Patent Abstract:
A semiconductor device includes: a drift layer of a first conductivity type; a collector layer of a second conductivity type located on the drift layer; a collector electrode located on the collector layer; a base layer of the second conductivity type located in a region isolated from the collector layer on the drift layer; a plurality of trenches formed at certain intervals to extend from the top surface of the base layer into the drift layer and thereby divide the base layer to main cell regions and dummy cell regions; a first emitter layer of the first conductivity type selectively formed in the surface layer of the base layer in each main cell region to extend along adjacent one of the trenches; gate electrodes formed in the trenches sandwiching each main cell region among said plurality of trenches via a gate insulating film; an emitter electrode located over the base layer and the first emitter layer in each main cell region; and a second emitter layer of the first conductivity type selectively formed so as to be scattered in the surface layer of the base layer in each dummy region and having a surface area smaller than that of the first emitter layer.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims benefit of priority under 35 USC §119 to Japanese Patent Application No. 2004-8042, filed on Jan. 15, 2004, the contents of which are incorporated by reference herein.  
       BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to a semiconductor device and it is directed to an insulating gate type bipolar transistor suitable for use as a power supply switching element, for example.  
         [0004]     2. Related Background Art  
         [0005]     In the field of power semiconductor devices, there is a strong request for low on-voltage and reduction of turn-off loss in addition to enhancement of resistance to high breakdown voltage and availability for larger current. To meet these requirements, IEGT (Injected Enhanced Gate Transistor) has been developed as a further improvement of IGBT (Insulated Gate Bipolar Transistor).  
         [0006]     The IEGT is a powering semiconductor device that has realized low on-resistance by rendering the emitter side of an n-type base layer have the peak of carrier concentration rendering it accumulate holes to enhance the efficiency of electron injection from the emitter electrode at the time of turning on.  
         [0007]      FIG. 11  is a cross-sectional diagram showing an example of a trench-structured vertical IEGT by a related art. In the IEGT  90  shown here, a p-type collector layer  114  formed on one side of an n-type drift layer (n-type base layer in this example)  100  via an n-type buffer layer  112 . On the opposite side of the n-type drift layer  100 , a p-type impurity diffusion layer is formed, and a plurality of trenches TR are formed to penetrate the p-type impurity diffusion layer from its surface and reach an inner region of the n-type drift layer  100 . Thus, the p-type impurity diffusion layer is divided to main cell regions MC and dummy cell regions DC that are used as p-type main base layers  116  and p-type dummy base layers  118 , respectively.  
         [0008]     In the surface layer of each p-type main base layer  116  of the main cell region MC, n-type emitter layers  124  are formed selectively. The surface of each p-type dummy base layer  118  of the dummy cell region DC is covered by an insulating film  132  to keep the potential of the p-type dummy base layer  118  floating.  
         [0009]     A collector electrode  126  is formed on the p-type collector layer  114 . An emitter electrode  128  is formed over the p-type main base layer  116  and the n-type emitter layers  124 , and it is connected to the n-type emitter layer  124 . In each trench TR, a gate electrode  122  is buried via a gate insulating film  120 . As a result of the explained structure, an n-type channel MOSFET for electron injection using the p-type main base layer  116  as a channel region and selectively connecting the n-type emitter layers  124  to the n-type drift layer  100  is formed in each main cell region MC.  
         [0010]     In the IEGT  90  shown in  FIG. 11 , the drift layer  100  of the main cell region MC has the carrier concentration profile having the peak on the part of the emitter electrode  128 . Therefore, a sufficiently narrow current path is formed, which connects the n-type drift layer  100  and the emitter electrode  128 . As a result, in the on-state of the IEGT  90 , the current path increases the resistance to the flow of holes moving from the n-type drift layer  100  toward the emitter electrode  128  through the p-type main base layer  116  of the main cell region MC, and hence limits the discharge of holes to the emitter electrode  128 . This results in enhancing the electron injection efficiency from the n-type emitter layer  124  to the n-type drift layer  100 , promoting the conductivity modulation of the n-type drift layer  100 , and attaining a low on-voltage.  
