U.S. patent application number 15/637361 was filed with the patent office on 2019-01-03 for reverse conducting igbt incorporating epitaxial layer field stop zone and fabrication method.
The applicant listed for this patent is Alpha and Omega Semiconductor (Cayman) Ltd.. Invention is credited to Wenjun Li, Brian Schorr, Chris Wiebe, Hongyong Xue, Lei Zhang.
Application Number | 20190006467 15/637361 |
Document ID | / |
Family ID | 64738343 |
Filed Date | 2019-01-03 |
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United States Patent
Application |
20190006467 |
Kind Code |
A1 |
Xue; Hongyong ; et
al. |
January 3, 2019 |
REVERSE CONDUCTING IGBT INCORPORATING EPITAXIAL LAYER FIELD STOP
ZONE AND FABRICATION METHOD
Abstract
An RC-IGBT includes a semiconductor body formed having a base
region incorporating a field stop zone where the base region and
the field stop zone are both formed using an epitaxial process and
the field stop zone has an enhanced doping profile to realize
improved soft-switching performance for the semiconductor device.
In alternate embodiments, RC-IGBT device, including the epitaxial
layer field stop zone, are realized through a fabrication process
that uses front side processing only to form the backside contact
regions and the front side device region. The fabrication method
forms an RC-IGBT device using front side processing to form the
backside contact regions and then using wafer bonding process to
flip the semiconductor structure onto a carrier wafer so that front
side processing is used again to form the device region.
Inventors: |
Xue; Hongyong; (Portland,
OR) ; Zhang; Lei; (Portland, OR) ; Schorr;
Brian; (Beaverton, OR) ; Wiebe; Chris;
(Hillsboro, OR) ; Li; Wenjun; (Portland,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Alpha and Omega Semiconductor (Cayman) Ltd. |
Grand Cayman |
|
KY |
|
|
Family ID: |
64738343 |
Appl. No.: |
15/637361 |
Filed: |
June 29, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 29/861 20130101;
H01L 29/7395 20130101; H01L 29/1095 20130101; H01L 29/0834
20130101; H01L 29/36 20130101; H01L 29/66333 20130101; H01L
29/66348 20130101; H01L 29/7397 20130101 |
International
Class: |
H01L 29/10 20060101
H01L029/10; H01L 29/739 20060101 H01L029/739; H01L 29/66 20060101
H01L029/66 |
Claims
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. A method for fabricating a reverse conducting insulated gate
bipolar transistor (RC-IGBT) device including a field stop zone,
the method comprising: providing a first semiconductor substrate
being lightly doped; forming, by an epitaxial process, a first
epitaxial layer of a first conductivity type on the first
semiconductor substrate, the first epitaxial layer having a
constant doping level, the first epitaxial layer forming a base
region of the RC-IGBT device; forming, by the epitaxial process, a
second epitaxial layer of the first conductivity type on the first
epitaxial layer, the second epitaxial layer having a doping profile
including non-constant and varying doping levels, the second
epitaxial layer forming a field stop zone of the RC-IGBT device;
forming a buffer layer on the second epitaxial layer; forming, by
ion implantation, first regions of the first conductivity type and
second regions of a second conductivity type, opposite the first
conductivity type, in the buffer layer; forming a bonding layer on
the buffer layer; attaching a carrier wafer to the bonding layer
formed on the buffer layer to form a semiconductor structure having
a first side being the first semiconductor substrate and a second
side being a back side of the carrier wafer; grinding the
semiconductor structure from the first side to remove the first
semiconductor substrate and at least a part of the first epitaxial
layer, an exposed surface of the first epitaxial layer being a
front side of the semiconductor structure; forming, from the front
side of the semiconductor structure, a body region of the second
conductivity type, and forming a source region of the first
conductivity type in the body region; forming a gate dielectric
layer and a conductive gate on the front side of the semiconductor
structure; and removing the carrier wafer and the bonding layer to
expose the first regions of the first conductivity type and the
second regions of the second conductivity type in the buffer
layer.
8. The method of claim 7, wherein forming, by the epitaxial
process, the second epitaxial layer of the first conductivity type
on the first epitaxial layer comprises: forming the second
epitaxial layer having a graded doping profile, the second
epitaxial layer having a first side adjacent the first epitaxial
layer and a second side adjacent the buffer layer, the graded
doping profile having a first doping level at the first side and a
second doping level at the second side of the second epitaxial
layer, the doping level varying linearly between the first side and
the second side of the second epitaxial layer from the first doping
level to the second doping level.
9. The method of claim 8, wherein the first doping level is lower
than the second doping level.
10. The method of claim 9, wherein the first doping level is higher
than or the same as the constant doping level of the first
epitaxial layer.
11. The method of claim 7, wherein forming, by the epitaxial
process, the second epitaxial layer of the first conductivity type
on the first epitaxial layer comprises: forming the second
epitaxial layer having a multiple stepped flat doping profile
having a first doping level as a background doping level and having
multiple flat top regions with step increase in doping levels from
the first doping level, the multiple flat top regions being spaced
apart within the second epitaxial layer.
12. The method of claim 11, wherein the multiple flat top regions
have the same or different doping levels.
13. The method of claim 12, wherein the multiple flat top regions
have decreasing doping levels from a first flat top region adjacent
the first side of the second epitaxial layer to the a flat top
region adjacent the second side of the second epitaxial layer.
14. The method of claim 11, wherein each of the flat top regions
has a thickness, the thickness of the multiple flat top regions
being the same or different.
15. The method of claim 14, wherein the multiple flat top regions
have decreasing thicknesses from a first flat top region adjacent
the first side of the second epitaxial layer to a last flat top
region adjacent the second side of the second epitaxial layer.
16. The method of claim 11, wherein the background doping level is
higher than or the same as the constant doping level of the first
epitaxial layer.
17. The method of claim 7, wherein forming, by the epitaxial
process, the second epitaxial layer of the first conductivity type
on the first epitaxial layer comprises: forming the second
epitaxial layer having a multiple spike doping profile having a
first doping level as a background doping level and having multiple
spike doping regions with spike increase in doping levels from the
first doping level, the multiple spike doping regions being spaced
apart within the second epitaxial layer.
18. The method of claim 7, wherein forming a gate dielectric layer
and a conductive gate on the front side of the semiconductor
structure comprises: forming a trench gate dielectric layer and a
trench gate, the trench gate dielectric layer and the trench gate
being formed in a trench formed in the front side of the
semiconductor structure.
