Abstract:
A power transistor for use in an audio application is laid out to minimize hot spots. Hot spots are created by non-uniform power dissipation or overly concentrated current densities. The source and drain pads are disposed relative to each other to facilitate uniform power dissipation. Interleaving metal fingers and upper metal layers are connected directly to lower metal layers in the absence of vias to improve current density distribution. This layout improves some fail detection tests by 17%.

Description:
BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    The disclosure generally relates to the field of power transistors. 
         [0003]    2. Description of the Related Art 
         [0004]    Power circuits are generally susceptible to issues related to power dissipation, such as concentrated heat and current densities. Power dissipation, simply put, is the product of current flowing through a device that has some amount of resistance. The dissipation of power in a device over a period of time produces undesirable heat, which may, if in sufficient quantity, cause melting in portions of the device. Melting in semiconductor devices generally leads to operational failure. 
         [0005]    Current density is a measurement of electric current through an area and can also lead to device malfunction. For example, when the path for current to flow becomes restricted to an area that is relatively small for the amount of current flowing, the current density increases. A sufficient increase in current density begins to break down the material through which the current is flowing. This breakdown, similar to undesirable amounts of heat, generally leads to device failure. 
       BRIEF SUMMARY 
       [0006]    The following disclosure relates to a transistor with improved heat and current density disbursement. In one embodiment, metal layers associated with a source are interleaved with metal layers associated with a drain. The metal layers of this embodiment are interleaved with fingers of metal. 
         [0007]    In another embodiment, the metal fingers include a lower metal layer and an upper metal layer, and the upper metal layer is deposited directly on the lower metal layer without the use of a via or inter-metal connector. 
         [0008]    In one embodiment, pads for the source and drain are substantially parallel to one another so as to distribute the current density across a long edge of a source pad or a drain pad. Distributing the current density across a long edge of a source pad or a drain pad will increase the non-destructive current capacity of the transistor. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0009]    In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale or in the exact shape of the operating product. 
           [0010]      FIG. 1A  is a block diagram illustrating a prior art power transistor layout. 
           [0011]      FIG. 1B  is a view of a partial cross section the power transistor layout of  FIG. 1A . 
           [0012]      FIG. 2A  is a block diagram illustrating a power transistor layout, in accordance with an embodiment. 
           [0013]      FIG. 2B  is a view of a partial cross section of the power transistor layout of  FIG. 2A . 
           [0014]      FIG. 3  is a circuit diagram of an open ground transistor test, in accordance with an embodiment. 
           [0015]      FIG. 4  is a circuit diagram illustrating a short-to-plus unpowered transistor test, in accordance with an. 
           [0016]      FIG. 5  is a circuit diagram illustrating an amplifier application of a transistor, in accordance with an embodiment. 
           [0017]      FIGS. 6A ,  6 B, and  6 C are block diagrams representing a layout of a portion of the power transistor, in accordance with an embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures and methods associated with integrated circuits and semiconductor manufacturing/packaging processes have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. 
         [0019]    Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is, as “including, but not limited to.” 
         [0020]    Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
         [0021]    As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the context clearly dictates otherwise. 
         [0022]      FIGS. 1A and 1B  illustrate three hot spot locations that occur with power transistor layout  100 . The hot spot locations depend upon the distance of fingers from pads, length of fingers, and placement of pads with respect to fingers.  FIG. 1A  shows a block diagram of the power transistor layout  100 , which includes a source pad  102 , a drain pad  104 , a drain pad  106 , and a source pad  108 . The zig-zag lines of  FIG. 1A  represent interleaved fingers of a metal layer  101  and illustrate separation between the source metal layer bases surrounding the source pads and drain metal bases surrounding the drain pads. For example, as shown in  FIG. 1A , source metal layer base  103  surrounds source pad  102  and drain metal layer base  105  surrounds drain pad  106 . 
         [0023]    Transistor layout  100  includes the sources and drains of four transistors. Two n-channel transistors extend from source pad  102 . One n-channel transistor is formed between source pad  102  and drain pad  104 . Another n-channel transistor is formed between source pad  102  and drain pad  106 . Similarly, two p-channel devices extend from source pad  108 . One p-channel transistor is formed between source pad  108  and drain pad  104 . Another p-channel transistor is formed between source pad  108  and drain pad  106 .  FIG. 1A  does not illustrate the gates of the transistors. Furthermore, the area surrounding the source and drain pads represent a metal layer that connects a source or drain of a transistor to a source or drain pad. 
