Abstract:
A semiconductor device includes a semiconductor layer, a first diffused region formed in the semiconductor layer, a second diffused region formed in the first diffused region, a trench formed in the semiconductor layer, a gate electrode disposed in the trench, a top surface of the gate electrode being lower than a top surface of the semiconductor layer and sagging downwards in a center thereof, a non-doped silicate glass film disposed in the trench and formed over the gate electrode, a top surface of the silicate glass film sagging downwards in a center thereof, an oxide film disposed in the trench and formed over the non-doped silicate glass film, a top surface of the oxide film sagging downwards in a center, and a source electrode formed over the semiconductor layer so that the source electrode contacts the first and second diffusion regions, and the oxide film at the top surface thereof.

Description:
The present application is a Continuation application of U.S. patent application Ser. No. 12/659,454, now U.S. Pat. No. 8,072,026, filed on Mar. 9, 2010, which claims priority from U.S. patent application Ser. No. 11/984,043, now U.S. Pat. No. 7,704,827, filed on Nov. 13, 2007, and which claims priority from Japanese Patent Application No. 2006-331619, filed on Dec. 8, 2006, the entire contents of each of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a semiconductor device and a method for manufacturing semiconductor device. Particularly, the present invention relates to a vertical MOSFET having a trench gate electrode and a method for manufacturing the same. 
     2. Description of Related Art 
     With rapid development of microfabrication technology, a semiconductor device continues to be integrated highly. Especially, it is well known that a vertical MOSFET (UMOSFET) having a gate electrode buried in a trench has low on-resistance and high breakdown voltage. Further, high integration is required for lower on-resistance and cost reduction (Japanese Unexamined Patent Application Publication No. 2005-86140 and No. 2001-36074). As one of methods for high integration, it is known that the gate trench is formed deeply in an epitaxial layer so as to shorten an aperture of the gate trench. For another method, it is known that an interlayer insulator is buried completely in the gate trench to shorten the aperture of the trench (Japanese Unexamined Patent Application Publication No. 2003-101027, No. 2000-252468 and U.S. Pat. No. 6,351,009). 
     Hereinafter, a related manufacturing process of UMOSFET, having the interlayer insulator buried in the gate trench completely, will be described. An N-channel type of UMOSFET is taken for instance. As shown in  FIG. 9 , an n− type epitaxial layer  82  is formed on a semiconductor substrate  81  by an epitaxial growth. A gate trench  83  is formed to the surface of the n− type epitaxial layer  82  so that the gate trench  83  reaches to the inner of the n− epitaxial layer  82 . A gate insulator  84  is formed on the inner side of the gate trench  83 . Further, a polysilicon  85  as a gate electrode is buried in the gate trench  83  with the gate insulator interposed therebetween. A high temperature oxide film (an HTO film)  86  is formed on the polysilicon  85  and the surface  82   a  of the n− type epitaxial layer. 
     A p type diffused base layer  87  and an n+ type diffused source layer  88  are formed on the surface  82   a  of the n− type epitaxial layer with ion implantation doping though the HTO film  86 . A boron phosphorus silicate glass film (a BPSG film)  89  is formed on the HTO film  86 . The BPSG film  89  has a flowability. Hence, the surface of the BPSG film  89  is planarized by a heat treatment after forming the BPSG film  89 . An etch-back process is performed from the surface of the planarized BPSG film  89  to the depth of an aperture of the gate trench. So, the HTO film  86  and the BPSG film  89  formed on the n− type epitaxial layer  82  are removed. As shown in  FIG. 10 , a source electrode is formed on the entire surface of the semiconductor device. A drain electrode  91  is formed on the back side of semiconductor substrate  81 . Hence, the cell pitch can be reduced, because the interlayer insulator (the BPSG film  89 ) between the gate electrode (the polysilicon  85 ) and the source electrode  90  is buried wholly in the gate trench  83 . 
     In the UMOSFET configured as described above, the polysilicon  85  as the gate electrode is positioned in the lower portion of the gate trench  83 . It is because the BPSG film  89  as the interlayer insulator is buried in the gate trench completely. Hence, it needs to form the n+ type diffused source layer  88  in the lower portion of the gate trench  83  depending on the position of the polysilicon  85 . The process of heat treatment to planarize the BPSG film  89  includes the process to diffuse the n+ type diffused source layer  88  also in order to reduce number of process. Here, this process needs high temperature as to diffuse the n+ diffused source layer  88  sufficiently. However, the thickness of the HTO film  86  between the BPSG film  89  and the n− type epitaxial layer  82  is formed to be thin. It is because the p type diffused base layer  87  and the n+ type diffused source layer  88  are formed by ion implantation doping though the HTO film  86  as described above. Hence, if the heat treatment to planarize the BPSG film  89  is set to be high temperature, the diffusion of boron and phosphorus from the BPSG film  89  to the n− type epitaxial layer  82  is promoted. So, it makes the controllability of the manufacturing the semiconductor device worse. 