19. The method of claim 7, wherein forming the buffer layer on the
second epitaxial layer comprises forming a third epitaxial layer as
the buffer layer, the third epitaxial layer having the first
conductivity type.
20. The method of claim 7, wherein forming a bonding layer on the
buffer layer comprises forming a thermal oxide layer on the buffer
layer.
21. The method of claim 7, wherein the first conductivity type
comprises N-type conductivity and the second conductivity type
comprises P-type conductivity.
22. The method of claim 7, wherein forming a gate dielectric layer
and a conductive gate on the front side of the semiconductor
structure comprises: forming the gate dielectric layer on a front
surface on the front side of the semiconductor structure; and
forming the conductive gate on the gate dielectric layer on the
front surface on the front side of the semiconductor structure.
Description
BACKGROUND OF THE INVENTION
[0001] Semiconductor devices, such as discrete diodes and discrete
insulated gate bipolar transistors, are typically formed in a
semiconductor body including a lightly doped base region formed on
a heavily doped substrate as the backside cathode/collector. The
device region, such as the pn junction of the semiconductor device,
is formed on the top or front side of the semiconductor body. In
order to realize soft switching behavior in these semiconductor
devices, especially when the thickness of the base region has to be
kept thin, the semiconductor body often incorporates a field stop
zone away from the device region and close to the backside
substrate. The field stop zone is a region having the same doping
type as the base region but with increased doping level as compared
to the base region. The field stop zone has the effect of
preventing the space charge region of the pn junction from
propagating too far into the lightly doped base region. In
practice, the field stop zone prevents the space charge region of
the pn junction from reaching the backside cathode/collector. In
this manner, the base region can be formed using the desired low
doping levels and with the desired thickness while achieving soft
switching for the semiconductor device thus formed.
[0002] Conventional methods for forming the field stop zone
typically involve using high energy backside dopant implantation.
The wafer is put through the front-side processing to form the
device region and then the wafer is subjected to backside grinding
to the desired thickness. Then, to form the field stop zone, one or
more backside implantation is performed to introduce dopants into
an area of the base region that is distant from the device region.
For example, conventional methods typically use proton implantation
or multiple helium or hydrogen implantations from the wafer
backside to form the field stop zone. Then, a thermal anneal is
carried out to activate the hydrogen-related donors. FIG. 1
duplicates FIG. 1 of U.S. Pat. No. 7,538,412 and illustrates an
IGBT formed including a field stop zone 26 formed by high energy
backside implantation. FIG. 2 duplicates FIG. 2a of the U.S. Pat.
No. 7,538,412 and illustrates an example doping profile of the
field stop region as a result of the multiple backside
implantations.
[0003] The conventional methods for forming the field stop zone in
a semiconductor body have many shortcomings. First, when high
energy backside implantation is used, it is difficult to form
deeply extending field stop zone, which requires extremely high
implantation energy which is either not feasible, limited by
implant equipment, or not manufacturable or associated with
unaffordable cost.
[0004] Second, when high energy backside implantation is used, the
ability to form the desired field stop zone doping profile becomes
limited. In some cases, a large number of implantations is needed
to form the desired doping profile. Large number of implantations
is not desirable and can be costly.
[0005] Lastly, since the backside implantation and anneal are
carried out after wafer front-side processing is done, the anneal
temperature for the backside implant cannot be too high. For
example, the anneal temperature for the backside implant cannot
exceed 500.degree. C. or 550.degree. C. because of the
metallization layer formed on the front side. The available anneal
temperature range limits the implantation dose and energy that can
be used for the backside implant because higher implant dose or
higher implant energy requires longer thermal process to anneal the
implant damage or defects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Various embodiments of the invention are disclosed in the
following detailed description and the accompanying drawings.
[0007] FIG. 1 duplicates FIG. 1 of U.S. Pat. No. 7,538,412 and
illustrates an IGBT formed including a field stop zone 26 formed by
high energy backside implantation.
[0008] FIG. 2 duplicates FIG. 2a of the U.S. Pat. No. 7,538,412 and
illustrates an example doping profile of the field stop region as a
result of the multiple backside implantations.
[0009] FIG. 3, which includes FIGS. 3(a) to 3(c), are
cross-sectional views of semiconductor devices that can be
constructed using the epitaxial layer field stop zone in
embodiments of the present invention.
[0010] FIG. 4, which includes FIGS. 4(a) to 4(b), are
cross-sectional views of examples of semiconductor body
incorporating an epitaxial layer field stop zone which can be used
to form semiconductor devices in embodiments of the present
invention.
[0011] FIG. 5, which includes FIGS. 5(a) and 5(b), illustrates a
semiconductor body incorporating an epitaxial layer field stop zone
and a graded doping profile which can be formed in the field stop
zone in embodiments of the present invention.
[0012] FIG. 6, which includes FIGS. 6(a)-6(c), illustrates a
semiconductor body incorporating an epitaxial layer field stop zone
and a stepped doping profile which can be formed in the field stop
zone in embodiments of the present invention.
[0013] FIG. 7, which includes FIGS. 7(a)-6(c), illustrates a
semiconductor body incorporating an epitaxial layer field stop zone
and a spike doping profile which can be formed in the field stop
zone in embodiments of the present invention.
[0014] FIG. 8, which includes FIGS. 8(a) and 8(b), are
cross-sectional views of RC-IGBT semiconductor devices that can be
constructed using the epitaxial layer field stop zone in
embodiments of the present invention.
[0015] FIG. 9, which includes FIGS. 9(a) to 9(h), illustrates the
semiconductor device fabrication method for forming an RC-IGBT in
embodiments of the present invention.
DETAILED DESCRIPTION
[0016] The invention can be implemented in numerous ways, including
as a process; an apparatus; a system; and/or a composition of
matter. In this specification, these implementations, or any other
form that the invention may take, may be referred to as techniques.
In general, the order of the steps of disclosed processes may be
altered within the scope of the invention.
[0017] A detailed description of one or more embodiments of the
invention is provided below along with accompanying figures that
illustrate the principles of the invention. The invention is
described in connection with such embodiments, but the invention is
not limited to any embodiment. The scope of the invention is
limited only by the claims and the invention encompasses numerous
alternatives, modifications and equivalents. Numerous specific
details are set forth in the following description in order to
provide a thorough understanding of the invention. These details
are provided for the purpose of example and the invention may be
practiced according to the claims without some or all of these
specific details. For the purpose of clarity, technical material
that is known in the technical fields related to the invention has
not been described in detail so that the invention is not
unnecessarily obscured.
