Patent Abstract:
A method for fabricating a high-voltage transistor with an extended drain region includes forming in a semiconductor substrate of a first conductivity type, first and second trenches that define a mesa having respective first and second sidewalls; then partially filling each of the trenches with a dielectric material that covers the first and second sidewalls. The remaining portions of the trenches are then filled with a conductive material to form first and second field plates. Source and body regions are formed in an upper portion of the mesa, with the body region separating the source from a lower portion of the mesa. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Full Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation of application Ser. No. 11/807,531 filed May 29, 2007, which is a continuation of application Ser. No. 11/021,933 filed Dec. 23, 2004, now U.S. Pat. No. 7,253,042, which is a continuation of application Ser. No. 10/722,792 filed Nov. 25, 2003, now U.S. Pat. No. 6,838,346, which is a continuation of application Ser. No. 10/278,551 filed Oct. 22, 2002, now U.S. Pat. No. 6,750,105, which is a division of application Ser. No. 09/948,879 filed Sep. 7, 2001, now U.S. Pat. No. 6,635,544, and is also related to co-pending application Ser. No. 10/278,432 filed Oct. 22, 2002, now U.S. Pat. No. 6,667,213, which applications are assigned to the assignee of the present application. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to semiconductor devices fabricated in a silicon substrate. More specifically, the present invention relates to field-effect semiconductor transistor structures capable of withstanding high voltages. 
       BACKGROUND OF THE INVENTION 
       [0003]    High-voltage, field-effect transistors (HVFETs) are well known in the semiconductor arts. Most often, HVFETs comprise a device structure that includes an extended drain region that supports the applied high-voltage when the device is in the “off” state. HVFETs of this type are commonly used in power conversion applications such as AC/DC converters for offline power supplies, motor controls, and so on. These devices can be switched at high voltages and achieve a high blocking voltage in the off state while minimizing the resistance to current flow in the “on” state. The blocking or breakdown voltage is generally denoted as Vbd. The acronym Rsp refers to the product of the resistance and surface area, and is generally used to describe the on-state performance of the device. An example of a prior art HVFET having an extended drain region with a top layer of a conductivity type opposite that of the extended drain region is found in U.S. Pat. No. 4,811,075. 
         [0004]    In a conventional HVFET the extended drain region is usually lightly doped to support high voltages applied to the drain when the device is off. The length of the extended drain region is also increased to spread the electric field over a larger area so the device can sustain higher voltages. However, when the device is on (i.e., conducting) current flows through the extended drain region. The combined decrease in doping and increase in length of the extended drain region therefore have the deleterious effect on the on-state performance of the device, as both cause an increase in on-state resistance. In other words, conventional high-voltage FET designs are characterized by a trade-off between Vbd and Rsp. 
         [0005]    To provide a quantitative example, a typical prior art vertical HVFET (NMOS-type) may have a Vbd of 600V with a Rsp of about 16 ohm-mm 2 . Increasing the length of the extended drain would affect device performance by increasing Vbd beyond 600V at the expense of a higher Rsp value. Conversely, reducing the length of the extended drain would improve the on-state resistance to a value below 16 ohm-mm 2 , but such a change in the device structure would also cause Vbd to be reduced to less than 600V. 
         [0006]    A device structure for supporting higher Vbd voltages with a low Rsp value is disclosed in U.S. Pat. Nos. 4,754,310, 5,438,215, and also in the article entitled, “ Theory of Semiconductor Superjunction Devices ” by T. Fujihira, Jpn. J. Appl. Phys., Vol. 36, pp. 6254-6262, October 1977. In this device structure the extended drain region comprises alternating layers of semiconductor material having opposite conductivity types, e.g., PNPNP . . . . As high voltage is applied to the layers of one conductivity type, all of the layers are mutually depleted of charge carriers. This permits a high Vbd at much higher conducting layer doping concentrations as compared to single layer devices. The higher doping concentrations, of course, advantageously lower the Rsp of the transistor device. For example, in the article entitled, “ A new generation of high voltage MOSFETs breaks the limit line of silicon ” by G. Deboy et al., IEDM tech. Digest, pp. 683-685, 1998, the authors report a vertical NMOS device with a Vbd of 600V and a Rsp of about 4 ohm-mm 2 . 