         [0011]     The IEGT  90  shown in  FIG. 11 , however, involves the problem that the gate voltage runs to overshoot due to so-called negative capacitance, and thereby becomes impossible to control the voltage change rate dV/dt during the on-time. This problem is explained below with reference to  FIGS. 12 and 13 . In the attached figures, common and equivalent elements are labeled with common reference numerals, and their explanation will be repeated only when necessary.  
         [0012]      FIG. 12  is a graph showing an example of voltage and current waveform at the on-time of the IEGT  90  shown in  FIG. 11 . In this graph, V ge  is a gate-emitter voltage, V ce  is a collector-emitter voltage, and I c  is a collector current.  
         [0013]     In this experiment, the voltage of the IEGT was 1200 V, the voltage applied between the collector and the emitter was 600V, and the gate resistance R g  was 51 Ω. Resistance between the p-type dummy base layer  118  and the emitter electrode  128  was 10 Ω.  
         [0014]     As shown in  FIG. 12 , the collector-emitter voltage change ratio (dV/dt) of the IEGT  90  shown in  FIG. 11  was as large as 20 kV/μs or more in the initial stage of the mirror period t 1 ˜t 2  (the period for charging between the gate and the collector with the voltage applied between the gate and emitter), and the waveform vibrated seriously.  
         [0015]      FIG. 13  is a graph showing an example of the gate charge characteristics during the on-time of the IEGT  90  shown in  FIG. 11 , which was obtained by a simulation. In this graph, V ge  is the gate-emitter voltage, V ce  is the connector-emitter voltage, and Q g  is the gate charge. Solid lines show characteristics obtained by dynamic calculation whereas broken lines show characteristics obtained by static calculation (V ce =0V and V ce =600V). Conditions of the IEGT in this simulation are equal to those explained in conjunction with  FIG. 12  except the parameters of this simulation.  
         [0016]     In the IEGT  90  shown in  FIG. 11 , the gate-emitter voltage V ge  (hereinbelow referred to as  Vge(on) ) in the mirror period (the period t 1 -t 2  in  FIG. 12 ) is contained in the V ge  region where Q g  decreases as V ge  increases in the static characteristics of V=600V. In this case, the waveform of Q g  significantly vibrates on the dynamic characteristics as shown in  FIG. 13 .  
         [0017]     The phenomenon of the decrease of Q g  with the increase of V ge  is called negative capacitance (negative capacitance of the gate) because C g =dQ g /dV ge  becomes a negative value. The negative capacitance is known as being the cause of bringing about current unbalance upon parallel driving of a semiconductor device (see, for example, Japanese Patent Laid Open (kokai) 2000-40951 and IEEE Device Letters, vol. 18, pp 121-123.)  
         [0018]     As seen in the dynamic characteristics of  FIG. 13 , once the gate emitter voltage V ge  (on) in the mirror period enters in the V ge  region exhibiting the negative capacitance, the gate-emitter voltage V ge  vibrates. This results in increasing the gate-emitter voltage V ge  in a short time and permitting rapid electrical conduction of the collector current to invite a large dV/dt.  
         [0019]     Through some researches, the Inventor has confirmed that the overshoot of the gate-emitter voltage V ge  by such negative capacitance occurs because the potential of the p-type dummy base layer in the dummy cell region is not kept floating completely.  
         [0020]     In greater detail, even when the device is designed to keep the potential of the p-type dummy base layer floating as explained before, if the potential in the off-time is fixed near the zero potential via a parasitic resistance caused by the parasitic structure (for example, partial connection to the cell end or the junction terminal end), after the device is turned on, immediately upon the rise of the gate-emitter voltage V ge  (on) to the threshold voltage V th , holes injected thereby suddenly increase the potential of the p-type dummy base layer and ultimately bring about the overshoot of the gate-emitter voltage V ge .  
         [0021]     On the other hand, if the emitter contact is formed over the entire surface of the dummy base layer, then the problem of uncontrollability of dV/dt will be overcome. In this case, however, the IE effect will be lost, and the low V ce (sat)  characteristics cannot be realized.  
         [0022]     To prevent this problem, the use of the structure described in Japanese Patent Laid Open (kokai) 2000-40951, for example, leads to realization of complete floating configuration of the dummy base layer while maintaining the IE effect.  
