CN109478521A - 半导体装置 - Google Patents

半导体装置 Download PDF

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Publication number
CN109478521A
CN109478521A CN201780044550.5A CN201780044550A CN109478521A CN 109478521 A CN109478521 A CN 109478521A CN 201780044550 A CN201780044550 A CN 201780044550A CN 109478521 A CN109478521 A CN 109478521A
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Prior art keywords
metal parts
electrode plate
electrode
semiconductor element
metal
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CN201780044550.5A
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CN109478521B (zh
Inventor
藤野纯司
井本裕儿
小川翔平
石原三纪夫
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Mitsubishi Electric Corp
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Mitsubishi Electric Corp
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Abstract

具备:半导体元件(21、22),具有表面电极;电极板(63),在俯视时面积大于半导体元件(21、22)的表面电极,由铝或者铝合金构成;以及金属部件(61、62),具有与半导体元件(21、22)的表面电极利用焊料(31、32)来接合的接合面,在俯视时面积小于半导体元件(21、22)的表面电极,该金属部件由与电极板(63)不同的金属构成,紧固于电极板(63),将半导体元件(21、22)的表面电极和电极板(63)进行电连接。

Description

半导体装置
技术领域
本发明涉及具备半导体元件的半导体装置。
背景技术
半导体装置是在壳体内设置适合于高电压和大电流的用途的功率用半导体元件,并将经由形成于基板的电路图案、引线框等布线部件而与半导体元件的电极电连接的主端子设置到壳体的外侧并进行封装而成的。对半导体装置的主端子连接外部的电路,半导体装置通过控制在外部的电路中流过的电流来控制所搭载的设备的动作。半导体装置易于搭载到设备内,所以利用于从工业设备至家电设备的广泛的领域。
在半导体装置中使用的半导体元件为具有表面电极和背面电极并向表面电极与背面电极之间施加高电压而流过大电流的纵型构造。在半导体装置中,对由热传导率大的陶瓷材料构成的绝缘基板接合半导体元件的背面电极,对半导体元件的发热高效地进行排热。另外,通过将引线框等电极板利用焊料直接接合到半导体元件的表面电极,减小与半导体元件的表面电极连接的布线部的电阻。电极板的面积大于半导体元件的表面电极,在半导体装置内与一个或者多个半导体元件的表面电极接合。电极板由铜、铝等导电率大的金属形成,在电极板由铝形成的情况下,以使焊料润湿的方式对电极板的表面实施镀铜等金属化处理。
在以往的半导体装置中,在电极板中形成从电极板的表面突出的半切部以及从半切部进一步突出的压花加工部,半切部的突出的一侧与半导体元件的表面电极通过焊料而被接合。压花加工部抵接到半导体元件的表面电极而被焊料接合,从而在半导体元件的表面电极与电极板的半切部之间确保与压花加工部的高度相同的厚度的焊料量(例如参照专利文献1)
现有技术文献
专利文献1:日本特开2012-74543号公报
发明内容
然而,在专利文献1记载的以往的半导体装置中,电极板的面积大于半导体元件的表面电极,所以有时由于焊料接合时的加热而产生电极板的翘曲、热变形,电极板与半导体元件的表面电极之间的距离变大,在电极板中焊料润湿扩展而被摄取,所以存在电极板与半导体元件的表面电极之间的焊料接合部的焊料量不足这样的问题点。
本发明是为了解决如上所述的问题而完成的,其目的在于提供一种半导体装置,即使使用焊料接合对半导体元件的表面电极电连接电极板,也能够防止被电极板摄取焊料。
本发明所涉及的半导体装置具备:半导体元件,具有表面电极;电极板,在俯视时面积大于半导体元件的表面电极,该电极板由铝或者铝合金构成;以及金属部件,具有与半导体元件的表面电极利用焊料来接合的接合面,在俯视时该金属部件的面积小于半导体元件的表面电极,该金属部件由与电极板不同的金属构成,紧固于电极板,将半导体元件的表面电极和电极板进行电连接。
根据本发明所涉及的半导体装置,使由铝或者铝合金构成的电极板和金属部件紧固而利用焊料来接合半导体元件的表面电极和金属部件,所以焊料不会润湿电极板,因此能够防止被电极板摄取焊料。
附图说明
图1是示出本发明的实施方式1中的半导体装置的俯视图。
图2是示出本发明的实施方式1中的半导体装置的剖面图。
图3是示出本发明的实施方式1中的半导体装置的制造方法的剖面图。
图4是示出本发明的实施方式1中的半导体装置的第1引线框的制造方法的部分剖面图。
图5是示出本发明的实施方式1中的半导体装置的第1引线框的另一制造方法的部分剖面图。
图6是示出本发明的实施方式1中的半导体装置的第1引线框的又一制造方法的部分剖面图。
图7是示出本发明的实施方式2中的半导体装置的剖面图。
图8是示出本发明的实施方式3中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。
图9是示出本发明的实施方式3中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的其它结构的部分剖面图。
图10是示出本发明的实施方式3中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的其它结构的部分剖面图。
图11是示出本发明的实施方式4中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。
图12是示出本发明的实施方式4中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的其它结构的部分剖面图。
图13是示出本发明的实施方式5中的半导体装置的俯视图。
图14是示出本发明的实施方式5中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。
图15是示出本发明的实施方式5中的其它结构的半导体装置的俯视图。
图16是示出本发明的实施方式6中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。
图17是示出本发明的实施方式7中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。
图18是示出本发明的实施方式7中的半导体装置的由金属管构成的金属部件的结构的立体图。
图19是与图2对应的图,是示出金属部件由层叠的多个金属层构成的半导体装置的剖面图。
图20是与图8对应的图,是示出金属部件由层叠的多个金属层构成的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。
图21是与图10对应的图,是示出金属部件由层叠的多个金属层构成的第1引线框和半导体元件的表面电极的焊料接合部的其它结构的部分剖面图。
图22是与图14对应的图,是示出金属部件由层叠的多个金属层构成的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。
(符号说明)
21、22:半导体元件;31、32:焊料;33、34:表面电极;60:第1引线框;61、62、161、162、163、164、165、166、167:金属部件;63:电极板;162a:插入部;162b:接合部;163a:凹部;165a、165b:夹持部;100、200、300、400:半导体装置。
具体实施方式
实施方式1.
