Novel Low Voltage Power Mosfets With Improved Dc And Switching Characteristics PDF Download

A sustainable future requires efficient power electronic converters at any stage of the electrical energy consumption. Silicon carbide (SiC) is one of the most technologically advanced wide bandgap semiconductors that can outperform silicon limits for power devices. SiC power MOSFETs are of the greatest interest since they are unipolar gate-controlled switches with high blocking voltage capability and reasonably low specific on-resistance. The focus of this thesis is on the design optimisation and process technology refinement towards the improvement of high-voltage SiC MOSFETs. Previous developments in our group were taken as a reference for this work. The results of this research allowed the fabrication of large-area SiC power MOSFETs with voltage ranges targeting 1.7 kV up to 6.5 kV.The inherent properties of SiC entail challenging technological solutions to successfully integrate a power MOSFET of such high-voltage capability. To ensure suitable blocking capability, different planar edge termination structures have been designed, optimised by TCAD simulation and implemented on PiN diodes. The termination schemes considered are single-zone JTE, FGRs and a novel RA-JTE structure combining JTE with rings. RA-JTE design, with the lowest sensitivity to fabrication process deviations and a lower consumed area, achieved more than 90% of the ideal breakdown voltage and suitable blocking capability up to 6.5 kV.The optimisations performed on the unit-cell of the SiC power MOSFET target both the layout design and the fabrication process. The optimisation has been performed by TCAD modelling and experimental evaluation of specific test structures. Several techniques to improve the performance of the fabricated devices have been considered: i) the use of an offset retrograde p-body profile to provide an adequate Vth value while preventing p-body punch-through, ii) a submicronic self-aligned channel definition, iii) a boron treatment to the gate oxide to improve channel mobility, iv) a discrete location of the p-contact to reduce cell-pitch, v) the use of a lower-doped-source (LDS) to improve reliability, vi) the optimisation of the JFET area, and vii) the integration of gate runners to improve the switching performance. As a result of these investigations, a full mask-set were designed and used for processing wafers of several voltage-class in different batches. All the fabrication steps have been carried out at IMB-CNM cleanroom. The electrical characterisation of large-area devices has evidenced an optimal Vth in the range of 5 V, a proper gate control, and a good blocking capability. We obtained relatively high specific on-resistance due to the large cell pitch dimensions required by IMB-CNM cleanroom design rules as well as a still low channel mobility. Fabricated SiC MOSFETs are capable of switching at high bus voltages (tested up to 80% of the rated voltage). Although, their switching performance is limited by internal gate resistance. Fabricated devices have shown better short-circuit capability (>15 μs) than existing commercial devices, mainly due to the cell design considerations.The evaluation of electrical performance evidenced the successful functionality of the fabricated VDMOS up to 6.5 kV and validates our new RA-JTE termination design. On the other hand, the novel boron doping treatment to the gate oxide clearly demonstrated to improve the on-resistance of our devices in all voltage classes without affecting breakdown and short-circuit capabilities. Nevertheless, it strongly compromises stability and reliability at temperatures above 100 °C. These results show that the MOS interface quality is still the major issue for the development of reliable SiC power MOSFETs.Finally, alternative SiC structures have also been investigated to take advantage of the SiC superior material properties. These include a SiC IGBT showing conductivity modulation, and a preliminary SiC CMOS cell able to operate at high temperatures.