[0018] In embodiments of the present invention, a semiconductor
device includes a semiconductor body having a base region
incorporating a field stop zone where the base region and the field
stop zone are both formed using an epitaxial process. Furthermore,
the epitaxial layer field stop zone is formed with an enhanced
doping profile to realize improved soft-switching performance for
the semiconductor device. In some embodiments, the enhanced doping
profile formed in the field stop zone includes varying,
non-constant doping levels. In some embodiments, the enhanced
doping profile includes one of an extended graded doping profile, a
multiple stepped flat doping profile, or a multiple spike doping
profile. The epitaxial layer field stop zone of the present
invention enables complex field stop zone doping profiles to be
used to obtain the desired soft-switching characteristics in the
semiconductor device.
[0019] In embodiments of the present invention, the semiconductor
device that can be formed using the epitaxial layer field stop zone
includes discrete PN junction diodes and insulated gate bipolar
transistor (IGBT) devices. Furthermore, in some embodiments, the
semiconductor device is a reverse conducting IGBT (RC-IGBT) device
where the field stop zone with enhanced doping profile is
incorporated to improve the soft-switching characteristics of the
RC-IGBT.
[0020] The epitaxial layer field stop zone with enhanced doping
profile formed in a semiconductor device realizes many advantages
over conventional field stop zone formed using backside ion
implantations. In particular, the epitaxial process makes it
possible to form the field stop zone with sophisticated doping
profiles which are not possible or very difficult to form using
backside implantation method. In this manner, the doping profile of
the field stop zone can be tailored to meet specific requirements
of the semiconductor device and to realize specific electrical
characteristics for the semiconductor device. The epitaxial layer
field stop zone with the enhanced doping profile improves the soft
switch performance of IGBT and diode devices, reducing current
ringing and reverse voltage spiking. The epitaxial layer field stop
zone with the enhanced doping profile is also beneficial to achieve
balance between improved short-circuit ruggedness and desired
leakage current characteristics on IGBT devices. The overall
electrical characteristics for the semiconductor device can be
greatly improved.
[0021] Second, by using the epitaxial layer field stop zone in
accordance with embodiments of the present invention, the
semiconductor device can be formed without using backside
processing on thin wafer and the field stop zone process is
compatible with existing front-side processing. Forming the field
stop zone using the epitaxial process is thus more cost effective
and process friendly as compared to the conventional method of
backside ion implantation.
[0022] Third, by using the epitaxial process to form the field stop
zone and the base region, the thickness of the base region, which
is the depth of the field stop zone, can be well controlled to
obtain the desired depth for the field stop zone. Control of the
depth of the field stop zone is not easily achieved using the
conventional backside implantation method.
[0023] Epitaxial Field Stop Zone
[0024] FIG. 3, which includes FIGS. 3(a) to 3(c), are
cross-sectional views of semiconductor devices that can be
constructed using the epitaxial layer field stop zone in
embodiments of the present invention. Referring to FIG. 3(a), a
discrete PN junction diode 10 is formed in a semiconductor body
including a heavily doped N+ substrate 12 and an N-type epitaxial
layer 13 formed thereon. The N+ substrate 12 forms the backside
cathode of the diode 10. An N-type base region (N-Base) 15 and a
field stop zone 14 are formed in the N-type epitaxial layer 13
where the field stop zone 14 is formed using an enhanced doping
profile, such as extended graded doping profile or multiple stepped
flat doping profile or others. The field stop zone 14 is formed in
a lower portion of the epitaxial layer 13, adjacent to the
substrate 12, and the N-base 15 is formed on the field stop zone
14. A P-body region 16 is formed in the top or front side of the
N-Base 15, away from the field stop zone 14. A heavily doped P-type
(P+) region 17 is formed in the P-body region 16 as the anode of
the diode 10. As thus configured, a PN junction is formed between
the P-body 16 and N-Base 15. The field stop zone 14 functions as
the drift region of the diode 10 and prevents the space charge
region formed at the P-body and N-Base junction from extending to
the N+ substrate 12. Specific field stop zone doping profiles can
be selected for the field stop zone 14 to achieve the desired soft
switching characteristics. In embodiments of the present invention,
the field stop zone has a doping profile having doping levels that
vary within the field stop zone. That is, the doping levels in the
field stop zone are not constant throughout the field stop
zone.
[0025] Referring to FIG. 3(b), a discrete IGBT 20 is formed in a
semiconductor body including a P-type substrate 22 and an N-type
epitaxial layer 23 formed thereon. The P-type substrate 22 forms
the backside collector/drain of the IGBT 20. An N-type base region
(N-Base) 25 and a field stop zone 24 are formed in the N-type
epitaxial layer 23 where the field stop zone 24 is formed using an
enhanced doping profile, such as extended graded doping profile or
multiple stepped flat doping profile or others. The field stop zone
24 is formed in a lower portion of the epitaxial layer 23, adjacent
to the substrate 22, and the N-base 25 is formed on the field stop
zone 24. A P-body region 26 is formed in the top or front side of
the N-Base 25, away from the field stop zone 24. The P-body region
26 houses a heavily doped N+ emitter/source region 27. A conductive
gate 29 of the IGBT is formed on and insulated from the top or
front side of the epitaxial layer 23 by a gate dielectric layer 28.
The conductive gate 29 is typically a polysilicon layer and the
gate dielectric layer 28 is typically a thin gate oxide layer. In
the present example, the conductive gate 29 is positioned in the
center of the front side of the semiconductor body and the N+
source region 27 and the P-body region 26 are formed on the sides
of the gate 29 or surround the gate 29. As thus configured, the
IGBT 20 is formed with a PN junction between the P-body 26 and
N-Base 25. The field stop zone 24 functions as the drift region of
the IGBT 20 and prevents the space charge region formed at the
P-body and N-Base junction from extending to the P-type substrate
22. Specific field stop zone doping profiles can be selected for
the field stop zone 24 to achieve the desired soft switching
characteristics. In embodiments of the present invention, the field
stop zone has a doping profile having doping levels that vary
within the field stop zone. That is, the doping levels in the field
stop zone are not constant throughout the field stop zone.
