A method of fabricating a VRG
MOSFET includes the steps of: (a) forming a VRG multilayer stack; (b) forming a trench in the stack; (c) depositing an ultra thin, amorphous
semiconductor (alpha-semic) layer on the sidewalls of the trench (portions of the ultra
thin layer on the sidewalls of the trench will ultimately form the channel or
ultra thin body (UTB) of the
MOSFET); (d) forming a thicker, alpha-semic sacrificial layer on the ultra
thin layer; (e) annealing the alpha-semic
layers to recrystallize them into
single crystal layers; (f) selectively removing the recrystallized sacrificial layer; and (g) performing additional steps to complete the VRG
MOSFET. In general, the sacrificial layer should facilitate the recrystallization of the ultra
thin layer into
single crystal material. In addition, the etch rate of the sacrificial layer should be sufficiently higher than that the ultra thin layer so that the sacrificial layer can be selectively removed in the presence of the ultra thin layer after recrystallization. The latter condition is illustratively satisfied by
doping the sacrificial layer and by not (intentionally)
doping the ultra thin layer. In accordance with one embodiment of our invention, step (g) includes filling the trench with
oxide to form a thick back
oxide region. In accordance with another embodiment of our invention, step (g) includes depositing a
thin oxide layer (the back
oxide) in the trench and then filling the remainder of the trench with a polycrystalline region (the back gate). VRG MOSFETs fabricated in accordance with our invention are expected to be electrostatically scalable with precise dimensional control. In addition, they can be fully depleted. Novel UTB device designs are also described.