         [0007]    Another approach to the problem of achieving high-voltage capability is disclosed in the paper, “ Realization of High Breakdown Voltage in Thin SOI Devices ” by S. Merchant et al., Proc. Intl. Symp. on Power Devices and ICs, pp. 31-35, 1991. This paper teaches an extended drain region that comprises a thin layer of silicon situated on top of a buried oxide layer disposed on top of a semiconductor substrate. In operation, the underlying silicon substrate depletes charge from the thin silicon layer at high voltages. The authors claim that high values of Vbd are obtained as long as the top silicon layer is sufficiently thin and the buried oxide layer is sufficiently thick. For instance, a lateral NMOS device with Vbd of 600V and Rsp of about 8 ohm-mm 2  is obtained using this approach. 
         [0008]    Other background references of possible interest to those skilled in the art include U.S. Pat. Nos. 6,184,555, 6,191,447, 6,075,259, 5,998,833, 5,637,898, International Application No. PCT/IB98/02060 (International Publication No. WO 99/34449), and the article, “ High Performance  600 V Smart Power Technology Based on Thin Layer Silicon - on - Insulator ” by T. Letavic et al., Proc. ISPSD, pp. 49-52, 1997. 
         [0009]    Although the device structures described above achieve high Vbd with relatively low on-state resistance as compared to earlier designs, there is still an unsatisfied need for a high-voltage transistor structure that can support still higher voltages while achieving a much lower on-state resistance. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings, wherein: 
           [0011]      FIG. 1  is a cross-sectional side view of a vertical high-voltage, field-effect transistor (HVFET) device structure in accordance with one embodiment of the present invention. 
           [0012]      FIG. 2  is a cross-sectional side view of one embodiment of a lateral HVFET fabricated in accordance with the present invention. 
           [0013]      FIG. 3A  is a top view of lateral HVFET fabricated in accordance with another embodiment of the present invention. 
           [0014]      FIG. 3B  is a cross-sectional side view of the lateral HVFET shown in  FIG. 3A , taken along cut lines A-A′. 
           [0015]      FIG. 4  is a cross-sectional side view of another embodiment of a vertical HVFET device structure fabricated according to the present invention. 
           [0016]      FIGS. 5A-5K  are cross-sectional side views of a vertical HVFET device structure taken at various stages in a fabrication process in accordance with yet another embodiment of the present invention. 
           [0017]      FIG. 6  is a cross-sectional side view of still another embodiment of a vertical HVFET device structure fabricated according to the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    A high-voltage field-effect transistor having an extended drain region and a method for making the same is described. The HVFET has a low specific on-state resistance and supports high voltage in the off-state. In the following description, numerous specific details are set forth, such as material types, doping levels, structural features, processing steps, etc., in order to provide a thorough understanding of the present invention. Practitioners having ordinary skill in the semiconductor arts will understand that the invention may be practiced without many of these details. In other instances, well-known elements, techniques, and processing steps have not been described in detail to avoid obscuring the invention. 
         [0019]      FIG. 1  is a cross-sectional side view of a vertical n-channel (i.e., NMOS) HVFET  20  in accordance with one embodiment of the present invention. It should be understood that the elements in the figures are representational, and are not drawn to scale in the interest of clarity. It is also appreciated that a p-channel transistor may be realized by utilizing the opposite conductivity types for all of the illustrated diffusion/doped regions. Furthermore, although the figure appears to show two separate devices, those of skill will understand that such transistor structures are commonly fabricated in an annular, inter-digitated, or otherwise replicated manner. 
         [0020]    The device structure of  FIG. 1  includes an insulated-gate, field-effect transistor (IGFET) having a gate  30  (comprised, for example, of polysilicon), and a gate-insulating layer  29  that insulates gate  30  from the underlying semiconductor regions. Gate-insulating layer  29  may comprise ordinary silicon dioxide or another appropriate dielectric insulating material. The extended drain region of vertical HVFET  20  comprises two or more parallel N-type drift regions  22  situated between p-type body regions  26  and extending down to the N+ substrate  21 . For instance,  FIG. 1  shows drift region  22   a  extending from beneath gate oxide  29   a  between P-body regions  26   a  &amp;  26   b  down to N+ substrate  21 . Similarly, drift region  22   b  extends from gate oxide  29   b  between P-body regions  26   c  &amp;  26   d  down to N+ substrate  21 . 
