Pseudo self aligned radhard MOSFET and process of manufacture

1. A method of fabricating a semiconductor device on a substrate of a first conductivity type, the method comprising:

forming a sacrificial oxide layer on the substrate;

forming a sacrificial masking layer on the sacrificial oxide layer;

forming a body and source implant pattern in the sacrificial masking layer, exposing a portion of the surface of the sacrificial oxide layer;

implanting and diffusing a dopant in the substrate through the body and source implant pattern to form a body region of the second conductivity type;

removing the exposed sacrificial oxide within a portion of the body and source implant pattern, exposing a first portion of the top surface of the substrate bounded by sidewalls of the sacrificial masking layer;

implanting a dopant in the substrate through the body and source implant pattern to form a source region of the first conductivity type;

forming spacer walls on the sidewalls of the sacrificial masking layer to define a UIS implant pattern;

implanting a dopant in the substrate through the UIS implant pattern to form a UIS region of the second conductivity type;

diffusing the source region to form a channel region with a body region boundary and a source region boundary that are tightly aligned;

removing the spacer walls, remnants of the sacrificial masking layer, and remnants of the sacrificial oxide layer to expose the top surface of the substrate;

forming a late gate oxide layer on the exposed top surface of the substrate;

forming a polysilicon layer on the late gate oxide layer; and

removing a portion of the polysilicon layer above the source region in the substrate to expose a first surface of the late gate oxide layer overlaying the source region and to retain a portion of the polysilicon layer on the gate oxide layer overlapping the channel region.

2. The method of claim 1 , further comprising:

insulating the portion of the polysilicon overlapping the channel region;

removing the exposed late gate oxide; and

forming a source contact to the source region.

3. The method of claim 1 wherein the late gate oxide is thermally grown on the upper surface of the substrate over the body, source and UIS regions to be substantially free from interface and oxide traps.

4. The method of claim 1 in which the substrate includes a wafer layer of a first doping concentration and an epitaxial layer having a second doping concentration less than the first doping concentration, and wherein the second doping concentration increases in a gradient proceeding from the upper surface to the wafer layer.

5. The method of claim 1 in which the sacrificial masking layer includes polysilicon.

6. The method of claim 1 in which the sacrificial masking layer includes oxynitride or nitride.

7. A method of fabricating a semiconductor device on a substrate of a first conductivity type, the method comprising:

forming a sacrificial layer above an upper surface of the substrate;

forming a body and source implant pattern by removing a region of the sacrificial layer above a body and source implant portion of the top surface of the substrate;

implanting a body region of a second conductivity type in the substrate through the body and source implant pattern;

implanting a source region of the first conductivity type in the substrate through the body and source implant pattern, wherein the source region is tightly aligned to the body region;

forming a spacer layer above the body and source implant portion of the top surface of the substrate;

forming a UIS implant pattern by removing a region of the spacer layer above a UIS implant portion of the top surface of the substrate not covered by the sacrificial layer;

implanting a UIS region of the second conductivity type in the substrate through the UIS implant pattern, wherein the UIS region is tightly aligned to the source region;

forming at least one channel region between an edge of the body region and an edge of the source region, wherein the channel region is symmetrical around a vertical center axis through the source region;

exposing the upper surface of the substrate;

forming a late gate oxide on the upper surface over the channel region; and

forming a region of polysilicon on the late gate oxide overlapping the channel region.

8. The method of claim 7 wherein the gate oxide is thermally grown on the upper surface of the substrate over the body, source and UIS regions to be substantially free from interface and oxide traps.

9. The method of claim 7 in which the substrate includes a wafer layer of a first doping concentration and an epitaxial layer having a second doping concentration less than the first doping concentration, and wherein the second doping concentration increases in a gradient proceeding from the upper surface to the wafer layer.

10. The method of claim 7 , further comprising:

insulating the portion of the polysilicon overlapping the channel region;

removing the exposed late gate oxide; and

forming a source contact to the source region.

11. The method of claim 10 in which implanting a source region includes forming a pair of source regions spaced apart about a central body contact region to be contacted by the source contact.

12. The method of claim 7 in which the sacrificial layer includes a sacrificial oxide layer and a sacrificial masking layer on the sacrificial oxide layer which can be removed in selected regions to expose the sacrificial oxide layer.

13. The method of claim 12 in which the sacrificial masking layer includes polysilicon.

14. The method of claim 12 in which the sacrificial masking layer includes oxynitride or nitride.