Abstract: In a vertical switch having various doped layers, such as npnp or npn layers, and an array of trenched gates, a p-body layer is formed over an n? drift layer. A portion of the p-body layer is inverted by the voltage on the gate to form an n-channel to turn the device on. The device is improved by forming the p-body by epitaxial growth, rather than by injection and diffusion. In this way, the distance between trenched gates can be more reliably selected to maximize current density and efficiency without any significant adverse effects due to variances in trench depth. Further, since the dopant concentration in the p-body layer is more reliably known, the depth of the trenches can be more easily selected to achieve a desired breakdown voltage at specified operating voltages.

Abstract: A method of forming a layered, high power vertical insulated-gate switch uses an n-type substrate. A p-well is formed by implantation in the top surface of the substrate followed by implanting n-type dopants in the p-well to form n+ source regions. Trenched gates are formed extending through the n+ source regions and into the p-well. The wafer is transferred to a carrier and the bottom surface of the wafer substrate is thinned by CMP. An n-buffer layer is then epitaxially grown on the bottom surface using low temperature epitaxy (LTE). The low temperature does not substantially diffuse the dopants in the overlying regions. A bottom p+ layer is then formed by LTE. Anode and cathode metal electrodes are then formed. The n-buffer layer and p+ layers can be precisely formed for optimal efficiency and the LTE maintains the dopant profiles of the overlying regions.

Abstract: An insulated gate turn-off (IGTO) device, formed as a die, has a layered structure including a p+ layer (e.g., a substrate), an n? epi layer, a p-well, an n-layer over the p-well, p+ regions over the n-layer, trenched gate regions formed in the p-well, and n+ regions between the gate regions, so that vertical npn and pnp transistors are formed. The device is formed of a matrix of cells. To turn the device on, a positive voltage is applied to the gate, referenced to the cathode. The cells contain a vertical p-channel MOSFET, for shorting the base of the npn transistor to its emitter, to turn the npn transistor off when the p-channel MOSFET is turned on by a slight negative voltage applied to the gate. One or more p-layers are implanted into the p-well, below the n-layer, for independently controlling the turn-on and turn-off threshold voltages and the breakdown voltage.

Abstract: In a trench-gated device, the effective depth of a gate-induced inversion layer into a p-body is made more consistent to make the operating characteristics of the device more consistent. In one example, the p-body is formed over an n-drift layer, and an n+ source layer is formed over the p-body. Trenches are then etched that extend through the p-body and into the n-drift layer. Next, a p-doped layer is grown or deposited in the trenches. In one embodiment, the p-doped layer remains in the trench. In another embodiment, the p-dopants in the layer are diffused into the trench walls, and the layer is removed. This added p-type layer in or around the trenches contacts the side of the p-body to effectively form a very controllable deeper portion of the p-body. A gate oxide is formed, and the insulated trenches are filled with a conductor, such as doped polysilicon.

Abstract: In a vertical power device with trenched insulated gates, there is an npnp layered structure. The vertical gates turn on the device with a suitable gate bias to conduct a current between a top electrode and a bottom electrode. In an example, implanted n+ source regions are formed in the top surface within a p-well. Between some gates, the overlying dielectric is opened up, by etching, to expose distributed p-type contact regions for the p-well. The dielectric is also opened up to expose areas of the n+ source regions. The top electrode metal directly contacts the exposed p-type contact regions and the n+ source regions to provide distributed emitter-to-base short across the cellular array to improve device performance in the presence of transients. The p-contact regions are isolated from the n+ source regions, prior to the deposition of the metal electrode, due to the p-type contact regions not abutting the n+ source regions.

Abstract: Trenches having a gate oxide layer are formed in the surface of a silicon wafer for vertical gates. Conductive doped polysilicon is then deposited in the trenches to form a relatively thin layer of doped polysilicon along the sidewalls. Thus, there is a central cavity surrounded by polysilicon. Next, the cavity is filled in with a much higher conductivity material, such as aluminum, copper, a metal silicide, or other conductor to greatly reduce the overall resistivity of the trenched gates. The thin polysilicon forms an excellent barrier to protect the gate oxide from diffusion from the inner conductor atoms. The inner conductor and the polysilicon conduct the gate voltage in parallel to lower the resistance of the gates, which increases the switching speed of the device. In another embodiment, a metal silicide is used as the first layer, and a metal fills the cavity.

Abstract: A trenched, vertical MOS-gated switch is described that uses only three or four masking steps to fabricate. In one embodiment, one mask is used to form first trenches having a first depth, wherein the first trenches are filled with doped polysilicon to form gates to control the conduction of the switch. A second mask is used to form second trenches having a shallower second depth. The second trenches are filled with the same metal used to form the top source electrode and gate electrode. The metal filling the second trenches electrically contacts a top source layer and a body region. A third mask is used to etch the metal to define the source metal, the gate electrode, and floating rings in a termination region surrounding the active area of the switch. An additional mask may be used to form third trenches in the termination region that are deeper than the first trenches.

Abstract: A high power vertical insulated-gate switch is described that includes a parallel cell array having inner cells and an edge cell. The cells have a vertical npnp structure with a trenched field effect device that turns the device on and off. The edge cell is prone to breaking down at high currents. Techniques used to cause the current in the edge cell to be lower than the current in the inner cells, to improve robustness, include: forming a top n-type source region to not extend completely across opposing trenches in areas of the edge cell; forming the edge cell to have a threshold voltage of its field effect device that is greater than the threshold voltage of the field effect devices in the inner cells; and providing a resistive layer between the edge cell and a top cathode electrode electrically contacting the inner cells and the edge cell.

