DE102013113736A1 - Method for producing a metal-ceramic substrate and metal-ceramic substrate - Google Patents
Method for producing a metal-ceramic substrate and metal-ceramic substrate Download PDFInfo
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Abstract
Die Erfindung betrifft ein Verfahren zur Herstellung eines Metall-Keramik-Substrates (1) umfassend zumindest eine Keramikschicht (2) mit einer Ober- und Unterseite (2.1, 2.2) und zumindest eine Metallisierung (3, 4), bei dem die Ober- und/oder Unterseite (2.1, 2.2) der zumindest einen Keramikschicht (2) mit einem Metall oder einer Metalllegierung mittels eines Kaltgasspritzverfahrens derart beschichtet wird, dass eine Metallisierung (3, 4) auf der Ober- und/oder Unterseite (2.1, 2.2) der zumindest einen Keramikschicht (2) entsteht und dass die mit der zumindest einen Metallisierung (3, 4) beschichtete Keramikschicht (2) in einem Behandlungsraum (5) bei einem Gasdruck (P) zwischen 500 und 2000 bar und einer Behandlungstemperatur (T) zwischen 300°C bis 1000°C mittels eines heißisostatischen Pressverfahrens nachbehandelt wird. The invention relates to a method for producing a metal-ceramic substrate (1) comprising at least one ceramic layer (2) having a top and bottom (2.1, 2.2) and at least one metallization (3, 4), in which the top and / or underside (2.1, 2.2) of the at least one ceramic layer (2) with a metal or a metal alloy by means of a cold gas spraying process is coated such that a metallization (3, 4) on the top and / or bottom (2.1, 2.2) of at least one ceramic layer (2) is formed and that the with the at least one metallization (3, 4) coated ceramic layer (2) in a treatment chamber (5) at a gas pressure (P) between 500 and 2000 bar and a treatment temperature (T) between 300 ° C is treated to 1000 ° C by means of a hot isostatic pressing process.
Description
Die Erfindung betrifft ein Verfahren zum Herstellen eines Metall-Keramik-Substrates sowie ein nach diesem Verfahren hergestelltes Metall-Keramik-Substrat. The invention relates to a method for producing a metal-ceramic substrate and a metal-ceramic substrate produced by this method.
Metall-Keramik-Substrate in Form von Leiterplatten bestehend aus einer Keramikschicht und wenigstens einer mit einer Oberflächenseite der Keramikschicht verbundenen und zur Ausbildung von Leiterbahnen, Kontakten, Kontakt- oder Anschlussflächen strukturierten Metallisierung sind in verschiedensten Ausführungen bekannt. Derartige Metall-Keramik-Substrate finden beispielsweise Verwendung zum Aufbau von Leistungshalbleiter-Modulen, d.h. sind für höhere Betriebsspannungen, und zwar 600 V und mehr bestimmt. Eine der Anforderungen an derartige Leistungshalbleiter-Module ist eine ausreichend hohe Teilentladungsfestigkeit, wobei auch Metall-Keramik-Substrate dieser Anforderung genügen müssen. Weiterhin ist es wünschenswert eine zuverlässige Verbindung mit hoher Haftkraft der Metallisierung mit zumindest einer der Oberflächenseiten der Keramikschicht zu erhalten. Metal-ceramic substrates in the form of printed circuit boards consisting of a ceramic layer and at least one metallization connected to a surface side of the ceramic layer and structured to form printed conductors, contacts, contact surfaces or connection surfaces are known in various designs. Such metal-ceramic substrates find use, for example, in the construction of power semiconductor modules, i. are intended for higher operating voltages, namely 600 V and more. One of the requirements for such power semiconductor modules is a sufficiently high partial discharge resistance, whereby metal-ceramic substrates must meet this requirement. Furthermore, it is desirable to obtain a reliable high adhesion bond of the metallization with at least one of the surface sides of the ceramic layer.