首先,说明本发明的实施方式1中的半导体装置的结构。图1是示出本发明的实施方式1中的半导体装置的俯视图。另外,图2是示出本发明的实施方式1中的半导体装置的剖面图。此外,在图1中,省略密封树脂部70而示出。
在图1以及图2中,半导体装置100具备:绝缘基板10;半导体元件21、22,对设置于绝缘基板10的导体层11接合背面电极;第1引线框60,与半导体元件21、22的表面电极电连接并流过主电路电流;第2引线框67,与半导体元件21、22电连接并被输入用于控制半导体元件21、22的控制信号;密封树脂部70,覆盖半导体元件21、22及半导体元件21、22的周边部件;以及壳体50,收容这些结构部件。第1引线框60具备:电极板63,在俯视时面积大于半导体元件21、22的表面电极,由铝或者铝合金构成;以及金属部件61、62,在俯视时面积小于半导体元件21、22的表面电极,紧固于电极板63,并利用焊料接合到半导体元件21、22的表面电极。在此,主电路电流是指在使用半导体装置100构成的电路中流过的电流,半导体装置100被用于控制在表面电极与背面电极之间流过的主电路电流的导通以及切断。
绝缘基板10由氮化铝(AlN)等热传导率大的陶瓷基板等绝缘物基板构成,例如外形尺寸是40mm×25mm,厚度是0.6mm。在绝缘基板10的表面设置有由铜(Cu)或者铜合金等导电率大的金属形成的导体层11,在绝缘基板10的背面设置有由铜或者铜合金等热传导率大的金属形成的导体层13。表面侧的导体层11以及背面侧的导体层13虽然也可以由不同的材料形成,但为了降低制造成本而也优选由相同的材料形成。导体层11以及导体层13例如由厚度0.4mm的铜形成。
关于绝缘基板10,只要是可得到绝缘性且如铜那样焊料润湿的导体层可形成的基板则不限于氮化铝基板,例如也可以是氧化铝(Al2O3)、碳化硅(SiC)、氮化硅(Si3N4)等陶瓷基板,还可以是玻璃环氧基板、金属基体基板等陶瓷以外的基板。
在导体层11中,形成有用于使主电路电流流过半导体元件21、22的电路图案,半导体元件21、22通过焊料、芯片接合等的接合材料而被接合,所以导体层11优选为导电率大的金属。另外,导体层13通过焊料等接合材料而被接合到将由半导体元件21、22发生的热向半导体装置100的外部进行排热的散热器(未图示),所以优选为热传导率大的金属。因此,导体层11以及导体层13虽然优选为铜、铜合金,但也可以是在焊料不会润湿的铝、铝合金等导电率以及热传导率大的金属材料的表面通过金属化处理形成锡(Sn)、镍(Ni)、金(Au)、银(Ag)等并使焊料润湿的金属材料。
半导体元件21以及半导体元件22是二极管、IGBT(Insulated Gate BipolarTransistor,绝缘栅双极晶体管)、MOSFET(Metal-Oxide-Semiconductor Field-EffectTransistor,金属氧化物半导体场效应晶体管)等功率用半导体开关元件、控制用的IC(Integrated Circuit,集成电路)。在本发明中,说明半导体元件21是二极管且半导体元件22是IGBT的情况。半导体元件21、22由硅(Si)、碳化硅(SiC)、氮化镓(GaN)等半导体材料形成。半导体元件21、22例如外形尺寸是15mm×15mm,厚度是0.3mm。
如图1以及图2所示,在本发明中,说明半导体装置100为具备一对作为二极管的半导体元件21和作为IGBT的半导体元件22的1合1(1in 1)结构的半导体装置,但也可以是具备两对二极管和IGBT的2合1(2in 1)结构的半导体装置、具备六对二极管和IGBT的6合1(6in 1)结构的半导体装置。另外,也可以是代替IGBT而具备MOSFET等其它半导体开关元件的结构的半导体装置。
作为二极管的半导体元件21以及作为IGBT的半导体元件22具备:背面电极,隔着导体层11而与绝缘基板10接合;以及表面电极,设置于与背面电极相反侧的面。对表面电极连接第1引线框60。在半导体元件21、22的表面电极与背面电极之间流过主电路电流,半导体元件21、22根据输入到设置于半导体元件21、22的控制电极的控制信号,控制主电路电流的导通和切断。
作为二极管的半导体元件21在背面侧具有作为背面电极的阴极电极,在表面侧具有作为表面电极的阳极电极。另外,作为IGBT的半导体元件22在背面侧具有作为背面电极的集电极电极,在表面侧具有作为表面电极的发射极电极和作为控制电极的栅电极。作为控制电极的栅电极通过导线40而与第2引线框67电连接。控制电极不限于半导体元件22的栅电极,设置于半导体装置100内的温度传感器等的电极也称为控制电极。此外,在图1中示出半导体元件21的表面电极33以及半导体元件22的表面电极34,但在图2中进行了省略。
半导体元件21以及半导体元件22的背面电极利用焊料等接合材料(未图示)而接合到设置于绝缘基板10的导体层11。即,半导体元件21、22隔着导体层11将背面电极接合到绝缘基板10。对导体层11利用超声波接合等方法而接合有由铝、铝合金等导电率大的金属形成的端子板66。在端子板66中设置有主端子65,被固定到壳体50。由此,半导体元件21、22的背面电极和主端子65被电连接。在主端子65中,以能够将外部的布线部件进行螺纹固定的方式设置有螺纹孔。主端子65例如以宽度10mm、厚度0.6mm的大小形成,也可以根据需要而实施镀铜、镀镍。
第1引线框60是将由铜、铜合金等焊料润湿的金属材料形成的金属部件61、62紧固于由焊料不会润湿的铝或者铝合金形成的电极板63而构成的。电极板63在俯视时面积大于半导体元件21、22的表面电极,且面积大于金属部件61、62。另外,金属部件61、62在俯视时面积小于半导体元件21、22的表面电极,且面积小于电极板63。金属部件61、62既可以整体由铜、铜合金构成,也可以对由铜、铜合金形成的金属部件61、62实施镀银、镀镍等利用焊料润湿的金属材料进行的金属化处理。此外,金属部件61、62除了铜、铜合金以外也可以由镍、银、金等焊料润湿的金属形成,但铜、铜合金由于电传导以及成本优良所以是优选的。
另外,金属部件61、62除了铜、铜合金以外,也可以层叠热膨胀系数小的铜钨(Cu-W)烧成材料、铜/殷钢/铜(CIC)包层材料等多个金属层来形成,只要利用焊料而接合到半导体元件21、22的表面电极的部分由铜或者铜合金构成即可。即,金属部件61、62也可以仅利用由铜或者铜合金构成的第1金属层来构成,只要层叠包括第1金属层和由与第1金属层不同的金属构成的第2金属层的多个金属层来构成,并利用焊料而接合到半导体元件21、22的表面电极33、34的接合面设置于第1金属层即可。
此外,在本发明中所称的铝是指纯度为99.00%以上的铝、具体而言是指JIS规格中的1000系铝。另外,铝合金是指以铝为主成分的合金、具体而言是指JIS规格中的2000系~8000系的铝合金。另外,铜是指JIS规格中的1000系的铜,铜合金是指JIS规格中的2000系~7000系的铜合金。
电极板63和金属部件61、62未经由焊料等接合材料而被接合,电极板63和金属部件61、62接触而电连接。关于使金属部件61、62紧固于电极板63的方法的详情在后面叙述,例如如图1以及图2所示,向设置于电极板63的开口部插入金属部件61、62并紧贴,从而紧固电极板63和金属部件61、62。
电极板63例如由厚度0.6mm的铝或者铝合金形成,电极板63的表面也由与电极板63的内部相同的铝或者铝合金构成。即,电极板63整体由铝或者铝合金形成,且在电极板63的表面存在强力的自然氧化膜,所以不会使焊料润湿。电极板63为了电连接多个半导体元件的表面电极、或者与半导体装置的外部的电路电连接,在俯视时电极板63的面积大于半导体元件的表面电极。金属部件61、62例如由形成为外形尺寸为8mm×8mm、厚度为1mm的铜或铜合金构成。金属部件61、62例如既可以通过热套、热铆接、冲压加工而紧固于电极板63、或者也可以通过超声波接合、热压接来紧固金属部件61、62和电极板63。
