Patent Document

CROSS-REFERENCE TO RELATED APPLICATION 
     This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-063727, filed Mar. 7, 2001, the entire contents of which are incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a semiconductor device having an insulated gate bipolar transistor with a dielectric isolation structure and a method of manufacturing the same and, more particularly, to a semiconductor device used as a power IC, e.g., an IPD (Intelligent Power Device). 
     2. Description of the Related Art 
     Recently, many power semiconductor devices such as insulated gate bipolar transistors (to be referred to as IGBTs hereinafter) are used in purposes such as power conversion and power control of, e.g., inverters and converters. Hence, these power semiconductor devices are essential in the field of electric power. 
     A conventional lateral IGBT will be explained below with reference to FIGS. 1 and 2. 
     FIG. 1 is a cross-sectional view showing the structure of a lateral IGBT in a conventional dielectric isolated substrate. The above dielectric isolation structure isolates elements by a dielectric substance. As this dielectric isolation structure, an SOI (silicon on insulator) structure to be described below will be taken as an example. 
     As shown in FIG. 1, a silicon oxide film  102  is formed on an n − -type silicon layer  101 . An n − -type silicon layer  103  is formed on this silicon oxide film  102 . An SOI structure is formed by these n − -type silicon layer  101 , silicon oxide film  102 , and n − -type silicon layer  103 . 
     On this n − -type silicon layer  103 , a gate electrode  105  is formed with a gate insulating film  104  interposed between the n − -type silicon layer  103  and the gate electrode  105 . In addition, on this n − -type silicon layer  103 , an emitter electrode  106  and a collector electrode  107  are formed apart from the gate electrode  105 . A field oxide film  108  is formed on the n − -type silicon layer  103  between the gate electrode  105  and the collector electrode  107 . The gate electrode  105  is made of a polysilicon film about 4,000 Å thick. 
     A p-type base diffusion layer  109  is formed in the n − -type silicon layer  103  from a portion below the gate electrode  105  to a portion below the emitter electrode  106 . A p + -type diffusion layer  110  is formed between this p-type base diffusion layer  109  and the emitter electrode  106 . Furthermore, an n + -type diffusion layer  111  is formed on the p-type base diffusion layer  109 . 
     An n-type buffer diffusion layer  112  is formed in the n − -type silicon layer  103  below the collector electrode  107 . The main purpose of the n-type buffer diffusion layer  112  is to increase the collector-emitter withstand voltage. A p + -type diffusion layer  113  is formed between this n-type buffer diffusion layer  112  and the collector electrode  107 . A lateral IGBT in the conventional dielectric isolation substrate is constructed as above. 
     In this IGBT having the structure shown in FIG. 1, however, a parasitic npn transistor composed of the n + -type diffusion layer  111 , the p-type base diffusion layer  109 , and the n − -type silicon layer  103  easily operates and sometimes destroys the IGBT by latch up. That is, when this parasitic npn transistor operates, the base current of a parasitic pnp transistor made up of the p + -type diffusion layer  113 , the n-type buffer diffusion layer  112 , the n − -type silicon layer  103 , and the p-type base diffusion layer  109  increases. This amplifies the collector-emitter current of this parasitic pnp transistor. As a consequence, the collector-emitter current increases and destroys the IGBT. Especially when the impurity concentration in the p-type base diffusion layer  109  is low, the latch-up phenomenon causes more easily. To prevent this, the impurity concentration in the p-type base diffusion layer  109  can be increased. However, this makes it difficult to form an inversion layer in the channel region below the gate electrode  105 . 
     To improve a capability of ruggedness by the latch-up phenomenon, therefore, in an IGBT as shown in FIG. 2, a p-type diffusion layer  114  is formed below a p-type base diffusion layer  109  on the side of an emitter electrode  106 . This p-type diffusion layer  114  is formed by ion implantation before the formation of a gate electrode  105 . 