Zum Verbinden von die Metallisierung bildenden Metallfolien oder Metallschichten miteinander oder mit einem Keramiksubstrat bzw. einer Keramikschicht ist beispielsweise das sogenannte „DCB-Verfahren“ („Direct-Copper-Bonding“) bekannt. Dabei werden Metallschichten, vorzugsweise Kupferschichten oder -folien miteinander und/oder mit einer Keramikschicht verbunden, und zwar unter Verwendung von Metall- bzw. Kupferblechen oder Metall- bzw. Kupferfolien, die an ihren Oberflächenseiten eine Schicht oder einen Überzug („Aufschmelzschicht“) aus einer chemischen Verbindung aus dem Metall und einem reaktiven Gas, bevorzugt Sauerstoff aufweisen. Bei diesem beispielsweise in der
- – Oxidieren einer Kupferfolie derart, dass sich eine gleichmäßige Kupferoxidschicht ergibt;
- – Auflegen der Kupferfolie mit der gleichmäßigen Kupferoxidschicht auf die Keramikschicht;
- – Erhitzen des Verbundes auf eine Prozesstemperatur zwischen etwa 1025 bis 1083°C, beispielsweise auf ca. 1071°C;
- – Abkühlen auf Raumtemperatur.
- - Oxidizing a copper foil such that a uniform copper oxide layer results;
- - placing the copper foil with the uniform copper oxide layer on the ceramic layer;
- - Heating the composite to a process temperature between about 1025 to 1083 ° C, for example, to about 1071 ° C;
- - Cool to room temperature.
Ein Nachteil des DCB-Verfahrens besteht darin, dass prozessbedingte Fehlstellen zwischen der jeweiligen Kupferschicht und der Keramikschicht auftreten können. Diese Fehlstellen beeinträchtigen zwar die thermischen Eigenschaften eines unter Verwendung des DCB-Verfahrens hergestellten Metall-Keramik-Substrates kaum, jedoch ergibt sich aufgrund der Fehlstellen eine Verschlechterung der Teilentladungsfestigkeit des daraus hergestellten Leistungshalbleiter-Moduls. A disadvantage of the DCB method is that process-related defects can occur between the respective copper layer and the ceramic layer. Although these defects hardly affect the thermal properties of a metal-ceramic substrate produced by using the DCB method, there is a deterioration in the partial discharge resistance of the power semiconductor module produced therefrom due to the defects.
Ferner ist aus den Druckschriften
Aus der
Aus der
Zur Beschichtung eines Substrates mit einer Metallisierung sind diverse thermische Spritztechniken, insbesondere das so genannte Kaltgasspritzen bekannt, dessen Grundlagen beispielsweise in der
Ausgehend von dem voranstehend genannten Stand der Technik liegt der Erfindung die Aufgabe zugrunde, ein Verfahren zur Herstellung eines Metall-Keramik-Substrates aufzuzeigen, welches zumindest eine einschlussfreie Metallisierung mit hoher, gleichmäßig verteilter Haftkraft bzw. Anbindungsstärke ermöglicht. Die Aufgabe wird durch ein Verfahren gemäß dem Patentanspruch 1 und ein nach diesem Verfahren hergestelltes Keramiksubstrat gemäß Patentanspruch 16 gelöst. Based on the above-mentioned prior art, the present invention seeks to provide a method for producing a metal-ceramic substrate, which allows at least one inclusion-free metallization with high, uniformly distributed adhesive force or bonding strength. The object is achieved by a method according to claim 1 and a ceramic substrate produced according to this method according to claim 16.