如图2所示,第1引线框60的金属部件61、62的厚度大于电极板63的厚度,所以金属部件61以及金属部件62的一部分从电极板63突出。这样金属部件61、62以使金属部件61、62的一部分构成从电极板63的表面突出的凸部的方式具有突出部,金属部件61、62和电极板63被紧固而构成第1引线框60。此外,金属部件61、62无需一定具有从电极板63的表面突出的突出部,也可以针对电极板63的表面,金属部件61、62的与半导体元件21、22的接合面构成同一面或者凹部。但是,在金属部件61、62具有从电极板63的表面突出的突出部时,能够提高金属部件61、62的突出部和半导体元件21、22的焊料接合的接合强度,提高接合可靠性,所以是优选的。
如图2所示,第1引线框60的金属部件61和半导体元件21的表面电极通过焊料31而被接合,第1引线框60的金属部件62和半导体元件22的表面电极通过焊料32而被接合。焊料31以及焊料32是由以锡(Sn)和银(Ag)为主成分的Sn/Ag系、以锡和铜为主成分的Sn/Cu系、以锡和铋(Bi)为主成分的Sn/Bi系等润湿性相对铜而言优良的焊料材料来形成的。此外,即使在焊料31、32的材料中包含铅(Pb)也能得到本发明的效果,但包含铅的焊料由于环境负荷高,所以并非是优选的。
第1引线框60的电极板63由铝或者铝合金形成,所以在焊料接合时,焊料31、32不会润湿扩展到电极板63而被电极板63摄取。其结果,在金属部件61、62和半导体元件21、22的接合中使用的焊料的量不会不足,金属部件61、62和半导体元件21、22通过充足的量的焊料31、32而被接合。
半导体元件21、22的表面电极例如是12mm×12mm的大小,金属部件61、62的与半导体元件21、22的表面电极33、34的接合面的大小例如是8mm×8mm。即,如图1所示,在俯视时,金属部件61、62的整体比半导体元件21、22的表面电极33、34的外周更靠内侧,在俯视时,金属部件61、62的面积小于半导体元件21、22的表面电极33、34。另外,金属部件61、62在俯视时小于电极板63的面积。
因此,金属部件61、62的焊料接合面比半导体元件21、22的表面电极33、34的外周更靠内侧,且面积小于半导体元件21、22的表面电极33、34,所以焊料31、32成为向半导体元件21、22的表面电极33、34侧扩展且呈喇叭形扩展的圆角(fillet)形状。另外,金属部件61、62在从电极板63的表面突出的突出部中,在与半导体元件21、22的表面电极相向的突出部的底面以及设置于底面与电极板之间的突出部的侧面,与半导体元件21、22焊料接合,所以金属部件61、62和焊料31、32的接合面积增加。因此,将第1引线框60利用焊料31、32焊料接合到半导体元件21、22之后的检查中的焊料接合部的视觉辨认性优良,并且基于焊料31、32的接合应力被分散,所以能够提高焊料接合部的可靠性。
在半导体元件21、22的背面电极和绝缘基板10的导体层11的接合中,也可以代替焊料,使用使银(Ag)填料在环氧树脂中分散而得到的导电性粘接剂、或使Ag、Cu等金属纳米粒子在低温下烧成来接合的金属纳米粒子接合材料。另外,也可以在半导体元件21的表面电极33和金属部件61的接合、或者半导体元件22的表面电极34和金属部件62的接合中的任意一方中,使用导电性粘接剂或金属纳米粒子接合材料。由铝或铝合金形成的电极板63由于在表面具有自然氧化膜,所以在用导电性粘接剂或金属纳米粒子接合材料来接合时得不到良好的导电性,但金属部件61、62由铜或铜合金构成,自然氧化膜是多孔而比较容易被破坏,容易形成新生面,所以即使使用导电性粘接剂或金属纳米粒子接合材料来接合,也能够减小接合部的电阻。
第1引线框60在与设置有金属部件61、62的一侧相反的一侧的端部设置有主端子64,主端子64被固定到壳体50。在主端子64中,与主端子65同样地以能够将外部的布线部件进行螺纹固定的方式设置有螺纹孔。另外,主端子64例如以宽度10mm、厚度0.6mm的大小来形成,也可以根据需要而被实施镀铜、镀镍。通过以上的结构,主端子65和主端子64经由导体层11、半导体元件21、22、第1引线框60而被电连接,能够在主端子65与主端子64之间流过主电路电流。
第2引线框67由铜、铜合金或者铝、铝合金形成,被固定到壳体50。第2引线框67的一端露出到半导体装置100的外部,成为用于输入控制信号的控制端子。在由铝或铝合金形成第2引线框67的情况下,也可以对露出到半导体装置100的外部的控制端子的部分实施镀铜或镀镍而优化焊料的润湿性。
第2引线框67的另一端通过导线40而与设置于半导体元件22的表面侧的控制电极23电连接。导线40例如可以是直径为0.15mm的铝导线、进行了铝包覆的铜导线、或者金导线等,通过导线键合而被超声波接合到第2引线框67以及控制电极23。第2引线框和控制电极23不限于导线键合,也可以通过带式连接(ribbon bond)或将金属板进行了超声波接合的母线(busbar)来电连接。
壳体50通过PPS(Poly Phenylene Sulfide:聚苯硫醚)树脂或LCP(LiquidCrystal Polymer:液晶聚合物)树脂等而形成为框状。例如,外形尺寸是48mm×28mm,高度是12mm。在壳体50的底部,设置绝缘基板10,使导体层13露出到半导体装置100的外部。绝缘基板10通过在绝缘基板10的周围所设置的粘接材料80而被粘接固定到壳体50。
密封树脂部70由灌封树脂(potting resin)形成,覆盖导体层11、半导体元件21、22、第1引线框60、第2引线框67、导线40以及焊料31、32而被绝缘密封。此外,形成密封树脂部70的密封树脂只要能够确保绝缘性、且流入而在常温下硬化,则不限于灌封树脂,也可以是液状凝胶等。如以上那样,构成半导体装置100。
接下来,说明半导体装置100的制造方法。
图3是示出本发明的实施方式1中的半导体装置的制造方法的剖面图。图3(a)是示出直至对绝缘基板10接合半导体元件21、22为止的工序的图,图3(b)是示出直至在半导体元件21、22的表面电极与第1引线框60的金属部件61、62之间载置板焊料31a、32a为止的工序的图。另外,图3(c)是示出直至将半导体元件21、22的表面电极和第1引线框60的金属部件61、62进行焊料接合而将半导体元件22的控制电极和第2引线框67进行电连接为止的工序的图,图3(d)是示出直至形成密封树脂部70而完成半导体装置100为止的工序的图。
首先,如图3(a)所示,对在表面侧接合有导体层11且在背面侧接合有导体层13的绝缘基板10的导体层11,接合半导体元件21以及半导体元件22的背面电极。关于半导体元件21、22的背面电极和导体层11的接合,既可以通过焊料来接合,也可以利用金属纳米粒子接合材料来接合。但是,在用焊料来接合的情况下,为了在图3(c)所示的将半导体元件21、22的表面电极和第1引线框60进行焊料接合的工序时的加热中不使焊料再次熔融,而优选使用熔点比在半导体元件21、22的表面电极和第1引线框60的接合中使用的焊料31、32高的焊料。
接下来,如图3(b)所示,在框状的壳体50的底部配置接合了半导体元件21、22的绝缘基板10,在绝缘基板10的周围与壳体50之间埋入硅制的粘接材料80而进行粘接固定。粘接材料80填埋绝缘基板10与壳体50之间的间隙,从而能够防止在图3(d)所示的形成密封树脂部70的工序中填充到壳体50内的灌封材泄漏。
在壳体50中,预先通过插入成型而设置有由电极板63和金属部件61、62构成的第1引线框60、端子板66、第2引线框67,在壳体50的上部,固定有设置于第1引线框60的端部的主端子64和设置于端子板66的端部的主端子65。此外,后述使金属部件61、62紧固于电极板63的方法。
在向壳体50的预定位置插入绝缘基板10时,第1引线框60以使金属部件61、62的接合面与接合到绝缘基板10的半导体元件21、22的表面电极相向的方式固定到壳体50,第2引线框67以使导线键合部位于与接合到绝缘基板10的半导体元件22的控制电极对应的位置的方式固定到壳体50。
在接合到绝缘基板10的半导体元件21、22的表面电极与第1引线框60的金属部件61、62之间配置板焊料31a、32a,绝缘基板10的周围通过粘接材料80而被粘接固定到壳体50。