     Unfortunately, in this IGBT shown in FIG. 2, if the p-type diffusion layer  114  diffuses to a prospective channel region below the gate electrode  105 , the current-voltage characteristics such as the saturation voltage of a collector-emitter voltage Vce and a threshold voltage Vth are influenced. This increases variations in these current-voltage characteristics. 
     BRIEF SUMMARY OF THE INVENTION 
     A semiconductor device according to an aspect of the present invention comprises: a first-conductivity-type semiconductor substrate having a principal surface; a second-conductivity-type first semiconductor region and a second-conductivity-type second semiconductor region formed apart from each other in the principal surface of the semiconductor substrate; a second-conductivity-type third semiconductor region formed on the first semiconductor region, the third semiconductor region having an impurity concentration higher than that of the first semiconductor region; a first-conductivity-type fourth semiconductor region formed on the third semiconductor region; a first main electrode formed on the fourth semiconductor region; a second main electrode formed on the second semiconductor region; and a gate electrode formed, at least on the first semiconductor region and on the principal surface of the semiconductor substrate between the fourth semiconductor region and the second semiconductor region, with a gate insulating film interposed between the gate electrode and the first semiconductor region and the principal surface of the semiconductor substrate. 
     A manufacturing method of a semiconductor device according to an aspect of the present invention comprises: forming a second-conductivity-type first semiconductor region in the surface of a first-conductivity-type semiconductor substrate; forming a gate insulating film on the first semiconductor region and on the semiconductor substrate; forming a gate electrode on the gate insulating film; forming a second semiconductor region having an impurity concentration higher than that of the first semiconductor region in the first semiconductor region, by ion implantation using self-alignment which uses the gate electrode as a mask material; forming a first-conductivity-type third semiconductor region on the second semiconductor region, by ion implantation using self-alignment which uses the gate electrode as a mask material; and forming a second-conductivity-type fourth semiconductor region apart from the first semiconductor region, on the surface of the semiconductor substrate. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     FIG. 1 is cross-sectional view showing the structure of a lateral IGBT in a conventional dielectric isolated substrate; 
     FIG. 2 is a cross-sectional view showing the structure of another lateral IGBT in a conventional dielectric isolated substrate; 
     FIG. 3 is a cross-sectional view showing the structure of a lateral IGBT in a dielectric isolated substrate according to the first embodiment of the present invention; 
     FIG. 4 is a graph showing the maximum turn-off current of the IGBT of the first embodiment and that of a conventional IGBT; 
     FIG. 5 is a cross-sectional view showing the first step of a method of manufacturing the IGBT of the first embodiment; 
     FIG. 6 is a cross-sectional view showing the second step of the method of manufacturing the IGBT of the first embodiment; 
     FIG. 7 is a cross-sectional view showing the third step of the method of manufacturing the IGBT of the first embodiment; 
     FIG. 8 is a cross-sectional view showing the fourth step of the method of manufacturing the IGBT of the first embodiment; 
     FIG. 9 is a cross-sectional view showing the fifth step of the method of manufacturing the IGBT of the first embodiment; 
     FIG. 10 is a cross-sectional view showing the sixth step of the method of manufacturing the IGBT of the first embodiment; 
     FIG. 11A is a graph showing the diffusion profile of an impurity when the film thickness of a gate electrode is 5,000 Å or more; 
     FIG. 11B is a graph showing the diffusion profile of an impurity when the film thickness of a gate electrode is less than 5,000 Å; 
     FIG. 12 is a graph showing the current-voltage characteristics of the IGBT of the first embodiment and those of a conventional IGBT; and 
     FIG. 13 is a cross-sectional view showing the structure of a power IC having an IGBT according to the second embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present invention will be described below with reference to the accompanying drawings. 
     First Embodiment 
     FIG. 3 is a cross-sectional view showing the structure of a lateral IGBT in a dielectric isolated substrate according to the first embodiment of the present invention. 