Der wesentliche Aspekt des erfindungsgemäßen Verfahrens ist darin zu sehen, dass die Ober- und/oder Unterseite der zumindest einen Keramikschicht mit einem Metall oder einer Metalllegierung mittels Kaltgasspritzen derart beschichtet wird, dass eine Metallisierung auf der Ober- und/oder Unterseite der zumindest einen Keramikschicht entsteht und dass die mit zumindest einer Metallisierung beschichtete Keramikschicht bei einem Gasdruck zwischen 500 und 2000 bar und einer Behandlungstemperatur zwischen 300°C bis 1000°C nachbehandelt wird, und zwar mittels eines heißisostatischen Pressverfahrens. Hierdurch wird die Anbindungsstärke bzw. die Haftkraft der zumindest einen mittels Kaltgasspritzen erzeugten Metallisierung an der Keramikschicht erhöht und darüber hinaus das Entstehen von Fehlstellen bzw. so genannten Lunkern, insbesondere Mikrolunkern erheblich reduziert. Weiterhin vorteilhaft können mittels Kaltgasspritzen und einer Nachbehandlung mittels heißisostatischen Pressen im Vergleich zur DCB-Verbindungstechnologie Metallisierungen mit einer geringeren Schichtdicke von ca. 50–200 Mikrometer auf eine Keramikschicht aufgebracht werden. Weiterhin vorteilhaft können die Korngrößen beim HIP-Verfahren im Vergleich zum DCB-Verfahren ebenfalls eingestellt werden. Mittels Kaltgasspritzen kann beispielsweise eine Metallisierung mit einer Schichtdicke von bis 300 Mikrometer erzeugt werden. The essential aspect of the method according to the invention can be seen in that the top and / or bottom of the at least one ceramic layer is coated with a metal or a metal alloy by means of cold gas spraying such that a metallization on the top and / or bottom of the at least one ceramic layer arises and that the coated with at least one metallization ceramic layer is post-treated at a gas pressure between 500 and 2000 bar and a treatment temperature between 300 ° C to 1000 ° C, by means of a hot isostatic pressing method. As a result, the bonding strength or the adhesive force of the at least one metallization produced by means of cold gas spraying on the ceramic layer is increased and, moreover, the generation of imperfections or so-called voids, in particular micro-shrinkers, is considerably reduced. Further advantageously, by means of cold gas spraying and a post-treatment by means of hot isostatic pressing in comparison to the DCB connection technology metallizations with a smaller layer thickness of about 50-200 microns are applied to a ceramic layer. With further advantage, the particle sizes in the HIP process can also be adjusted in comparison to the DCB process. By means of cold gas spraying, for example, a metallization can be produced with a layer thickness of up to 300 microns.
In einer bevorzugten Ausführungsvariante wird mittels des Kaltgasspritzverfahrens eine geschlossene äußere Poren aufweisende, d.h. vorzugsweise gasdichte Metallisierung erzeugt. Unter einer gasdichten Metallisierung wird im Sinne der Erfindung eine Metallisierung mit einer Oberfläche mit geschlossenen Poren verstanden. Diese ist besonders gut für eine Nachbehandlung mittels eines HIP-Verfahrens geeignet, da mittels des HIP-Verfahrens vorzugsweise vollständig eingeschlossene Fehlstellen bzw. Hohlräume effektiv komprimiert werden können. In a preferred embodiment, by means of the cold gas spraying method, a closed outer pore-containing, i. preferably produces gas-tight metallization. In the sense of the invention, a gas-tight metallization is understood to mean a metallization having a surface with closed pores. This is particularly well suited for a post-treatment by means of a HIP process, since by means of the HIP process preferably fully enclosed voids or voids can be effectively compressed.
Um auch offene, d.h. äußere Poren der Metallisierungsoberfläche vermeiden, zumindest reduzieren zu können, können besonders vorteilhaft die mittels Kaltgasspritzen aufgebrachte Metallisierungen einer Diffusionsbehandlung oder einer Sinterbehandlung unterzogen werden, und zwar vorzugsweise vor Durchführung der Nachbehandlung mittels eines HIP-Verfahrens. In order to avoid open, ie outer pores of the metallization, at least to be able to reduce, particularly advantageous by means of cold gas spraying applied metallization of a diffusion treatment or a sintering treatment, preferably before carrying out the aftertreatment by means of a HIP process.
