Mask-surrogate semiconductor process employing dopant-opaque region

Abstract: A mask-defect-immune process for making semiconductor devices features the creation of one or more surrogate masks in semiconductor wafer material per se, thus to eliminate the requirement that plural masks be used, and that plural mask alignments be performed. The surrogate mask is generally created in a dopant-opaque region.

Description: This invention relates to a method for producing a field effect power MOS semiconductor device in a substrate structure including a gate outside layer, on an upper surface of a semiconductor substrate. For the purpose of illustration herein, a preferred manner of practicing the invention is described in the context of making field-effect, power-MOS transistors, in the manufacture of which the invention has been found to have particular utility. Application of the invention to the making of other specific semiconductor devices, of course, will be immediately apparent to those skilled in the art. In the prior art fabrication, on silicon wafers, of transistor devices, such as field-effect, power-MOS transistors, there has been a significant problem in (1) obtaining an acceptably high yield of relatively large-current-capability transistors without (2) driving the cost of production to extremely high and unacceptable levels. A major contributor to this problem in the past has been that the best known prior art fabrication techniques typically employ five or more independent masking, diffusion and metallization steps, with each offering a significant opportunity for the creation of a fatal error in a device. Generally speaking, the more the number of such steps, the greater the possibility for the occurrence of catastrophic defects. These defects come about primarily because of misalignment occurring during the successive masking steps, and also in situations where one or more of the masks may, individually, have localized defects. Also, there is a possibility of fatal defects occurring as a result of airborne contaminants that may collect on a mask or a wafer, and this possibility, of course, is also aggravated by the plurality of masking steps now required. As a consequence of this problem, it has not been economically feasible, with any expectation of achieving an acceptably high yield, to manufacture relatively large, high-current-capability devices. Put another way, the larger the design of the device, the greater is the likelihood that it will contain a fatal defect. To date, an economically practical size limit has been about 6 mm (0.25-inches) on each side of a device. Accordingly, the tendency in the past has been to reduce the size of individual devices so that the chance of a larger number of smaller devices surviving defects increases. However, these smaller devices, while emerging with an acceptable yield percentage, are capable only of handling relatively low-level currents, and thus low-power applications. Accordingly, they must be linked electrically in collections in some fashion in order to be able to handle relatively high-power applications. Efforts in the past to improve the yield of larger-surface-area devices has taken place primarily through directing attention to several matters, key among which are performing the manufacturing steps in the cleanest possible environment, creating masks under extremely expensive manufacturing conditions, and handling mask alignment through very sophisticated, precise alignment machines. These areas of attention are extremely expensive, and, as a practical matter, make their use economically unattractive vis-a-vis the final market price which, as a consequence, must be attached to a finished device. S.M. Sze, VLSI Technology, 1983, pp. 463-464, shows a state-of-the-art integrated circuit process for lateral NMOS logic gate fabrication. This process employs several masking and patterning steps that require critical alignment. It also shows an initial step, using a patterned nitride/oxide layer as an oxidation mask during field oxidation. The nitride/oxide layer is then removed and a new oxide layer is grown to serve as a gate oxide layer. This is described as a critical step; the integrity and cleanliness of the oxide are essential for proper device operation. The gate oxide layer remains exposed, however, during subsequent implant cycles and is, therefore, subject to contamination. EP-A-0 148 595 shows a method of fabricating a mesa power MOSFET using an overhang mask. The overhang mask is made of a thick oxide layer which is patterned to define subsequent body diffusion and isotropic trench etching steps. After trenching, a second gaseous diffusion step is effected to form a source region, which is further etched anisotropically to separate it into two source regions under the overhang mask. The oxide layer is then covered with conductive material to serve as the gate while a source contact is formed in the trench. Again, the gate oxide remains exposed and subject to contamination during subsequent process steps. Also, this approach requires a thick oxide layer to be effective as a mask, which undesirably limits the design of gate oxide thickness. Additionally, to form the source regions, this process requires gaseous diffusion after trenching. This makes it difficult to control formation of the functional regions that define the MOSFET channel in terms of both channel length and threshold voltage. Pat.Abs.Jap. vol 7 no 292 (E-219) 27/12/83 and JP-A-58168277 of 4/10/83 discloses a