     As shown in FIG. 3, a silicon oxide film (SiO 2 )  12  as a dielectric isolation film is formed on an n − -type silicon semiconductor layer  11 . An n − -type silicon semiconductor layer  13  is formed on this silicon oxide film  12 . An SOI (Silicon On Insulator) substrate is formed by these n − -type silicon layer  11 , silicon oxide film  12 , and n − -type silicon layer  13 . 
     On this n − -type silicon layer  13 , a gate electrode  15  is formed with a gate insulating film  14  interposed between the n − -type silicon layer  13  and the gate electrode  15 . This gate insulating film  14  is a silicon oxide film. The gate electrode  15  is made of a polysilicon film and has a film thickness of about 5,000 Å or more. On the n − -type silicon layer  13 , an emitter electrode  16  and a collector electrode  17  are formed apart from the gate electrode  15 . A field oxide film (SiO 2 )  18  is formed on the n − -type silicon layer  13  between the gate electrode  15  and the collector electrode  17 . 
     As shown in FIG. 3, a p-type base diffusion layer  19  is formed in the n − -type silicon layer  13  from a portion below the gate electrode  15  to a portion below the emitter electrode  16 . Between this p-type base diffusion layer  19  and the emitter electrode  16 , a p + -type diffusion layer  20  is so formed as to contact the emitter electrode  16 . In addition, between the p-type base diffusion layer  19  and the emitter electrode  16 , an n + -type diffusion layer  21  is so formed as to contact the emitter electrode  16 . This n + -type diffusion layer  21  is formed from a portion below the emitter electrode  16  to a portion below the gate electrode  15  and functions as a current path of this IGBT. 
     A p-type diffusion layer  22  is formed between the p-type base diffusion layer  19  and the p + - and n + -type diffusion layers  20  and  21 . The p+-type diffusion layer  20  is in contact with the p-type diffusion layer  22 , and the p-type diffusion layer  22  is in contact with the p-type base diffusion layer  19 . The p + -type diffusion layer  20  is a contact layer having a function of stabilizing the potentials of the p-type diffusion layer  22  and the p-type base layer  19  at the same potential as the emitter electrode  16 . 
     This p-type diffusion layer  22  is formed by self-aligned ion implantation using the gate electrode  15  as a mask. In this ion implantation, boron (B), for example, is doped at an acceleration voltage of 100 keV or more and a dose of about 1.0×10 13  to about 1.0×10 14  cm −2 . Note that in the ion implantation of the p-type base diffusion layer  19 , boron (B), for example, is doped at an acceleration voltage of 30 to 100 keV or more and a dose of about 1.0×10 13  to about 1.0×10 15  cm −2 . This p-type base diffusion layer  19  is formed by performing annealing a plurality of times after the ion implantation. The p-type diffusion layer  22  is formed by performing annealing a smaller number of times than that for the p-type base diffusion layer  19 , after the ion implantation is performed. Therefore, as shown in FIG. 3, the p-type base diffusion layer  19  is larger than the p-type diffusion layer  22  and has an impurity concentration lower than that of the p-type diffusion layer  22 . 
     An n-type buffer diffusion layer  23  is formed in the n − -type silicon layer  13  below the collector electrode  17 . A p + -type diffusion layer  24  is formed between this n-type buffer diffusion layer  23  and the collector electrode  17 . Furthermore, a dielectric interlayer  25  is formed on the n − -type silicon layer  13  including the gate electrode  15  and the field oxide film  18 . The lateral IGBT of the first embodiment is constructed as above. 