[0026] Referring to FIG. 3(c), a discrete trench IGBT 30 is formed
in a semiconductor body including a P-type substrate 32 and an
N-type epitaxial layer 33 formed thereon. The P-type substrate 32
forms the backside collector/drain of the trench gate IGBT 30. An
N-type base region (N-Base) 35 and a field stop zone 34 are formed
in the N-type epitaxial layer 33 where the field stop zone 34 is
formed using an enhanced doping profile, such as extended graded
doping profile or multiple stepped flat doping profile or others.
The field stop zone 34 is formed in a lower portion of the
epitaxial layer 33, adjacent to the substrate 32, and the N-base 35
is formed on the field stop zone 34. A P-body region 36 is formed
in the top or front side of the N-Base 35, away from the field stop
zone 34. The P-body region 36 houses a heavily doped N+
emitter/source region 37. A trench gate 39 of the IGBT 30 is formed
in a trench formed in the front side of the epitaxial layer 33. The
trench gate 39 is insulated from the sidewall of the trench by a
gate dielectric layer 38. The trench gate 39 is typically a
polysilicon layer and the gate dielectric layer 38 is typically a
thin gate oxide layer. In the present example, the trench gate 39
is positioned in the center of the front side of the semiconductor
body and the N+ source region 37 and the P-body region 36 are
formed on the sides of the trench gate 39 or surround the trench
gate 39. As thus configured, the trench gate IGBT 30 is formed with
a PN junction between the P-body 36 and N-Base 35. The field stop
zone 34 functions as the drift region of the trench IGBT 30 and
prevents the space charge region formed at the P-body and N-Base
junction from extending to the P-type substrate 32. Specific field
stop zone doping profiles can be selected for the field stop zone
34 to achieve the desired soft switching characteristics. In
embodiments of the present invention, the field stop zone has a
doping profile having doping levels that vary within the field stop
zone. That is, the doping levels in the field stop zone are not
constant throughout the field stop zone.
[0027] FIG. 4, which includes FIGS. 4(a) to 4(b), are
cross-sectional views of examples of semiconductor body
incorporating an epitaxial layer field stop zone which can be used
to form semiconductor devices in embodiments of the present
invention. Referring to FIG. 4(a), a semiconductor body 40 has an
N+ substrate 42 and an N-type epitaxial layer 43 formed thereon by
an epitaxial process. The epitaxial layer 43 is formed to include a
field stop zone epitaxial layer 44 formed on the N+ substrate 42
and an N-type base region (N-Base) 45 formed on the field stop zone
epitaxial layer 44. More specifically, the epitaxial process grows
the N-type epitaxial layer 43 onto the N+ substrate 42. The
epitaxial process is carried out by adjusting the N-type doping
concentration to form the desired doping profile for the field stop
zone 44 and then to form the constant doping level for the N-Base
45.
[0028] More specifically, during the first portion of the epitaxial
process, the N-type doping concentration being used is adjusted or
varied to form the epitaxial layer for the field stop zone 44
having the desired doping profile. The doping level is not constant
throughout the field stop zone 44 but instead a varying doping
level is used to create a doping profile that is useful in
supporting robust soft switching characteristics in the
semiconductor device to be formed. Then, when the field stop zone
epitaxial layer 44 is completed, the epitaxial process continues
with a constant N-type doping level to form the base region
epitaxial layer 45. In some embodiments, the base region epitaxial
layer 45 is lightly doped and the doping level for the N-base
region 45 establishes the minimum doping level of the field stop
zone. The field stop zone 44 includes regions having higher doping
levels than the N-base region with specific doping profile being
selected to achieve the desired soft switching behavior for the
semiconductor device to be formed. Furthermore, the doping levels
within the field stop zone 44 are not constant but vary within the
field stop zone to achieve the desired soft switching
characteristics.
[0029] In the embodiment shown in FIG. 4(a), the semiconductor body
40 includes an N+ substrate 42 which is useful for forming a PN
junction diode device. In other embodiments, the epitaxial layer
field stop zone can be applied in a semiconductor body including
other types of substrate, such as N-type or P-type substrate, and
heavily doped or lightly doped substrate of either dopant polarity.
The use of a specific substrate in the present description is
illustrative only and is not intended to be limiting. For example,
FIG. 4(b) illustrates a semiconductor body 48 including a P-type
substrate 41. The N-type epitaxial layer 43 is formed on the P-type
substrate 41 in the same manner as described above with reference
to FIG. 4(a) to form the field stop zone epitaxial layer 44 and the
N-Base epitaxial layer 45. The semiconductor body 48 is useful for
forming an IGBT device, including a trench gate IGBT device.
[0030] As thus formed, the semiconductor body 40 or 41 can then be
used to form the desired semiconductor device by applying front
side processing to the wafer surface of the N-base 45. No backside
processing is required for the semiconductor device as the field
stop zone is already formed. In embodiments of the present
invention, the epitaxial layer field stop zone is formed with
enhance doping profile to achieve the desired soft switching
behavior in the semiconductor device to be formed. The below
description provides examples of doping profiles which can be
formed in the field stop zone. The doping profile examples below
are illustrative only and are not intended to be limiting. One of
ordinary skilled in the art would appreciate that different doping
profiles can be achieved for the field stop zone by adjusting the
N-type doping concentration during the epitaxial process.
[0031] (1) Extended Graded Doping Field Stop Zone
[0032] FIG. 5, which includes FIGS. 5(a) and 5(b), illustrates a
semiconductor body incorporating an epitaxial layer field stop zone
and a graded doping profile which can be formed in the field stop
zone in embodiments of the present invention. FIG. 5(a) duplicates
FIG. 4(a) and illustrates the semiconductor body 40 including the
N+ substrate 42 and an N-type epitaxial layer 43 formed thereon.
FIG. 5(b) illustrates an extended graded doping profile 50 which
can be formed in the epitaxial layer field stop zone in the present
example. The doping profile shown in FIG. 5(b) illustrates the
N-type doping concentration from the N+ substrate 42 to the N-base
45 from left to right.
[0033] In the present example, the substrate 42 is a heavily doped
N-type substrate and thus the substrate 42 has a high N-type doping
concentration. The epitaxial process grows the epitaxial layer 43
on the substrate 42. The field stop zone has an extended graded
doping profile 50. That is, the field stop zone has a starting
doping level, lower than the doping level of the N+ substrate and
the doping level of the field stop zone decreases linearly to an
ending doping level. The N-Base region 45 is then formed with the
epitaxial layer having a constant doping level. The N-Base region
45 is typically lightly doped and thus the N-Base region 45 has a
low N-type doping level. The ending doping level of the field stop
zone 44 can be the same as or higher than the doping level of the
N-Base region 45.