In einer bevorzugten Ausführungsvariante wird die Diffusionsbehandlung der mit zumindest einer Metallisierung beschichtete Keramikschicht in einer Vakuumatmosphäre oder in einer Sauerstoffatmosphäre oder in einer Inertgasatmosphäre, vorzugsweise einer Argonatmosphäre durchgeführt. Vorteilhaft wird dadurch die Anbindungsstärke bzw. die Haftkraft zwischen der Metallisierung und der Keramikschicht weiter verbessert. In a preferred embodiment variant, the diffusion treatment of the ceramic layer coated with at least one metallization is carried out in a vacuum atmosphere or in an oxygen atmosphere or in an inert gas atmosphere, preferably an argon atmosphere. Advantageously, this further improves the bonding strength or the adhesion between the metallization and the ceramic layer.
In einer Ausführungsvariante werden die Oberseite der Keramikschicht mit einer ersten Metallisierung und die Unterseite der Keramikschicht mit einer zweiten Metallisierung versehen, wobei in die zweite Metallisierung zur Vergrößerung der Metallisierungsoberfläche eine Strukturierung und/oder mehrere Ausnehmungen unterschiedlicher Form und/oder Tiefe eingebracht werden. Alternativ oder zusätzlich können in die Oberseite oder die Unterseite der Keramikschicht vor der Beschichtung mit dem Metall oder einer Metalllegierung mittels des Kaltgasspritzverfahrens zur Vergrößerung der Keramikoberfläche eine Strukturierung und/oder mehrere Ausnehmungen unterschiedlicher Form und/oder Tiefe eingebracht werden. In one embodiment variant, the upper side of the ceramic layer is provided with a first metallization and the underside of the ceramic layer with a second metallization, wherein structuring and / or multiple recesses of different shape and / or depth are introduced into the second metallization to increase the metallization surface. Alternatively or additionally, a structuring and / or a plurality of recesses of different shape and / or depth can be introduced into the top side or the bottom side of the ceramic layer before coating with the metal or a metal alloy by means of the cold gas spraying method for enlarging the ceramic surface.
Weiterhin vorteilhaft wird zumindest eine Metallisierung aus Kupfer oder einer Kupferlegierung hergestellt, wobei die mit Kupfer oder einer Kupferlegierung beschichtete Keramikschicht bei einer Behandlungstemperatur zwischen 800°C und 1000°C nachbehandelt wird. Die Keramikschicht kann beispielsweise zur Herstellung einer Metallisierung aus Kupfer oder einer Kupferlegierung mittels eines Direct-Copper-Bonding-Verfahren mit einer Kupferschicht oder mit einer Kupferlegierungsschicht beschichtet werden. Further advantageously, at least one metallization is made of copper or a copper alloy, wherein the coated with copper or a copper alloy ceramic layer is post-treated at a treatment temperature between 800 ° C and 1000 ° C. For example, the ceramic layer can be coated with a copper layer or with a copper alloy layer by means of a direct copper bonding method for producing a metallization from copper or a copper alloy.
Alternativ oder zusätzlich wird die zumindest eine Metallisierung aus Aluminium oder einer Aluminiumlegierung hergestellt, wobei die mit Aluminium oder einer Aluminiumlegierung beschichtete Keramikschicht bei einer Behandlungstemperatur zwischen 400°C und 600°C nachbehandelt wird. Beispielsweise kann zur Herstellung der Metallisierung aus Aluminium oder einer Aluminiumlegierung die Keramikschicht mittels eines Lotverfahrens, insbesondere eines Aktivlotverfahrens mit einer Aluminiumschicht oder mit einer Aluminiumlegierungsschicht beschichtet werden. Alternatively or additionally, the at least one metallization is made of aluminum or an aluminum alloy, wherein the ceramic layer coated with aluminum or an aluminum alloy is after-treated at a treatment temperature between 400 ° C and 600 ° C. For example, to produce the metallization from aluminum or an aluminum alloy, the ceramic layer can be coated with an aluminum layer or with an aluminum alloy layer by means of a soldering process, in particular an active soldering process.
