embodiment of the method, the process of forming the bipolar transistor includes forming a first doped region of the first conductivity type in the lower portion of the first semiconductor region that fills the void, and forming a second doped region of second conductivity type in the upper portion of the first semiconductor region. The second doped region is adjacent to the drain region, such that the second doped region can function as the base region of the bipolar transistor. Depending on the embodiment, the different doped regions in the MOS and bipolar transistors can be formed in a variety of sequences. For example, the collector in the lower portion of the semiconductor region in the void can be doped first followed by a drive-in diffusion cycle.

In accordance with an alternative embodiment, a semiconductor device includes a semiconductor substrate of a first conductivity type, a dielectric layer overlying the semiconductor substrate, and a first semiconductor region overlying the dielectric layer. The device also includes an MOS transistor and a bipolar transistor. The MOS transistor includes a source region of the first conductivity in the first semiconductor region, a drain region of the first conductivity type in the first semiconductor region, and a body region of a second conductivity type between the drain region and the source region in the first semiconductor region. Here, the second conductivity type is understood to be opposite to the first conductivity type. For example, if the first conductivity type is n-type, then the second conductivity type is p-type, or vice versa. The MOS transistor also includes a gate extending over a surface portion of the body region, which forms a channel region of the MOS transistor. The device also includes a second semiconductor region of the second conductivity type overlying the semiconductor substrate, and a third semiconductor region of the first conductivity type overlying the second semiconductor region. The third semiconductor region is adjacent to the drain region of the MOS transistor. In an embodiment, the bipolar transistor has the drain region as an emitter, the third semiconductor region as a base, and the second semiconductor region as a collector. Additionally, the base and the gate are connected by a resistive element.

Many benefits are achieved over conventional techniques. For example, in an embodiment, a structure and method for forming a composite semiconductor device combining an MOS transistor built in an SOI layer with a bipolar transistor are provided. Depending on the embodiment, various features of the composite device include reduced on-resistance, higher breakdown voltage, or lower gate charges. Depending upon the embodiment, one or more of these benefits may be achieved. Additionally, a disclosed process embodiment is compatible with conventional process technology and would not require substantial modifications to the manufacturing processes or equipment. These and other benefits will be described in more detail throughout the present specification.

DETAILED DESCRIPTION OF THE INVENTION

As discussed above, even though LDMOS is widely used in power applications, conventional LDMOS suffers from many limitations. For example, the gate charge can be high due to the relatively large depletion regions. Also, the breakdown voltage BVdss for LDMOS is usually limited by the p-n junctions. Additionally, Rdson in the conventional LDMOS as shown inFIG. 1tends to be high because the current flows through a 90° path, first laterally along a surface region and then vertically into the drain at the back side of the substrate. Thus, it is desirable for LDMOS device structures and cost-effective manufacturing methods that offer improved device performance.

In accordance with embodiments of the present invention, a composite semiconductor device is provided that includes an MOS transistor built in an SOI layer combined with a bipolar transistor. The drain of the MOS transistor also forms the emitter of the bipolar transistor, and the base of the bipolar transistor is coupled to the gate of the MOS transistor by a resistive element. In an embodiment, the MOS transistor is an LDMOS built in SOI for power applications. Depending on the embodiment, the composite device can provide reduced on-resistance, higher breakdown voltage, and lower gate charges. In one embodiment, part of the bipolar transistor is built in a vertical semiconductor region connecting a front side semiconductor layer of the SOI with a back side substrate. Additionally, the invention also provides a method for forming the composite device.

FIG. 2Ashows a simplified cross-sectional view of a lateral diffused MOS transistor (LDMOS) on SOI according to an embodiment of the present invention. As shown, LDMOS transistor240includes a semiconductor substrate201. A dielectric layer203overlies the semiconductor substrate. A semiconductor layer210overlies the dielectric region203. In this specific embodiment, substrate201is heavily doped n-type which functions as a back side electrode. As shown, LDMOS240includes an MOS transistor, which includes an n-type source region225, n-type drain region220, and a p-type body region213in the semiconductor layer210. The body region213is located between the drain region and the source region. A gate221extends over a surface portion217of the body region. The surface portion217of the body region forms a channel region of the MOS transistor.

A gate insulating layer219extends over the surface portion217of p-type body region213. A gate conductive layer221extends over gate insulating layer225. A source electrode223is in contact with n+-type source region215and p-type body region213. Additionally, in this specific embodiment, an n-type lightly doped drain region218is located between the drain region220and the body region213, and a lightly doped source region216is located between the source region215and the body region213. In an embodiment, the n-type lightly doped drain region218is extended for sustaining high voltage in power device applications. A heavily doped n-type sinker region230connects the drain region820with the semiconductor substrate201to form a drain contact in the back side of the device.