     In this way, the UMOSFET having the interlayer insulator buries in the gate trench has the process lower controllability, because impurity like boron and phosphorus diffuse from the BPSG film at the heat treatment. 
     SUMMARY 
     According to one aspect of this invention, there is provided a method for manufacturing a semiconductor device comprising: forming a first oxide film on a surface of a semiconductor layer and a polysilicon in a trench, the trench formed in the semiconductor layer; forming a first diffused layer of a first conductivity type and a second diffused layer of a second conductivity type through the first oxide film; forming a second oxide film on the first oxide film; forming a flowable insulator film on the second oxide film; performing a heat treatment for planarizing the insulator film and diffusing the second diffused layer to prescribe depth; and etching the insulator film. 
     According to another aspect of this invention, there is provided a semiconductor device comprising: a semiconductor layer of a second conductive type; a first diffused region of a first conductive type formed in the semiconductor layer; a second diffused region of the second conductive type selectively formed in the first diffused region; a trench formed in the semiconductor layer; a polysilicon formed in the trench with an insulator intervening; a first oxide film formed on the polysilicon so that the first oxide film is buried in the trench; a second oxide film formed on the first oxide film so that the second oxide film is buried in the trench; a flowable insulator film on the second oxide film. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other objects, advantages and features of the present invention will be more apparent from the following description of certain preferred embodiments taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  shows a cross sectional view of the semiconductor device  10  according to a first embodiment; 
         FIG. 2  shows the first process of forming the semiconductor device  10 ; 
         FIG. 3  shows the second process of forming the semiconductor device  10 ; 
         FIG. 4  shows a relationship between temperature (degree Celsius) at a heat treatment and a minimum film thickness t (angstrom); 
         FIG. 5  shows a cross sectional view of the semiconductor device  40  according to a second embodiment; 
         FIG. 6  shows the first process of forming the semiconductor device  40 ; 
         FIG. 7  shows the second process of forming the semiconductor device  40 ; 
         FIG. 8  shows a cross sectional view of another semiconductor device  40 ′ according to the second embodiment; 
         FIG. 9  shows the first process of the related forming process of the semiconductor device; and 
         FIG. 10  shows the second process of the related forming process of the semiconductor device. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The invention will now be described herein with reference to illustrative embodiments. Those skilled in the art will recognize that many alternative embodiments can be accomplished using the teachings of the present invention and that the invention is not limited to the embodiments illustrated for explanatory purposes. 
     First Embodiment 
       FIG. 1  shows a cross sectional view of a semiconductor device according to a first embodiment of the invention. Hereinafter, “n+” means n type semiconductor which n type impurity heavily doped. “n−” means n type semiconductor which n type impurity lightly doped. Likewise, “p+” means p type semiconductor which p type impurity heavily doped. “p−” means p type semiconductor which p type impurity lightly doped. “X direction” means a horizontal direction of drawing sheet and “Y direction” means a vertical direction of drawing sheet. 
     As shown in  FIG. 1 , a semiconductor device  10  comprises an n+ type semiconductor substrate  11 . An n− type epitaxial layer  12  is formed on the n+ type semiconductor substrate  11 . A p type diffused base layer  17  (a first diffused layer) is formed on the n− type epitaxial layer  12 . A gate trench  13  is formed on the surface of the p diffused base layer. A plurality of the gate trenches  13  are formed in the X direction. A bottom of the gate trench  13  reaches to the n− epitaxial layer  12 . A gate insulator  14  is formed on an inner wall of the gate trench  13 . A polysilicon  15  is formed on an inner aspect of the gate insulator  14 . The HTO film  16  (a first oxide film) is formed in a lower portion in the Y direction than a surface of p type diffused base layer on the polysilicon  15 . A chemical vapor deposition oxide film (a CVD oxide film)  20  (a second oxide film) is formed so that the CVD oxide film  20  reaches around an aperture of the gate trench  13 . Beside the aperture of the gate trench  13 , an n+ type diffused source layer  18  (a second diffused layer) is formed. A source electrode  21  is formed on the n+ type diffused source layer  18 . The source electrode  21  is connected electrically to the n+ type diffused source layer  18  and the p type diffused base layer  17 . A drain electrode  22  is formed on the backside of the n+ type semiconductor substrate  11 . 
