CN111373529A - 用于允许恢复电源模块的管芯的互连部的系统 - Google Patents

用于允许恢复电源模块的管芯的互连部的系统 Download PDF

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CN111373529A
CN111373529A CN201880071612.6A CN201880071612A CN111373529A CN 111373529 A CN111373529 A CN 111373529A CN 201880071612 A CN201880071612 A CN 201880071612A CN 111373529 A CN111373529 A CN 111373529A
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interconnect
die
interconnects
periodic current
power supply
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CN111373529B (zh
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J·万楚克
J·布兰德雷洛
S·莫洛夫
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Mitsubishi Electric Corp
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Abstract

本发明涉及一种用于允许恢复电源模块的管芯的第一互连部的系统，该第一互连部将管芯连接到电路。该系统包括：电源模块的至少一个另一互连部；周期性电流源，该周期性电流源连接到所述至少一个另一互连部，用于产生流过所述至少一个另一互连部的周期性电流，以在预定持续时间期间在第一互连部的至少一部分中达到预定温度。本发明还涉及相关联的方法。

Description

用于允许恢复电源模块的管芯的互连部的系统
技术领域
本发明总体上涉及一种用于允许恢复电源模块的管芯的互连部的装置以及方法和系统。
背景技术
安装在应用中的电源模块由于它们由每种具有不同特性的各种层状材料组成而经历损耗。
电源模块在运行期间必须支持较大的温度漂移。运行固有的损耗表现为诸如焊料层或接合布线之类的各种界面层中裂纹的增加。
为了应对损耗，用更好的匹配材料来设计电源模块，但是这种解决方案通常会遭受电气性能不良和制造成本更高的困扰。此外，由于这些附加的制造成本，设计适应最严苛使用场景的电源模块是不切实际的，从而导致应力越大的应用具有越低的电源模块寿命。
通常，在发生损耗故障后，更换电源模块需要任务中的停机时间并且由于必须更换电源模块导致成本增加。在许多应用中，电源模块故障的停机时间成本和干预成本以及不可预测性是巨大的，并且在成本方面能够完全消除使用电力电子设备的好处。
电源模块的薄弱点是顶侧互连部，其中，铝接合布线和/或铜互连部中会遭受微结构裂纹。
发明内容
本发明旨在允许恢复电源模块的管芯的至少一个互连部。
为此，本发明涉及一种允许恢复电源模块的管芯的第一互连部的系统，该第一互连部将管芯连接到电路，其特征在于，该系统包括：
-所述电源模块的至少一个另一互连部，
-周期性电流源，该周期性电流源连接到所述至少一个另一互连部，用于产生流过所述至少一个另一互连部的周期性电流，以在预定持续时间期间在所述第一互连部的至少一部分中达到预定温度。
本发明还涉及一种允许恢复电源模块的管芯的第一互连部的方法，该第一互连部将管芯连接到电路，其特征在于，该方法包括以下步骤：
-向所述电源模块的至少一个另一互连部提供周期性电流源，用于产生流过所述至少一个另一互连部的周期性电流，以在所述第一互连部的至少一部分中达到预定温度，
-在预定持续时间期间将所述周期性电流控制在所述预定温度下。
因此，能够通过简单的干预来恢复电源模块的健康。
具体地，通过注入高频电流来瞄准互连部中的微结构裂纹，以便不仅提高互连部温度，而且还增加沿这些裂纹的压力，从而提高该区域中的扩散速率。扩散使裂纹愈合，因此提高了电源模块的寿命。
根据特定特征，第一互连部的第一端子连接至管芯，所述至少一个第二互连部的第一端子连接至第一互连部的第一端子，并且所述周期性电流源连接至所述互连部的第二端子，用于产生流过所述互连部的周期性电流。
因此，电源模块的简单且低成本的修改使得能够进行恢复过程。
注入周期性电流而不损坏半导体组件。由于该电流通过管芯的顶侧金属化部、互连部而短路，因此温度保持在临界硅温度以下，通常为175C。
根据特定特征，互连部是接合布线。