FIG. 2Bshows a simplified cross-sectional view of a lateral diffused bipolar MOS (LDBiMOS) transistor200according to another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize other variations, modifications, and alternatives. As shown, LDBiMOS transistor200includes a semiconductor substrate201. A dielectric layer203overlies the semiconductor substrate. A semiconductor layer210overlies the dielectric region203. In this specific embodiment, substrate201is heavily doped n-type which can function as a back side electrode. As shown, LDBiMOS transistor200includes an MOS transistor, which includes an n-type source region225, n-type drain region220, and a p-type body region213in the semiconductor layer210. The body region213is located between the drain region and the source region. A gate221extends over a surface portion217of the body region. The surface portion217of the body region forms a channel region of the MOS transistor.

A gate insulating layer219extends over the surface portion217of p-type body region213. A gate conductive layer221extends over gate insulating layer225. A source electrode223is in contact with n+-type source region215and p-type body region213. Additionally, in this specific embodiment, an n-type lightly doped drain region218is located between the drain region220and the body region213, and a lightly doped source region216is located between the source region215and the body region213.

InFIG. 2B, a p-type base region225is located adjacent the drain region220. An n-type collector region226is adjacent to the base region. The collector region226also overlies n-type region227over the semiconductor substrate201. The emitter region220, the base region225, and the collector region226form a bipolar transistor. In this embodiment, the drain region220also functions as an emitter region of the bipolar transistor. InFIG. 2B, the collector region226is coupled, through n+ region227, to the heavily doped substrate201, which can be used as a back side terminal.

As shown inFIG. 2B, a resistive element228is coupled between the gate221and the base region225. In a specific embodiment, the resistive element228can be a conventional resistor formed on the substrate. For example, the resistor can be a diffused resistor, a polysilicon resistor, or metal resistor, depending on the embodiment. The resistive element228is coupled to the gate and base region via interconnects formed on the substrate.

FIG. 3is a simplified schematic diagram for the lateral diffused bipolar MOS transistor (LDBiMOS) device200ofFIG. 2B. According to a specific embodiment of the invention, device300may be similar to device200ofFIG. 2B. As shown inFIG. 3, device300includes a bipolar transistor310in series with an MOS transistor312. The bipolar transistor310includes collector326, base325, and emitter320, whereas the MOS transistor includes drain320, source323, and gate321. As shown, the emitter320of the bipolar device is also the drain of the MOS transistor. Additionally, the base325of the bipolar transistor is coupled to the gate321of the bipolar transistor through a resistor328.

InFIG. 3, the collector terminal326is coupled to a supply voltage Vc. The source terminal323is coupled to a ground voltage. The gate terminal321is coupled to an applied gate voltage Vg. The base terminal325is coupled to the applied voltage Vg through resistor328. According to an embodiment, the operation of device300can be described as follows. When a gate voltage Vg is applied, the MOS transistor312is turned on, forcing the drain voltage Vd to be low. Part of the gate voltage Vg also appears at the base325of bipolar transistor310. Since the drain terminal320is also the emitter terminal for the bipolar transistor, this in turn causes the base-emitter junction to be forward biased. As a result, the bipolar transistor310is turned on.

InFIG. 3, device300can be viewed as a three-terminal power device with three applied voltages: power supply Vc at the collector terminal326, input signal Vg at the gate terminal321, and a ground voltage at the source terminal323. As a power transistor, device300can be characterized by power device parameters such as on-resistance Rdson, breakdown voltage BVdss, and gate charge Qgs. According to embodiments of the invention, the composite device300can provide improved device performance. The silicon-on-insulator region reduces the depletion regions and the associated junction capacitances, resulting in lower gate charge and higher breakdown voltage. The combination of the MOS and bipolar structures provides increased current flow and therefore reduces Rdson. Therefore, device300is capable of providing lower on-resistance, higher breakdown voltage, and lower gate charge, compared to a conventional LDMOS. The improved device performance has been confirmed in our simulation studies, as discussed below.

FIG. 4is a simplified graph showing the simulated breakdown voltage BVdss characteristics of a lateral diffused bipolar MOS transistor according to a specific embodiment of the present invention. As shown, the BVdss is about 30 V. In comparison, a convention LDMOS may have a BVdsss of about 14-15 V. Thus, the composite device has a breakdown voltage almost twice as high as that of a conventional device.