further power field effect MOS transistor Accordingly, a need remains for a better process for fabrication of power field effect MOS transistors, using a mask-surrogate pattern definer. The invention is a method, employing a mask-surrogate pattern definer, of producing a field-effect power MoS semi-conductor device in a substrate, including a gate oxide layer on an upper surface of a semiconductor substrate. The method is characterised by the following steps performed in the given order: forming a dopant protective layer over the gate oxide layer; masking and patterning the dopant protective layer by selectively removing a portion of the dopant protective layer to form a mask-surrogate pattern-definer having a defined outline characteristic so that the pattern-definer protects an underlying gate oxide region and a first portion of the upper surface of the substrate and to expose a second portion of the upper surface of the substrate within a region defined by the defined outline characteristic; performing a first doping step to introduce dopant into said exposed second upper surface portion of the substrate so as to form a first MOS region, being a MOS body region of a first conductivity type, said first region extending by a lateral dimension under a peripheral edge of the protective layer; performing a second doping step to introduce dopant into said exposed second upper surface portion so as to form a second MOS region, being a MOS body region of a second conductivity type, opposite the first MOS region; said second region being wholly contained in said first region and extending to a distance within said dimension along the upper surface of the substrate to define a MOS channel beneath said region of the gate oxide layer; the dopant protective layer being dopant opaque so as to prevent the introduced dopants from penetrating the underlying gate oxide region; simultaneously etching the dopant protective layer and the exposed upper surface of the substrate after the first and second doping steps to form a trench in the exposed upper surface portion of the substrate, the trench being formed to a trench depth greater than the depth of the second region but less than the depth of the first region, and formed of a width less than that of the second region such that separated regions of the second conductivity type are provided at sidewalls of the trench, the separated regions constituting source regions of the MOS semiconductor device; and depositing a layer of conductive material over the entire upper surface of the device to form simultaneously a first conductive layer in the trench in contact with both the source and body regions to form a short between said regions which extends continuously along the trench sidewalls and a second conductive layer overlying the entire gate oxide region. In the method of this invention, the pattern-definer protects an underlying gate oxide region and a first portion of the upper surface of the substrate during the doping steps to form the functional regions of the MOS device, the dopant protective layer being dopant opaque so as to prevent the introduced dopants from penetrating the underlying gate oxide region. Preferably, the trench side-walls are undercut beneath the gate oxide layer and are thus formed to protrude laterally toward one another within the trench so that a portion of the substrate containing the second region of said first conductivity type is exposed along the trench sidewalls. Moreover, because a layer of conductive material is deposited over the entire upper surface of the device to form a conductive layer in the trench in contact with the separated source regions and the body region, electrical contact to the source regions is produced to form a gate conductive layer of the MOS semiconductor device. The conductive material is thus deposited in two regions simultaneously, and preferably that forming the gate conductive layer will be separated from that in the trench. The trench is preferably formed to a trench depth and the source conductive layer is deposited in the trench to a thickness relative to the trench depth for spacing the source conductive layer below the oxide layer so as to contact the separated source regions of the substrate along the sidewalls of the trench and so that the gate and source conductive layers are electrically separated along said defined outline characteristic. To facilitate separation, the sidewalls can be undercut beneath the gate oxide layer. Preferably, the second region is formed to extend a lateral distance under the peripheral edge of the protective layer that is 60% - 80% of a depth of the first region from the upper surface of the substrate. The second doping step is preferably performed by ion implanting dopant into the exposed portion of the substrate prior to forming the trench so that the trenching step divides the doped substrate portion into separate source regions extending along each trench sidewall. The dopant protective layer preferably includes a polysilicon layer. Thus, with a silicon substrate present the step of forming the trench can include etching both silicon substrate and the polysilicon layer prior to depositing the conductive layer forming the gate conductive layer. For a better understanding of the invention and to show how the same can be carried into effect, reference will now be made, by way of example only to the accompanying drawings, wherein: FIGURE 1 is a simplified plan view, with a small portion broken away, illustrating a