         [0021]    Source electrode  32  is electrically connected to N+ source regions  27 , which are disposed in respective P-body regions  26 . For example, N+ source region  27   a  is disposed in P-body region  26   a ; N+ region  27   b  is disposed in P-body region  27   b , and so on. It is appreciated that a variety of alternative source electrode connections are also possible. The area of the P-body regions directly beneath gate  30  (between N+ source regions  27  and drift regions  22 ) comprises the IGFET channel region of the transistor. In this particular embodiment, the gate region is a metal-oxide semiconductor (MOS), and the IGFET is a NMOS transistor. Thus, the channel regions of HVFET  20  are defined at one end by N+ source regions  27  and at the other end by N-type drift regions  22 , which extend vertically from gate oxide  29  down to the N+ substrate  21 . Insulating layers  33  separate gate  30  from source electrode  32 . The drift regions define a path for current flow, herein referred to as the first direction. 
         [0022]    The n-type drift regions  22  are separated laterally by insulating regions or dielectric layers  28 . This direction of separation is substantially orthogonal to the first direction and is herein referred to as the second direction. In the embodiment of  FIG. 1 , dielectric layers  28  extend vertically from beneath P-body regions  26  down to N+ substrate  21  along the full vertical length of the drift regions  22 . By way of example, dielectric layers  28  may comprise silicon dioxide, but other insulating materials, such as silicon nitride, may also be used. Disposed within each of the dielectric layers  28 , and fully insulated from the semiconductor substrate  21  and drift regions  22 , is a field plate member  24 . Field plate members  24  comprise a conducting layer of material such as heavily doped polysilicon, metal, metal alloys, etc. As shown in the embodiment of  FIG. 1 , each of the field plate members  24  is electrically connected to source electrode  32 . Alternatively, the field plate members may be connected to a separate electrode. Gates  30  are also connected to a separate electrode (not shown). Drain electrode  31  provides electrical connection to the bottom of N+ substrate  21 . 
         [0023]    The extended drain region of vertical NMOS high-voltage transistor  20  of  FIG. 1  consists of a plurality of laterally interleaved layers of doped semiconductor material (e.g., n-type drift regions  22 ), insulating material (e.g., silicon dioxide dielectric layer  28 ), and conducting material (e.g., heavily-doped polysilicon). In the on state, a sufficient voltage is applied to the gate such that a channel of electrons is formed along the surface of the P-body regions  26 . This provides a path in the first direction for electron current flow from source electrode  32 , N+ source regions  27 , through the channel regions formed in P-body regions  26 , down through the N-type drift regions  22 , through the N+ substrate  21 , to drain electrode  31 . 
         [0024]    Practitioners in the semiconductor arts will note that in a conventional vertical HVNMOS transistor, the N-type drift region is normally very thick (i.e., long) and lightly doped; both of which contribute to high on state resistance. In the device structure of  FIG. 1 , on the other hand, the doping in the N-type drift regions may be considerably higher, such that the on-state resistance is dramatically lowered. Lowering the on-state resistance is achieved in HVFET  20  by the use of multiple, parallel-arranged extended drain or drift regions. 
         [0025]    In the off state, a high voltage (e.g., 200V-1200V) is applied across the respective drain and source electrodes  31  and  32 . As the voltage increases, the presence of field plate regions  24  on opposite sides of drift regions  22  cause the N-type drift regions to become depleted of free carriers. Ideally, the doping profile in the drift regions  22  is tailored such that the resulting electric field is approximately constant along the path from the drain to the source. For example, the doping concentration may be highest near the N+ substrate  21 , lowest the near the P-body regions  26 , and linearly graded in between. 
         [0026]    The thickness of both the N-type drift regions  22  and oxide layers  28  should be designed so as to guard against premature avalanche breakdown. Avalanche breakdown can be avoided by making the drift region relatively narrow in the second direction, which reduces the ionization path and thereby increases the critical electric field at which avalanche occurs. In the same regard, making oxide layers  28  relatively wide in the second direction allows the device structure to support a larger voltage for a given critical electric field. 