Abstract: An insulated gate turn-off (IGTO) device, formed as a die, has a layered structure including a p+ layer (e.g., a substrate), an n? drift layer, a p-well, trenched insulated gates formed in the p-well, and n+ regions between at least some of the gates, so that vertical npn and pnp transistors are formed. A cathode electrode is on top, and an anode electrode is on the bottom of the substrate. The device is formed of a matrix of cells. To turn the device on, a positive voltage is applied to the gates, referenced to the cathode electrode. To direct high energy electrons away from a gate oxide layer on the sidewalls of the trenches, boron is implanted between the trenches so p+ regions are formed in the mesas of the less-doped p-well. The p+ regions break down during an over-voltage event before the p-well breaks down in the mesas.

Abstract: A lateral insulated gate turn-off device includes an n-drift layer, a p-well formed in the n? drift layer, a shallow n+ type region formed in the well, a shallow p+ type region formed in the well, a cathode electrode shorting the n+ type region to the p+ type region, a trenched first gate extending through the n+ type region and into the well, a p+ type anode region laterally spaced from the well, an anode electrode electrically contacting the p+ type anode region, and a trenched second gate extending from the p+ type anode region into the n-drift layer. For turning the device on, a positive voltage is applied to the first gate the reduce the base width of the npn transistor, and a negative voltage is applied to the second gate to effectively extend the p+ emitter of the pnp transistor further into the n-drift layer to improve performance.

Abstract: An insulated gate turn-off (IGTO) device, formed as a die, has a layered structure including a p+ layer (e.g., a substrate), an n? epi layer, a p-well, trenched insulated gate regions formed in the p-well, and n+ regions between the gate regions, so that vertical NPN and PNP transistors are formed. The device may be formed of a matrix of cells or may be interdigitated. To turn the device on, a positive voltage is applied to the gate, referenced to the cathode. The cells further contain a vertical p-channel MOSFET, for rapidly turning the device off. The p-channel MOSFET may be made a depletion mode device by implanting boron ions at an angle into the trenches to create a p-channel. This allows the IGTO device to be turned off with a zero gate voltage while in a latch-up condition, when the device is acting like a thyristor.

Abstract: An insulated gate turn-off thyristor has a layered structure including a p+ layer (e.g., a substrate), an n-epi layer, a p-well, vertical insulated gate regions formed in the p-well, and an n? layer over the p-well and between the gate regions, so that vertical npn and pnp transistors are formed. After forming the p-well, boron ions are implanted into the exposed surface of the p-well to form a p+ region. The n-epi layer is then grown over the p-well and the p+ region, and the boron in the p+ region is diffused upward into the n-epi layer and downward to form an intermediate p+ region. The p-well's highly doped intermediate region enables improvement in the npn transistor efficiency as well as enabling more independent control over the characteristics of the n-type layer (emitter) and the overall dopant concentration and thickness of the p-type base to optimize the thyristor's performance.

Abstract: A vertical bidirectional insulated gate turn-off (IGTO) device includes a top half formed over a top surface of a substrate and a bottom half formed over the bottom surface of the substrate. A top electrode is formed over the top half, and a bottom electrode is formed over the bottom half. The layered structure forms vertical NPN and PNP transistors. Each half includes trenched gates. When a first polarity voltage is applied across the electrodes, one of the halves may be turned on by biasing its gates to conduct current between the top and bottom electrodes. When a voltage of an opposite polarity is applied across the electrodes, the other one of the halves may be turned on by biasing its gates to conduct current between the two electrodes. In one embodiment, biasing the gates increases the beta of the NPN transistor to turn on the device.

Abstract: An insulated gate turn-off (IGTO) device, formed as a die, has a layered structure including a P+ layer (e.g., a substrate), an N? epi layer, a P-well, vertical insulated gates formed in the P-well, and N+ regions between at least some of the gates, so that vertical NPN and PNP transistors are formed. A source/emitter electrode is on top, and a drain/cathode electrode is on the bottom of the substrate. The device is formed of a matrix of cells. To turn the device on, a positive voltage is applied to the gates, referenced to the source/emitter electrode. Some of the cells are passive, having gates that are either not connected to the active gates or having gates that are shorted to their associated N+ regions, to customize the input capacitance and lower the saturation current. Other techniques are described to form the passive cells.

Abstract: An insulated gate turn-off (IGTO) device, formed as a die, has a layered structure including a p+ layer (e.g., a substrate), an n? epi layer, a p-well, vertical insulated gate electrodes formed in the p-well, and n+ regions between the gate electrodes, so that vertical npn and pnp transistors are formed. The device is formed of a matrix of cells. To turn the device on, a positive voltage is applied to the gate electrodes, referenced to the cathode. To speed up the removal of residual electrons in the p-well after the gate electrode voltage is removed, a p+ region is added adjacent the n+ regions, and an n-layer is added below the p+ region. The cathode electrode directly contacts the p+ region and the n+ regions. During turn-off, the p+ region provides holes which recombine with the residual electrons to rapidly terminate the current flow.