     Next, a method for manufacturing the semiconductor device  10  configured as above is explained hereinafter.  FIG. 2  shows a first process for manufacturing semiconductor device  10 . Firstly, the epitaxial layer  12  is formed on the n+ type semiconductor substrate  11  by an epitaxial growth. The gate trench  13  is formed to a surface  12   a  of the epitaxial layer so that a bottom of the gate trench  13  reaches to the epitaxial layer  12 . The gate insulator  14  is formed inside the gate trench  13 . The polysilicon  15  is buried in the gate trench  13  with the gate insulator  14  interposed therebetween. The surface of the polysilicon  15  is positioned at a lower portion than the surface of the epitaxial layer  12   a . The HTO film  16  is formed over the polysilicon  15  and the surface  12   a  of the n− type epitaxial layer. At this time, as shown in  FIG. 2 , p type of impurity is implanted to the surface of the epitaxial layer  12   a  through the HTO film  16  to form the p type diffused base layer  17 . In the same way, n type of impurity is implanted to a predetermined portion of the p type diffused base layer  17  through the HTO film  16 . Hence, the n+ type diffused source layer  18  is formed beside the aperture of the gate trench  13 . 
     Next, as shown in  FIG. 3 , the CVD oxide film  20  is formed on the HTO film  16 . At this time, the CVD oxide film  20  is formed along a shape of lower layer. Hence, a CVD oxide film  20   a  located above the gate trench  13  is deposited with lower position than a CVD oxide film  20   b  located above the surface of the epitaxial layer  12   a . The BPSG having a flowability is deposited on the CVD oxide film  20 . A surface of the deposited BPSG film  19  has an asperity along a surface ( 20   a ,  20   b ) of the CVD oxide film  20  below the BPSG film  19  (not shown). 
     At this time, a heat treating is performed to planarize the BPSG film  19 , as shown in  FIG. 3 . This process of heat treating combines the process to diffuse the n+ diffused source layer  18  injected by ion implantation so that the n+ source layer  18  is diffused as high as the polysilicon  15 . This is for cutting the number of the processes. An etch-back process is performed to the surface of the BPSG film  19  until the surface of CVD oxide film  20  is positioned as high as around the aperture of the gate trench  13 . Hence, the semiconductor device  10  is formed as shown in  FIG. 1 . The BPSG film  19  is used for planarization the surface of the CVD oxide film  20  and the HTO film  16  which are not flat as shown in  FIG. 1 . 
     For the semiconductor device formed in this way, the CVD oxide film  20  (as shown in  FIG. 3 ) formed below the BPSG film  19  can prevent boron and phosphorus of the BPSG film  19  from diffusing to the semiconductor layer (such as p base layer  17 , the n+ diffused source layer  18  and the n− epitaxial layer  12 ). Hence, the n+ diffused source layer  18  is diffused adequately by the heat treating. Concurrently, it can reduce the diffusion of boron and phosphorus the BPSG film  19  includes to the semiconductor layer. As a result, it can enhance a controllability of manufacturing the semiconductor device  10 . 
     It is necessary to set a thickness t of the CVD oxide film  20 , so that the CVD oxide film  20  prevent adequately boron and phosphorus of the BPSG film  19  from diffusing to the semiconductor layer. At a high temperature treatment where process temperature is from 900 to 1100 degree Celsius, a diffusion coefficient of phosphorus is larger than a diffusion coefficient of boron. Hence, it may determine the thickness t of the CVD oxide film  20  considering the diffusion coefficient of phosphorus and production tolerance. Here, phosphorus concentration of the BPSG film  19  is about from 3 to 5 mol % and boron concentration of the BPSG film  19  is about from 10 to 11 mol %. A diffusion coefficient of phosphorus in SiO 2  is about 1×10 −14 (cm 2 /sec) at 1000 degree Celsius. A diffusion coefficient of phosphorus in Si is about 5×10 −13  (cm 2 /sec) at 1000 degree Celsius. A diffusion coefficient of phosphorus in Si at 1000 degree Celsius is about fiftyfold of in SiO 2 . 
     On the other hand, in analysis of SIMS (Secondary Ionization Mass Spectrometer), a depth of phosphorus diffusion in Si after 30 minutes of the heat processing at 1000 degree Celsius is about 1.0 μm. Based on the result in this analysis, it is estimated that a depth of phosphorus diffusion in SiO 2  after 30 minutes of the heat processing at 1000 degree Celsius is about 200 angstrom that is one-fifty of the depth of phosphorus diffusion in Si. As described above, it is estimated that the preferable thickness t of the CVD oxide film  20  is more than 200 angstrom at 1000 degree Celsius of the heat processing. A listing as below shows an estimated preferable minimum film thickness t of the CVD oxide film  20  at 900, 950, 1000 and 1100 degree Celsius estimated in the same way described above. 
     