接下来,如图3(c)所示,使在半导体元件21、22的表面电极与第1引线框60的金属部件61、62之间配置的板焊料31a、32a熔融、凝固,通过焊料31、32进行焊料接合。另外,通过导线40将半导体元件22的控制电极和第2引线框67进行电连接,接合端子板66和设置于绝缘基板10的导体层11。
在半导体元件21、22的表面电极与第1引线框60的金属部件61、62之间配置的板焊料31a、32a通过回流炉、加热板而被加热并熔融。板焊料31a、32a使用在比对绝缘基板10的导体层11接合半导体元件21、22的接合材料的熔点低的温度下熔融的焊料,在导体层11与半导体元件21、22的背面电极之间的接合材料不会再次熔融的温度下进行加热。
熔融的焊料31、32润湿到半导体元件21、22的表面电极,并且润湿到第1引线框60的金属部件61、62。金属部件61、62在俯视时比半导体元件21、22的表面电极的外周更靠内侧,在俯视时面积比半导体元件21、22的表面电极小,所以如图3(c)所示形成如下圆角:呈现相对半导体元件21、22的表面电极而接触角小且呈喇叭形扩展的形状,呈现不仅润湿扩展到第1引线框60的金属部件61、62的突出部的底面而且还润湿扩展到侧面的形状。
另外,第1引线框60的电极板63由铝或者铝合金形成,所以熔融的焊料31、32不会润湿电极板63,从而熔融的焊料31、32不会润湿扩展到电极板63。因此,焊料31、32不会被电极板63摄取,在半导体元件21、22与第1引线框60的金属部件61、62之间保持预定量的焊料31、32,用于焊料接合的焊料的量不会不足。另外,金属部件61、62在俯视时面积小于半导体元件21、22的表面电极,所以焊料也不会多余地润湿扩展到金属部件61、62的表面,用于焊料接合的焊料的量不会不足。
之后,熔融的焊料31、32被冷却,成为凝固的焊料31、32,半导体元件21、22的表面电极和金属部件61、62被焊料接合。焊料31、32仅设置于半导体元件21、22与金属部件61、62之间,不会扩展到在俯视时面积比半导体元件21、22的表面电极大的电极板63,所以在半导体元件21、22的表面电极与金属部件61、62之间存在充足的量的焊料,进行牢固且可靠性高的焊料接合。
此外,构成金属部件61、62的接合面的与半导体元件21、22的表面电极相向的面可以是平面,但也可以是形成有突起的面、呈现尖的形状的面、或者向半导体元件21、22的表面电极侧呈现凸的形状的曲面。
并且,通过基于导线键合的超声波接合来接合半导体元件22的控制电极和第2引线框67。即,利用导线40将半导体元件22的控制电极和第2引线框67进行电连接。另外,通过超声波接合来接合端子板66和设置于绝缘基板10的导体层11。利用这些超声波接合的接合既可以在半导体元件21、22的表面电极和第1引线框60的金属部件61、62的焊料接合之前进行,也可以之后进行。通过以上的焊料接合以及超声波接合,在导体装置100的主端子64与主端子65之间电连接半导体元件21、22。
接下来,如图3(d)所示,在壳体50内用灌封树脂形成密封树脂部70,对壳体50进行绝缘密封。使加热到60℃的灌封树脂流入到壳体50内并进行真空脱泡,在100℃下进行1.5小时加热之后,在140℃下进行1.5小时加热,并使灌封树脂硬化而形成密封树脂部70。通过以上的工序,完成半导体装置100。
接下来,说明第1引线框的制造方法。
图4是示出本发明的实施方式1中的半导体装置的第1引线框的制造方法的部分剖面图。图4示出第1引线框60的金属部件62和其周边的电极板63,示出通过热套而使金属部件62和电极板63紧固的方法。图4(a)是示出对电极板63进行加热而使形成于电极板63的开口部的面积扩大的状态的图,图4(b)是示出对电极板63进行冷却而使形成于电极板63的开口部缩小,金属部件62和电极板63通过热套而被紧固的状态的图。在图4中,将金属部件61省略而示出,但金属部件61也通过与金属部件62相同的方法而紧固于电极板63。
首先,通过冲压加工等而在由铝或者铝合金构成的电极板63形成开口部。另外,通过冲压加工等而形成由铜或铜合金等焊料会润湿的金属材料构成的金属部件62。如上所述,在例如以外形尺寸为8mm×8mm、厚度为1mm而形成金属部件62的情况下,形成于电极板63的开口部成为比8mm×8mm稍微小的大小,例如成为7.99mm×7.99mm。
接下来,如图4(a)所示对电极板63进行加热,通过热膨胀而使形成于电极板63的开口部扩大。例如,在由铝形成电极板63并由铜形成金属部件62的情况下,铝的线性热膨胀系数(linear thermal expansion coefficient)是23ppm/K,铜的线性热膨胀系数是16ppm/K。在将金属部件62的温度设为常温(例如25℃),并将电极板63的温度加热到比金属部件62的温度高例如325K的温度(例如350℃)时,电极板63的开口部的大小变大约0.75%,所以成为约8.05mm×约8.05mm,大于金属部件62的外形尺寸8mm×8mm。因此,如图4(a)所示,能够向电极板63的开口部嵌入金属部件62。
接下来,如图4(b)所示,在向电极板63的开口部嵌入金属部件62的状态下,对电极板63进行冷却,使电极板63和金属部件62成为相同的温度。在电极板63被冷却时,形成于电极板63的开口部变小,所以电极板63和金属部件62紧贴,金属部件62在被插入到电极板63的开口部的状态下被紧固。即,电极板63被紧固于金属部件62。电极板63的开口部被形成为小于金属部件62的外形尺寸,但在电极板63被冷却时,电极板63的开口部和金属部件62变形而成为两者紧贴的状态,形成第1引线框60。另外,能够通过简易的加工而将比铜更轻的铝用作电极板。
关于这样形成的第1引线框60,在由铜形成的金属部件62和由铝形成的电极板63中线性热膨胀系数存在差,所以在由于由流过半导体装置100的主电路电流引起的焦耳热、半导体元件21、22的发热而使第1引线框的温度上升的情况下,电极板63的开口部的大小有时大于金属部件62的外形尺寸。在上述例子的情况下,在第1引线框60的温度比常温(例如25℃)上升180K温度(例如成为205℃)时,电极板63的开口部和金属部件62的外形尺寸成为相同的大小,电极板63和金属部件62的紧贴性开始降低。但是,如果第1引线框60的温度是200℃以下,则电极板63和金属部件62紧贴,所以可得到电阻小的良好的电传导。此外,在第1引线框的温度成为200℃以上的情况下,进一步减小形成于电极板63的开口部的大小即可。如以上那样,能够通过热套来制造第1引线框60。
这样制造的第1引线框60是使金属部件61、62和电极板63并非隔着接合材料而是相互接触并紧固而构成的,所以电传导以及热传导优良,并且不会发生接合材料的腐蚀、剥离等,所以可得到高的可靠性。
接下来,说明制造第1引线框的另一制造方法。图5是示出本发明的实施方式1中的半导体装置的第1引线框的另一制造方法的部分剖面图。图5与图4同样地,示出第1引线框60的金属部件62和其周边的电极板63,示出对金属部件62进行冲压加工而使金属部件62和电极板63紧固的方法。图5(a)是示出向形成于电极板63的开口部嵌入比开口部稍小地形成的金属部件62a的状态的图,图5(b)是示出对金属部件62a进行冲压加工而增大外形尺寸,使金属部件62和电极板63紧固的状态的图。在图5中与图4同样地,将金属部件61省略而示出,但金属部件61也通过与金属部件62相同的方法而被紧固于电极板63。
首先,如图5(a)所示,在电极板63形成开口部,通过冲压加工等而形成外形尺寸比电极板63的开口部小的金属部件62a。例如,也可以在将电极板63的开口部的大小设为8mm×8mm的情况下,将金属部件62a的外形尺寸形成为7.9mm×7.9mm,将厚度形成为1mm。然后,向电极板63的开口部嵌入金属部件62a。
接下来,如图5(b)所示,通过冲压加工向金属部件62a的厚度方向施加压力而挤压金属部件62a。其结果,关于挤压金属部件62a而形成的金属部件62,与厚度方向垂直的外形尺寸变大,在向电极板63的开口部插入金属部件62的状态下被紧固,而完成第1引线框60。金属部件62和电极板63紧贴,所以可得到电阻小的良好的电传导。如以上那样,能够通过冲压加工来制造第1引线框60。