field-effect, power-MOS transistor (semiconductor device) which has been manufactured in accordance with the steps of the present invention. FIGURE 2 is an enlarged, fragmentary, perspective view illustrating a section of the device of Figure 1 taken generally along the line 2-2 in Figure 1. FIGURES 3-16, inclusive, are enlarged, fragmentary views taken generally in the area bracketed by the letters A-A in Figure 2, illustrating successive steps according to one manner of practicing the invention. FIGURE 17 is a view, similar to the last-described views, which illustrates an alternative manner of practicing the invention. Turning now to the drawings, and directing attention first of all to Figures 1 and 2, indicated generally at 10 is an N-channel, field-effect, power-MOS transistor (semiconductor device) which has been manufactured according to one manner of practicing the steps of the present invention. Transistor 10 is typical in construction to like prior art devices, and includes a gate 12, a drain 14 and a source 16. In the particular transistor embodiment shown in these two figures, gate 12 includes three "fingers" 12ª, 12b, 12c. In the description which now immediately follows, certain dimensions are given. These dimensions are specific to a transistor designed to act as a 500-volt switch. Looking particularly at Fig. 2 for a moment, one can clearly see the various layers and functional regions which make up transistor 10. More specifically, in drain 14 there is a base N- doped layer 18, and an N- doped epitaxial layer 20. Also included in the structure of transistor 10 is a P-doped layer 22 which forms the so-called "body" in the transistor, and residing therein an N+ doped layer 24 which forms the source in the transistor. Residing immediately above the last-mentioned three layers is a gate-oxide layer (SiO₂) 26, and two metallization layers 28, 30. These two metal layers are typically formed, and herein are formed, of aluminum. Layer 28 acts as an electrical contact for the source, and layer 30 forms previously mentioned gate 12. With attention now drawn to Figs. 3-16, inclusive, let us consider how transistor 10 was formed in accordance with one manner of practicing the invention. Layers 18, 20 reside in the usual commercially available silicon wafer, and may be thought of herein as forming the "starting material" for the manufacture of transistor 10. In the particular structure now being described, layer 18 has a thickness of about 15-mils and a resistivity of about 0.007-0.02-ohm-centimeters. Epitaxial layer 20 has a thickness herein of about 36-44-microns, and a resistivity of about 16-22-ohm-centimeters. Gate-oxide layer 26 has a thickness herein of about 2400-Angstroms, and is conventionally thermally grown through oxidation in a diffusion furnace at a temperature of around 1100°C. Layers 18, 20, 26 herein make up what is referred to as a substrate structure. Fig. 4 illustrates the preparation of a new layer 32 which overlies layer 26. Layer 32 herein, also referred to as a dopant-opaque region, takes the form of polysilicon, which is prepared through conventional chemical vapor deposition to have a thickness of roughly 7000-Angstroms (10Å=1nm). This layer, which ultimately disappears, as will be explained, plays a significant role both in avoiding multiple masking steps, and in controlling proper doping to create the desire junctions. There are several considerations which relate to the selection of the material to be used for layer 32. More specifically, the material in this layer must be etchable in a medium which is different than that in which layer 26 is etchable. Further, layer 32 must be capable of withstanding (i.e., retaining structural integrity) at the high temperatures which characterize conventional diffusion steps. Finally, layer 32 must be impenetrable (100% penetration) to the doping substances which are used to form previously mentioned layers 22, 24. Particular materials other than polysilicon which may be used for this layer include silicon nitride, refractory-metal silicide, and doped oxides. Prepared by any conventional pinhole-free technique as a layer 34 over layer 32 (see Fig. 5) is a negative photoresist. A positive photoresist could also be used to form this layer. According to the manner of practicing the invention which is now being described, only a single masking step, involving a single, independent mask, is required. This is a key factor minimizing the likelihood that any fatal defect will occur during subsequent processing steps. Put another way, and as will become apparent, any such defect which could possibly result in subsequent steps will result, with very few exceptions, from the existence of an internal defect in the mask used per se. If such a defect turns up, a new defect-free mask can easily be prepared. So, turning attention briefly to Fig. 6, the single, independent mask which is employed herein during the photolithography steps is shown generally at 36. As will be well understood by those skilled in the art, the pattern which will ultimately result in transistor 10 is suitably created in mask 36, and in Fig. 6, mask 36 can be seen to include light-transparent areas, such as area 36 a , and light-opaque areas, such as area 36 b . The assembly illustrated in Fig. 6 is exposed to light during a typical photolithography step, and as a consequence, the photoresist layer ends up with regions exposed (outside the dashed lines) and regions not exposed (inside the dashed lines) to light. Fig. 7 illustrates