       
         
               
               
               
             
           
               
                   
                   
               
               
                   
                 TEMPERATURE 
                   
               
               
                   
                 AT HEAT TREATMENT 
                 FILM THICKNESS t 
               
               
                   
                   
               
             
             
               
                   
                 no more than 900 degree Celcius 
                 t &gt; 24 angstrom 
               
               
                   
                 no more than 950 degree Celcius 
                 t &gt; 80 angstrom 
               
               
                   
                 no more than 1000 degree Celcius 
                 t &gt; 200 angstrom 
               
               
                   
                 no more than 1100 degree Celcius 
                 t &gt; 1200 angstrom 
               
               
                   
                   
               
             
          
         
       
     
       FIG. 4  shows a relation between temperature (degree Celsius) of the heat process and minimum film thickness t of the CVD oxide film  20 . The data of the relation between temperature at the heat process and minimum film thickness in the listing above is plotted on a semi-logarithmic graph. This plotted data is approximated by expression line L. Based on the graph in  FIG. 4 , the thickness t of the CVD oxide film  20  can be set more than the value of expression line L for processing temperature after forming the BPSG film  19 . Furthermore, considering an embeddability, cost of manufacturing, variation of etching process to remove the CVD oxide film  20 , the preferable thickness t of the CVD oxide film  20  is 24-10000 angstrom. 
     In the first embodiment, an n channel type of UMOSFET is explained for example, but this invention can be applied to a p type of UMOSFET. Applied to a p type of UMOSFET, advantages of this invention can be obtained. When this embodiment is applied to the p type of UMOSFET, conductivity type of semiconductor device in  FIG. 1  is inverted. 
     Second Embodiment 
       FIG. 5  shows a cross sectional diagram of semiconductor device  40  according to a second embodiment of this invention. One feature of the second embodiment is that an NSG film  41  (None-doped Silicate Glass film) (a third oxide film) is formed below the HTO oxide film  16 . Hereinafter, the same number is given to the same composition as the first embodiment. 
     As shown in  FIG. 5 , the semiconductor device  40  comprises the n+ type semiconductor substrate  11 . The n− type epitaxial layer  12  is formed on the n+ type semiconductor substrate  11 . The p type diffused base layer  17  is formed on the n− epitaxial layer  12 . The gate trench  13  is formed at the surface of the p type diffused base layer  17 . A plurality of the gate trenches  13  are formed in the X direction. The gate insulator  14  is formed on the sidewall of the gate trench  13 . The polysilicon  15  is formed on the gate insulator  14 . 
     An NSG film  41  is formed on the polysilicon  15  in the gate trench  13 . A dielectric strength of the NSG film  41  is as strong as the CVD oxide film, and the NSG film  41  has a reflowability. Hence, the NSG film  41  is preferable material for an interlayer insulator formed in the gate trench  13 . The HTO film  16  is formed on the NSG film  41  in the gate trench  13 . The CVD oxide film  20  is formed on the HTO film  16  so as to reach the aperture portion of the gate trench  13 . The n+ diffused layer  18  is formed beside the aperture of the gate trench  13 . 
     Next, a manufacturing method of the semiconductor device  40  configured as above is described hereinafter.  FIG. 6  shows the first manufacturing process of the semiconductor device  40 . First, the epitaxial layer  12  is formed on the n+ semiconductor substrate  11  by the epitaxial growth. A plurality of the gate trenches  13  are formed in the X direction so that the bottom of the gate trench  13  reaches the epitaxial layer  12 . The gate insulator  14  is formed on an inner aspect of the gate trench  13 . The polysilicon  15  is formed on an inner aspect of the gate insulator  14 . The NSG film  41  is deposited to the polysilicon  15 . Here, the NSG film  41  is formed in the gate trench  13 , and not on the surface  12   a  of the epitaxial layer. The HTO film  16  is deposited on the NSG film  41  and the epitaxial layer  12 . At this state, an impurity is implanted to the n− epitaxial layer  12  through the HTO film  16  so that p diffused base layer  17  and the n+ diffused source layer  18  are formed in the n− epitaxial layer  12 . 