这样制造的第1引线框60与通过热套来制造的情况同样地,是使金属部件61、62和电极板63并非隔着接合材料而是相互接触并紧固而构成的,所以电传导以及热传导优良,并且不会发生接合材料的腐蚀、剥离等,所以可得到高的可靠性。
图6是示出本发明的实施方式1中的半导体装置的第1引线框的又一制造方法的部分剖面图。图6与图4同样地,示出第1引线框60的金属部件62和其周边的电极板63,示出通过激光焊接来接合金属部件62和电极板63的方法。图6(a)是示出向形成于电极板63的开口部嵌入比开口部稍小地形成的金属部件62的状态的图,图6(b)是示出通过激光焊接使金属部件62和电极板63紧固的状态的图。在图6中与图4同样地,将金属部件61省略而示出,但金属部件61也通过与金属部件62相同的方法而被紧固于电极板63。
首先,如图6(a)所示,在电极板63形成开口部,形成外形尺寸比形成于电极板63的开口部小的金属部件62。例如,也可以在将电极板63的开口部的大小设为8mm×8mm的情况下,将金属部件62a的外形尺寸形成为7.9mm×7.9mm,将厚度形成为1mm。然后,向电极板63的开口部嵌入金属部件62。
接下来,如图6(b)所示,对电极板63和金属部件62的接合部照射激光而进行激光焊接。其结果,在电极板63和金属部件62的接合部中形成由铜和铝的合金构成的焊接痕62b,金属部件62和电极板63被紧固,完成第1引线框60。金属部件62接合到电极板63而被紧固,所以可得到电阻小的良好的电传导。如以上那样,能够通过激光焊接来制造第1引线框60。另外,通过热处理等而促进电极板63与金属部件62之间的金属扩散,从而能够使电传导、热传导或者机械性强度增大。在该情况下,在金属部件62与电极板63之间的至少一部分中形成有伴随金属扩散的接合部。
如以上那样,能够通过热套、冲压加工、激光焊接向电极板63的开口部插入金属部件61、62并进行紧固从而制造第1引线框60,但第1引线框60的制造方法不限于上述方法。例如,既可以接合未形成开口部的电极板63和金属部件61、62而使金属部件61、62和电极板63紧固,也可以一边施加超声波一边附加载荷而进行超声波接合、或者一边加热到铝的再结晶温度以上一边附加载荷而进行热压接、或者通过摩擦搅拌焊接等而使金属部件61、62和电极板63接合并紧固。另外,电极板63的面积在俯视时大于金属部件61、62的面积。即,关于与半导体元件的表面电极平行地配置的面的面积,电极板63大于金属部件61、62。
此外,在由铜或铜合金形成金属部件61、62的情况下,为了防锈处理,也可以对金属部件61、62的表面进行焊料包覆、Ni/Au镀敷等金属化处理。通过这样的金属化处理而形成于金属部件61、62的表面的金属膜在利用焊料来接合金属部件61、62和半导体元件21、22的表面电极时熔融到焊料内,所以不会残存于焊料接合后的金属部件61、62的表面,从焊料内检测出在金属化处理中所使用的金属元素。
接下来,说明半导体装置100的作用效果。
如上所述,在本发明的半导体装置100中,由铝或者铝合金构成且由于在表面具有自然氧化膜而焊料不会润湿的电极板63被紧固于由铜或者铜合金等焊料会润湿的金属形成的金属部件61、62,从而形成第1引线框60。因此,为了将半导体元件21、22的表面电极和第1引线框60进行电连接,即使在半导体元件21、22的表面电极与金属部件61、62之间配置焊料并使焊料熔融,所熔融的焊料也仅润湿到半导体元件21、22的表面电极上以及金属部件61、62的表面上。即,所熔融的焊料不会润湿扩展到由铝或者铝合金形成的电极板63。即,使焊料仅润湿到在俯视时面积比半导体元件21、22的表面电极小的金属部件61、62的表面上,不会使焊料润湿扩展到在俯视时面积比半导体元件21、22的表面电极大的电极板63,所以能够降低焊料接合所需的焊料量。
其结果,在半导体元件21、22的表面电极与金属部件61、62之间确保半导体元件21、22的表面电极和金属部件61、62的接合所需的量的焊料,利用充足的量的焊料31、32对半导体元件21、22的表面电极和金属部件61、62进行焊料接合,所以能够抑制在半导体元件21、22的表面电极与第1引线框60之间发生开放不良。而且,被加热而熔融的焊料所润湿的区域不限于半导体元件21、22的表面电极上和金属部件61、62的表面上,所以能够将在半导体元件21、22的表面电极和金属部件61、62的焊料接合部中所设置的焊料31、32的量降低到适合的量,能够降低由焊料31、32施加到半导体元件21、22的表面电极的应力。
在半导体装置100中流过的主电路电流例如是几十A以上这样的大电流,所以为了高效地排出半导体元件21、22的发热等在半导体装置100内发生的热而配置于半导体装置100的底部且接合有半导体元件21、22的背面电极的绝缘基板10使用由氮化铝(AlN)等热传导率大的陶瓷形成的陶瓷基板。并且,构成为对半导体元件21、22的表面电极直接用焊料来接合第1引线框60。因此,半导体元件21、22的表面电极以及背面电极被施加由于接合到表面电极以及背面电极的部件的线性热膨胀系数与半导体元件的线性热膨胀系数之差而发生的热应力。
第1引线框60的电极板63由铝构成时的线性热膨胀系数是23ppm/K,金属部件61、62由铜构成时的线性热膨胀系数是16ppm/K。另外,半导体元件21、22的线性热膨胀系数在半导体元件21、22的材料为Si的情况下是3~3.5ppm/K,在为SiC的情况下是4.2~4.7ppm/K,在为GaN的情况下是3.2~5.6ppm/K。GaN是各向异性,所以线性热膨胀系数的值根据方向而大幅变化。而且,接合有半导体元件21、22的氮化铝制的绝缘基板10的线性热膨胀系数在包括设置于绝缘基板10的两面的导体层11以及导体层13在内的整体中约为10ppm/K。
关于与半导体元件21、22的线性热膨胀系数的差,表面电极侧的由铝构成的电极板63或者由铜构成的金属部件61、62大于背面电极侧的绝缘基板10。因此,相比于利用由铝构成的电极板来形成第1引线框的整体、并对由铝构成的电极板实施镀铜而利用焊料来接合电极板和半导体元件的表面电极,在如本发明的半导体装置100那样利用与由铜构成的金属部件61、62紧固的由铝构成的电极板63来构成第1引线框60、并利用焊料来接合金属部件61、62和半导体元件21、22的表面电极时,能够减小施加到半导体元件21、22的表面电极的热应力,所以能够提高半导体元件21、22的可靠性。
而且,在半导体元件21、22由碳化硅(SiC)形成的情况下,有在半导体元件21、22的温度超过200℃的状态下被连续使用的情况。在仅用实施镀铜的由铝构成的电极板来构成第1引线框、并利用焊料来接合电极板和半导体元件的表面电极而成的半导体装置中,在如半导体元件的温度超过200℃这样的铝的再结晶温度的温度下被连续使用时,构成第1引线框的电极板的铝的晶粒粗大化,而发生对电极板实施的镀铜膜的龟裂、剥离,使电极板和半导体元件的表面电极的焊料接合部的可靠性降低。
但是,在本发明的半导体装置100中,使由铝或者铝合金构成的电极板63和焊料接合部由铜或者铜合金构成的金属部件61、62紧固而构成第1引线框60,所以金属部件61、62具有比铝高的耐热性,即使在如半导体元件21、22的温度超过200℃的状态下被连续使用,也能够充分地提高半导体元件21、22的表面电极和金属部件61、62的焊料接合部的可靠性。
另外,在以往的半导体装置中,在用由铝或者铝合金构成的电极板来构成第1引线框的情况下,对电极板实施镀铜,使焊料润湿到电极板。但是,在向铝或者铝合金的镀敷处理中需要高级的技术,即使用铝或者铝合金来形成电极板,其结果仍需要与用铜或者铜合金来形成电极板的情况同等以上的成本。而且,发生在焊料接合时薄的镀铜膜的铜溶出到所熔融的焊料内的所谓焊料侵蚀、或使用半导体装置时的镀铜膜的剥离,所以难以在焊料接合部中确保高的可靠性。
但是,在本发明的半导体装置100中,使由铝或者铝合金构成的电极板63和由铜或者铜合金等焊料会润湿的金属构成的金属部件61、62紧固而构成第1引线框60,所以能够低成本地制造第1引线框60,金属部件61、62不存在剥离、焊料侵蚀等问题,所以能够在焊料接合部中确保高的可靠性。
实施方式2.
