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I've often heard that trench MOSFETs have a narrower FBSOA than planar MOSFETs due to their cell design. The explanation I've commonly seen is that the cell design has a negative Rds(on) temperature coefficient, so if a single cell gets warmer than the others it has a tendency to receive a greater proportion of the current and go into thermal runaway. I've heard this referred to as the Spirito effect in the context of operating MOSFETs in a linear manner.

The implication appears to be that the runaway behaviour arises from the trench MOSFET being constructed from lots of smaller MOSFET "cells" in parallel. However, given descriptions I've seen of planar MOSFET construction, they don't seem to be constructed from one single monolithic cell. The literature refers to planar MOSFETs as having gates, plural, in practice. It isn't clear to me why there is such a distinction between the two from a thermal runaway perspective.

I've also read that the narrow FBSOA of trench MOSFETs is in part due to the lower Rds(on) causing a "higher point of intersection between two transfer curves at different temperatures". This was sourced to "Improved SOA analysis for trench MOSFETs using the Spirito approach" by Kwan et. al., but I was unable to find the original material being referenced. This statement is unclear to me. My rough intuition is that this is about a current equilibrium between cells not being reached until a higher temperature, but it feels a bit vague.

Could someone shed some light on this? What aspect(s) of the trench construction cause this difference in thermal runaway behaviour? Why are planar MOSFETs considered more immune to these behaviours? And what is meant by the higher point of intersection between the transfer curves?

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    \$\begingroup\$ Note, Rds(on) has a positive tempco; you're talking about the linear mode operation, which roughly speaking has to do with the negative Vgs(th) tempco. \$\endgroup\$ Commented Oct 17, 2022 at 1:42
  • \$\begingroup\$ Ah, yes, sorry, you're right - I was confusing the Rds(on) tempco and the Vgs(th) tempco. \$\endgroup\$
    – Polynomial
    Commented Oct 17, 2022 at 2:27

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Realize that all MOSFETs have negative tempco of Vgs(th) in linear mode, at least over a significant portion of their operating range. Thermal runaway is a necessary and ever-present characteristic of all MOSFETs.

The question is not whether it can, but under what conditions it will run away.

The thing with vintage (lateral) MOSFETs is, they can have a neutral to positive tempco, or source resistance dominates (degenerating transconductance and with a +TC), at fairly modest currents, well within the power dissipation rating. And with fairly generous power dissipation ratings relative to the V,I capacity (i.e. the die area is large, power density is low), they're easy to heatsink adequately.

That doesn't mean runaway was impossible: just that a situation has to be more contrived. For instance, say you put two in parallel, matched, but no heatsinking (or even with insulation), and run them up. One inevitably overheats, perhaps at just a few watts, perhaps tens (but perhaps not hundreds, for which you'd need a proper heatsink to reach anyway). That's contrived, as I said, and far from good practice -- but consider the thought experiment: for any given transistor, there is some thermal conductivity between portions of the die, and therefore some temperature differential in response to a power differential. With discrete dies, we've simply dialed that differential up to the maximum.

So, we conclude that the ratio of tempco to differential thermal resistance is key.

The fact that, on a monolithic device (single die), on a thick copper back plate, the thermal conductivity is quite high, means that fairly poor tempco and high power density are still reasonable. Thus we have denser devices still behaving well.

Come to think of it, I wonder if that's the trick: SuperJunction transistors have higher power density than ever, but it may be the die thinning dominates, and the copper backplane is more conductive than pure silicon, and the die smaller for given V,I ratings anyway, so the temperature drop across the die can still remain modest. (This comes from the peculiar observation that a lot of SJ MOSFETs offer full DC SOA.)

Regarding low voltage types -- planar vs. trench -- it could be that the curves are subtly altered, I don't know about this specifically. But if a counterexample would do, they certainly exist: consider IRFP4768PbF | Infineon, the SOA is limited at a mere 7V (and 70A..!). It is a "HEXFET", probably the "advanced generation" (7th?), which would be finest pitch in the family (cell size in the low 100s nm perhaps?), before moving to trench and SJ.

Incidentally, I've never seen even-numbered HEXFET generations; I wonder how much of that is real development versus marketing? Also, are there still new HEXFETs being released? I don't recall.