the next step, wherein photoresist, and specifically those regions which have not been exposed to light, is removed conventionally by a suitable photoresist developer. Such a removed region is shown generally at 38. Fig. 8 illustrates the next subsequent step, wherein the polysilicon layer is now etched, by any commercial etching technique, to transfer the image previously created in photoresist layer 34 into layer 32. Accordingly, a matching image for region 38 is created in layer 32, and such is indicated generally as a region at 40. Region 40 is referred to herein as a mask-surrogate pattern-definer, and more specifically, as a primary, mask-surrogate pattern-definer. The term "mask-surrogate pattern-definer" is used to point out an important operational feature of the invention, namely that through the creation of such a pattern-definer in the structure itself, one completely eliminates the need for the use of any independent mask other than mask 36. Obviously, this is an important contribution to the creation of a device free from masking-related defects, in that, such a defect can no longer develop in the structure through the subsequent processing steps. The pattern-definer thus formed has a defined outline (edge configuration). As will become apparent in the description which continues, this outline per se, with no alteration, is used as the only necessary self-alignment masking agency in manufacturing steps that follow. Photoresist layer 34 is now removed by any convenient conventional technique, and this is illustrated in Fig. 9. The process now continues into what are referred to generally herein as doping steps. Fig. 10 illustrates a first implant step, which takes the form of a boron implant that will result, as will be explained, in previously mentioned layer 22. The boron implant step is performed in a conventional implanter at an energy level of about 160-KEV to produce an implant density in layer 20 of about 6X10¹³-atoms-per-cubic-centimeter. Dashed line 42 illustrates the material implanted in layer 20 by this step, and this implant extends to a depth in layer 20 of about 0.27-micrometers. As can be seen, dashed line 42 extends laterally beyond the boundaries of pattern-definer 40, and this results from the action of the gate-oxide layer which functions as a dispersion medium. A dashed line shown at 44 illustrates that there is some penetration of boron into layer 32, but not a complete penetration of this layer. Layer 32's opaqueness to boron penetration functions, importantly, to achieve properly controlled doping in this step. While boron has been described herein as the first implant substance, others which could be used to perform, ultimately, the same function, include bismuth and aluminum. Fig. 11 illustrates the first diffusion step, which is performed in a conventional diffusion furnace at a typical temperature of about 1150°C for about 3-8 hours. Here, as can be seen, what results is the beginning of previously described layer 22. Typically, this diffused region has a depth, shown at 46 in Fig. 11, or about 3-6 microns. This region extends laterally beyond the margins of pattern-definer 40 by a dimension, shown generally at 48, which is about 60-80% of dimension 46. Fig. 12 illustrates the next step in the procedure, wherein layer 26 is etched by any commercial etching technique to transfer into layer 26 a matching pattern (image of first pattern-definer 40). Thus, as is illustrated generally at 49, there results a region in layer 26 which matches (in outline) region 40, and which is referred to herein as a secondary mask-surrogate pattern-definer. Fig. 13 illustrates a second implant step which is performed herein using phosphorus. This step, as was true of the first implant step, takes place in a conventional implanter at an energy level of about 160-KEV to produce a final implant density of about 5X10¹⁵ to 1X10¹⁶-atoms-per-cubic-centimeter. The implant which results in layer 20 is indicated by dashed line 50, and this extends to a depth, indicated at 52, of about 0.2-microns. It should be noted that, as is indicated by dashed line 50, the implant just performed is contained completely within diffused region 22, and extends laterally slightly beyond the boundaries of pattern-definer 40. Dashed line 51 indicates slight penetration of phosphorus into layer 32, but nowhere complete penetration. Thus, here too, dopant opaqueness in layer 32 functions significantly, as mentioned in connection with the boron doping implant step, to control and effect a proper final doped result. While phosphorus has been used specifically herein to perform this implant, other materials which could be used include arsenic and antimony. Fig. 14 illustrates the second and final diffusion step which is conducted to create transistor 10. This diffusion also takes place in a diffusion furnace, typically at a temperature of about 1100°C for about 1-3-hours. What results, completely within the region indicated at 22, is a new diffused region which will result ultimately in previously described source layer 24. Layer 24 has a depth dimension, shown at 54, of about 1-3-microns, and a lateral-extension dimension, shown at 56, (extension beyond the boundaries of pattern-definer 40) which is about 60-80% of dimension 54. A consequence of this second diffusion step is the growth in region 49 of a thin oxide film 57 on the surface of layer 20. At this point in the procedure, this oxide is removed by any suitable conventional etching technique. Fig. 15 