     In the IGBT having this structure, the p-type diffusion layer  22  covers the lower portions of the n + -type diffusion layer  21  and the p + -type diffusion layer  20  without diffusing to a channel region below the gate electrode  15 . This channel region means a surface region of the p-type base diffusion layer  19  in contact with the gate insulating film  14  below the gate electrode  15 . This can decrease the resistivity (increase the impurity concentration) in the region (p-type diffusion layer  22 ) below the n + -type diffusion layer  21 . This makes the parasitic npn transistor described above difficult to operate, and also makes a parasitic pnp transistor difficult to operate. Furthermore, latch up occurring when these parasitic npn and pnp transistors operate can be prevented. Consequently, a large ON current flowing upon latch up can also be suppressed, so it is possible to protect this IGBT from being destroyed by such a large electric current. Accordingly, we can improve a capability of ruggedness by the latch-up phenomenon. 
     FIG. 4 shows the maximum turn-off current of a conventional IGBT having no p-type diffusion layer  22  and that of the IGBT of this embodiment. The turn-off current is one index which indicates the current ruggedness of an IGBT. As shown in FIG. 4, the maximum turn-off current of the IGBT of this embodiment is twice that of the conventional IGBT or more. This indicates that the electric current performance of the IGBT of this embodiment is twice that of the conventional IGBT or more. 
     Next, a method of manufacturing the lateral IGBT of the first embodiment by using an SOI wafer will be explained. 
     FIGS. 5 to  10  are cross-sectional views showing the steps of the method of manufacturing the IGBT of the first embodiment. 
     As shown in FIG. 5, a silicon oxide film  12  is formed on an n − -type silicon semiconductor substrate  11 . Another silicon oxide film  12  is formed on an n − -type silicon semiconductor substrate  13 . Subsequently, the silicon oxide films  12  of the two silicon substrates  11  and  13  are adhered by bonding, thereby forming an SOI substrate as shown in FIG.  6 . 
     In addition, as shown in FIG. 6, in the upper layer of the ne-type silicon substrate  13 , a p-type base diffusion layer  19  and an n-type buffer diffusion layer  23  are formed apart from each other by ion implantation. In this ion implantation of the p-type base diffusion layer  19 , boron (B), for example, is doped at an acceleration voltage of 30 to 100 keV or more and a dose of about 1.0×10 13  to about 1.0×10 14  cm −2 . Both the p-type base diffusion layer  19  and the n-type buffer diffusion layer  23  are annealed after the doping of impurity ions, thereby forming regions of predetermined sizes. The depth of the p-type base diffusion layer  19  from the surface of the n − -type silicon substrate  13  is 1.5 to 4.0 μm. 
     After that, as shown in FIG. 7, a field oxide film (SiO 2 )  18  is formed by LOCOS on the n − -type silicon substrate  13  between the p-type base diffusion layer  19  and the n-type buffer diffusion layer  23 . This field oxide film  18  is spaced a predetermined distance from the p-type base diffusion layer  19 , and partially overlaps the n-type buffer diffusion layer  23 . 
     Next, as shown in FIG. 8, a silicon oxide film (gate insulating film)  14  is formed by thermal oxidation on the p-type base diffusion layer  19  and the n − -type silicon substrate  13 . In addition, conductive polysilicon is deposited on the gate insulating film  14  to form a conductive polysilicon film. This conductive polysilicon film is then patterned to form a gate electrode  15 . The film thickness of this gate electrode  15  is 5,000 Å or more. 
     As shown in FIG. 9, ion implantation is performed by self-alignment using the gate electrode  15  as a mask material in the upper layer of the p-type base diffusion layer  19 , forming a p-type diffusion layer  22 . In this ion implantation, boron (B), for example, is doped at an acceleration voltage of 100 keV or more and a dose of about 1.0×10 13  to 1.0×10 15  cm −2 . The impurity concentration in the p-type diffusion layer  22  is higher than that in the p-type base diffusion layer  19 . 
     After that, as shown in FIG. 10, a p + -type diffusion layer  20  is formed in the upper layer of the p-type diffusion layer  22  by ion implantation. This ion implantation for forming the p + -type diffusion layer  20  is executed after a region except for the p + -type diffusion layer  20  is protected with a mask material. Furthermore, in the upper layer of this p-type diffusion layer  22 , an n + -type diffusion layer  21  is formed by covering the p + -type diffusion layer  20  with a mask material and performing ion implantation by self-alignment using the gate electrode  15  as another mask material. 