FIG. 5is a simplified graph showing the simulated drain current versus drain voltage characteristics of the lateral diffused bipolar MOS (LDBiMOS) transistor ofFIG. 4. With the bias voltage 2.0 V at the base and 10 V at the gate, the Rdson is about 106 ohms, as shown inFIG. 4. In contrast, a convention LDMOS may have an Rdson of about 3K ohms. Therefore, Rdson of 106 ohms provided by the LDBiMOS is approximately 30 times lower.

FIG. 6is a simplified graph comparing the simulated on-resistance Rdson for various lateral diffused MOS transistors (LDMOS) according to an embodiment of the present invention. InFIG. 6, the dotted line labeled “control” indicates an Rdson of approximately 3K ohms for a conventional LDMOS. The open circles denote the on-resistances of LDMOS devices formed in silicon-on-insulator (SOI) structures, such as device240inFIG. 2A. In these LDMOS devices, the MOS transistor is formed in the silicon layer overlying an oxide region, with a sinker region connects the drain to the back side terminal. As can be seen, the Rdson decreases with thinner top layer of silicon in the SOI structure. Further improvement can be achieved in an LDBiMOS device which includes a bipolar transistor structure to an LDMOS device built using an SOI structure, such as device200ofFIG. 2B. As shown by the solid circle, the LDBiMOS achieves a much lower Rdson of about 106 ohms.

FIG. 7is a simplified graph comparing the simulated gate charge Qgs for various lateral diffused MOS (LDMOS) transistors according to an embodiment of the present invention. As shown, an LDMOS built in a bulk substrate has the highest Qgs, followed by an LDMOS built on a 380 nm-thick SOI layer. In comparison, an LDBiMOS with a 10 nm-thick SOI exhibits by far the lowest Qgs. Since a low Qgs is associated with a fast device switching speed, the LDBiMOS can achieve a higher switching speed.

Thus, according to some embodiments of the present invention, forming an LDMOS device on an SOI structure can reduce the on-resistance Rdson. The reduction in Rdson is more pronounced when the silicon layer of the SOI is relatively thin, as shown inFIG. 6. Additionally, the Rdson and Qgs are further reduced in an LDBiMOS device that combines an LDMOS on SOI and a bipolar transistor.

Although the above has been shown using a selected group of components for the composite device LDBiMOS, there can be many alternatives, modifications, and variations. For example, some of the components may be expanded and/or combined. Other components may be inserted to those noted above. Depending upon the embodiment, the arrangement of components may be interchanged with others replaced. Further details of these components are found throughout the present specification and more particularly below.

FIGS. 8A through 8Eare simplified cross-sectional view diagrams illustrating a method for manufacturing a lateral diffused bipolar MOS (LDBiMOS) device according to an embodiment of the present invention. These diagrams are merely examples, which should not unduly limit the scope of the claims herein. One skilled in the art would recognize other variations, modifications, and alternatives. As shown inFIG. 8A, the method includes providing a semiconductor-on-insulator (SOI) layer802on a semiconductor substrate801of a certain conductivity type. The semiconductor-on-insulator layer802includes a semiconductor layer810overlying a dielectric layer803. In a specific embodiment, substrate801is a heavily doped n-type silicon substrate. In a specific embodiment, the SOI layer802includes a layer of silicon810overlying a layer of silicon oxide. Depending on the embodiment, the SOI layer may be formed by a variety of known methods, such as recrystallization, oxygen implant, or other methods involving bonding and/or cleaving, etc.

InFIG. 8B, a void804is formed in the SOI layer802to expose a portion of the substrate801at the bottom of the void. The void can be made by masking, etching the silicon layer810, and then etching the oxide layer803. Here, the masking and etching steps can be carried out using conventional processes.

InFIG. 8C, a silicon region805is formed to fill the void. In a specific embodiment, the silicon region805can be formed using an epitaxial growth process, while the silicon region outside the void can be protected by a dielectric layer, such as silicon oxide or silicon nitride (not shown). As shown, the silicon region805provides a region of semiconductor material that is in contact with both the semiconductor layer810and the substrate801. With the device structure inFIG. 8C, further processing can be carried out to form either an LDMOS on SOI (e.g.FIG. 2A) or an LDBiMOS (e.g.FIG. 2B).

InFIG. 8D, an LDBiMOS is formed, which includes an MOS transistor840and a bipolar transistor850are formed. The device structures inFIG. 8Dhave similar features as those inFIG. 2B. For example, the MOS transistor840includes a drain region820, a source region815, and a body region813in the semiconductor layer810. The MOS transistor also has a gate821which is separated from the body region813by a gate dielectric819. The bipolar transistor850includes an emitter820, a base825, and a collector826. As shown, n+ region820functions as both a drain region for the MOS transistor and an emitter region for the bipolar transistor. The base825is in an upper portion of the silicon region805, whereas the collector826is in a lower portion826of the silicon region805.