illustrates a subsequent step in which silicon in the upper portion of layer 20 is etched to produce the trench shown generally at 60. In transistor 10, the silicon in the wafer mentioned earlier has a crystal orientation herein of <100>. The etch just referred to is performed anisotropically using potassium hydroxide. Preferably, the potassium hydroxide etch just mentioned is followed by an isotropic, planar etch using a mixture of nitric, acetic and hydrofluoric acids to remove any trace of remaining potassium, and to enlarge the trench slightly by what might be thought of as a removed wall thickness of about 0.25-0.5-microns, thus to create an overhang for the underside of layer 26. This is illustrated by dashed line 62 in Fig. 15. It is important that these etches be controlled to assure that trench 60 extends completely through the second-described diffusion region 24, but not completely through the first-described diffusion region 22. It is also important that the etching thus performed creates a sufficiently upright wall in trench 60 which will positively assure electrical separation, during a later processing step, of the metallization in previously described layers 28, 30. Fig. 15 also demonstrates yet another consequence of the planar etch--namely the removal of layer 32. Fig. 16 illustrates a final step in the manner now being described of practicing the invention. The step herein illustrated is the so-called metallization, or conductive-material-deposition, step where aluminum is preferably cold-evaporated to create source layer 28 and gate layer 30. It is important that this step be conducted in such a manner that metal which forms layer 28 contact layer 24, but not contact layer 30. The isotropic etch described previously relative to Fig. 15, in conjunction with employing cold-evaporation for creating the metallization layers, helps to assure non-contact between layers 28, 30. With completion of the metallization step, the basic formation of transistor 10 is complete. It should be obvious now to those skilled in the art that, according to this manner of practicing the invention, the use of a single, independent mask to create, ultimately, the two defined-outline mask-surrogate pattern-definers in the structure itself, substantially eliminates the possibility of a fatal defect occurring. Another way of looking at this is that once the independent masking step is performed, all of the other critical steps--the two diffusions, the etching and the metallization-- become "self-aligning". This is a key contribution of the invention. As was mentioned earlier, there is yet another significant manner of practicing the invention. This is illustrated generally in Fig. 17. As an aid to understanding what is shown in Fig. 17, this figure should be related to previously described Fig. 9. This alternative manner of practicing the invention is one wherein no independent mask is used. Rather, under computer control, what has been referred to earlier as the first, mask-surrogate pattern-definer 40 is removal-formed directly in layer 32, either by laser-beam impingement, or by ion-beam bombardment. Also, instead of using such a technique to remove material in the formation of a mask-surrogate pattern-definer, the same technique could be employed to deposit such a pattern-definer. Thereafter, all of the other steps described earlier are performed in the same respective manners. Accordingly, one should now see how the method proposed by the invention offers a dramatic improvement over the best-known prior art procedures. Bluntly stated, mask-dependent, catastrophic errors or defects in a finally produced semiconductor device are completely obviated. Doping is precisely and effectively controlled. As a significant consequence, the entire usable area of a silicon wafer can be employed with assurance, even in the manufacture of a single, extremely large device, that it will be free from a mask-dependent failure. In addition to the obvious advantages discussed above which result from employment of the method of the present invention, there are certain others which are worth noting. Obviously, by minimizing, in one case to zero, the number of masking steps required, manufacturing time and the number of required manufacturing personnel are reduced. Also, less expensive processing equipment can be used than is now required. Additionally, by shrinking the overall processing time, this reduces the work-in-process inventory, and, of course, such is an important expense consideration. A point to note in this connection is that, through employing the technique of the invention in the computer-controlled laser/ion beam applications, one can design and generate a semiconductor device easily in an extremely short period of time--even as short as a single day. Yet another advantage offered by the invention is that it eliminates the kind of defects which can result from temperature and humidity changes that occur in the working environment over the time now required to complete multiple masking steps. The mask-surrogate pattern-definers which are created, built into the structure as they are, eliminate these possibilities. Thus, one should see how the important objects of the invention, and the advantages claimed for it, are readily obtained. While alternate manners of practicing the invention have been described herein, it is understood that variations and modifications are possible without departing from the spirit of the invention as defined in the claims which follows.