         [0024]    The large arrow  111  represents one of the four current paths and illustrates three points in which heat or current density may cause failure. Pad corner  110  represents a point near the corner of source pad  108 . A least resistive path for current to flow from source  108  to drain  106  exists at pad corner  110 . During operation of transistor layout  100 , the corners of source pad  108 , such as pad corner  110 , are susceptible to becoming hot spots. Hot spots are locations where heat or current density increases the temperature of the metal layer at a location that may cause melting and lead to lower performance or inoperability of transistor layout  100 . 
         [0025]    The metal melting in transistor layout  100  is due to the Joule effect. An increase in current carried by the transistor during non-destructive tests, as will be described in association with  FIGS. 3 and 4 , creates hot spots at various locations on the shown metal layer  101 . Pad positioning contributes to non-uniform current distribution and higher specific Joule effect due to local layout topology. At hot spots, the shown metal layer  101  and underlying metals start to melt. The melting metal interrupts the current path, and the current carried by this path becomes more concentrated. The sequence of metal melting and current becoming more concentrated eventually produces destructive results. 
         [0026]    Metal finger base  112  illustrates a second potential hot spot. A base of a metal finger is the location at the metal layer from which a finger extends. Current entering metal finger base  112  transitions from a lower current density to a higher current density due to the current constricting and flowing through vias to lower metal layers. As discussed in association with the Joule effect, an increase in current concentration can create a hot spot at which the metal layer melts. 
         [0027]      FIG. 1B  is a view of a partial cross section the power transistor layout of  FIG. 1A . This cross section represents the junction between interleaved metal fingers of the source metal layer base  103  of the shown upper metal layer  101  in  FIG. 1A  and drain metal layer base  105  of the shown metal layer  101  in  FIG. 1A . Also shown is a lower metal layer  117  below the metal layer  101  shown in  FIG. 1A . As current  113  flows from the drain metal layer base  105  through vias  115  to lower metal layer  117 , one can more readily recognize the current concentration that occurs that may destroy the metal vias  115  at the regions located where the drain metal layer base  105  and source metal layer base  103  are adjacent to each other. Finger end  114  illustrates a third potential hot spot. This hot spot is due to major current density from the lower metal layer  117  passing through a via  115  to the upper metal layer  101  of  FIG. 1A  and  FIG. 1B . 
         [0028]      FIGS. 2A and 2B  illustrate embodiments that mitigate the destructive effects of hot spots. Shown in  FIG. 2A  is block diagram of a power transistor layout  200  in accordance with one such embodiment. Transistor layout  200  includes source pad  102 , drain pad  202 , drain pad  204 , drain pad  206 , drain pad  208 , and source pad  108 . The zig-zag lines of  FIG. 2A  represent interleaved fingers of a metal layer  201  and illustrate separation between the source metal layer bases surrounding the source pads and drain metal bases surrounding the drain pads. For example, as shown in  FIG. 2A , source metal layer base  203  surrounds source pad  102  and drain metal layer base  205  surrounds drain pad  204 , and metal finger section  212  is an example of a metal finger section extending from drain metal layer base  205  interleaved with metal fingers extending from source metal layer base  203 . 
         [0029]    Power transistor layout  200  includes the sources and drains of four transistors. Two n-channel transistors extend from source pad  102 . One n-channel transistor is formed between source pad  102  and drain pad  202 . Another n-channel transistor is formed between source pad  102  and drain pad  204 . Similarly, two p-channel devices extend from source pad  108 . One p-channel transistor is formed between source pad  108  and drain pad  206 . Another p-channel transistor is formed between source pad  108  and drain pad  208 .  FIG. 2A  does not illustrate the gates of the transistors. Furthermore, the area surrounding the source and drain pads represent a metal layer that connects a source or drain of a transistor to a source or drain pad. 
         [0030]    The four transistors can be coupled as full Complementary Metal Oxide Semiconductor (CMOS) output drivers, with their drains the n and p channel transistors coupled together to provide a high power output in a manner well known in the art. The power transistor layout  200  can be considered to be used having two legs, a first leg at the p and n channel transistors on one side and a second leg of the other p and n channel transistors on the other side. 
