JP6341074B2 - 半導体装置の製造方法 - Google Patents
半導体装置の製造方法 Download PDFInfo
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- JP6341074B2 JP6341074B2 JP2014246956A JP2014246956A JP6341074B2 JP 6341074 B2 JP6341074 B2 JP 6341074B2 JP 2014246956 A JP2014246956 A JP 2014246956A JP 2014246956 A JP2014246956 A JP 2014246956A JP 6341074 B2 JP6341074 B2 JP 6341074B2
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Description
本発明の第1実施形態について説明する。まず、本実施形態にかかる製造方法により製造される反転型のトレンチゲート構造の縦型MOSFETを有するSiC半導体装置の構造について図1を参照して説明する。なお、図1では、縦型MOSFETの2セル分しか記載していないが、図1に示す縦型MOSFETと同様の構造のものが複数セル隣り合うように配置されている。
まず、高濃度にn型不純物がドープされたSiC単結晶からなるn+型半導体基板1の表面にn型ドリフト層2がエピタキシャル成長させられたエピ基板を用意する。
n型ドリフト層2の上に、酸化膜などのマスク材料をデポジションしたのち、これをパターニングすることで、凹部2aの形成予定領域、つまりp型ディープ層3bの形成予定領域が開口するマスク20を形成する。そして、このマスク20を用いて、RIE(Reactive Ion Etching)などの異方性エッチングを行う。これにより、マスク20の開口部においてn型ドリフト層2の表層部を除去し、凹部2aを形成する。凹部2aの深さおよび幅については、この後に行われる各工程による熱拡散を考慮して、最終的なp型ディープ層3bの出来上がりの深さおよび幅が狙い値となるように設定している。
凹部2aの形成に用いたマスク20を除去したのち、凹部2a内を含むp型ドリフト層2の表面に、p型チャネル層3aおよびp型ディープ層3bを構成するp型不純物層3をエピタキシャル成長させる。例えば、CVD(Chemical Vapor Deposition)装置を用いて、雰囲気中に例えばシラン(SiH4)ガスとプロパン(C3H8)ガスを同時に導入しつつ、そのガス中にドーパントを含むガスを導入しながらエピタキシャル成長を行うことで、p型不純物層3を形成できる。このとき、p型不純物層3のうち凹部2a内に形成された部分の表面の中央部に窪みが残るようにし、この窪みによってコンタクトトレンチ3cが構成されるようにしている。
p型不純物層3の表面を覆いつつ、トレンチ6の形成予定領域が開口する図示しないエッチングマスクを配置する。そして、エッチングマスクを用いた異方性エッチングを行ったのち、必要に応じて等方性エッチングや犠牲酸化工程を行うことでトレンチ6を形成する。これにより、p型チャネル層3aを貫通してn型ドリフト層2に達しつつ、p型ディープ層3bよりも浅く、かつ、隣り合うp型ディープ層3bの間において、p型ディープ層3bから離間するように配置されたトレンチ6を形成することができる。
p型不純物層3の表面にn+型ソース領域4の形成予定領域が開口するマスク(図示せず)を形成したのち、この上からn型不純物を高濃度にイオン注入することでn+型ソース領域4を形成する。同様に、p型不純物層3の表面にp+型コンタクト領域5の形成予定領域が開口するマスク(図示せず)を形成したのち、この上からp型不純物を高濃度にイオン注入することでp+型コンタクト領域5を形成する。
層間絶縁膜10を成膜したのち、層間絶縁膜10をパターニングしてn+型ソース領域4やp型不純物層3を露出させるコンタクトホールを形成すると共に、ゲート電極8を露出させるコンタクトホールを別断面に形成する。
コンタクトホール内を埋め込むように電極材料を成膜したのち、これをパターニングすることでソース電極9や図示しないゲート配線を形成する。そして、n+型半導体基板1の裏面側にドレイン電極11を形成することで、図1に示した縦型MOSFETが完成する。