Die Keramikschicht wird aus einer Oxid-, Nitrid- oder Karbidkeramik wie Aluminiumoxid (Al2O3) oder Aluminiumnitrid (AlN) oder Siliziumnitrid (Si3N4) oder Siliziumkarbid (SiC) oder aus Aluminiumoxid mit Zirkonoxid (Al2O3 + ZrO2) hergestellt. The ceramic layer is made of an oxide, nitride or carbide ceramic such as alumina (Al 2 O 3) or aluminum nitride (AlN) or silicon nitride (Si 3 N 4) or silicon carbide (SiC) or alumina with zirconia (Al 2
Ebenfalls ist Gegenstand der vorliegenden Erfindung ein nach dem erfindungsgemäßen Verfahren hergestelltes Metall-Keramik-Substrat umfassend zumindest eine Keramikschicht, dessen Ober- und Unterseite mit zumindest einer erfindungsgemäß angebundener Metallisierung. Likewise provided by the present invention is a metal-ceramic substrate produced by the process according to the invention, comprising at least one ceramic layer whose top and bottom are provided with at least one metallization bonded to the invention.
Die Ausdrucke „näherungsweise“, „im Wesentlichen“ oder „etwa“ bedeuten im Sinne der Erfindung Abweichungen vom jeweils exakten Wert um +/–10%, bevorzugt um +/–5% und/oder Abweichungen in Form von für die Funktion unbedeutenden Änderungen. The expressions "approximately", "substantially" or "approximately" in the context of the invention mean deviations from the respective exact value by +/- 10%, preferably by +/- 5% and / or deviations in the form of changes insignificant for the function ,
Weiterbildungen, Vorteile und Anwendungsmöglichkeiten der Erfindung ergeben sich auch aus der nachfolgenden Beschreibung von Ausführungsbeispielen und aus den Figuren. Dabei sind alle beschriebenen und/oder bildlich dargestellten Merkmale für sich oder in beliebiger Kombination grundsätzlich Gegenstand der Erfindung, unabhängig von ihrer Zusammenfassung in den Ansprüchen oder deren Rückbeziehung. Auch wird der Inhalt der Ansprüche zu einem Bestandteil der Beschreibung gemacht. Further developments, advantages and applications of the invention will become apparent from the following description of exemplary embodiments and from the figures. In this case, all described and / or illustrated features alone or in any combination are fundamentally the subject of the invention, regardless of their summary in the claims or their dependency. Also, the content of the claims is made an integral part of the description.