         [0031]      FIG. 2B  is a view of a partial cross section of the power transistor layout of  FIG. 2A . This cross section represents the junction between interleaved metal fingers of the source metal layer base  203  of the shown upper metal layer  201  in  FIG. 2A  and drain metal layer base  205  of the shown upper metal layer  201  in  FIG. 2A . In one embodiment, drain metal layer base  205  of the upper metal layer  201  is deposited directly on a lower metal layer  221 , bypassing the use of via structures, at least in the region of the metal finger section  212 . Alternatively, in another embodiment the upper drain metal layer base  205  is deposited directly on the lower metal layer  221  for most of the length of the metal finger section  212 . The direct connection of drain metal layer base  205  of the shown upper metal layer  201  with lower metal layer  221  serves several functions. 
         [0032]    Directly connecting the drain metal layer base  205  to lower metal layer  221  improves heat distribution resulting from power dissipation. Each oxide or silicon layer has a significant inherent thermal resistance. Analogous to current flowing through electrical resistance, thermal resistance impedes the flow of heat from one process layer to another. The separation of the drain metal layer base  205  from lower metal layer  221  by an interlayer dielectric, such as is shown in  FIG. 1B , impedes the distribution of heat that is generated by power dissipated in the drain metal layer base  205 . Ideally, generated heat will be conducted to the substrate to minimize the likelihood of altering or melting the electrically conductive metal structures. The disclosed embodiment of  FIG. 2B  which illustrates drain metal layer base  205  directly connected to lower metal layer  221  significantly reduces the thermal resistance between the metal layers and therefore reduces the risk of hot spots, which may occur in locations similar to those around pad corner  110  and finger base  112  shown in  FIG. 1A . 
         [0033]    Directly connecting drain metal base layer  205  to lower metal layer  221  reduces current density issues. Metal finger section  210  of lower metal layer  221  extends beneath source metal layer base  203 . Not shown is a lower source metal finger portion which also extends beneath drain metal layer base  205 . Metal finger section  212  comprises an overlap of drain metal layer base  205  and lower metal layer  221 . Base plate section  214  illustrates an overlap of drain metal layer base  205  and lower metal layer  221  in the metal layer from which the metal finger section  212  protrudes. The overlap of drain metal layer base  205  and lower metal layer  221  at metal finger section  212  and base plate section  214  distributes the current flowing through the finger so as to reduce the current density. In the absence of either the metal finger section  212  or the base plate section  214 , the maximum total current value is significantly reduced. 
         [0034]    The following equations explain the function of the power geometry. The current flowing through base plate section  214  can be represented as: 
         [0000]        IMx =( I   finger 210 /(2* I   finger 210 + I   finger 212 )* I,   
         [0000]    where, 
         [0035]    I=total current 
         [0036]    I finger 210 =the current through metal finger section  210 , and 
         [0037]    I finger 212 =the current through metal finger section  212 . 
         [0000]    The total current I is equal to the current through finger section  210  and  212  as well as base plate section  214 . The current through base plate section  214  is represented by: 
         [0000]        IMx=[ 1− I   finger 210 /(2* I   finger 210 + I   finger 212 )]* I. 
 
         [0038]    In one embodiment, the ratio of the length of metal finger section  212  divided by metal finger section  210  is between 1.7 and 2.1. 
         [0039]      FIG. 3  illustrates subjecting one leg of power transistor layout  200  to a short to open ground (“STOG”) test. The STOG test simulates the floating ground that may occur in car audio applications of a power transistor in one use of an embodiment of transistor layout  200 . A floating ground in a car audio application may damage a power transistor by forward biasing a parasitic pn junction inherent in mosfet devices. In the STOG test, the capacitor C is precharged with a voltage, a switch SW 1  is opened some time thereafter, and the parasitic body-drain pn junction of the n-channel device is forward biased. In one embodiment, the C is charged to 16.5 volts to perform the STOG test. The embodiment of transistor layout  200  more evenly dissipates power and disperses current density so as to effect approximately a 17% increase over the prior art in the voltage level that can be applied to transistor layout  200  without damaging the device. 
         [0040]      FIG. 4  illustrates subjecting one leg of power transistor layout  200  to a short to plus unpowered (“SPU”) test. The SPU test simulates the charging of a capacitive load, such as speakers with the needed interconnecting wires, followed by the sudden loss of the power supply to transistor layout  200 . In such an event, the pn junction of the p-channel device would become forward biased and begin conducting. The SPU test evaluates the strength of the p-channel device to withstand such undesirable conditions. The embodiment illustrated by transistor layout  200  demonstrates approximately a 14% improvement over the prior art for the SPU test. In one embodiment, a charged capacitive load is simulated by applying 16.5 volts to drain pad  208  for the SPU test without damaging the device. 