     Also, a p + -type diffusion layer  24  is formed on the n-type buffer diffusion layer  23  by the same formation step as for the p + -type diffusion layer  20 . 
     All of the p-type diffusion layer  22 , the p + -type diffusion layers  20  and  24 , and the n + -type diffusion layer  21  are annealed after the doping of impurity ions, thereby forming regions of predetermined sizes. The depth of the p-type diffusion layer  22  from the surface of the n − -type silicon substrate  13  is less than that of the p-type base diffusion layer  19  from the surface of the ne-type silicon substrate  13 . When the depth of the p-type base diffusion layer  19  is 1.5 μm, the depth of the p-type diffusion layer  22  is 1.0 to 1.2 μm. The depth of the p + -type diffusion layer  20  from the surface of the n − -type silicon substrate  13  is less than 0.5 μm. 
     On the structure shown in FIG. 3, a dielectric interlayer  25  is formed by CVD. Subsequently, contact holes are formed by etching system (for example RIE) in the dielectric interlayer  25  on the p + -type diffusion layer  20 , the n + -type diffusion layer  21 , and the p + -type diffusion layer  24 . A metal such as aluminum (Al) is buried in these contact holes. Unnecessary Al is removed by etching system (for example RIE) to form an emitter electrode  16  and a collector electrode  17  as shown in FIG.  3 . Through the above steps, the lateral IGBT in the dielectric isolation substrate of the first embodiment is completed. 
     In the manufacturing method described above, to prevent the diffusion of the p-type diffusion layer  22  to the prospective channel region below the gate electrode  15 , a p-type impurity is doped by self-alignment using the gate electrode  15  as a mask material after the formation of the gate electrode  15 , thereby forming the p-type diffusion layer  22 . That is, the gate electrode  15  serves as a film for stopping the implantation of the p-type impurity when this p-type impurity is ion-implanted, thereby preventing the implantation of the p-type impurity into the channel region. Note that the impurity doping for forming the p-type diffusion layer  22  is performed after the formation of the gate electrode  15 , i.e., after the thermal diffusion of the p-type base diffusion layer  19  and the n-type buffer diffusion layer  23 . Hence, to form the p-type diffusion layer  22  below the n + -type diffusion layer  21 , ion implantation must be performed using a high acceleration voltage of 100 keV or more. 
     By this manufacturing method, the lower portion of the n + -type diffusion layer  21  can be covered with the p-type diffusion layer  22  without diffusing this p-type diffusion layer  22  to the channel region below the gate electrode  15 . Accordingly, it is possible to decrease the resistivity (increase the impurity concentration) in the region below the n + -type diffusion layer  21 . This makes it possible to reduce the influence of latch up produced by the combined effect of the parasitic npn and pnp transistors described earlier, and to improve a capability of ruggedness by the latch up phenomenon. 
     In addition, as described previously, the p-type diffusion layer  22  is formed by self-alignment using the gate electrode  15  as a mask material. This can eliminate a positional deviation of the p-type diffusion layer  22  from the gate electrode  15 . Consequently, current-voltage characteristics having little variations can be obtained in the IGBT. 
     Also, the film thickness of polysilicon for forming the gate electrode  15  is 5,000 Å or more. Accordingly, when ion implantation for forming the p-type diffusion layer  22  is performed, no impurity ions punch through the gate electrode  15  to reach the p-type base diffusion layer  19 . 
     FIG. 11A is a graph showing an impurity diffusion profile when the film thickness of the gate electrode  15  is 5,000 Å or more. FIG. 11B is a graph showing an impurity diffusion profile when the film thickness of the gate electrode  15  is less than 5,000 Å. FIGS. 11A and 11B demonstrate that if the film thickness of the gate electrode  15  is less than 5,000 Å, p-type impurity ions punch through the gate electrode  15  to reach the channel region (p-type diffusion layer  22 ) below the gate electrode  15 . 