         [0027]    By way of example, a device manufactured in accordance with  FIG. 1  having a drift region that is about 50 um high and about 0.4-0.8 um wide, with an oxide layer width in the approximate range of 3.0-4.0 um is capable of supporting about 800V. In such a device, the doping in the drift region may be linearly graded from about 5×10 15  cm −3  near the P-body regions to about 1×10 17  cm −3  near the N+ substrate. The on-state resistance of such a device is about 1.0 ohm-mm 2 . 
         [0028]    Practitioners in the art will appreciate that the device performance for HVFET  20  may be improved when manufactured as a smaller total cell pitch (i.e., combined width of field plate, oxide layer and drift regions) because the contribution of each drift region is fairly constant. 
         [0029]    Referring now to  FIG. 2 , there is shown a lateral NMOS high-voltage transistor  40  in accordance with another embodiment of the present invention. HVFET  40  of  FIG. 2  operates according to the same principles discussed in connection with the transistor structure of  FIG. 1 , except that current flows laterally, as opposed to vertically, through the drift regions. Note that in the embodiment of  FIG. 2 , field plate members  44  are fully insulated from the semiconductor material by oxide layers  49 . 
         [0030]    In this example, field plate member  44   a  is disposed within oxide layer  49   a  just below the source and drain electrodes  46  and  45 , respectively. Field plate member  44   b  is disposed within oxide layer  49   b  below N-type drift region  42   a  and above N-type drift region  42   b . The field plate members may be connected to a field plate electrode at a certain location out of the plane of the figure. The N-type drift region, which comprises the extended drain of the transistor, extends laterally from beneath P-body region  48  across to N+ drain region  43 . N+ drain region  43  connects both drift regions  42   a  &amp;  42   b  with drain electrode  45 . 
         [0031]    An N+ source region  47 , which is electrically connected to source electrode  46 , is disposed adjacent P-body region  48 . The HVFET  40  utilizes a vertical MOS gate structure  12  that comprises a gate electrode  56  that connects to gate  55 . In this embodiment, gate  55  comprises a layer of polysilicon that extends vertically from gate electrode  56 . Gate  55  extends below the P-body region, and may extend down to oxide layer  50 , as shown. Gate  55  is insulated from N+ source region  47 , P-body region  48 , and N-type drift region  42  by gate oxide  53 . An oxide region  58  separates gate electrode  56  from source electrode  46 . 
         [0032]    Oxide layer  50  insulates N+ substrate  41  from gate  55 , N-type drift region  42 , and N+ drain region  43 . As can be seen, oxide layer  50  extends laterally over N+ substrate  41  beneath each of the regions  42 ,  43 , and  55 . Substrate electrode  57  provides electrical connection to the bottom of N+ substrate  41 . The substrate may serve as the bottom field plate for drift region  42   b.    
         [0033]    The on-state and off-state operations of HVFET  40  are similar to those described for the embodiment of  FIG. 1 . In this case, however, the source and drain electrodes are located on the top surface. This means that electrons flows down through N+ source region  47 , across the channel region formed in P-body region  48  adjacent to gate oxide  53 , laterally across the N-type drift regions  42 , and up through the N+ drain region  43  before reaching the drain electrode. 
         [0034]    Note that even though  FIG. 2  shows a trench gate structure, planar gate structures could also be used. Additionally, a trench drain structure could also be used in an alternative implementation. Furthermore, although the embodiment of  FIG. 2  shows the extended drain region comprising two laterally-extending, parallel N-type drift regions  42   a  and  42   b , other embodiments may utilize more than two parallel drift regions. In other words, the embodiment of  FIG. 2  is not limited to just two drift regions, but could include any number of layers of drift, oxide, and field plate regions within manufacturing limits. 
         [0035]      FIGS. 3A &amp; 3B  illustrate another embodiment of a lateral HVFET in accordance with the present invention.  FIG. 3A  is a top view of a lateral HVNMOS transistor  60 , and  FIG. 3B  is a cross-sectional side view of the same device, taken along cut lines A-A′, which extends through drift region  62   a . (Note that the source electrode  66 , drain electrode  65 , gate  75 , gate oxide  73  and oxide layer  79  are not depicted in  FIG. 3A  to avoid confusion. These elements are shown in the cross-sectional side view of  FIG. 3B .) 