In any case, it's certainly possible for planar devices to run into such limits, as-is, given ideal circuit connection (i.e. not paralleling naively) and heatsinking. Some of it varies with design, I imagine they can optimize for SOA, but clearly there are examples where they optimize without regard for that, and indeed make some pretty awful SOAs in the pursuit of maximum switching area.

Mind, this is all observational, based on data books, datasheets and appnotes, and occasionally informed by die photos. Incidentally, past... generation 5 I think?, HEXFETs haven't been "hex" at all, but the same stripe layout everyone else uses. It's probably not possible to achieve high density and yield on finer pitches with the traditional hex layout. AFAIK, it's still planar: the same self-aligned gate process, lateral channel, and vertical drift region that's always been used, just the arrangement is in stripes rather than a grid.

(Incidentally, SJ is planar too, on top I mean, at least as far as I've seen from diagrams. A planar structure interfaces well with the SJ pillars, and, I suppose, the higher current density enabled by a trench structure just doesn't matter when these devices are currently limited by the pitch of the pillars themselves.)

But yeah, compare that to trench: the channels can be packed that much more densely (roughly speaking, twice per cell), and maybe the tempco is different, I don't know.

Die thickness (and thus thermal resistance between regions) will be comparable for all low-to-medium voltage types: limited by mechanical handling probably. The ultimate limit is the depletion region thickness, perhaps a couple µm; but a legitimately thin film of Si isn't very practical for handling, heh. I believe they are largely made on n+ doped wafers, i.e. highly conductive substrate, so the thickness doesn't matter too much, and then the drift region and active circuitry are epitaxied then diffused on top (n- drift, p channel/substrate, n+ source).

(This contrasts with SiC devices, where the maximum doping level just isn't very high, or dopant activation at operating temperatures is incomplete; die thinning is done with much greater pressure there. This is basically why SiC schottky for example have such an exaggerated resistive slope to them -- this even after best efforts to grind away the excess!)

This is very much a question that should be asked of an active semiconductor engineer -- but there are very few indeed posting here, that I know of, let alone that are able to discuss current or even past technology. For more detail, you'll have to peruse academic papers, or find researchers or engineers working on this stuff (and willing to talk about it). Cheers.

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All power MOSFETs are constructed from smaller cells in parallel.

Trench FETs are 'better' than lateral ones because they have less parasitic series resistance (in the drain). Thermal runaway can occur when the negative VTH threshold has a stronger effect than the positive drain resistance (and channel resistance) effects. This generally requires VGS just a bit above threshold on the device (if it is >> threshold there is just a simple high power problem). Runaway also requires that the thermal coupling between regions is less than the differential power increase from differential temperature increase - this is much worse at higher VDS.

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  • \$\begingroup\$ So what you're saying is that in trench FETs the magnitude of the Vgs(th) tempco is typically larger than the parasitic drain resistance? Could you explain why the relative magnitude of the parasitic drain resistance is relevant here? I'm also still unclear on the intersection point. \$\endgroup\$
    – Polynomial
    Commented Oct 17, 2022 at 2:30
  • \$\begingroup\$ It's basically d(ID)/dT generating d(power), and if the local thermal resistance is too high they generates dT. If that > 1, you get runaway. At low VDS (in triode) drain resistance matters. At high VDS, not so much \$\endgroup\$
    – jp314
    Commented Oct 17, 2022 at 2:55
  • \$\begingroup\$ I understand the mechanism behind the individual cell runaway, I'm just confused as to why trench experiences that effect more heavily than planar constructions. Are you saying that the higher parasitic drain resistance in a planar FET acts to reduce transconductance, and therefore reduces the increase in Ids as a function of Vgs, which in turn reduces the overall effect of the negative Vgs(th) tempco? \$\endgroup\$
    – Polynomial
    Commented Oct 17, 2022 at 3:19
  • \$\begingroup\$ Yes -- although this is only apparent when VDS is low enough that drain resistance affects the current flowing. in that case, VDS is reasonably low, so thermal runaway isn't as likely anyway. \$\endgroup\$
    – jp314
    Commented Oct 17, 2022 at 4:44
  • \$\begingroup\$ That leaves me even more confused. If the impact of the planar FET's drain resistance is only apparent at low Vds and low current, why is it responsible for the difference in FBSOA, the relevance of which is usually characterised by high Vds? \$\endgroup\$
    – Polynomial
    Commented Oct 17, 2022 at 21:12

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