[0034] In embodiments of the present invention, the graded doping
profile of the field stop zone can be tuned to obtain the desired
layer thickness and doping level for the field stop zone.
Furthermore, the layer thickness of the N-base region 45 can be
tuned to obtain the desired depth of the field stop zone from the
wafer surface. Accordingly, by using the epitaxial process, a field
stop zone with a deeply extended graded doping profile can be
formed at a desired depth from the wafer surface. The thickness and
doping level of the field stop zone 44 define the depletion layer
depth and determines the working voltage of the semiconductor
device to be formed. By incorporating the field stop zone with the
graded doping profile, large operating voltage changes will not
result in dramatic changes in the depletion layer depth. In this
manner, voltage spiking and current ringing are reduced and the
semiconductor device to be formed has improved soft switching
behavior.
[0035] In one embodiment, the epitaxial process for forming the
epitaxial layer 43 uses two N-type doping concentration set points
during the epitaxy growth process to form the field stop zone. The
epitaxial process begins the epitaxy growth at the field stop zone
starting doping concentration. The epitaxy growth rate is fixed
while the doping gas flow is reduced gradually so that when the
desired thickness for the field stop zone is reached, the epitaxial
process is at the field stop zone ending doping concentration.
Accordingly, the rate of doping gas flow reduction is a function of
the desired graded doping and the thickness of the field stop zone.
After the field stop zone is formed, the epitaxial process
continues at a constant N-type doping concentration set point to
form the base region epitaxial layer. The constant N-type doping
concentration set point for the base region can be the same as or
less than the field stop zone ending doping concentration.
[0036] (2) Multiple Stepped Flat Doping Field Stop Zone
[0037] FIG. 6, which includes FIGS. 6(a)-6(c), illustrates a
semiconductor body incorporating an epitaxial layer field stop zone
and a stepped doping profile which can be formed in the field stop
zone in embodiments of the present invention. FIG. 6(a) duplicates
FIG. 4(a) and illustrates the semiconductor body 40 including the
N+ substrate 42 and an N-type epitaxial layer 43 formed thereon.
FIGS. 6(b) and 6(c) illustrate examples of the stepped doping
profiles 55, 60 which can be formed in the epitaxial layer field
stop zone in the present embodiment. The doping profiles shown in
FIGS. 6(b) and 6(c) illustrate the N-type doping concentration from
the N+ substrate 42 to the N-base 45 from left to right.
[0038] In the embodiment shown in FIG. 6(b), the substrate 42 is a
heavily doped N-type substrate and thus the substrate 42 has a high
N-type doping concentration. The epitaxial process grows the
epitaxial layer 43 on the substrate 42. The field stop zone 43 has
a multiple stepped flat doping profile 55. That is, the field stop
zone has a background doping level and multiple flat top regions
with step increase in doping levels. The flat top regions are
spaced apart in the field stop zone. The N-Base region 45 is then
formed with the epitaxial layer having a constant doping level. The
N-Base region 45 is typically lightly doped and thus the N-Base
region 45 has a low N-type doping level. The background doping
level of the field stop zone 44 can be the same as or higher than
the doping level of the N-Base region 45.
[0039] In the example shown in FIG. 6(b), the field stop zone
includes three flat top regions having substantially the same width
or same epitaxial layer thickness and with increasing doping
levels. That is, the flat top region closer to the substrate has
lower doping level than the flat top region farthest from the
substrate and the doping level increases gradually from the first
flat top region near the substrate to the last flat top region near
the N-base region.
[0040] In other embodiments, the width or thickness of the flat top
regions, the spacing of the flat top regions and the doping level
of the flat top regions can be tuned to obtain the desired doping
profile for the field stop zone. In particular, the doping levels
or the thickness of the flat top region can be selected based on
the application voltage of the semiconductor device to be formed.
For example, in other embodiments, the flat top regions can all
have the same doping levels. In another example, the flat top
regions can have different width or epitaxial layer thicknesses
while having the same or different doping levels. The doping levels
can increase towards the N-base region or decrease towards the
N-base region. In one example, the flat top region closes to the
N-base region can have a higher doping level or an increased
thickness as compared to the flat top regions closer to the
substrate to stop the spread of the depletion layer under certain
application voltage levels so as to reduce current ringing.
[0041] FIG. 6(c) illustrates an alternate embodiment of the stepped
flat doping profile 60 where the field stop zone includes multiple
stepped flat top regions having the same doping level but with
different epitaxial layer thickness. In the example shown in FIG.
6(c), the flat top regions increase in layer thickness, illustrated
as increasing width in the doping profile in FIG. 6(c), from the
first flat top region near the substrate to the last flat top
region near the N-base region.
[0042] The multiple stepped flat doping profiles described herein
can be applied in a field stop zone to improve the soft-switching
behavior of the semiconductor device to be formed. The stepped
doping levels and the thicknesses of the flat top regions as well
as the number of flat top regions can be selected to tune the
electric field shape or electric field distribution for improved
ruggedness in the semiconductor device thus formed. Furthermore,
the layer thickness of the N-base region 45 can be tuned to obtain
the desired depth of the field stop zone from the wafer surface.
Accordingly, by using the epitaxial process, a field stop zone with
a multiple stepped flat doping profile can be formed at a desired
depth from the wafer surface.
[0043] In one embodiment, the epitaxial process forms the multiple
stepped flat doping profile as the field stop zone in the epitaxial
layer 43 by setting the epitaxy growth doping gas flow to the
background doping level and then applying and holding the doping
gas flow for the flat top regions. More specifically, the epitaxial
process begins the epitaxy growth by setting the doping gas flow to
the background doping concentration. The epitaxy growth rate is
fixed. As the epitaxy growth progresses, the doping gas flow is
increased to form the stepped flat top region and the increased
doping gas flow is held for the target flat top region thickness.
After the desired flat top region is formed, the doping gas flow
returns to the background doping concentration set point and the
epitaxy process continues until the next flat top region is to be
formed. After the field stop zone is formed, the epitaxial process
continues at a constant N-type doping concentration set point to
form the base region epitaxial layer. The constant N-type doping
concentration set point for the base region can be the same as or
less than the field stop zone background doping concentration.