         [0023]     However, in the structure described in Japanese Patent Laid Open (kokai) 2000-40951, if the cell length is changed, for example, when the current capacitance is different, then the structure must be changed as well accordingly. Therefore, the structure disclosed in Japanese Patent Laid Open (kokai) 2000-40951 involves the problem that it lacks compatibility or commonness as a unit structure.  
       BRIEF SUMMARY OF THE INVENTION  
       [0024]     According to a first aspect of the present invention, there is provided a semiconductor device comprising: 
        a drift layer of a first conductivity type;     a collector layer of a second conductivity type located on the drift layer;     a collector electrode located on the collector layer;     a base layer of the second conductivity type located in a region isolated from the collector layer on the drift layer;     a plurality of trenches formed at certain intervals to extend from the top surface of the base layer into the drift layer and thereby divide the base layer to main cell regions and dummy cell regions;     a first emitter layer of the first conductivity type selectively formed in the surface layer of the base layer in each main cell region to extend along adjacent one of the trenches;     gate electrodes formed in the trenches sandwiching each main cell region among said plurality of trenches via a gate insulating film;     an emitter electrode located over the base layer and the first emitter layer in each main cell region; and     a second emitter layer of the first conductivity type selectively formed so as to be scattered in the surface layer of the base layer in each dummy region and having a surface area smaller than that of the first emitter layer.        
 
         [0034]     According to a second aspect of the present invention, there is provided a semiconductor device comprising: 
        a drift layer of a first conductivity type;     a collector layer of a second conductivity type located on the drift layer;     a collector electrode located on the collector layer;     a base layer of the second conductivity type located in a region isolated from the collector layer on the drift layer;     a plurality of trenches formed at certain intervals to extend from the top surface of the base layer into the drift layer and thereby divide the base layer to main cell regions and dummy cell regions;     a first emitter layer of the first conductivity type selectively formed in the surface layer of the base layer in each main cell region to extend along adjacent one of the trenches;     gate electrodes formed in the trenches sandwiching each main cell region among said plurality of trenches via a gate insulating film;     an emitter electrode located over the base layer and the first emitter layer in each main cell region; and     a second emitter layer selectively formed in the surface layer of the base layer in each dummy cell region,     wherein resistance value of a floating resistor as a resistance between the base layer of the dummy cell region and the emitter electrode is adjusted to be smaller than the resistance value causing rise of the gate-emitter voltage due to negative capacitance of the gate in a period to charge the gate and the collector by a voltage applied between the gate and the emitter when the device is turned on.       
 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0045]     In the accompanying drawings:  
         [0046]      FIG. 1  is a plan view showing schematic configuration of a semiconductor device according to a first embodiment of the invention;  
         [0047]      FIG. 2  is a cross-sectional view taken along the B-B line of  FIG. 1 ;  
         [0048]      FIG. 3  is a cross-sectional perspective view taken along the A-A cut line of  FIG. 1 ;  
         [0049]      FIG. 4  is a graph showing the voltage and the current waveforms at the turn-on time of the IEGT shown in  FIG. 1 ;  
         [0050]      FIG. 5  is a graph showing an example of gate charge characteristics appearing when the IEGT  1  is turned on, which are obtained by simulation;  
         [0051]      FIG. 6A  is a graph showing a relation of dV/dt and on-voltage relative to the resistance value R float  of the floating resistor, which is obtained by simulation;  
         [0052]      FIG. 6B  is a graph showing a relation of the range NCR of V ge  exhibiting negative capacitance and on-voltage relative to the resistance value R float  of the floating resistor;  
         [0053]      FIG. 7  is a plan view schematically showing the configuration of a semiconductor device according to a second embodiment of the invention;  
         [0054]      FIG. 8  is a plan view schematically showing the configuration of a semiconductor device according to a third embodiment of the invention;  
         [0055]      FIG. 9  is a plan view schematically showing the configuration of a semiconductor device according to a fourth embodiment of the invention;  
         [0056]      FIG. 10  is a cross-sectional view schematically showing the configuration of a semiconductor device according to a fifth embodiment of the invention;  
         [0057]      FIG. 11  is a cross-sectional diagram showing an example of a trench-structured vertical IEGT by a related art;  
         [0058]      FIG. 12  is a graph showing an example of voltage and current waveform at the on-time of the IEGT shown in  FIG. 11 ; and  
         [0059]      FIG. 13  is a graph showing an example of the gate charge characteristics during the on-time of the IEGT shown in  FIG. 11 , which was obtained by a simulation. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0060]     Some embodiments of the invention will be explained below with reference to the drawings. In the explanation made below, the first conductivity type refers to the n-type and the second conductivity type refers to the p-type.  