         [0036]    The lateral device structure of  FIG. 3  is similar to that shown in  FIG. 2 . But rather than orient the drift, oxide, and field plate layered regions on top of one another (vertically), the embodiment of  FIG. 3  has these regions oriented side-by-side. Unlike the embodiment of  FIG. 2 , each of the N-type drift regions  62 , oxide layers  69 , and field plate members  64  extend from underlying insulating layer  70  toward the upper substrate surface. Each of the N-type drift regions  62  and field plate members  64  are insulated from N+ substrate  61  by insulating layer  70 . In one embodiment, layer  70  comprises silicon dioxide. An additional electrode  77  provides electrical connection to the bottom of N+ substrate  61 . 
         [0037]    The planar gate and drain configurations of HVNMOS transistor  60  are illustrated in the side view of  FIG. 3B . Alternatively, a trench drain structure and/or a trench gate structure may be utilized. In this embodiment, a gate member  75  is disposed above P-body region  68  and is insulated from the semiconductor substrate by a gate oxide  73 . Source electrode  66  contacts N+ source region  67 , which is disposed in P-body region  68 . P-body region  68  is itself shown disposed in N-type drift region  62 . 
         [0038]    N+ drain region  63  is disposed at the opposite end of the N-type drift region  62  and is electrically connected to drain electrode  65 . 
         [0039]    The embodiments of  FIGS. 2 and 3  show the field plate members being coupled to the lowest chip potential, e.g., ground. The source may be tied to the field plate members (at the lowest chip potential), or, alternatively, the source region may be left floating. In other words, the embodiments of  FIGS. 1-3  are not limited to a source follower configuration. Each of the transistor structures of the present invention may be implemented as a four-terminal device, wherein the drain, source, field plate members, and insulated gate members are connected to a separate circuit terminal. In another embodiment, the field plate and insulated gate members may be connected together. 
         [0040]    With reference now to  FIG. 4 , there is shown a cross-sectional side view of another embodiment of a vertical HVNMOS transistor  80  constructed according to the present invention. The device structure shown in  FIG. 4  is similar to that of  FIG. 1 , except that the planar gate has been replaced by a trench gate structure. As in the vertical device structure of  FIG. 1 , transistor  80  comprises a plurality of parallel-arranged N-type drift regions  82  that extend vertically from P-body regions  86  down to the N+ substrate  81 . Each of the drift regions  82  is adjoined on both sides by an oxide layer  88 . For example, N-type drift region  82   a  is bounded on one side by oxide layer  88   a  and on the opposite side by oxide layer  88   b.    
         [0041]    Disposed within each of the oxide layers  88 , and fully insulated from the drift region and substrate semiconductor materials, is a field plate member  84  that may be electrically connected to source electrode  92 . The N-type drift regions  82 , oxide layers  88 , and field plate members  84  collectively comprise a parallel layered structure that extends in a lateral direction, which is perpendicular to the direction of current flow in the on-state. When transistor  80  is in the on-state, current flows vertically from the drain electrode  91  through the parallel N-type drift regions  82 , through the MOS channel formed on the sidewalls of the P-body region, to the source electrode  92 . 
         [0042]    The trench gate structure of vertical HVNMOS transistor  80  comprises gate members  90  disposed between field plate members  84  and P-body regions  86 . In the embodiment of  FIG. 4 , a pair of N+ source regions  87  is disposed in each of P-body regions  86  on opposite sides. Each P-body region  86  is located at one end of a corresponding N-type drift region  82 . A thin gate-insulating layer  89  (e.g., oxide) insulates each of gate members  90  (e.g., polysilicon) from the P-body semiconductor material. 
         [0043]    For example,  FIG. 4  shows gate members  90   a  &amp;  90   b  disposed along opposite sides of P-body region  86   a . N+ source regions  87   a  &amp;  87   b  are disposed in P-body region  86   a  at opposite sides adjacent to the gate members; both regions  87   a  &amp;  87   b  are electrically connected to source electrode  92 . P-body region  86   a  adjoins the source electrode at one end and drift region  82   a  at the other end. When transistor  80  is in the on-state conducting channel regions are formed along the sides of P-body region  86   a  such that current flows from source electrode  92 , through N+ regions  87 , across P-body  86 , down through N-type drift regions  82  and N+ substrate  81 , to drain electrode  91 . 