[0044] (3) Multiple Spike Doping Field Stop Zone
[0045] FIG. 7, which includes FIGS. 7(a)-6(c), illustrates a
semiconductor body incorporating an epitaxial layer field stop zone
and a spike doping profile which can be formed in the field stop
zone in embodiments of the present invention. FIG. 7(a) duplicates
FIG. 4(a) and illustrates the semiconductor body 40 including the
N+ substrate 42 and an N-type epitaxial layer 43 formed thereon.
FIGS. 7(b) and 7(c) illustrate examples of the spike doping
profiles 65, 70 which can be formed in the epitaxial layer field
stop zone in the present embodiment. The doping profiles shown in
FIGS. 7(b) and 7c) illustrate the N-type doping concentration from
the N+ substrate 42 to the N-base 45 from left to right.
[0046] In the embodiment shown in FIG. 7(b), the substrate 42 is a
heavily doped N-type substrate and thus the substrate 42 has a high
N-type doping concentration. The epitaxial process grows the
epitaxial layer 43 on the substrate 42. The field stop zone 43 has
a multiple spike doping profile 65. That is, the field stop zone
has a background doping level and multiple spike doping regions
with spike increase in doping levels. The spike doping regions are
spaced apart in the field stop zone. The N-Base region 45 is then
formed with the epitaxial layer having a constant doping level. The
N-Base region 45 is typically lightly doped and thus the N-Base
region 45 has a low N-type doping level. The background doping
level of the field stop zone 44 can be the same as or higher than
the doping level of the N-Base region 45.
[0047] In the example shown in FIG. 7(b), the field stop zone
includes two spike doping regions having substantially the same
width or same epitaxial layer thickness and with the same doping
level. In other embodiments, the number of flat top regions within
the field stop zone, the width or thickness of the spike doping
regions, the spacing of the spike doping regions and the doping
level of the spike doping regions can be tuned to obtain the
desired doping profile for the field stop zone. In particular, the
doping levels or the thickness of the spike doping region can be
selected based on the application voltage of the semiconductor
device to be formed. For example, in other embodiments, the spike
doping regions can all have the same doping levels. In another
example, the spike doping regions can have different width or
epitaxial layer thicknesses while having the same or different
doping levels. The doping levels can increase towards the N-base
region or decrease towards the N-base region. In one example, the
spike doping region closes to the N-base region can have a higher
doping level or an increased thickness as compared to the spike
doping regions closer to the substrate to stop the spread of the
depletion layer under certain application voltage levels so as to
reduce current ringing.
[0048] FIG. 7(c) illustrates an alternate embodiment of the spike
doping profile 70 where the field stop zone includes three spike
doping regions with increasing doping levels from the first spike
doping region near the substrate to the last spike doping region
ear the N-Base region. Furthermore, the spike doping regions of
FIG. 7(d) has increasing thickness, illustrated as increasing width
in the doping profile in FIG. 7(c), from the first spike doping
region near the substrate to the last spike doping region near the
N-base region.
[0049] The multiple spike doping profiles described herein can be
applied in a field stop zone to improve the soft-switching behavior
of the semiconductor device to be formed. The doping levels and the
thicknesses of the spike doping regions as well as the number of
spike doping regions can be selected to tune the electric field
shape or electric field distribution for improved ruggedness in the
semiconductor device thus formed. Furthermore, the layer thickness
of the N-base region 45 can be tuned to obtain the desired depth of
the field stop zone from the wafer surface. Accordingly, by using
the epitaxial process, a field stop zone with a multiple spike
doping profile can be formed at a desired depth from the wafer
surface.
[0050] In one embodiment, the epitaxial process forms the multiple
spike doping profile as the field stop zone in the epitaxial layer
43 by setting the epitaxy growth doping gas flow to the background
doping level and then changing the doping gas flow rapidly to form
the spike doping regions. More specifically, the epitaxial process
begins the epitaxy growth by setting the doping gas flow to the
background doping concentration. The epitaxy growth rate can be
adjustable or non-constant. As the epitaxy growth progresses, the
doping gas flow is increased rapidly and turned off rapidly to form
the spike doping region. After the desired spike doping region is
formed, the doping gas flow returns to the background doping
concentration set point and the epitaxy process continues until the
next spike doping region is to be formed. After the field stop zone
is formed, the epitaxial process continues at a constant N-type
doping concentration set point to form the base region epitaxial
layer. The constant N-type doping concentration set point for the
base region can be the same as or less than the field stop zone
background doping concentration.
[0051] It is instructive to note that while the conventional
backside implantation method to form the field stop zone can form
one or more peaks in the doping profiles, the conventional backside
implantation method is not capable of giving fine control over the
location, the thickness or width and the peak doping level of the
spike doping regions. When high energy implantation method is used,
only coarse control over the doping profile can be realized.
Furthermore, high energy implantation method cannot form a flat top
doping region. The epitaxial layer field stop zone of the present
invention can be formed with precise control over the location, the
thickness and the peak doping levels of the field stop zone doping
profile, ensuring improved soft switching behavior.
[0052] With the semiconductor body of FIGS. 5-7 thus formed
including the epitaxial layer field stop zone with enhanced doping
profile, front side processing is then carried out to form the
device region of the semiconductor device to be formed. The device
region, such as the pn junction of the semiconductor device, is
formed on the top or front side of the semiconductor body. For
example, a PN junction diode can be formed in the semiconductor
body by forming a P-body and a P+ region on the front side of the
semiconductor body, as shown in FIG. 3(a). In another example, a
semiconductor body using a P-type substrate may be used to form an
IGBT device. The semiconductor body is subjected to front side
processing including forming the P-body region, the N+ source
region, the gate dielectric layer and the conductive gate, as shown
in FIG. 3(b). A trench gate IGBT can also be formed, such as shown
in FIG. 3(c).
[0053] RC-IGBT (Reverse Conducting IGBT)
[0054] In embodiments of the present invention, an RC-IGBT includes
a semiconductor body formed having a base region incorporating a
field stop zone where the base region and the field stop zone are
both formed using an epitaxial process, as described above with
reference to FIGS. 4-7. The epitaxial layer field stop zone is
formed with an enhanced doping profile to realize improved
soft-switching performance for the semiconductor device. In some
embodiments, the enhanced doping profile formed in the field stop
zone includes varying, non-constant doping levels. In some
embodiments, the enhanced doping profile formed in the field stop
zone includes one of an extended graded doping profile, a multiple
stepped flat doping profile, or a multiple spike doping profile, as
described above with reference to FIGS. 5-7.