因此，恢复过程能够应用于需要灵活且低成本可制造性的封装。
根据特定特征，接合布线是铝合金接合布线。
因此，修复过程可应用于在现有电源模块封装的状态中找到的标准合金。
根据特定特征，周期性电流源是频率高于100KHz且RMS值为82A至108安培的方波或正弦波信号。
因此，能够从标准电源电子转换器技术开发电流源注入。
根据特定特征，预定温度在150℃至200℃之间，并且预定持续时间在150至100小时之间。
因此，能够在用于维护的转换器停机的小窗口内执行恢复过程。
根据特定特征，互连部是铜通孔，周期性电流源连接到另外两个互连部，并且电源模块还包括一个感应线圈，所述感应线圈连接到所述两个互连部，以在预定持续时间期间在第一互连部的至少一部分中达到预定温度。
因此，能够通过施加局部热量而不直接接触铜通孔的方式，在嵌入式封装中启动恢复过程。
根据特定特征，所述互连部是铜通孔，所述周期性电流源连接到另外两个互连部，并且所述电源模块还包括一个磁结构，所述磁结构连接到所述两个互连部，以在所述预定持续时间期间在所述第一互连部的至少一部分中达到所述预定温度。
因此，能够通过施加局部热量和感应电流而不直接接触铜通孔，在嵌入式封装中启动恢复过程。
通过阅读下面的示例性实施方式的描述，本发明的特征将变得更加清楚，所述描述是参照附图进行的。
附图说明
[图1]
图1表示电源模块的铝接合布线顶侧互连部的示例。
[图2]
图2表示至少具有使本发明能够实现的补充连接部的电源模块的侧视图。
[图3a]
图3a表示接合布线中的裂纹和接合布线中的脉冲电流流动的放大图。
[图3b]
图3b表示接合布线中的裂纹、接合布线中的脉冲电流流动和根据本发明的裂纹的愈合过程的放大图。
[图4]
图4表示具有使本发明能够实现的至少一个补充连接部和至少一个嵌入式感应线圈的电源模块的侧视图。
[图5]
图5表示具有使本发明能够实现的至少一个补充连接部和至少一个嵌入式磁结构的电源模块的侧视图。
[图6]
图6表示根据本发明的控制器的架构的示例。
[图7]
图7表示用于控制功率管芯的至少一个顶连接部的愈合过程的算法。
具体实施方式
图1表示电源模块的铝接合布线顶侧互连部的示例。
接合布线Bd经由金属化层Me固定在管芯Di上。
接合布线Bd经受微结构裂纹Cr。图2表示至少具有使本发明能够实现的补充连接部的电源模块的侧视图。
经典电源模块包括顶互连部Cn20和Cn21。互连部Cn20和Cn21分别固定在直接铜接合DCB的铜层20和21上，该直接铜接合DCB固定至底板BP和散热器HS。
互连部Cn21和铜层21通过接合布线Bd21连接至管芯Di，该接合布线Bd21可能遭受微结构裂纹。
根据本发明，电源模块还包括固定在直接铜接合DCB的铜层22上的辅助互连部Cn22。互连部Cn22、铜层22通过辅助接合布线Bd22连接到管芯Di。
互连部Cn21、Cn22、铜层22和22、接合布线Bd21和Bd22形成电气路径。
当互连部Cn21和Cn22连接到电源(例如高频电流电源)时，电流流过互连部Cn21、Cn22、铜层22和22、接合布线Bd21和Bd22。
根据本发明，高频电流以规则的间隔流过互连部Cn21、Cn22、铜层22和22、接合布线Bd21和Bd22，以维持高结构完整性的状态。具体地，通过注入高频电流来瞄准铝接合布线中的微结构裂纹，以不仅提高接合布线温度，而且还增加沿这些裂纹的压力，从而增加该区域中的扩散速率。扩散会使裂纹愈合，因此提高电源模块的寿命。
由于高频电流通过顶侧金属化部Me、l接合布线、Bd21和Bd22以及互连点Cn21和Cn22短路，因此注入了高频电流而不会损坏半导体组件，并且温度保持低于临界Si温度，通常为175C。
请注意，附加接合布线的数量应至少等于传统电源模块中已经存在的接合布线的数量。
作为实现的示例，管芯具有6条接合布线，并且注入的高频电流的RMS值为82A至108A，以使每条接合布线中的电流密度保持在95A/mm2至143A/mm2之间，以在14mm接合布线连接部上具有150℃至200℃的峰值接合布线温度(假设环境温度为35℃)。
该高温足以在50至100小时(即，干预时间)的时段引起显著影响接合布线微结构的自愈合性质所需的高扩散速率。自愈合效应的关键因素是在裂纹中热应力的持续时间和温度高低，以实现高材料扩散速率。
这里必须注意，能够考虑使用其他铝合金(即，Al-Cu)，以改善自愈合特性或具有更高的自扩散速率。
高频电流注入是由于趋肤效应进一步增加沿着裂纹边缘在接合布线中的电阻所必需的。作为示例，对于400um的铝接合布线，可以注入500kHz的电流，这应对应于115um的趋肤深度，并且对于相同的电流大小，接合布线中的损耗增加了四倍。该电流可以由500KHz的方波或正弦波信号组成。
图3a表示接合布线中的裂纹和接合布线中的脉冲电流流动的放大图。