         [0044]    Practitioners in the art will appreciate that the pair of N+ source regions  87  shown disposed in each P-body region  86  of  FIG. 4  may alternatively be replaced by a single N+ region that extends across the full width of region  86  adjacent to source electrode  92 . In this case, the P-body region may be connected to the source electrode at various points (dimensionally into the page of the figure.) In one embodiment, source electrode  92  may protrude through N+ source  87  to contact the underlying P-body region  86  (see  FIG. 5K ). 
         [0045]    The trench gate structure of the embodiment of  FIG. 4  potentially offers an advantage of a simplified manufacturing process, due to the elimination of the T-shaped semiconductor regions shown in  FIG. 1 . Also, the vertical HVNMOS structure of transistor  80  may provide lower on-resistance due to the elimination of the JFET structure formed between the P-body regions. 
         [0046]      FIGS. 5A-5K  illustrate the various processing steps that may be employed to fabricate a vertical high-voltage transistor in accordance with the present invention. The described fabrication method may be used not only to form the device of  FIG. 5K , but also the vertical device structure shown in  FIG. 4 . 
         [0047]      FIG. 5A  shows a vertical high-voltage transistor after the initial processing step of forming an epitaxial layer  101  of n-type semiconductor material on an N+ substrate  100 . To support applied voltages in the range of 200V to 1000V the device structure should have an epitaxial layer that is about 15 um to 120 um thick. By way of example, the epitaxial layer of the device shown in  FIG. 5  is 40 um thick. The N+ substrate  100  is heavily doped to minimize its resistance to current flowing through to the drain electrode, which is located on the bottom of the substrate in the completed device. Substrate  100  may be thinned, for example, by grinding or etching, and metal may be deposited on its bottom surface to further reduce the on-resistance of the transistor. Most often, these processing steps would be performed after the topside processing has been completed. 
         [0048]    The thickness and doping of epitaxial layer  101  largely determine the Vbd of the device. The doping may be carried out as the epitaxial layer is being formed. The optimal doping profile is linearly graded from the drain (at the bottom, adjacent to N+ substrate  100 ) to the source (at the top). Tailoring the doping concentration so that it is heavier near the substrate  100  results in a more uniform electric-field distribution. Linear grading may stop at some point below the top surface of the epitaxial layer  101 . By way of example, for the embodiment shown in  FIG. 5  the doping concentration is approximately 2×10 15  cm −3  near the P-body region to about 6×10 16  cm −3  near the N+ substrate  100 . 
         [0049]    After the epitaxial layer  101  has been formed, the top surface of layer  101  is appropriately masked and deep trenches are then etched into, or alternatively completely through, the epitaxial layer.  FIG. 5B  shows a cross-sectional view of the device structure following etching of epitaxial layer  101  and part of substrate  100 . Note that the lateral width of the etched trenches is determined by the combined thickness of the dielectric and conductive refill layers, as described below. 
         [0050]    Spacing between adjacent trenches is determined by the required thickness of the remaining mesa of epitaxial layer material, which, in turn, is governed by the breakdown voltage requirements of the device. It is this mesa of epitaxial material that eventually forms the N-type drift region of the device structure. It should be understood that this mesa of material might extend a considerable lateral distance in an orthogonal direction (into the page). Although the embodiment of  FIG. 5  illustrates a device having an extended drain region that comprises a single N-type drift region, it is appreciated that the vertical high-voltage transistor of  FIG. 5  may be constructed with a plurality of parallel-arranged N-type drift regions. Ideally, it is desired to make the lateral thickness (i.e., width) of the N-type drift region(s) as narrow as can be reliably manufactured in order to achieve a very high Vbd with a low Rsp. Of course, a larger lateral thickness is easier to manufacture, but the specific on-resistance of the device suffers with a larger lateral thickness since the current is required to flow across a larger silicon area. In one implementation, the thickness is in the approximate range of 0.4 to 1.2 microns. In this example, the thickness of the mesa is about 1 um. 
         [0051]      FIG. 5C  shows the device structure of  FIG. 5B  after partial filling of the etched trenches with a dielectric material, e.g., silicon dioxide. As shown, in the embodiment of  FIG. 5  oxide region  102   a  covers one side of etched epitaxial region  101 , while oxide region  102   b  covers the other side of epitaxial region  101 . Oxide region  102  also covers the top surface of N+ substrate  100  in each of the trenches. 