图7是示出本发明的实施方式2中的半导体装置的剖面图。在图7中,附加与图1以及图2相同的符号的部分表示相同或者对应的结构,省略其说明。与本发明的实施方式1不同的结构在于,半导体装置200不具备壳体以及密封树脂部,而通过使用模具树脂的转移模具(transfer mold)来密封。
如图7所示,在半导体装置200中,使由铜或者铜合金等焊料会润湿的材料构成的金属部件61、62和由铝或者铝合金构成的电极板63紧固而构成第1引线框60。金属部件61、62通过焊料而被接合到与绝缘基板10接合的半导体元件21、22的表面电极。
在构成第1引线框60的电极板63中,在与紧固有金属部件61、62的一侧相反的一侧的端部设置有与外部的电路连接的主端子部68。主端子部68露出到半导体装置200的外部,根据需要而实施镀镍、镀铜等利用焊料会润湿的金属的金属化处理。另外,设置有与绝缘基板10的导体层11接合的端子板(未图示),在端子板的与接合到导体层11的一侧相反的一侧的端部,设置有与外部的电路连接的主端子部(未图示)。
并且,通过转移模具利用密封树脂部71来密封半导体装置200的结构部件。设置于绝缘基板10的背面侧的导体层13被设置成露出到密封树脂部71的外部,构成为能够将导体层13利用焊料等接合材料而接合到排热用的散热器(未图示)。
即使是如以上那样构成的半导体装置200,也对利用焊料来接合到半导体元件21、22的表面电极、并在俯视时比半导体元件21、22的表面电极的外周更靠内侧且面积比半导体元件21、22的表面电极以及电极板53小的金属部件61、62,紧固由铝或者铝合金构成的电极板63而构成第1引线框60,所以焊料31、32不会润湿扩展到电极板63,焊料31、32不会被电极板63摄取,因此能够在半导体元件21、22的表面电极和金属部件61、62的接合中确保充足的量的焊料,能够得到与实施方式1同样的效果。
实施方式3.
图8是示出本发明的实施方式3中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。此外,在图8中,示出半导体元件22和金属部件62的焊料接合部的结构,但半导体元件21和金属部件61的焊料接合部也成为同样的结构。在图8中,附加与图1以及图2相同的符号的部分表示相同或者对应的结构,省略其说明。与本发明的实施方式1的不同之处在于构成第1引线框60的电极板63和金属部件62的紧固构造。
如图8所示,在本实施方式3的半导体装置中,将半导体元件22的背面电极通过焊料等接合材料36而接合到设置于绝缘基板10的表面侧的导体层11,将第1引线框60通过焊料32而接合到半导体元件22的表面电极。第1引线框60由通过焊料32接合到半导体元件22的表面电极的金属部件62和紧固于金属部件62的电极板63构成。电极板63经由金属部件62而与半导体元件22的表面电极电连接。
如图8所示,在由铝或者铝合金构成的电极板63中,设置有由从电极板63的表面凹陷而形成的盲孔(blind hole)构成的开口部,向由设置于电极板63的盲孔构成的开口部插入金属部件62,紧固电极板63和金属部件62。通过热套或热铆接来接合电极板63和金属部件62,从而能够使金属部件62和电极板63紧固。
图9是示出本发明的实施方式3中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的其它结构的部分剖面图。在图9中,附加与图8相同的符号的部分表示相同或者对应的结构,省略其说明。与图8的结构的不同之处在于对构成第1引线框60的电极板63的表面接合金属部件62并紧固的构造。
如图9所示,对由铝或者铝合金构成的电极板63的表面粘贴由铜或者铜合金等焊料会润湿的金属构成的金属部件62来紧固。即,金属部件62的整体成为从电极板63的表面突出的突出部。金属部件62能够通过超声波接合粘贴到电极板63来紧固。另外,金属部件62也可以通过镀敷或印刷等成膜工艺而形成于电极板63的表面。
在金属部件62的厚度薄的情况下,在用焊料与半导体元件22的表面电极进行接合时,由于构成金属部件62的铜等金属材料溶出到所熔融的焊料内的所谓焊料侵蚀,有时金属部件62的一部分消失而焊料接合强度降低。因此,金属部件62需要是通过焊料侵蚀也不会消失的厚度。即,金属部件62的厚度为10μm以上,优选为50μm以上。并且,相比于通过镀敷等成膜工艺来形成金属部件62,优选为用金属板或金属箔来形成金属部件62,并接合到电极板63。因此,根据接合金属部件62时的处理的难易度,金属部件62的厚度更优选为100μm以上。此外,金属部件62的厚度不限于图9所示的结构的半导体装置,在本发明的所有实施方式所示的半导体装置的结构中为10μm以上,优选为50μm以上,更优选为100μm以上。此外,在金属部件是层叠多个金属层而构成的情况下,具有利用焊料与半导体元件的表面电极接合的接合面的金属层的厚度为10μm以上,优选为50μm以上,更优选为100μm以上。
图10是示出本发明的实施方式3中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的其它结构的部分剖面图。在图10中,附加与图8相同的符号的部分表示相同或者对应的结构,省略其说明。与图8的结构的不同之处在于,以使金属部件62的焊料接合面相对构成第1引线框60的电极板63的表面而成为同一面的方式紧固电极板63和金属部件62的构造。
金属部件62被插入到设置于构成第1引线框60的电极板63的开口部并紧固。电极板63的被接合焊料32的一侧的表面和金属部件62的被接合焊料32的接合面构成同一面。即,金属部件62不具有从电极板63的表面突出的突出部。因此,仅在金属部件62的与半导体元件22的表面电极相向的面设置有焊料32,相比于金属部件62具有突出部的图8、图9或者实施方式1以及2所示的半导体装置,接合焊料32的面积更少,所以焊料32的接合强度降低。但是,金属部件62也可以如图10所示,电极板63的被接合焊料32的一侧的表面和金属部件62的被接合焊料32的接合面是同一面。金属部件62在俯视时比半导体元件22的表面电极的外周更靠内侧,所以焊料32以向半导体元件22的表面电极侧呈喇叭形扩展的圆角形状来形成,能够得到高的接合可靠性。
另外,在图10中,将金属部件62插入到设置于电极板63的贯通电极板63的开口部并紧固,但也可以向如图8所示的由设置于电极板63的盲孔构成的开口部插入金属部件62并紧固。即使在该情况下,也可以使电极板63的被接合焊料32的一侧的表面和金属部件62的被接合焊料32的接合面是同一面。
实施方式4.