[0055] An RC-IGBT or reverse conducting IGBT is an IGBT device with
a backside N+ region to enable current to be conducted from the
backside of the RC-IGBT device. In an IGBT, such as IGBT 20 of FIG.
3(b), includes a PNP bipolar transistor formed by the P-type
substrate 22, the N-drift/N-base region 24, and the P-body region
26 and a MOS transistor formed by the N+ source region 27, the gate
29 and the N-drift region as the drain. The IGBT 20 cannot conduct
current from the backside--that is, current cannot go through the
P-body to the N-base/N-drift region to the P-substrate.
[0056] An RC-IGBT device integrates an IGBT and a freewheeling
diode in the same device structure and thereby enables backside
current conduction. FIG. 8, which includes FIGS. 8(a) and 8(b), are
cross-sectional views of RC-IGBT semiconductor devices that can be
constructed using the epitaxial layer field stop zone in
embodiments of the present invention. Referring to FIG. 8(a), an
RC-IGBT 80 is constructed in the same manner as the IGBT 20 of FIG.
3(b) except for the addition of the N+ region 83 on the backside,
the collector terminal, of the device, as the backside contact
region. As thus configured, a diode is formed by the P-body region
86 and the N+ region 83 and backside current conduction is made
possible. Referring to FIG. 8(b), a trench gate RC-IGBT 90 is
constructed in the same manner as the trench gate IGBT 90 of FIG.
3(c) except for the addition of the N+ region 93 on the backside,
the collector terminal, of the device, as the backside contact
region. As thus configured, a diode is formed by the P-body region
96 and the N+ region 93 and backside current conduction is made
possible.
[0057] In embodiments of the present invention, the RC-IGBT 80 of
FIG. 8(a) is formed in a semiconductor body including an N-type
epitaxial layer 83 where the N-type epitaxial layer 83 incorporates
a field stop zone 84 constructed in the same manner as described
above with references to FIGS. 4 to 7. The field stop zone 84
improves the soft switching behavior of the RC-IGBT device.
Similarly, in embodiments of the present invention, the trench gate
RC-IGBT 90 of FIG. 8(b) is formed in a semiconductor body including
an N-type epitaxial layer 93 where the N-type epitaxial layer 93
incorporates a field stop zone 94 constructed in the same manner as
described above with references to FIGS. 4 to 7. The field stop
zone 94 improves the soft switching behavior of the trench gate
RC-IGBT device.
[0058] RC-IGBT devices require both N+ and P contact regions at the
backside of the device structure. Forming doped regions on both the
front side and the back side of a wafer, especially for thin
wafers, can be challenging. In embodiments of the present
invention, RC-IGBT devices, with surface gate or trench gate, are
realized through a fabrication process that uses front side
processing only to form the backside contact regions and the front
side device region and incorporate an epitaxial layer field stop
zone with enhanced doping profile. The fabrication process enables
RC-IGBT devices to be formed with the backside contact regions and
the epitaxial layer field stop zone even for thin wafer
thicknesses.
[0059] Conventional methods for forming RC-IGBT devices including
performing the front side processing to form the device region
(gate dielectric, gate polysilicon, body region, source region,
contact and metallization) on the front side of the wafer. The
wafer is then flipped over and background to the desired thickness.
Then backside processing is carried out to form the N+ and P
contact regions. The field stop zone may be formed by backside
implantation as well. Laser anneal or a low temperature anneal is
then performed to activate the implanted dopants of the field stop
zone and the N+ and P regions. The conventional back grind and
backside implantation methods for forming RC-IGBT devices are
undesirable for the reasons described above, including the
requirement for backside processing, the inability to control the
profile of the field stop zone and the limitation of the anneal
temperature that can be used. In particular, the conventional
method requires performing backside lithographic process on thin
wafers which requires special lithographic equipment to pattern the
wafer backside for the N+ and P regions, special thin film
equipment to strip the photoresist on thin wafers, and modification
to the implant equipment to perform implantation on thin wafers.
Also, the conventional method also requires special laser anneal
equipment that can handle thin wafers to perform annealing of the
implanted N+ and P regions.
[0060] In embodiments of the present invention, a semiconductor
device fabrication method for forming an RC-IGBT incorporating an
epitaxial layer field stop zone uses only front side processing to
form the backside N+ and P contact regions. FIG. 9, which includes
FIGS. 9(a) to 9(h), illustrates the semiconductor device
fabrication method for forming an RC-IGBT in embodiments of the
present invention. Referring to FIG. 9(a), the method starts with a
lightly doped wafer substrate 120 of either N-type or P-type. Then
an epitaxial process is carried out to form an N-type epitaxial
layer 122 on the substrate 120. The epitaxial process is carried
out by first using a constant doping level to form a first portion
of the epitaxial layer which would become the N-base region. The
epitaxial process then continues with changing doping levels to
form the second portion of the epitaxial layer which would become
the field stop zone. The doping levels of the epitaxial process can
be changed in the manner as described above with reference to FIGS.
5-7 to form the desired field stop zone doping profile. For
example, the second portion of the epitaxial layer can be formed to
have an extended graded doping profile, a multiple stepped flat
doping profile, or a multiple spike doping profile, suitable for
the application of the RC-IGBT.
[0061] It is instructive to note that the epitaxial process for
forming the N-base and the field stop zone in the method of the
present embodiment is reversed in reference to the process
described above in FIGS. 4-7. In the aforementioned description for
forming a PN junction diode or an IGBT, the semiconductor body is
formed by growing the epitaxial layer on a given substrate where
the substrate would become the backside of the semiconductor device
to be formed. The epitaxial growth starts with the field stop zone
on the substrate and then continues onto the N-base region. In the
method of the present invention for forming the RC-IGBT, the
lightly doped substrate 120 is a sacrificial substrate to enable
the formation of the RC-IGBT backside N+ and P contact regions
using only front side processing. Therefore, the present method
forms the semiconductor body in a reverse order--by forming the
N-base region first and then forming the field stop zone. One of
ordinary skill in the art would appreciate that the doping profiles
in FIGS. 5-7 can be applied for an epitaxial process which grows
the epitaxial layer from the N-base to the field stop zone. In this
case, the doping profile desired for the field stop zone can be
achieved by adjusting the epitaxy doping concentration of the field
stop zone as the epitaxial process continues from the end of the
N-base region into the field stop zone in a manner to achieve the
field stop zone profiles from right to left as shown in FIG.