本発明の第2実施形態について説明する。本実施形態は、第1実施形態に対してp型不純物層3の形成工程を変更したものであり、その他については第1実施形態と同様であるため、第1実施形態と異なる部分についてのみ説明する。
本発明の第3実施形態について説明する。本実施形態は、第1実施形態に対してアライメントマーク部の形成工程を加えたものであり、その他については第1実施形態と同様であるため、第1実施形態と異なる部分についてのみ説明する。
本発明の第4実施形態について説明する。本実施形態は、第1実施形態に対してコンタクト領域5を構成するためのコンタクトトレンチ3cの形状を変更したものであり、その他については第1実施形態と同様であるため、第1実施形態と異なる部分についてのみ説明する。
本発明の第5実施形態について説明する。本実施形態も、第1実施形態に対してコンタクト領域5を構成するためのコンタクトトレンチ3cの形状を変更したものであり、その他については第1実施形態と同様であるため、第1実施形態と異なる部分についてのみ説明する。
本発明の第6実施形態について説明する。本実施形態も、第1実施形態に対してコンタクト領域5を構成するためのコンタクトトレンチ3cの形状を変更したものであり、その他については第1実施形態と同様であるため、第1実施形態と異なる部分についてのみ説明する。
本発明は上記した実施形態に限定されるものではなく、特許請求の範囲に記載した範囲内において適宜変更が可能である。
2 n型ドリフト層
2a 凹部
3a p型チャネル層
3b p型ディープ層
3c コンタクトトレンチ
4 n+型ソース領域
5 p+型コンタクト領域
6 トレンチ
8 ゲート電極
9 ソース電極
11 ドレイン電極
31 アライメントマーク
Claims (10)
- 第1または第2導電型の半導体基板(1)上に、該半導体基板よりも低不純物濃度とされた第1導電型のドリフト層(2)を形成する工程と、
前記ドリフト層の表面にマスク(20)を配置した後、該マスクを用いてエッチングを行うことで、前記ドリフト層を部分的に除去した第1凹部(2a)を前記半導体基板の表面と平行な断面において複数離間させて形成する工程と、
前記マスクを除去したのち、前記第1凹部内において第2導電型のディープ層(3b)を構成すると共に、前記ドリフト層の表面において第2導電型のチャネル層(3a)を構成する第2導電型不純物層(3)を形成する工程と、
複数の前記ディープ層の間において、前記第2導電型不純物層の表面から前記チャネル層を貫通して前記ドリフト層に達し、かつ、前記ディープ層よりも浅いトレンチ(6)を形成したのち、前記トレンチの表面にゲート絶縁膜(7)を形成し、さらに前記トレンチ内において、前記ゲート絶縁膜の上にゲート電極(8)を形成することでトレンチゲート構造を形成する工程と、
前記チャネル層の表層部に第1導電型不純物をイオン注入することにより、前記ドリフト層よりも高濃度の第1導電型のソース領域(4)を形成する工程と、
前記チャネル層のうち前記第1凹部の中央位置に対応する部分の表層部に第2導電型不純物をイオン注入することにより、前記チャネル層よりも高濃度の第2導電型のコンタクト領域(5)を形成する工程と、
前記ソース領域および前記コンタクト領域に電気的に接続されるソース電極(9)を形成する工程と、
前記半導体基板の裏面側にドレイン電極(11)を形成する工程と、を含み、
前記第2導電型不純物層を形成する工程では、前記第2導電型不純物層のうち前記第1凹部の中央位置に対応する部分の表面に、窪みにて構成されるコンタクトトレンチ(3c)が形成されるエピタキシャル成長条件とし、
前記コンタクト領域を形成する工程では、前記コンタクトトレンチの底部に前記コンタクト領域を形成し、
前記第2導電型不純物層を形成する工程は、
前記第2導電型不純物層のうちの前記ディープ層となる部分の形成工程として、前記第1凹部の中央部に対応する位置に前記ドリフト層の表面よりも深い窪みが残るように前記ディープ層となる部分を形成する工程と、
前記第2導電型不純物層のうちの前記チャネル層となる部分の形成工程として、前記チャネル層の表面に前記コンタクトトレンチが残るように、前記窪み内を含めて前記ドリフト層の表面に、前記チャネル層となる部分を形成する工程と、を含むことを特徴とする半導体装置の製造方法。 - 前記半導体基板の半導体材料として炭化珪素を用い、前記ドリフト層および前記第2導電型不純物層を炭化珪素で構成していることを特徴とする請求項1に記載の半導体装置の製造方法。
