Small cell low contact resistance rugged power field effect devices and method of fabrication

A multicellular, field-effect power semiconductor device comprising:

• a body of semiconductor material having opposed first and second major surfaces and a first region of one type conductivity extending to said first major surface;
• an insulated gate electrode disposed on said first major surface, said insulated gate electrode having a plurality of apertures therein;
• and
• a plurality of cells, each associated with one of said apertures in said gate electrode, each of said cells including:
• a second region of opposite type conductivity extending into said first region from said first major surface beneath the gate-electrode aperture for that cell;
• a third region of said one type conductivity disposed in said second region and extending to said first major surface within said gate electrode aperture for that cell and extending under said gate electrode;
• the outer boundaries of said second and third regions being self aligned with respect to the gate-electrode aperture for that cell;
• said second region including a channel portion disposed between said first and third regions, beneath said insulated gate electrode and self-aligned with respect to the gate-electrode aperture for that cell;
• said third region having an aperture therein which is disposed within and self aligned with respect to the gate-electrode aperture for that cell and in which said second region extends to said first surface;
• said second region including a more heavily doped surface portion extending to said first major surface within said aperture in said third region, the intercept of said more heavily doped portion of said second region with said first surface being self-aligned with respect to said gate-electrode aperture for that cell;
• said second and third regions having a high conductivity layer selected from the group consisting of metals and metal-silicides disposed thereon in ohmic contact therewith, said high conductivity layer being self-aligned with respect to said aperture in said gate electrode and spaced from said gate electrode;
• a layer of dielectric material disposed over said body of semiconductor material and having a plurality of contact apertures therein, said high conductivity layer of each cell having one of said contact apertures situated thereover, each of said contact apertures being substantially smaller in lateral extent than said high conductivity layer over which it is disposed, and the lateral dimensions of each of said contact apertures being the same as or smaller than the lateral dimensions of the surface intercept of said second region of the particular cell with said high conductivity layer;
• and
• a layer of metallization disposed over said dielectric layer, extending into said contact apertures and into ohmic contact with each of said high conductivity layers.

A multicellular, field effect, power semiconductor device comprising:

• a body of semiconductor material having opposed first and second major surfaces and a first region of one type conductivity extending to said first major surface;
• an insulated gate electrode disposed on said first major surface, said insulated gate electrode having a plurality of apertures therein;
• and
• a plurality of cells, each associated with one of said apertures in said gate electrode, each of said cells including:
• a second region of opposite type conductivity extending into said first region rom said first major surface beneath the gate-electrode aperture for that cell;
• a third region of said one type conductivity disposed in said second region and extending to said first major surface within said gate electrode aperture for that cell and extending under said gate electrode;
• the outer boundaries of said second and third regions being self aligned with respect to the gate-electrode aperture for that cell;
• said second region including a channel portion disposed between said first and third regions, beneath said insulated gate electrode and self-aligned with respect to the gate-electrode aperture for that cell;
• said third region having an aperture therein which is the shape of said gate-electrode aperture for that cell, said aperture in said third region being smaller than said gate-electrode aperture for that cell and disposed concentric to said gate-electrode aperture for that cell;
• and
• said second region including a more heavily doped surface portion extending to said first major surface within said aperture in said third region, the intercept of said more heavily doped portion of said second region with said first surface having the shape of said gate-electrode aperture for that cell, being smaller than said gate-electrode aperture for that cell and being concentric to said gate-electrode aperture for that cell.