图11是示出本发明的实施方式4中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。此外,在图11中,示出半导体元件22和金属部件62的焊料接合部的结构,但与实施方式3所示的半导体装置同样地,半导体元件21和金属部件61的焊料接合部也成为同样的结构。在图11中,附加与图1、图2以及图8相同的符号的部分表示相同或者对应的结构,省略其说明。与本发明的实施方式1的不同之处在于构成第1引线框60的金属部件162的构造。
如图11所示,第1引线框60包括由铝或者铝合金构成的电极板63和由铜或者铜合金等焊料会润湿的金属材料构成的金属部件162,金属部件162和电极板63被紧固。金属部件162具有:插入部162a,插入到设置于电极板63的开口部;以及接合部162b,具有通过焊料32而与半导体元件22的表面电极接合的接合面。在俯视时,接合部162b的面积大于插入部162a的面积。即,在俯视时金属部件162的接合面的面积大于设置于电极板63的开口部的面积。另外,在俯视时,接合部162b的面积小于半导体元件22的表面电极的面积。
金属部件162通过热套、冲压加工等在实施方式1中说明的方法,向电极板63的开口部插入插入部162a而紧固于电极板63。并且,金属部件162的接合部162b构成从电极板63的表面突出的突出部,通过焊料32来接合半导体元件22的表面电极和金属部件162的接合部162b。由此,第1引线框60和半导体元件22被电连接。
通过这样由插入到电极板63的插入部162a和具有在俯视时面积比电极板63的开口部大的接合面的接合部162b构成金属部件162,即使在电极板63的宽度并非充分宽而与接合部162b的宽度相等的情况下,也能够充分地确保将金属部件162通过焊料32接合到半导体元件22的表面电极的接合面积,进而牢固地进行金属部件162和电极板63的紧固。其结果,能够在第1引线框60与半导体元件22之间确保良好的电传导以及热传导。
此外,在图11中,金属部件162的接合部162b从电极板63的表面突出,所以接合部162b还可以称为突出部,但接合部162b也可以未必从电极板63的表面突出。即,也可以在电极板63中形成有容纳接合部162b那样的凹陷部,接合部162b被收容到凹陷部内,防止接合部162b从电极板63的表面突出。
图12是示出本发明的实施方式4中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的其它结构的部分剖面图。此外,在图12中,与图11同样地示出半导体元件22和金属部件62的焊料接合部的结构,但半导体元件21和金属部件61的焊料接合部也成为同样的结构。在图12中,附加与图11相同的符号的部分表示相同或者对应的结构,省略其说明。与图11的不同点在于,构成第1引线框60的金属部件163具有相对金属部件163的接合面而凹陷的凹部163a。
如图12所示,第1引线框60是将电极板63和金属部件163紧固而构成的。在金属部件163中,在设置了焊料32的接合面设置有凹部163a,凹部163a成为贯通金属部件163的贯通孔。因此,焊料32进入到凹部163a内而被设置。此外,凹部163a不限于贯通金属部件163的贯通孔,呈现从金属部件163的接合面凹陷的形状,只要是焊料32进入到凹部163a内的形状即可。
通过这样在金属部件163的接合面设置焊料32进入的凹部163a,从而在设置于半导体元件22的表面电极与金属部件163之间的焊料32的量过剩的情况下,多余的量的焊料被吸入到凹部163a,能够防止扩展到半导体元件22的表面电极和金属部件163的接合部的周围并附着到周围的部位而发生短路不良。
此外,图12所示的凹部也可以设置于具有图11所示的插入部和接合部的金属部件,即使是图11所示的形状的金属部件也可得到同样的效果。
实施方式5.
图13是示出本发明的实施方式5中的半导体装置的俯视图。另外,图14是示出本发明的实施方式5中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。在图13以及图14中,附加与图1相同的符号的部分表示相同或者对应的结构,省略其说明。与本发明的实施方式1的不同之处在于第1引线框60的构造。此外,在图13中,将密封树脂部省略而示出。
如图13以及图14所示,对用铝或者铝合金形成的电极板63紧固由用铜或者铜合金等焊料会润湿的金属形成的金属管构成的金属部件165,从而构成半导体装置300的第1引线框60。构成金属部件165的金属管呈现扁平的管形状。电极板63具有以从电极板63分支的方式设置的延伸部63a和延伸部63b,使管状的金属部件164盖住延伸部63a,使管状的金属部件165盖住延伸部63b,通过热压接使金属部件164、165紧固于电极板63的延伸部63a、63b。
如图14所示,金属部件165具有相向地设置的一对夹持部165a、165b,电极板63的延伸部63b被一对夹持部165a、165b夹持而紧固于金属部件165。夹持部165a、165b分别由作为金属管的金属部件165的管壁构成。金属部件164也是同样的。金属部件164、165例如具有外侧的长轴为6mm、短轴为2mm且厚度为0.4mm的椭圆状的剖面,形成为长度为8mm的管状。电极板63的延伸部63a、63b例如以长度10mm、宽度4mm、厚度0.6mm来形成。
如图14所示,将通过接合材料36而与绝缘基板10的导体层11接合的半导体元件22的表面电极和紧固于第1引线框60的电极板63的金属部件165用焊料32来接合。即,电极板63经由金属部件165而与半导体元件22的表面电极电连接。金属部件164也同样地构成,电极板63经由金属部件164而与半导体元件21的表面电极电连接。
如图13所示,金属部件164在俯视时比半导体元件21的表面电极33的外周更靠内侧,金属部件165在俯视时比半导体元件22的表面电极34的外周更靠内侧。另外,金属部件164在俯视时面积小于半导体元件21的表面电极33,金属部件165在俯视时面积小于半导体元件22的表面电极34。其结果,如图14所示,接合半导体元件22的表面电极和金属部件165的焊料32呈现向半导体元件22的表面电极侧呈喇叭形扩展那样的圆角形状,半导体元件22的表面电极和金属部件165牢固地且高可靠性地被接合。半导体元件21的表面电极和金属部件164的接合也是同样的。
图15是示出本发明的实施方式5中的其它结构的半导体装置的俯视图。在图15中,附加与图13相同的符号的部分表示相同或者对应的结构,省略其说明。与图13的半导体装置的不同之处在于第1引线框60的构造。在图15中,与图13同样地将密封树脂部省略而示出。
如图15所示,在半导体装置400中,使利用由铜或者铜合金等焊料会润湿的材料形成的金属管来构成的金属部件166、167紧固于电极板63,而构成第1引线框60。金属部件166、167与图13、图14所示的金属部件同样地呈现扁平的管形状。与图13的半导体装置不同,电极板63不具有进行了分支那样的延伸部,使管状的金属部件166、167盖住电极板63,在电极板63的预定位置紧固金属部件166、167。与图14所示的构造同样地,金属部件166、167具有相向地设置的一对夹持部,一对夹持部夹持电极板63,从而金属部件166、167和电极板63被紧固。金属部件166、167例如具有外侧的长轴为8mm、短轴为2mm且厚度为0.4mm的椭圆状的剖面,形成为长度为6mm的管状,电极板63例如以宽度6mm、厚度0.6mm来形成。然后,对金属部件166、167进行热压接而紧固于电极板63。
如图15所示,金属部件166、167在俯视时比半导体元件21、22的表面电极33、34的外周更靠内侧。另外,金属部件166、167在俯视时面积小于半导体元件21、22的表面电极33、34。通过用焊料来接合金属部件166和半导体元件21的表面电极33,并用焊料来接合金属部件167和半导体元件22的表面电极34,从而第1引线框60与半导体元件21、22电连接。半导体装置400与在实施方式1中说明的半导体装置同样地,在半导体元件21、22的表面电极与金属部件166、167之间确保所需的量的焊料,所以可得到牢固且可靠性高的接合。
另外,如在本实施方式5中说明那样,与电极板63紧固的金属部件成为通过相向地设置的一对夹持部来夹持电极板63的结构,所以通过使用如电工钳那样的简易的工具的施工方法,也能够使焊料的润湿性良好的金属部件紧固于由焊料不会润湿的铝或者铝合金构成的电极板63,能够降低半导体装置的制造成本。此外,在本实施方式5中,成为由金属管构成金属部件并盖住电极板的形状,但金属部件只要是夹持电极板的形状就不限于金属管,例如,也可以由折弯而以具有U字状的剖面形状的方式形成的金属板构成。
此外,在本实施方式5中,由铜或者铜合金等焊料会润湿的金属构成金属部件,但金属部件也可以使用内径侧由铝形成且外径侧由铜形成的复合管。即,金属部件也可以是外形侧的第1金属层由铜形成且层叠于第1金属层的内径侧的第2金属层由铝形成的复合管。通过用这样的由铝和铜构成的复合管来形成金属部件,能够利用内径侧的铝使电极板和金属部件的接合性变得良好,能够利用外径侧的铜进行与半导体元件的表面电极的焊料接合。
实施方式6.