       First Embodiment  
       [0061]      FIG. 1  is a plan view showing schematic configuration of a semiconductor device according to the first embodiment of the invention.  FIG. 2  is a cross-sectional view taken along the B-B line of  FIG. 1 , and  FIG. 3  is a cross-sectional perspective view taken along the A-A cut line of  FIG. 1 .  
         [0062]     As shown in the cross-sectional view of  FIG. 2 , the IEGT  1  according to this embodiment includes an n-type drift layer (n-type base layer)  10 , n-type buffer layer  12 , p-type collector layer  14 , first p-type base layers  16 , second p-type base layers  18 , first emitter layers  24 , second emitter layers  32 , trenches TR, gate insulating films  20 , gate electrodes  22 , emitter electrodes  28 , via contacts  30  and collector electrode  26 .  
         [0063]     The p-type collector layer  14  lies on one side of the n-type drift layer  10  via the n-type buffer layer  12 . On the other side of the n-type drift layer  10 , a p-type base layer ( 16 ,  18 ) is formed. A plurality of trenches TR are formed at certain intervals so as to penetrate the p-type base layer from its surface and reach a region in the n-type drift layer  10 . Thus, main cell regions MC and dummy cell regions DC are defined in the surface region of the p-type base layer, and the p-type base layer is divided to the first base layer  16  and the second base layer  18  in each unit region. Instead of dividing the common p-type base layer by the trenches TR, it is also possible to form the first p-type base layer  16  and the second p-type base layer  18  as independent layers.  
         [0064]     The first emitter layers  24  are selectively formed in the surface layer of each p-type base layer  16 . The emitter electrode  28  is located to locally contact the surfaces of the first emitter layers  24  opposed and the surface of the first base layer  16  between the opposed first emitter layers  24  in each main cell region MC.  
         [0065]     The gate electrode  22  is formed in each trench TR so as to be covered by the gate insulating film  20 . The collector electrode  26  is located in contact with the collector layer  14 .  
         [0066]     The second emitter layer  32  is one of unique features of the IEGT  1  according to this embodiment, and it is selectively formed in the surface layer of the second base layer  18  in a pattern of narrow isolated layers (see  FIG. 1 ) in the dummy cell regions DC. In this embodiment, the second emitter layers  32  are formed to make an opposed pair in each dummy cell region DC, and respective ends of the second emitter layers  32  contact nearest trenches TR as also shown in the cross-sectional perspective view of  FIG. 3 . The second emitter layers  32  make a current path for transferring holes to the emitter electrode  28  to an extent not affecting the electron injection efficiency from the emitter electrode  28  to the n-type drift layer  10  in the on-time of the device.  
         [0067]     As also shown in  FIG. 3 , each via contact  30  is located in contact with the surface regions of the second emitter layers  32  and the location of the second base layer  18  sandwiched by the second emitter layers  32  (emitter contact region Rec 2 ) is located so as to electrically connect the second base layer  18  to the emitter electrode  28 . The via contacts  30  and the emitter layers  32  form floating resistors  34 . Therefore, resistance value of each floating resistor  34  is adjusted by shapes or geometries of the emitter layer  32  and the via contact  30 .  
         [0068]      FIG. 4  is a graph showing the voltage and the current waveforms at the turn-on time of the IEGT  1  according to this embodiment, which was obtained experimentally. In the IEGT  1  according to this embodiment, actually used in this experiment, resistance voltage was 1200 V, voltage applied to the collector and the emitter was 600 V, and the gate resistance Rg was 51 Ω.  