     FIG. 12 is a graph showing the current-voltage characteristics of the IGBT of the first embodiment. FIG. 12 also shows the current-voltage characteristics of a conventional IGBT. 
     FIG. 12 shows that when the film thickness of the gate electrode  15  is 5,000 Å or more, a collector-emitter voltage Vce and a threshold voltage Vth are almost the same as those of the conventional IGBT. However, if the film thickness of the gate electrode  15  is less than 5,000 Å, both the collector-emitter voltage Vce and the threshold voltage Vth are higher than those of the conventional IGBT. The foregoing reveal that when the film thickness of the gate electrode  15  is 5,000 Å or more, no p-type impurity ions punch through the gate electrode  15 ; if the film thickness of the gate electrode  15  is less than 5,000 Å, p-type impurity ions punch through the gate electrode  15  to reach the channel region below this gate electrode  15 . 
     Second Embodiment 
     A power IC to which the IGBT of the above first embodiment is applied will be described below as the second embodiment. 
     FIG. 13 is a cross-sectional view showing the structure of this power IC having the IGBT structure, according to the second embodiment of the present invention. 
     As shown in FIG. 13, the IGBT of the first embodiment is formed in a region (power output portion) isolated by a polysilicon film  31  as a trench isolation film. The alternate long and short dashed lines in FIG. 13 correspond to a unit cell of the IGBT explained in the first embodiment. 
     Also, a diode is formed in another region (logic portion) isolated by the polysilicon film  31  as a trench isolation film. 
     A method of manufacturing the diode will be described below. 
     On an n − type silicon substrate  13 , a field oxide film  18  is formed by the same step as the formation step of the field oxide film  18  of the IGBT. This field oxide film  18  is so formed that prospective anode and cathode regions of the Zener diode are open. 
     Next, in the prospective anode region surrounded by the field oxide film  18 , a p-type diffusion layer  22  is formed by the same step as the formation step of the p-type diffusion layer  22  of the IGBT. In addition, a p + -type diffusion layer  20  is formed on this p-type diffusion layer  22  by the same step as the formation step of the p + -type diffusion layers  20  and  24  of the IGBT. 
     Subsequently, in the prospective cathode region surrounded by the field oxide film  18 , an n + -type diffusion layer  21  is formed by the same step as the formation step of the n + -type diffusion layer  21  of the IGBT. 
     After that, a dielectric interlayer  25  is formed on the above structure by the same step as the formation step of the dielectric interlayer  25  of the IGBT. In addition, in this dielectric interlayer  25  on the p + -type diffusion layer  20  and the n + -type diffusion layer  21 , contact holes are formed by the same step as the formation step of the contact holes of the IGBT. A metal such as aluminum (Al) is buried in these contact holes by the same step as for the IGBT. Furthermore, unnecessary Al is removed by the same step (etching system (for example RIE) as for the IGBT, thereby forming an anode electrode  32  and a cathode electrode  33 . Through the above steps, a Zener diode having a dielectric isolation structure is completed. 
     In this power IC fabrication method, the p-type diffusion layer  22  of the IGBT in the power output portion can be formed by using the formation step of the p-type diffusion layer  22  necessary in the logic portion. This fabrication method is advantageous because the number of manufacturing steps does not increase. 
     The above-mentioned embodiments can be practiced singly or in the form of an appropriate combination. Also, each of the above embodiments includes inventions in various stages. So, these inventions in various stages can be extracted by properly combining a plurality of components disclosed in each embodiment. 
     As described above, each embodiment of the present invention can provide a semiconductor device having a lateral IGBT capable of improving ruggedness by the latch-up phenomenon and reducing variations in the current-voltage characteristics, and to provide a method of manufacturing the same. 
     Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit and scope of the general inventive concept as defined by the appended claims and their equivalents.

Technology Category: 5