图16是示出本发明的实施方式6中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。此外,在图16中,与实施方式4所示的图12同样地示出半导体元件22和金属部件62的焊料接合部的结构,但半导体元件21和金属部件61的焊料接合部也成为同样的结构。在图16中,附加与图12相同的符号的部分表示相同或者对应的结构,省略其说明。与实施方式所示的图12的不同点在于构成第1引线框60的金属部件62构成为铆接环形状。
如图16所示,金属部件62是环状的部件615。环状的部件615由铜构成。环状的部件615在中央设置有开口部。环状的部件615通过铆接而被插入固定到开口部。即,环状的部件615在插入到电极板63的开口部之后通过铆接加工而被固定。环状的部件615被电极板65的两面挤压而扩展得比电极板63的开口部大。另外,也可以在金属部件62与电极板63之间的至少一部分中,形成伴随金属扩散的接合部。
环状的部件615被电极板65的两面挤压而扩展得比电极板63的开口部大,从而能够将金属部件62针对电极板63的接合面积确保得较大。而且,环状的部件615的中央的开口部具有调整剩余焊料的功能。另外,还能够通过热处理等来促进部件之间的金属扩散,从而可得到使机械性强度增大等效果。
实施方式7.
图17是示出本发明的实施方式7中的半导体装置的第1引线框和半导体元件的表面电极的焊料接合部的结构的部分剖面图。在图17中,附加与实施方式5所示的图14相同的符号的部分表示相同或者对应的结构,省略其说明。与本发明的实施方式5所示的图14的不同之处在于金属管的构造。
图18是示出由金属管构成的金属部件165的结构的立体图。金属管中的与半导体元件21、22的表面电极33、34面对的部分的一部分构成为具有弹簧特性。金属部件62的一部分通过蚀刻、冲压加工而形成与管部分独立的具有弹簧特性的突起部616。突起部616构成为能够在管部分的短轴方向上弹性变形。
通过使金属管中的与半导体元件21、22的表面电极33、34面对的部分的一部分具有弹簧特性,从而即使在电极板63的加工精度不足的情况下,也能够容易地进行焊接。由此,能够降低施加到焊料接合部的应力。
接下来,参照图19~图22,说明图2、图8、图10、图14各自所示的各金属部件由多个金属层构成的情况。图19~图22各自与图2、图8、图10、图14各自分别对应。图19~图22各自只要没有特别提及就具备与图2、图8、图10、图14各自分别同样的结构。
如图19所示,金属部件61由第1金属层611和层叠于第1金属层611的第2金属层612构成。第2金属层612比第1金属层611更靠绝缘基板10侧地配置。金属部件62由第1金属层621和层叠于第1金属层621的第2金属层622构成。第2金属层622比第1金属层621更靠绝缘基板10侧地配置。
如图20所示,金属部件62由第1金属层621和层叠于第1金属层621的第2金属层622构成。第2金属层622比第1金属层621更靠绝缘基板10侧地配置。
如图21所示,金属部件62由第1金属层621和层叠于第1金属层621的第2金属层622构成。第2金属层622比第1金属层621更靠绝缘基板10侧地配置。
如图22所示,金属部件165由第1金属层1651和层叠于第1金属层1651的第2金属层1652构成。第2金属层1652配置于第1金属层1651的内侧。

Claims (14)

1.一种半导体装置,具备:
半导体元件,具有表面电极;
电极板,在俯视时面积大于所述半导体元件的所述表面电极,所述电极板由铝或者铝合金构成;以及
金属部件,具有与所述半导体元件的所述表面电极利用接合材料来接合的接合面,在俯视时所述金属部件的面积小于所述半导体元件的所述表面电极,所述金属部件由与所述电极板不同的金属构成,紧固于所述电极板,将所述半导体元件的所述表面电极和所述电极板进行电连接。
2.根据权利要求1所述的半导体装置,其中,
所述金属部件具有从所述电极板的表面突出的突出部,
所述突出部具有与所述半导体元件的所述表面电极相向的底面和设置于所述底面与所述电极板之间的侧面,
所述接合面由所述底面以及所述侧面构成,所述接合材料设置于所述底面以及所述侧面。
3.根据权利要求1或者2所述的半导体装置,其中,
所述金属部件仅由具有所述接合面的第1金属层构成。
4.根据权利要求1或者2所述的半导体装置,其中,
所述金属部件由层叠的多个金属层构成,
所述多个金属层包括具有所述接合面的第1金属层以及由与所述第1金属层不同的金属构成的第2金属层。
5.根据权利要求3或者4所述的半导体装置,其中,
所述金属部件的所述第1金属层由铜或者铜合金构成。
6.根据权利要求3至5中的任意一项所述的半导体装置,其中,
所述金属部件的所述第1金属层的厚度是10μm以上。
7.根据权利要求1至6中的任意一项所述的半导体装置,其中,
在所述金属部件的所述接合面设置有凹部,
在所述凹部内设置有所述接合材料。
8.根据权利要求1至7中的任意一项所述的半导体装置,其中,
所述电极板设置有开口部,所述金属部件被插入到所述开口部。
9.根据权利要求8所述的半导体装置,其中,
在俯视时,所述金属部件的所述接合面的面积大于所述电极板的所述开口部的面积。
10.根据权利要求1至7中的任意一项所述的半导体装置,其中,
所述金属部件具有相向地设置的一对夹持部,
所述电极板被所述金属部件的所述夹持部夹持。
11.根据权利要求10所述的半导体装置,其中,
所述金属部件由金属管构成,所述夹持部由所述金属管的管壁构成。
12.根据权利要求11所述的半导体装置,其中,
所述金属管中的与所述半导体元件的所述表面电极面对的部分的一部分具有弹簧特性。
13.根据权利要求9所述的半导体装置,其中,
所述金属部件是环状的部件,通过铆接而被插入固定到所述开口部。
14.根据权利要求1至7中的任意一项所述的半导体装置,其中,
在所述金属部件与所述电极板之间的至少一部分中形成有伴随金属扩散的接合部。
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