         [0069]     As shown in  FIG. 4 , in the IEGT  1  according to the instant embodiment, since the second base layer  18  is connected to the emitter electrode  28  via the via contact  30 , potential of the base layer  18  is not fixed to zero even in the off-time. A local channel region is then formed in the dummy cell region DC in the second base layer  18  under the second emitter regions when the device is turned on. Therefore, dV/dT at the initial stage of the mirror period t 1 -t 2  is reduced to approximate 5 kV/μs, and waveform vibration is suppressed as well. This is in contrast to the conventional IEGT in which the voltage change ratio (dV/dt) is approximate 20 kV/μs and the waveform vibrates violently (see  FIG. 12 ).  
         [0070]      FIG. 5  is a graph showing an example of gate charge characteristics appearing when the IEGT  1  is turned on, which were obtained by simulation. Conditions of IEGT used in the simulation were identical to those explained in conjunction with  FIG. 4  except the parameters of this simulation.  
         [0071]     In the IEGT  1  according to this embodiment, the region of V ge  exhibiting the negative capacitance is shifted to the high-voltage side, and V ge(on)  is not included in this region. In this case, almost no vibration is found in the waveform of Q g  in the dynamic characteristics. This is in contrast to the conventional IEGT in which V ge (on)  is in the V ge  region exhibiting negative capacitance and the waveform of Q g  violently vibrates in the dynamic characteristics (see  FIG. 13 ).  
         [0072]     In the instant embodiment, resistance value R float  of the floating resistor  34  is adjusted by the shape of the second n-type emitter layers  32  locally formed as isolated regions in the surface layer of the second p-type base layer  18  and the shape of the via contact  30 . Adjustment of the resistance value R float  to an appropriate value contributes to preventing the V ge (on)  from being included in the V ge  region exhibiting the negative capacitance and preventing vibrations of V ge  and high dV/dt caused thereby while maintaining the IE effect.  
         [0073]      FIG. 6A  is a graph showing a relation of dV/dt and on-voltage relative to the resistance value R float  of the floating resistor, which is obtained by simulation.  FIG. 6B  is a graph showing a relation of the range NCR of V ge  exhibiting negative capacitance and on-voltage relative to the resistance value R float  of the floating resistor.  
         [0074]     In these graphs, V ce (sat)  is the collector-emitter voltage (saturation voltage) in the on-sate, V ge (on)  is the gate-emitter voltage under no vibrations in the mirror period, and V th  is the gate threshold voltage. Conditions of IEGT used in the simulation are identical to those explained in conjunction with  FIG. 4  except the parameters of this simulation. The desirable range of the resistance value R float  of the floating resistor  34  is the range where V ce (sat)  is low and dV/dt is small in  FIG. 6A . Under these experimental conditions, the desirable range of R float  is approximately 0.3-3 Ω.  
         [0075]     As shown in  FIG. 6B , the higher the resistance value R float  of the floating resistor  34 , the lower the value of the range NCR 1 ˜NCR 6  of V ge  exhibiting negative capacitance. In NCR 3 ˜NCR 6  where R float  is equal to or larger than 5 Ω, their ranges overlap V ge (on)  or are located under V ge (on) . This means that V ge (on)  of the mirror period is included in the V ge  region exhibiting negative capacitance. Therefore, V ge  vibrates and rises in a short time. Here is the problem that a large dV/dt is brought about by a sudden flow of the collector current.  
         [0076]     On the other hand, the range of V ge  in the instant embodiment belongs to NCR 1  and NCR 2  where R float  is equal to or lower than 3 Ω, and these ranges are positioned above V ge (on) . In this case, since V ge  takes the turn-on state before affected by the negative capacitance, overshoot of V ge  is prevented, and dV/dt is controlled in an appropriate value. The aforementioned relation between R float  and V ge (on)  has been described in U.S. patent application No. 10,354,048, the contents of which are incorporated herein by reference.  
         [0077]     As such, according to the IEGT  1  of the instant embodiment, it is possible to realize a semiconductor element excellent in controllability of dV/dt without losing the V ce (sat)  characteristics by the IE effect.  