         [0041]      FIG. 5  illustrates power transistor layout  200  (shown in  FIGS. 2A and 2B ) being used in one or more stages of an audio amplifier having audio input  502  and additional input from circuitry  504 , and an amplified audio output  506 , in accordance with an embodiment. In one embodiment transistor layout  200  is a first stage A  508  of an audio amplifier  500 . In another embodiment, transistor layout  200  is a last stage Z  510  of an audio amplifier. In yet another embodiment transistor layout  200  is one or more stages between the first and the last stages of an audio amplifier. 
         [0042]    A few points are noted regarding the upper metal layers  101  and  201  shown in  FIGS. 1A and 2A , respectively, and the lower metal layers  117  and  221  shown in  FIGS. 1B and 2B , respectively. The thermal resistance of metal layers  117  and  221  is lower than the one seen from metal layers  101  and  201 , and in an optimal case the increment is about 9%. The metal electrical resistance plays a major role. A safe point on the analysis is that the Joule effects increase the metal temperature. The vias  115  between metal metal layer  117  and metal and metal layer  101  are a source of electrical power because the current flowing from source to drain passes through them and concentrates on the finger-end zone. The metal plates around the pads (e.g., source metal layer base  103  surrounding source pad  102  and drain metal layer base  105  surrounding drain pad  106 ) are useful to make the current more uniform for power dissipation. 
         [0043]    It is desirable to exploit as much of the lower metal layer  221  as possible to use its vantage to better dissipate energy and impose on it the optimal current with respect to the Joule effect. A way to use this vantage is to join, where possible, metal layer  221  with metal layer  201 . Several advantages include: metal layer  201  is better capable of dissipating energy, it increases the via number to the maximum (full plate), and it reduces the current which pass from metal layer  201  to metal layer  221  through the via at the finger-end. 
         [0044]    It may also be advantageous to have a metal plate around the pad (e.g., drain metal layer base  205  surrounds drain pad  204 ) in order to get more uniform current to avoid concentrating current on the finger. Having a K factor around 0.67 at the finger end is also advantageous. In terms of the ratio between the length of metal finger section  212  plus the length of base plate section  214 , which is the overlap of drain metal layer base  205  and lower metal layer  221 , divided by the length of metal finger section  210  of lower metal layer  221  overlapping source metal layer base  203 , an advantageous ratio is ˜1.8. Note a way to verify the ratio is through simulation, even if locally, a rule of thumb could be to measure the ratio between finger length and plate length. Practically, a ratio close to 1.8 gives a finger length that leads to enough area of metal plate around the source of the drain pad. Better connections to the pad come from exploiting lower metal layer  221 . 
         [0045]    Lastly, maximizing the finger pitch may be desirable in order to reduce the percentage of oxide between the fingers. It is advantageous give attention to the limit of metal electro-migration of the fingers. In one embodiment, the finger pitch is 12 um, while the spacing between the finger is 4 um. Such dimensions would produce the following result: 
         [0000]      efficiency=8 um finger metal/12 um pitch=67%. 
         [0000]    In another embodiment a pitch of 50 um is used with a spacing of 4 um in order to have: 
         [0000]      efficiency=46 um/50 um=92% 
         [0000]    with an increasing of 25% of current capability of the finger-base. 
         [0046]      FIG. 6A  is a block diagram representing a layout of a portion of the power transistor, in accordance with an embodiment. In  FIG. 6A  a plate of aluminum  601  is deposited along the lower metal layer in order to connect lower metal layer with an upper metal layer. The pitch of the finger  603  is 50 um. The finger overlap length plus finger length divided by finger overlap ratio is about 1.8. The finger  603  is connected to the pad  605 . 
         [0047]      FIG. 6B  illustrates the finger  607  connected to the source or drain pad  609 , in accordance with an embodiment. 
         [0048]      FIG. 6C  illustrates an example orientation  610  of metal of the fingers, in accordance with an embodiment. 
         [0049]    The foregoing detailed description has set forth various embodiments of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. 
         [0050]    The various embodiments described above can be combined to provide further embodiments. From the foregoing it will be appreciated that, although specific embodiments have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the teachings. Accordingly, the claims are not limited by the disclosed embodiments.