Die Erfindung wird im Folgenden anhand der Figuren an Ausführungsbeispielen näher erläutert. Es zeigen: The invention will be explained in more detail below with reference to the figures of exemplary embodiments. Show it:
Die Keramikschicht
Die Keramikschicht
Die Metallisierungen
Das Beschichten der Ober- und/oder Unterseite
In
Hierdurch wird die Oberseite
Hier setzt die Erfindung an und schlägt ein verbessertes Verfahren zur Herstellung eines Metall-Keramik-Substrates
Die prinzipielle Funktionsweise des heißisostatischen Pressverfahrens bzw. so genannten HIP-Verfahrens oder HIP-Prozesses ist bekannt. Der auf die zu behandelten Schichten vorzugsweise flächig aufgebrachte Druck P wird hierbei mittels eines Gases oder Fluides erzeugt. Vorteilhaft kann bei Verwendung des HIP-Verfahrens zur Nachbehandlung einer durch Kaltgasspritzen hergestellten flächigen Verbindung zwischen den Metallisierungen
Auch kann auf der Ober- oder Unterseite
Die Metallisierungen
Beim Kaltgasspritzen können Metallisierungen mit vereinzelt offenen, äußeren Poren entstehen. Um eine für die Durchführung des HIP-Verfahrens optimale, und zwar gasdichte Metallisierung
Die Diffusionsnachbehandlung der mit der zumindest einer Metallisierung
Zur Vergrößerung der Metallisierungsoberfläche beispielsweise der zweiten Metallisierung
Alternativ können vor Beschichtung der Ober- oder Unterseite
Auch kann die Entstehung einer Oxidschicht durch eine Vorbehandlung der Keramikschicht
Insbesondere ist bei Verwendung einer Aluminiumnitrid-Keramikschicht
Bei Verwendung einer Siliziumnitrid-Keramikschicht
In einer weiteren Ausführungsvariante wird die erste Metallisierung
In einer Ausführungsvariante des erfindungsgemäßen Verfahrens wird eine der Metallisierungen
Auch kann auf die durch Kaltgasspritzen erzeugten Metallisierungen
In einer alternativen Ausführungsvariante gemäß
Die Erfindung wurde voranstehend an Ausführungsbeispielen beschrieben. Es versteht sich, dass zahlreiche Änderungen sowie Abwandlungen möglich sind, ohne dass dadurch der der Erfindung zugrunde liegend Erfindungsgedanke verlassen wird. The invention has been described above by means of exemplary embodiments. It is understood that numerous changes and modifications are possible, without thereby departing from the invention underlying the idea of the invention.
BezugszeichenlisteLIST OF REFERENCE NUMBERS
- 1 1
- Metall-Keramik-Substrat Metal-ceramic substrate
- 2 2
- Keramikschicht ceramic layer
- 2.1 2.1
- Oberseite top
- 2.2 2.2
- Unterseite bottom
- 3 3
- erste Metallisierung first metallization
- 4 4
- zweite Metallisierung second metallization
- 5 5
- Behandlungsraum treatment room
- 6 6
- dritte Metallisierung third metallization
- 7 7
- vierte Metallisierung fourth metallization
- D D
- Düsenanordnung nozzle assembly
- P P
- Behandlungsdruck treatment pressure
- T T
- Behandlungstemperatur treatment temperature
- TS TS
- mit Partikeln beladener Trägergasstrom laden with particles carrier gas stream
ZITATE ENTHALTEN IN DER BESCHREIBUNG QUOTES INCLUDE IN THE DESCRIPTION
Diese Liste der vom Anmelder aufgeführten Dokumente wurde automatisiert erzeugt und ist ausschließlich zur besseren Information des Lesers aufgenommen. Die Liste ist nicht Bestandteil der deutschen Patent- bzw. Gebrauchsmusteranmeldung. Das DPMA übernimmt keinerlei Haftung für etwaige Fehler oder Auslassungen.This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.
Zitierte PatentliteraturCited patent literature
- US 3744120 [0003] US 3744120 [0003]
- DE 2319854 [0003] DE 2319854 [0003]
- DE 2213115 [0005] DE 2213115 [0005]
- EP 153618 A [0005] EP 153618 A [0005]
- EP 1716624 B1 [0006] EP 1716624 B1 [0006]
- EP 1774841 B1 [0007] EP 1774841 B1 [0007]
- EP 0484533 B1 [0008] EP 0484533 B1 [0008]
Claims (16)
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CN111726938A (en) * | 2020-06-15 | 2020-09-29 | 江苏百旭电子新材料科技有限公司 | FCCL flexible copper clad laminate and manufacturing method thereof |
CN111867259A (en) * | 2020-07-30 | 2020-10-30 | 南京凯泰化学科技有限公司 | Preparation method of ceramic copper-clad plate |
CN115884953A (en) * | 2020-07-30 | 2023-03-31 | 罗杰斯德国有限公司 | Method for producing a cermet substrate and cermet substrate produced by means of such a method |
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