JP2007335782A - 半導体装置モジュールの製造方法及び半導体装置モジュール - Google Patents
半導体装置モジュールの製造方法及び半導体装置モジュール Download PDFInfo
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Abstract
【解決手段】金属ベース基材上に絶縁層を形成し、その上に銅箔パターンを形成する(ステップS3)。次に、銅箔パターンの一部を被覆するように、ソルダーレジスト層を絶縁層上に形成し(ステップS4)、金属膜表面が露出した銅箔パターン表面に水溶性の耐熱性プリフラックスを塗布する(ステップS5)。次に、金属膜上にクリーム半田を塗布し(ステップS6)、この上に半導体素子を設置するために(ステップS7)、リフローする(ステップS8)。不純物を除去した後(ステップS9)、超音波接合法によって、ワイヤを半導体素子の電極部及び銅箔パターンに直接接合させる(ステップS10)。これにより、半導体装置モジュールの低コスト化及び歩留まりの向上を図ることができる。
【選択図】図1
Description
また、本発明では、半導体装置モジュールに関し、金属ベース基材上に絶縁層を形成し、絶縁層上にパターニングされた第1の金属膜及び第2の金属膜を形成し、第1の金属膜及び第2の金属膜の一部を被覆するように、絶縁層上にソルダーレジスト層を形成し、第1の金属膜表面が露出した部分に、半田、または半田と金属片を介して半導体素子を設置し、半導体素子の電極部と第2の金属膜表面が露出した部分を金属線を介して電気的に直接接合するようにした。
先ず、第1の実施の形態について説明する。
図1は第1の実施の形態の超音波接合方法の原理説明図である。
図2は第1の実施の形態の半導体装置の要部断面模式図である。ここで、図2(A)は金属膜上に半田を介して、半導体素子を設置させた場合の要部断面模式図であり、図2(B)は金属膜上に半田及び金属片を介して、半導体素子を設置させた場合の要部断面模式図である。
図3はCu膜形成工程の要部断面図である。
そして、絶縁層20上に、めっきまたは圧延法により金属膜、例えばCu膜25を形成させる(ステップS2)。Cu膜25の膜厚は、18μm〜3mmである。
図3に示すCu膜25を形成した後に、Cu膜25を所定の回路パターンにエッチング加工し、銅箔パターンを形成する。即ち、Cu膜30と、Cu膜40を形成する(ステップS3)。そして、図4に示すように、Cu膜30及びCu膜40のそれぞれの一部を被覆するように、ソルダーレジスト層50を絶縁層20上に形成する(ステップS4)。そして、次工程においてCu膜30及びCu膜40表面の酸化防止をするために、金属膜表面が露出したCu膜30及びCu膜40表面に、水溶性の耐熱性プリフラックスを塗布する(ステップS5)。
Cu膜30上に、クリーム半田60を塗布した後(ステップS6)、クリーム半田60上に、半導体素子70を設置する(ステップS7)。半導体素子70は、例えば、IGBT(Insulated Gate Bipolar Transistor)等のパワー半導体、またはダイオード等である。次に、半導体素子70とCu膜30をクリーム半田60を介して接合させるためリフローする(ステップS8)。そして、リフローにて生じた不純物、例えばフラックス、半田ボール等を洗浄により除去する(ステップS9)。
金属線であるワイヤ状のアルミニウム線80を半導体素子70の電極部及びCu膜40に、超音波接合法により直接接合させて、半導体素子70の電極部とCu膜40を導通させる(ステップS10)。ここでのアルミニウム線80の断面の直径は50μm〜1mmである。50μm以下では、アルミニウム線80の断線が生じる確率が高くなり、1mm以上ではアルミニウム線80の機械強度が増加し、超音波接合に不具合が生じる。このため、アルミニウム線80の断面の直径は50μm〜1mmが望ましい。また、その接合部では、金属間化合物であるAlCu合金が形成する。