       Second Embodiment  
       [0078]      FIG. 7  is a plan view schematically showing the configuration of a semiconductor device according to the second embodiment of the invention. The IEGT  3  shown here includes a second emitter layers  38  extending in form of an island to contact at its opposite ends with the trenches defining each dummy cell region DC. The contact region Rec 4  of the via contact with the emitter electrode  28  in each dummy cell region DC includes only the central portion of the top surface of the second emitter layer  38  and its peripheral portion. The other configuration of the IEGT  3  is substantially identical to that of the IEGT  1  shown in  FIG. 1 .  
         [0079]     Also when the island-shaped second emitter layer  38  is used for emitter contact, functions and effects of the IEGT  3  of this embodiment are substantially the same as the first embodiment.  
       Third Embodiment  
       [0080]      FIG. 8  is a plan view schematically showing the configuration of a semiconductor device according to the third embodiment of the invention. Similarly to the IEGT  1  shown in  FIG. 1 , the IEGT  4  shown here comprises second emitter layers  32  selectively formed as isolated regions in the surface layer of each second base layer  18  to make a pair, both of which are in contact with trenches TR at their respective ends. On the other hand, the second emitter regions  32  and the second base layer  18  are connected to the emitter electrode  28  in a contact region Rec 40  similar to the emitter contact in the main cell region MC via a via contact not shown.  
         [0081]     The IEGT  4  according to the instant embodiment having this configuration also has the same functions and effects as those of the first embodiment.  
       Fourth Embodiment  
       [0082]      FIG. 9  is a plan view schematically showing the configuration of a semiconductor device according to the fourth embodiment of the invention. The IEGT  5  shown here comprises a second emitter layer  38  having the same geometry as that of the IEGT  3  shown in  FIG. 7  and located in the surface layer of each second base layer  18 . The second emitter layers  38  and the second base layer  18  are connected to the emitter electrode  28  in the contact region Rec 40 , which is similar to that of the IEGT  4  according to the third embodiment already explained, via a via contact not shown.  
         [0083]     The IEGT  5  according to the instant embodiment having this configuration also has the same functions and effects as those of the first embodiment.  
       Fifth Embodiment  
       [0084]      FIG. 10  is a cross-sectional view schematically showing the configuration of a semiconductor device according to the fifth embodiment of the invention. The foregoing embodiments have been explained taking vertical type IEGTs  1 ,  3  through  5 . In the instant embodiment, however, a lateral type power semiconductor device equivalent to the former IEGT in function is taken as an example.  
         [0085]     The IEGT  6  shown in  FIG. 10  is formed on a SOI (silicon-on-insulator) substrate having a semiconductor support layer  64 , insulating layer  62  and a semiconductor active layer  60 . The active layer  60  is used as a high-resistance n-type drift layer (n-type base layer)  10 . On a right portion of  FIG. 10 , a p-type collector layer  66  and a collector electrode  68  are located. In a region of a left portion of  FIG. 10 , which is remote from the p-type collector layer  66 , a p-type base layer is formed on the n-type drift layer  10 , and trenches TR are formed from the top surface of the p-type base layer. Thus, the p-type base layer is divided to the first base layer  16  of the main cell region MC and the second base layer  18  of the dummy cell region DC. Around the trenches TR, the same structure as the upper part of the IEGT  1  of  FIG. 2  is formed.  
         [0086]     In the IEGT  1  shown in  FIG. 2 , having the vertical structure in which the collector electrode  26  and the emitter electrode  28  are formed to sandwich the substrate, the main current flows vertically through the n-type drift layer  10 . In contrast, in the IEGT  6  shown in  FIG. 11 , having the lateral type structure in which the collector electrode  68  and the emitter electrode  28  are located on a common side of the substrate, the main current flows laterally in the n-type drift layer  10 . In the other respects, however, both these types of devices work under identical operational principles. As such, the present invention is applicable not only to vertical type IEGTs but also to lateral type IEGTs.  
         [0087]     The invention has been explained by way of some embodiments. These embodiments, however, should not be construed to any limitation of the present invention. Rather, the present invention should be understood to include all possible embodiments and modification to the shown embodiments which can be embodied without departing from the scope and spirit thereof as set forth in the appended claims.

Technology Classification (CPC): 7