         [0052]    The dielectric material may be introduced into the trenches using a variety of well-known methods. For instance, regions  102  may be grown thermally, deposited by chemical vapor deposition, and/or spun on in liquid form. For a given lateral thickness of epitaxial layer material  101 , the thickness of the dielectric layer may be set to provide a required breakdown voltage, with thicker dielectric layers providing a higher Vbd. However, thicker dielectric layers increase the cell pitch of the transistor structure and result in higher specific on-resistance. In one implementation, the 600V device structure of  FIG. 5  has an oxide layer lateral thickness of 4 um. For devices with other V bd  performance, this thickness may be in the range of about 2 um-5 um. 
         [0053]      FIG. 5D  illustrates the device structure of  FIG. 5C  following the steps of filling the remaining portions of the trenches with a conductive material and planarizing the surface to form field plate regions  103 . For example, the conductive material may comprise a heavily doped polysilicon, a metal (or metal alloys), and/or silicide. Conductor regions  103   a  and  103   b  form the field plate members of the device. In most cases, field plate members  103   a  and  103   b  should be made as narrow as can be reliably manufactured, since the field plate members occupy silicon area without directly contributing to device conductivity or breakdown voltage characteristics. In one embodiment, the lateral thickness of field plate members  103  is approximately 0.5 um-1.0 um. The planarization of the surface may be performed by conventional techniques such as chemical-mechanical polishing. 
         [0054]    At this point in the process, fabrication of the extended drain region of the device is essentially complete. The remaining processing steps may be adapted to produce a stand-alone, high-voltage, depletion-mode MOSFET device structure (as shown in  FIG. 5G  and  FIG. 6 ) or a high-voltage FET that incorporates a low-voltage MOSFET structure (e.g.,  FIG. 5K ), or other high-voltage devices. 
         [0055]      FIG. 5E  is a cross-sectional side view of the device structure of  FIG. 5D  after the introduction of an N+ source region  105  at the top surface of epitaxial layer  101 . Source region  105  may be formed using ordinary deposition, diffusion, and/or implantation processing techniques. 
         [0056]    After formation of the N+ source region  105  an interlevel dielectric layer  106  is formed over the device. In the embodiment of  FIG. 5 , interlevel dielectric layer  106  comprises ordinary silicon dioxide that may be deposited and patterned by conventional methods. Openings are formed in dielectric layer  106  and a conductive layer of material (e.g., metal, silicide, etc.) is deposited and patterned to produce the structure shown in  FIG. 5F . In this cross-sectional view, source electrode  109  provides electrical connection to N+ source region  105 , and electrodes  110   a  and  110   b  provide electrical connection to field plate members  103   a  and  103   b , respectively. 
         [0057]      FIG. 5G  shows the device structure of  FIG. 5F  following formation of a drain electrode  111  on the bottom of N+ substrate  100 . For example, drain electrode  111  may be formed using the conventional technique of metal sputtering. As described earlier, the bottom of the substrate may first be subjected to grinding, implanting, etc., to lower the drain contact resistance. 
         [0058]    The device of  FIG. 5G  represents a completed high-voltage transistor having a stand-alone drift region; that is, the device of  FIG. 5G  does not include a low-voltage, series MOSFET structure at the top of the epitaxial layer. Instead, the extended drift region formed by the epitaxial layer, itself, performs the function of the MOSFET without the inclusion of a P-body region. Practitioners in the arts will note that in this device structure current cannot be completely turned-off, since there exists a continuous n-type path for electrons to flow from source electrode  109  to drain electrode  111 . Current flow in the device structure of  FIG. 5G , however, does saturate when the mesa-like epitaxial layer  101  is pinched-off at high drain voltages. 
         [0059]    The device structure of  FIG. 6  achieves pinch-off of the extended drain region at lower voltages than the device of  FIG. 5G . This is achieved by reducing the spacing between the field plate members  103  and epitaxial layer  101  near the top of the N-type drift region, thereby increasing the capacitance to pinch-off the vertical drift region at a relatively low voltage.  FIG. 6  shows a multi-tiered field plate structure extending laterally into oxide regions  102   a  &amp;  102   b  to control the pinch-off voltage and, therefore, the saturation current. Alternatively, the field plate members may comprise a single step, a linearly graded lateral extension, or some other profile shape designed to achieve the same result. 