Claims: A method, employing a mask-surrogate pattern definer, of producing a field-effect power MOS semiconductor device (10) in a substrate structure including a gate oxide layer (26) on an upper surface of a semiconductor substrate, the method being characterised by the following steps performed in the given order: forming a dopant protective layer (32) over the gate oxide layer (26); masking and patterning (34, 36) the dopant protective layer (32) by selectively removing a portion of the dopant protective layer to form a mask-surrogate pattern-definer (40) having a defined outline characteristic so that the pattern-definer protects an underlying gate oxide region (49) and a first portion of the upper surface of the substrate and to expose a second portion of the upper surface of the substrate within a region defined by the defined outline characteristic; performing a first doping step to introduce dopant (42) into said exposed second upper surface portion of the substrate so as to form a first MOS region (22), being a MOS body region of a first conductivity type, said first region extending by a lateral dimension (48) under a peripheral edge of the protective layer; performing a second doping step to introduce dopant (50) into said exposed second upper surface portion so as to form a second MOS region (24), being a MOS body region of a second conductivity type, opposite the first MOS region (22); said second region (24) being wholly contained in said first region (22) and extending to a distance within said dimension (48) along the upper surface of the substrate to define a MOS channel beneath said region (49) of the gate oxide layer (26); the dopant protective layer (32) being dopant opaque so as to prevent the introduced dopants (42, 50) from penetrating the underlying gate oxide region (49); simultaneously etching the dopant protective layer and the exposed upper surface of the substrate after the first and second doping steps to form a trench (60) in the exposed upper surface portion of the substrate, the trench being formed to a trench depth greater than the depth (52) of the second region but less than the depth (46) of the first region (22), and formed of a width less than that of the second region (24) such that separated regions (24′) of the second conductivity type are provided at sidewalls of the trench, the separated regions (24′) constituting source regions of the MOS semiconductor device (10); and depositing a layer of conductive material over the entire upper surface of the device to form simultaneously a first conductive layer (28) in the trench in contact with both the source and body regions to form a short between said regions which extends continuously along the trench sidewalls and a second conductive layer (30) overlying the entire gate oxide region (49). A method according to claim 1 in which the sidewalls are undercut beneath the gate oxide region (49). A method according to claim 1 or 2 in which the trench sidewalls are formed by etching including anisotropic etching to protrude laterally towards one another proceeding depthwise within the trench (60) so that a portion of the substrate containing the second region (24) of said second conductivity type is exposed along an upper region of the trench sidewalls so as to be contacted to the conductive layer. A method according to any one of claims 1 to 3, wherein the conductive material layer is deposited so that said conductive layer (28) in the trench, when deposited, is separated from said conductive layer (30) overlying the gate oxide region (49). A method according to any one of claims 1 to 4 in which the trench (60) is formed to a trench depth and the conductive layer (28) is deposited in the trench to a thickness relative to the trench depth for spacing the conductive layer (28) below the oxide layer so as to contact the separated regions (24′) of the substrate along the sidewalls of the trench and so that the two said conductive layers are electrically separated along said defined outline characteristic. A method according to any one of claims 1 to 5, wherein formation of the second region (24) of said second conductivity type is such that said lateral dimension (48) thereof extends under the peripheral edge of the protective layer to 60% - 80% of the distance the first region extends down from the upper surface of the substrate. A method according to any one of claims 1 to 6 in which the second doping step includes ion implanting dopant (50) into the exposed portion of the substrate prior to forming the trench (60) so that the trench divides the doped substrate portion into separate source regions (24) extending along each trench sidewall. A method according to any one of claims 1 to 7 in which the dopant protective layer (32) includes a polysilicon layer. A method according to any one of claims 1 to 8 in which the dopant layer is completely removed during the step of etching to form the trench to expose the gate oxide layer (26) and the second conductive layer (30) is deposited in direct contact with the gate oxide layer (26).

Inventors: HOLLINGER THEODORE G, HOLLINGER, THEODORE G.
Applicants: ADVANCED POWER TECHNOLOGY, ADVANCED POWER TECHNOLOGY INC.
Application year: 1987
Main classification: H01L21
IPC codes: H01L21, H01L29