Depending on the embodiment, the MOS transistor840and the bipolar transistor850can be formed using various known processes. In particular, the doped regions can be formed using masked or unmasked implantation processes, which can be followed by appropriate diffusion steps if necessary. Additionally, either the bipolar transistor or the MOS transistor can be formed first, and the various device regions can be formed in different orders.

In a specific embodiment, the MOS transistor can be formed by first forming an n-type well region (not shown) in the semiconductor layer810, followed by the formation of the gate dielectric819overlying the well region. Next, polysilicon gate821is formed overlying the gate dielectric819and then patterned using conventional processes. The lightly doped drain, spacers, and source and drain regions can be formed using conventional processes. InFIG. 8D, a mask process is used to form the asymmetric lightly doped drain region818and the lightly doped source region816. Similarly, a masking process is used to form the asymmetric drain region820and source region815. In a specific

In an alternative embodiment, the MOS transistor can be formed using a laterally-diffused process. First, an implant and drive-in processes is used to form the p-type body region813in the n− well region and further extending under the gate. A long lightly doped drain (LDD) region818is also defined in this step. Subsequently, lightly doped source region816, spacers822, source region815, and drain region820can be formed using conventional methods. Of course, there can be other variations or modifications.

In an embodiment, the collector region826and the base region825of the bipolar transistor can be formed using conventional patterning, implantation, and drive-in diffusion processes. InFIG. 8D, the n+ region827is formed by dopant out diffusion from substrate801during the epitaxial growth of region805. The n-type collector region826can be formed in a lower portion of the semiconductor region805by implanting n-type dopants followed by a diffusion process. The p-type base region825can be similarly formed by implantation and diffusion in an upper portion of the semiconductor region805. As required in a bipolar transistor, the based region825is adjacent to the emitter region820. In a specific process, the collector and base regions can be formed before the formation of the MOS transistor.

InFIG. 8E, a resistive element828is formed overlying the semiconductor substrate and is coupled to the base825and to the gate821. Depending on the embodiment, the resistive element can be formed using various conventional processes. For example, the resistor element can be a diffusion resistor formed in a doped region in the semiconductor layer, a doped polysilicon region, or a metal resistor. After the resistor is formed, conductive lines831and832can be formed overlying the semiconductor layer for connecting the resistive element to the base and the gate, respectively. These conductive lines can also be fabricated using conventional processes.

In an embodiment, the method also includes forming an electrode823coupled to the source region815. InFIG. 8E, the electrode is shown as a metal region including TiN and/or W. As shown, the source electrode is also coupled to the body region813. A collector electrode (not shown) can be formed for connection to the substrate801, which is coupled to the collector region826through the n+ region827. Additionally, a gate electrode (not shown) can be formed and coupled to the gate. In the embodiment shown in the schematic diagram inFIG. 3, the source electrode is used as a ground terminal, the collector electrode is coupled to a power supply Vc, and the gate electrode serves as an input terminal to receive an input voltage Vg.

The above sequence of processes provides a method for forming a composite semiconductor device according to embodiments of the present invention. As shown, the method uses a combination of processes including a way of combining an SOI MOS transistor and a bipolar transistor to form a composite device capable of improved device performance. Other alternatives can also be provided where steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein. Additionally, even though the discussion has been made in the context of an n-type LDMOS and an NPN bipolar transistor, it is understood that the techniques provided herein are applicable to other semiconductor devices as well.

For example, by reversing the polarity of the doped regions, an alternative embodiment can include a combination of a p-type LDMOS and a PNP bipolar transistor. Alternatively, an MOS field effect transistor (MOSFET) on SOI can be used instead of the LDMOS. In one embodiment, the bipolar transistor includes an emitter, a base, and a collector in an L-shaped configuration, as shown inFIG. 2B. In another embodiment, the emitter, base, and collector can be arranged in a vertical configuration. Alternatively, the bipolar transistor can be a lateral transistor with emitter, base, and collector formed in a surface region of a semiconductor substrate.

In another embodiment, starting with the device structure inFIG. 8C, an LDMOS on SOI can be formed as shown inFIG. 8F. LDMOS840is similar to LDMOS240inFIG. 2A. LDMOS840and sinker region830can be formed using known processes. Some of the processes have been discussed above in connection withFIG. 8DandFIG. 8E. Of course, there can be other variations, modifications, and alternatives. For example, by reversing the polarity of the doped regions, an alternative embodiment can include a combination of a p-type LDMOS and a PNP bipolar transistor. Alternatively, an MOS field effect transistor (MOSFET) instead of the LDMOS can be formed on SOI with a sinker region connecting to the semiconductor substrate.