このような方法によれば、アルミニウム線80を半導体素子70の電極部及び銅箔パターンであるCu膜40に超音波接合法により直接接合させるので、銅箔パターン上にボンディングパッドを形成させる必要がなく、ボンディングパッド表面にNiやAuめっきを施す手間を省くことができる。また、ボンディングパッドとその下地の位置ずれから生ずるワイヤと披接合部間の接合不良を低減させることができる。その結果、低コストで歩留まりのよい半導体装置のモジュールの製造が実現可能になる。
図7は第2の実施の形態の超音波接合方法の原理説明図である。
例えば、金属ベース基材上に絶縁層を形成した後に(ステップS20)、その上に金属膜を形成する(ステップS21)。次に、金属膜を形成した後に、金属膜をエッチング加工により所定のパターンを形成し、第1の金属膜及び第2の金属膜が形成した銅箔パターンを形成する(ステップS22)。
また、絶縁層20の材質は、エポキシ系樹脂の他、エポキシ系樹脂を主成分とした複合材料に、SiO2(シリカ)またはAl2O3(アルミナ)のうち少なくとも1つを混錬させたものでもよい。
20 絶縁層
25、30、40 Cu膜
45 金属片
50 ソルダーレジスト層
60 クリーム半田
61 高温半田
70 半導体素子
80 アルミニウム線
Claims (10)
- 金属ベース基材上に絶縁層を形成する工程と、
形成した前記絶縁層上に第1の金属膜及び第2の金属膜をパターニングする工程と、
前記第1の金属膜及び前記第2の金属膜の一部を被覆するように、前記絶縁層上にソルダーレジスト層を形成する工程と、
前記第1の金属膜表面が露出した部分に、半田、または半田と金属片を介して半導体素子を設置する工程と、
前記半導体素子の電極部と前記第2の金属膜表面が露出した部分を金属線を介して電気的に直接接合する工程と、
を有することを特徴とする半導体装置モジュールの製造方法。 - 前記半導体素子の前記電極部と前記第2の金属膜表面が露出した前記部分を前記金属線を介して電気的に直接接合する際には、超音波接合法によって、前記半導体素子の前記電極部と前記金属線、並びに前記第2の金属膜表面が露出した前記部分と前記金属線を直接接合させることを特徴とする請求項1記載の半導体装置モジュールの製造方法。
- 前記半導体素子の前記電極部と前記第2の金属膜表面が露出した前記部分を前記金属線を介して電気的に直接接合する前に、前記第2の金属膜表面が露出した前記部分に耐熱性プリフラックスまたはストリッパブルレジストを塗布する工程を有することを特徴とする請求項1記載の半導体装置モジュールの製造方法。
- 前記金属線の材質は、アルミニウム、またはニッケルを微量に含有したアルミニウムであることを特徴とする請求項1記載の半導体装置モジュールの製造方法。
- 前記第1の金属膜及び前記第2の金属膜の材質は銅であることを特徴とする請求項1記載の半導体装置モジュールの製造方法。
- 前記金属線の断面形状が円形状である場合には、前記金属線の径は50μm〜1mmであることを特徴とする請求項1記載の半導体装置モジュールの製造方法。
- 金属ベース基材上に形成された絶縁層と、
前記絶縁層上にパターニングされた第1の金属膜及び第2の金属膜と、
前記第1の金属膜及び前記第2の金属膜の一部を被覆するように、前記絶縁層上に形成されたソルダーレジスト層と、
前記第1の金属膜表面の露出した部分の上層に半田、または半田と金属片を介して設置された半導体素子と、
前記半導体素子の電極部と前記第2の金属膜表面の露出した部分を電気的に直接接合する金属線と、
を有することを特徴とする半導体装置モジュール。 - 前記金属線の材質は、アルミニウム、またはニッケルを微量に含有したアルミニウムであることを特徴とする請求項7記載の半導体装置モジュール。
- 前記第1の金属膜及び前記第2の金属膜の材質は銅であることを特徴とする請求項7記載の半導体装置モジュール。
- 前記金属線の断面形状が円形状である場合には、前記金属線の径は50μm〜1mmであることを特徴とする請求項7記載の半導体装置モジュール。
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