在图3a中，箭头表示流过接合布线Bd的高频电流。
在电源模块封装件中，铝(99％铝合金)接合布线通常是最薄弱的组件，这些线的剥离是最常见的故障模式。由于接合布线在正常操作过程中遭受热疲劳，因此在接合布线内到芯片金属化表面的界面处从外边缘朝向中心形成裂纹。当接合布线界面中的裂纹在接合布线Bd中处于微观水平(即1-10um)时，优选地施加高频注入电流。如果电源模块被设计为20年的工作寿命，即假设由于热循环而导致热机械磨损，则维护间隔可以是例如大约5年。
高频注入电流如箭头所示地流过铝接合布线。由于裂纹是高电阻的局部点，因此与注入电路的其他部分相比，在接合布线中的裂纹区Zna会产生大量热量。局部热量引起向外热膨胀，使裂纹的侧面在高压和高温下聚在一起，从而使得在裂纹中发生材料扩散。在这些条件下经过一段时间之后，裂纹将愈合，如图3b所示，并且图3a中的裂纹区Zna将移动到图3b中的裂纹区Znb。
图4表示具有使本发明能够实现的至少一个补充连接部和至少一个嵌入式感应线圈的电源模块的侧视图。
电源模块包括处于标为Vi1、Vi2和Vi3的通孔的形式的互连部(例如铜层)，所述互连部将管芯Di连接到外部组件。
使用焊料130将管芯Di固定在直接铜接合(DCB)基板140、150、160的铜层140上，陶瓷150固定在铜底板160上，该铜底板160固定在冷却板上。
根据本发明，对于一个互连部，电源模块还至少包括嵌入式感应线圈In1和In2以及辅助互连部Expt41和Extp42。
以这种方式，电流通过互连部Extp41和Extp42注入，因为嵌入的感应线圈层In1和In2以加热线圈沿着每个铜通孔Vu1、Vi2和Vi3往复的方式放置，所以在每个铜通孔中感应加热。通常，因为通孔长度大于其宽度，因此可以放置这些嵌入式线圈，但是在对于每个通孔的匝数与层叠复杂度之间自然存在折中。
图5表示具有使本发明能够实现的至少一个补充连接部和至少一个嵌入式磁结构的电源模块的侧视图。
电源模块包括处于标为Vi51、Vi52和Vi53的通孔的形式的互连部(例如铜层)，其将管芯Di连接到外部组件。
使用焊料130将管芯Di固定在直接铜接合(DCB)基板140、150、160的铜层140上，陶瓷150固定在铜底板160上，该铜底板160固定在冷却板上。
根据本发明，针对一个互连部，电源模块至少还包括嵌入式磁结构Mm1、Mm2、Mm3和Mm4。诸如镍铁片之类的材料可以嵌入在PCB结构内。与变压器的方式类似，该结构以感应电流从铜通孔流过互连部表面和金属化表面的方式布置。磁结构Mm1和Mm2形成第一变压器，并且磁结构Mm3和Mm4形成第二变压器。
图6表示根据本发明的控制器的架构的示例。
控制器10具有例如基于通过总线601和由如图7所公开的程序控制的处理器600连接在一起的组件的架构。
总线601将处理器600链接到只读存储器ROM 602、随机存取存储器RAM 603和输入输出I/O IF接口605。
存储器603包含旨在接收变量和与图7中公开的算法有关的程序的指令的寄存器。
处理器600通过输入输出I/O IF 605接收集电极电流Ic、由温度传感器感测到的温度或热敏参数反馈，并且因此控制流过补充互连部的电流，使得将电源模块中的功耗控制在特定水平以诱导愈合状态。依据电源模块中修复材料的特性，可能需要使温度保持恒定，在这种情况下，能够将嵌入电源模块的热电偶用于调整目的，或者能够采用热敏电参数(例如，某电流Ic的Vg)。
只读存储器或可能的闪存602包含与图7中公开的算法有关的程序的指令，当控制器10通电时，至随机存取存储器603。
控制器10可以通过由诸如PC(个人计算机)、DSP(数字信号处理器)或微控制器之类的可编程计算机器执行一组指令或者程序以软件来实现；或者通过机器或诸如FPGA(现场可编程门阵列)或ASIC(专用集成电路)之类的专用组件以硬件实现。
换句话说，控制器10包括使得辊10能够执行与如图7中公开的算法有关的程序的电路或包括电路的设备。
图7表示用于控制焊料层的加热状态以实现根据本发明的愈合过程的算法。
在示例中公开了本算法，其中该算法由控制器10的处理器600执行。
在步骤S700，恢复过程被禁用。
在下一步骤S701，处理器600使高频电流流过连接器Cn21和Cn22、或Extp41和Ext42、或Extp51和Ext52，并控制加热状态控制回路。
在给定的持续时间期间调整温度，例如，对于铝合金接合布线在150℃，30分钟。
在步骤S702，处理器600检查给定的持续时间是否完成。如果给定的持续时间完成，则处理器600移至步骤S703。否则，处理器600返回到步骤S701。
在步骤S703，处理器600禁用恢复过程。
自然地，在不脱离本发明的范围的情况下，可以对上述本发明的实施方式进行许多变型。