- 前記マスクを用いて前記第1凹部を形成する際に、同時に、該マスクを用いて前記第1凹部とは異なる部分に第2凹部(30)を形成し、
前記第2導電型不純物層を形成したときに、前記第2凹部にも窪みを残し、該窪みをアライメントマーク(31)として、前記トレンチゲート構造を形成する工程、前記ソース領域を形成する工程および前記コンタクト領域を形成する工程のマスク合わせを行うことを特徴とする請求項1または2に記載の半導体装置の製造方法。 - 前記第2導電型不純物層を形成する工程では、前記コンタクトトレンチを底面と側面を含む複数の面を持つ形状で形成することを特徴とする請求項1ないし3のいずれか1つに記載の半導体装置の製造方法。
- 第1または第2導電型の半導体基板(1)上に、該半導体基板よりも低不純物濃度とされた第1導電型のドリフト層(2)を形成する工程と、
前記ドリフト層の表面にマスク(20)を配置した後、該マスクを用いてエッチングを行うことで、前記ドリフト層を部分的に除去した第1凹部(2a)を前記半導体基板の表面と平行な断面において複数離間させて形成する工程と、
前記マスクを除去したのち、前記第1凹部内において第2導電型のディープ層(3b)を構成すると共に、前記ドリフト層の表面において第2導電型のチャネル層(3a)を構成する第2導電型不純物層(3)を形成する工程と、
複数の前記ディープ層の間において、前記第2導電型不純物層の表面から前記チャネル層を貫通して前記ドリフト層に達し、かつ、前記ディープ層よりも浅いトレンチ(6)を形成したのち、前記トレンチの表面にゲート絶縁膜(7)を形成し、さらに前記トレンチ内において、前記ゲート絶縁膜の上にゲート電極(8)を形成することでトレンチゲート構造を形成する工程と、
前記チャネル層の表層部に第1導電型不純物をイオン注入することにより、前記ドリフト層よりも高濃度の第1導電型のソース領域(4)を形成する工程と、
前記チャネル層のうち前記第1凹部の中央位置に対応する部分の表層部に第2導電型不純物をイオン注入することにより、前記チャネル層よりも高濃度の第2導電型のコンタクト領域(5)を形成する工程と、
前記ソース領域および前記コンタクト領域に電気的に接続されるソース電極(9)を形成する工程と、
前記半導体基板の裏面側にドレイン電極(11)を形成する工程と、を含み、
前記第2導電型不純物層を形成する工程では、前記第2導電型不純物層のうち前記第1凹部の中央位置に対応する部分の表面に、窪みにて構成されるコンタクトトレンチ(3c)が形成されるエピタキシャル成長条件とし、
前記コンタクト領域を形成する工程では、前記コンタクトトレンチの底部に前記コンタクト領域を形成し、
前記第2導電型不純物層を形成する工程では、前記コンタクトトレンチを底面と側面を含む複数の面を持つ形状で形成することを特徴とする半導体装置の製造方法。 - 前記第2導電型不純物層を形成する工程は、
前記第2導電型不純物層のうち、前記ディープ層となる部分と前記チャネル層となる部分を同じエピタキシャル成長によって同時に形成することを特徴とする請求項5に記載の半導体装置の製造方法。 - 前記第2導電型不純物層を形成する工程では、前記コンタクトトレンチの前記底面を平面で形成することを特徴とする請求項4ないし6のいずれか1つに記載の半導体装置の製造方法。
- 前記第2導電型不純物層を形成する工程では、前記コンタクトトレンチの前記底面もしくは前記底面と前記側面との境界部を丸みの帯びた形状で形成することを特徴とする請求項4ないし6のいずれか1つに記載の半導体装置の製造方法。
- 前記第2導電型不純物層を形成する工程では、前記第2導電型不純物層のうち前記第1凹部の側面上に形成される部分の成長レートとなる横方向成長レートよりも前記第1凹部の底面上に形成される部分の成長レートとなる縦方向成長レートの方が大きくなるようにすることを特徴とする請求項4ないし8のいずれか1つに記載の半導体装置の製造方法。
- 前記第2導電型不純物層を形成する工程では、複数の前記ディープ層が並ぶ方向における前記コンタクトトレンチの幅を同方向における前記第1凹部の幅よりも小さくすることを特徴とする請求項1ないし9のいずれか1つに記載の半導体装置の製造方法。
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