         [0060]    Those skilled in the arts will appreciated that for certain circuit applications it may be advantageous to utilize the stand-alone transistor structure of  FIG. 5G  (or  FIG. 6 ) in series with an ordinary external, low-voltage switching MOSFET. In such an application the low-voltage (e.g., 40V) MOSFET could be used for switching purposes in order to completely turn off current flow in the high-voltage (e.g., 700V) transistor device. 
         [0061]    Referring now to  FIGS. 5H-5K , there is shown an alternative processing sequence that may be used to fabricate a vertical HVNMOS transistor that includes an insulated gate MOS structure. 
         [0062]    Trenches  112   a  and  112   b  are formed in respective dielectric layers  102   a  and  102   b  on opposite sides of epitaxial layer  101  to accommodate the formation of the insulated gate structure. The depth of trenches  112   a  and  112   b  extends from the surface of N+ source region  105  to a depth governed by the intended MOSFET channel length and field plating considerations. In this example, the trench depth is about 1-5 um. By way of example, trenches  112  may be formed by appropriate application of a patterned masking layer to the semiconductor substrate followed by conventional dry or wet etching techniques into oxide layer  102 . 
         [0063]      FIG. 5J  shows the device after formation of gate dielectric layers  116  and gate members  113  within trenches  112 . The gate dielectric layers  116   a  &amp;  116   b  may be formed by growing or depositing oxide on the sidewalls of the stacked N+ source, P-body, and epitaxial regions. The device threshold voltage determines the thickness of layers  116 . In one embodiment, layers  116  comprise silicon dioxide having a thickness on the order of 250-1000 angstroms. 
         [0064]    In the embodiment shown, a portion of dielectric layers  102  isolates field plate members  103  from gate members  113 . Alternatively, trenches  112  may expose the top portion of field plate  103  and the same processing steps used to create layers  116  may also be used to form dielectric layers on the sidewalls of the field plates to isolate the field plates from the gate members. 
         [0065]    Once dielectric layers  116  have been formed on the sidewalls of trenches  112 , a conductive material, such as doped polysilicon, may be deposited to fill the remaining portions of the trenches. In this implementation, the doped polysilicon forms the gate members  113   a  and  113   b  of the MOS transistor structure.  FIG. 5J  shows the device after introduction of a P-body region  107  and a N+ source region  105  at the top surface of epitaxial region  101 . In the completed device, application of a sufficient voltage to gate members  113  causes a conductive channel to be formed along the sidewall portions of P-body region  107  between N+ source region  105  and epitaxial region  101 . The channel length is therefore determined by the thickness of P-body region  107 , which, for the particular embodiment shown, may be approximately 0.5 um-3.0 um, with the N+ source region  105  in the range of about 0.1-0.5 um. A shorter channel length results in a lower channel resistance, which likewise reduces the on-resistance of the device. It should be understood, however, that a too short channel would cause punch-through problems. 
         [0066]      FIG. 5K  shows the completed HVFET device structure following formation of an interlevel dielectric layer  106  (e.g., silicon dioxide, silicon nitride, etc.). This layer may be deposited and patterned to form contact openings. In the embodiment shown, the etching of layer  106  is followed by etching of the field plates, gate members, N+ and P-body regions. This is followed by deposition and patterning of a conductive layer (e.g., metal, silicide, etc.) to create source electrode  109 , gate electrodes  115 , and field plate electrodes  110 , which provide electrical connection to the respective regions of the device. The optional etching step described above allows the source electrode to contact the P-body region without patterning the N+ source region, thus simplifying the process. A conductive layer may also be applied to the bottom of substrate  100  (after optional treatment by grinding, etching, implanting, etc.) to form the drain electrode  111 . 
         [0067]    Note that while source electrode  109  is shown extending down to P-body  107  in the cross-sectional view of  FIG. 5K , in other embodiments electrode may only extend to the upper surface of source region  105 . It should also be appreciated that electrode  109  does not separate region  105  into two separate source regions in the illustration of  FIG. 5K . Rather, electrode  109  is fabricated in the form of a plug that is surrounded by N+ material that comprises region  105 .

Technology Classification (CPC): 7