     As shown in  FIG. 7 , the CVD oxide film  20  is formed on the HTO film  16 . The BPSG film  19  is deposited on the CVD oxide film  20 . As described above, after depositing the BPSG film  19 , the surface of the BPSG film  19  has the ragged asperity along the surface of the BPSG film  19  (not shown). With the high heat processing, the ragged surface of the BPSG film  19  having a reflowability is planarized. An etch-back process is performed to the planarized surface of BPSG film  19  until the surface of CVD oxide film  20  is positioned as high as around the aperture of the gate trench  13 . So, the BPSG film  19 , the CVD oxide film  20  and the HTO film  16  on the epitaxial layer  12  are removed. In this way, the semiconductor device  40  as shown in  FIG. 5  is formed. The source electrode  21  and the drain electrode  22  are formed as same as the first embodiment. 
     In the semiconductor device  40  configured as above, as the NSG film  41  is formed between the HTO film  16  and the polysilicon  15 , the gap between the HTO film  16   a  on the gate trench  13  and the HTO film  16   b  on the surface  12   a  of epitaxial layer is less than the first embodiment (see  FIG. 6 ). Hence, at the process of forming the p type diffused base layer  17  and the n+ type diffused source layer  18 , it can prevent an impurity from diffusing through the sidewall of the gate trench  13 . As a result, it can prevent the n+ type diffused layer  18  from entering in deeply around the sidewall of the gate trench  13 . So, in the second embodiment, an effect of punch-through phenomena can be reduced more effectively than the first embodiment. Punch-through phenomena become prominent as gate length is shorter. As a result, it can further improve performance of the semiconductor. 
     For the semiconductor device  10  according to the first embodiment as shown in  FIG. 1  and the semiconductor device  40  according to the second embodiment, the BPSG film  19  formed in the process of manufacturing is wholly removed by etching. But, this is the case that the thickness of the HTO film  16  and the CVD oxide film  20  are correctly formed and the etch-back process is performed with required accuracy. However, even when the formed BPSG film  19  is not wholly removed, an advantage of this invention to prevent boron and phosphorus from diffusing from the BPSG film  19  can be obtained. 
       FIG. 8  shows a semiconductor device  40 ′ according the second embodiment in the case the BPSG film  19  is not wholly removed. This semiconductor device  40 ′ has the remained BPSG film  19  on the CVD oxide film  20 . In this semiconductor device  40 ′, even if the etch-back process is excessively performed to the NSG film  41  at the manufacturing process of the second embodiment, the thickness of interlayer insulator is enough ensured. Because the CVD oxide  20 , the HTO film  16 , the NSG film  41 , and the BPSG film  19  are layered on the gate trench  13 . Herewith, it can reduce tolerance for etching, and ensure the thickness of the interlayer insulator adequately. As a result, it can diffuse the n+ type diffused source layer  18  to reach the required depth by the heat treatment, and at the time it can restrain diffusing of the impurity. As a result, it can improve performance of UMOSFET having interlayer insulator wholly formed in the gate trench. 
     The case is described that the BPSG film  19  is remained in the second embodiment, but even if the BPSG film  19  may remain in the first embodiment, the advantage of this invention can be obtained also. Material of an oxide film (as the HTO film  16 , the CVD film  20 , the NSG film and the like) is not limited that. A variety of material can be applied to the oxide film. 
     It is apparent that the present invention is not limited to the above embodiments, but may be modified and changed without departing from the scope and spirit of the invention.