Claims (9)

1.一种用于允许恢复电源模块的管芯的第一互连部的系统，该第一互连部将所述管芯连接到电路，其特征在于，该系统包括：
-所述电源模块的至少一个另一互连部，
-周期性电流源，该周期性电流源连接到所述至少一个另一互连部，用于产生流过所述至少一个另一互连部的周期性电流，以在预定持续时间期间在所述第一互连部的至少一部分中达到预定温度。
2.根据权利要求1所述的系统，其特征在于，所述第一互连部的第一端子连接至所述管芯，所述至少一个第二互连部的第一端子连接至所述第一互连部的第一端子，并且所述周期性电流源连接至所述互连部的所述第二端子，用于产生流过所述互连部的周期性电流。
3.根据权利要求2所述的系统，其特征在于，所述互连部是接合布线。
4.根据权利要求3所述的系统，其特征在于，所述接合布线是铝合金接合布线。
5.根据权利要求2至4中的任一项所述的系统，其特征在于，所述周期性电流源是频率高于100KHz且RMS值为82A至108安培的方波或正弦波信号。
6.根据权利要求2至5中的任一项所述的系统，其特征在于，所述预定温度在150℃至200℃之间，并且所述预定持续时间在150小时至100小时之间。
7.根据权利要求1所述的系统，其特征在于，所述互连部是铜通孔，所述周期性电流源连接到另外两个互连部，并且所述电源模块还包括一个感应线圈，所述感应线圈连接到所述两个互连部，以在所述预定持续时间期间在所述第一互连部的至少一部分中达到所述预定温度。
8.根据权利要求1所述的系统，其特征在于，所述互连部是铜通孔，所述周期性电流源连接到另外两个互连部，并且所述电源模块还包括一个磁结构，所述磁结构连接到所述两个互连部，以在所述预定持续时间期间在所述第一互连部的至少一部分中达到所述预定温度。
9.一种用于允许恢复电源模块的管芯的第一互连部的方法，该第一互连部将所述管芯连接到电路，其特征在于，该方法包括以下步骤：
-向所述电源模块的至少一个另一互连部提供周期性电流源，用于产生流过所述至少一个另一互连部的周期性电流，以在所述第一互连部的至少一部分中达到预定温度，
-在预定持续时间期间将所述周期性电流控制在所述预定温度。
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