5-7.
[0062] Referring still to FIG. 9(a), the method grows an N-type
epitaxial layer 124 as a buffer layer. In some embodiments, the
buffer layer has a doping level that is lower than the doping level
of the N-base Epitaxial layer 122 but higher than the doping level
of the lightly doped N-type wafer substrate. Referring now to FIG.
9(b), the backside N+ and P regions of the RC-IGBT are formed in
the buffer layer 124 by masking and selectively implanting N-type
and P-type dopants. The implanted dopants will be activated and
will diffuse into the buffer layer 124 at a later anneal process.
In the present embodiment, the backside N+ contact regions 128 are
formed by masking the buffer layer 124 to expose regions 128 for
receiving a high dose N+ implant. Then, a blanket P-type implant is
performed to form the P contact regions 130 outside of the N+
contact region 128. After the implantation, the drive-in or anneal
process for the N+ implant and P-type implant can be performed
later in the fabrication process, such as together with the implant
regions in the device regions to be formed on the opposite side of
the semiconductor structure.
[0063] FIG. 9(c) illustrates the backside N+ regions 128 and P
regions 130 formed after a subsequent anneal process. The actual
anneal of the implanted dopants may occur during a later time in
the processing. The formation of the N+ regions 128 and P regions
130 in FIG. 9(c) is illustrative only. After the implantation step
for the N+ regions and P regions in the buffer layer 124, the wafer
is subjected a thermal oxidation process which forms a thermal
oxide layer 132 on the exposed surface of the wafer. Thus, the
thermal oxide layer 132 is formed on the buffer layer 124 as well
as on the lightly doped substrate 120. The thermal oxide layer 132
will be used as a bonding layer in subsequent processing. Up to
this point, the method has only employed front side processing of
the semiconductor structure formed on the substrate 120.
[0064] Referring to FIG. 9(d), the semiconductor structure as
formed in FIG. 9(c) is flipped upside down and is attached to a
carrier wafer 134. The thermal oxide layer 132 grown on the buffer
layer 124 helps the adhesion of the semiconductor structure to the
carrier wafer. With the semiconductor structure flipped, the N-type
epitaxial layer 122 now has the second portion forming the field
stop zone on the bottom with the first portion forming the N-base
region on top. The side of the semiconductor structure with the
lightly doped substrate 120 becomes the front side of the wafer. It
is instructive to note that the use of the terms "top" and "bottom"
and "front" and "back" are intended to denote relative directions
or positions of the layers in the semiconductor structure and is
not intended to indicate absolute direction or positioning of the
semiconductor structure.
[0065] Referring to FIG. 9(e), the front side of the wafer is
subjected to grinding and polishing to remove the sacrificial
substrate 120 and to thin the N-type epitaxial layer 122 down to
the desired N-base thickness. Although the N-type epitaxial layer
122 is thinned, the carrier wafer 134 provides thickness to the
semiconductor structure so that no special thin wafer processing
step or equipment is required.
[0066] Referring to FIG. 9(f), front side processing is then
carried out to form the device region 140 of the RC-IGBT
semiconductor device. For example, the body region, the
emitter/source region, the gate dielectric layer, the conductive
gate layer, the interlayer dielectric, the contact and the
metallization layer are formed using front side processing.
Referring to FIG. 9(g), after forming the device region 140, the
RC-IGBT device is completed. The semiconductor structure is then
subjected to back grinding and wet etch to remove the carrier wafer
134 to expose the backside contact regions previously formed. The
thermal oxide layer 132 between the backside contact layer and the
carrier wafer acts as an etch stop for the wet etch process to
remove the carrier wafer. The thermal oxide layer 132 is then also
removed, such as by wet etch, to expose the backside contact
regions.
[0067] Referring to FIG. 9(h), the back grinding removes the
carrier wafer and stops at the thermal oxide layer. Then, the
thermal oxide layer is etched, such as using wet etch, to expose
the N+ contact regions 128 and P contact regions 130 formed on the
backside of the device. The epitaxial layer field stop zone with an
enhanced doping profile is formed above the buffer layer 124 and
below the N-base region. It is instructive to note that the entire
RC-IGBT device 150 in FIG. 9(h) is formed using front side
processing only and without requiring thin wafer equipment or
process. That is, no backside lithography, backside implantation,
or laser anneal is required. The semiconductor device fabrication
method forms the RC-IGBT device 150 using front side processing to
form the backside contact regions and then using wafer bonding
process to flip the semiconductor structure onto a carrier wafer so
that front side processing is used again to form the device region.
The carrier wafer provides the thickness for the semiconductor
structure so that the fabrication of the RC-IGBT device does not
require special thin wafer processing equipment or process.
[0068] The semiconductor device fabrication method of the present
invention realizes an RC-IGBT which incorporates an epitaxial layer
field stop zone and uses only front side processing to form the
backside N+ and P contact regions. The semiconductor device
fabrication method of the present invention simplifies the
fabrication process, reducing cost and improving efficiency of the
manufacturing process while forming a semiconductor device with
improved soft-switching capability.
[0069] In the above described embodiment, the buffer layer 124 is
formed by the epitaxial process. In other embodiments, the buffer
layer can be formed by implantation of N-type dopants into the
N-type epitaxial layer 122 being formed to use as the N-base and
field stop zone.
[0070] In the above described embodiment, the P-type backside
contact region 130 is formed by implantation into a lightly doped
N-Epitaxial buffer layer. In other embodiments, the P-type backside
contact region 130 can be formed by epitaxial growth and N-type
dopants are then implanted into the P-type epitaxial layer to form
the N+ contact regions 128.
[0071] Furthermore, in the above described embodiment, the
semiconductor device fabrication method is described for forming a
surface gate RC-IGBT. In other embodiments, the semiconductor
device fabrication method of the present invention can be applied
to form a trench gate RC-IGBT by forming a trench on the front side
of the semiconductor structure and forming the trench gate
dielectric and the trench gate inside the trench. The same wafer
bonding method applies to enable the trench gate RC-IGBT to be
formed using front side processing only.
[0072] Although the foregoing embodiments have been described in
some detail for purposes of clarity of understanding, the invention
is not limited to the details provided. There are many alternative
ways of implementing the invention. The disclosed embodiments are
illustrative and not restrictive.
* * * * *