JP2008010703A - 半導体装置の部品間接合方法 - Google Patents

半導体装置の部品間接合方法 Download PDF

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Publication number
JP2008010703A
JP2008010703A JP2006180770A JP2006180770A JP2008010703A JP 2008010703 A JP2008010703 A JP 2008010703A JP 2006180770 A JP2006180770 A JP 2006180770A JP 2006180770 A JP2006180770 A JP 2006180770A JP 2008010703 A JP2008010703 A JP 2008010703A
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Prior art keywords
metal
joining
parts
joined
nanoparticles
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Withdrawn
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JP2006180770A
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English (en)
Inventor
Hiroki Kawasumi
太樹 川住
Yoshinari Ikeda
良成 池田
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Fuji Electric Co Ltd
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Fuji Electric Holdings Ltd
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Priority to JP2006180770A priority Critical patent/JP2008010703A/ja
Publication of JP2008010703A publication Critical patent/JP2008010703A/ja
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Abstract

【課題】半導体チップに絶縁基板，ヒートスプレッダなどの部品を金属ナノ粒子を含む金属ペーストを用いて接合させる際に、接合面全域で未接合部ができない手段を提供する。
【解決手段】金属ナノ粒子，金属ナノ粒子の常温での凝集を抑制する有機分散材，加熱により有機分散材と反応する分散材捕捉材および前記分散材と分散材捕捉材との反応物質を捕捉して揮散させる揮発性有機成分を含む金属ペースト５を用いて半導体装置の絶縁基板２／半導体チップ３／ヒートスプレッダ４の部品間を導電，伝熱接合する接合方法において、接合部品の接合面域に前記の金属ペーストを塗布した状態で、接合層５の層厚に対応する線径の金属コア６を分散配置して重ね合わせた上で、続く加熱工程を経て部品間を接合する。これにより、金属コア６をスペーサとして部品間に前記揮発性有機成分の熱分解ガスを逃がす蒸散経路を確保して、接合層内に未接合部が生じるのを防止できる。
【選択図】図１

Description

本発明は、パワー半導体デバイスなどを対象に、その絶縁基板の導体パターンと半導体チップとの間、および半導体チップとその上面に積層したヒートスプレッダとの間を、金属ナノ粒子を含む金属ペーストを用いて接合する半導体装置の部品間接合方法に関する。
まず、本発明の実施対象となる頭記のパワー半導体デバイスについて、従来例の組立構造を図３に示す。図において、１は放熱用銅ベース、２はアルミナなどのセラミック板２ａの上下両面に導体パターン（銅箔）２ｂ，２ｃを形成して前記銅ベース１の上に搭載して接合した絶縁基板（例えば、Direct Bonding Copper基板）、３は絶縁基板２の上面導体パターン（回路パターン）２ｃにマウントした半導体チップ（例えば、ＩＧＢＴ）、３ａは半導体チップ３の下面電極面にメタライズしたＮｉ／Ａｕメッキ膜、３ｂはチップ上面にメタライズしたアルミ膜、４は半導体チップ３の上面に接合したヒートスプレッダ（例えば、特許文献１参照）、５はヒートスプレッダ４を介して半導体チップ３の上面電極とこれに対応する導体パターン２ｃとの間に配線したリードフレーム（銅，アルミ材の導体）、６は導体パターン２ｃに接合した外部導出リードであり、銅ベース１／絶縁基板２の導体パターン２ｂ，絶縁基板２の導体パターン２ｃ／半導体チップ３，半導体チップ３の上面／ヒートスプレッダ４，ヒートスプレッダ４／リードフレーム５，絶縁基板２の導体パターン２ｃ／リード５，６の間をそれぞれ半田７により接合してモジュールを組立てている。
ところで、前記した半導体デバイスの各部品間を接合する半田について、昨今では環境保全の問題からＳｎ−Ｐｂ系の共晶半田を鉛フリー半田（例えばＳｎ−Ａｇ系半田）に代替する転換が進められている。しかしながら、鉛フリー半田はＳｎ−Ｐｂ半田に比べて融点が高く、また熱履歴により接合界面に生成する金属間化合物により半田接合部への応力集中が大きくなり、さらに過電流により半導体チップに半田の融点を超える熱が発生した場合には半田接合部に溶融，剥離，短絡などのダメージが発生するおそれがあるなど、このことが原因で半導体モジュールのパワーサイクル耐性，信頼性低下が大きな問題となっている。
一方、最近になり金属ナノ粒子の研究が進み、半導体デバイスの製造技術分野でも金属ナノ粒子の量子サイズ効果による低温焼結現象および高い表面活性を利用した低温焼成形の導電性ペースト（以下「ナノ金属ペースト」と称する）が開発されている（例えば、非特許文献１参照）。このナノ金属ペーストは、ＡｇあるいはＣｕなどの金属ナノ粒子と、金属ナノ粒子が常温で凝集するのを抑制してナノ粒子を独立分散状態に保持する有機分散材と、加熱により有機分散材と反応して金属ナノ粒子を裸にする分散材捕捉材，および前記分散材と分散材捕捉材との反応物質を捕捉してガス化する揮発性有機成分（溶剤）を金属粉（骨材）と混練してペースト化したものである。
さらに在来の半田接合の代わりに金属ナノ粒子を含む金属ペーストを用いて半導体デバイスの部品間を接合するようにしたものも知られている（例えば、特許文献２，特許文献３参照）。
ここで、前記のナノ金属ペーストを用いて金属部材（バルク材）の間を接合する場合に、従来の方法では一方の金属部材の接合面にナノ金属ペーストをスクリ−ン印刷法などにより塗布し、この上に相手側の金属部材を重ね合わせて軽い加圧力を加えた仮組立状態で、この仮組立体をリフロー炉に搬入して接合を行うようにしている。なお、加熱に伴う金属ナノ粒子間，および金属ナノ粒子と被接合金属部材との間の接合メカニズム，およびそのキュアー条件，接合強度，耐熱温度等の特性については、先記の非特許文献１および特許文献２に詳しく述べられており、加熱により活性化した金属ナノ粒子間，および金属ナノ粒子と金属粉，接合金属板との間で低温焼結による溶着／焼結（架橋）が進行し、最終的に抵抗率が低いマトリックス構造の接合層が形成される。
上記のように半導体デバイスの部品間接合法として、在来の半田接合に代えてナノ金属ペーストを用いて接合することにより、低い抵抗率と高い耐熱性，伝熱性，接合強度が得られ、またナノ金属粒子（銀，銅）の溶融温度以下では接合部が溶断することもないなど、半田接合に較べて高信頼性の接合が期待できる。
小田 正明，「ナノ金属粒子」，エレクトロニクス実装学会誌，２００２年，ｖｏｌ５，No６，ｐ５２３−５２８ 特開２００４−２４１７３４号公報（図１） 特開２００４−１２８３５７号公報（図３，図６） 特開２００４−２１３０３７１号公報
ところで、図３に示した半導体デバイスの部品接合について、発明者等がナノ金属ペーストを適用した場合の接合条件などに関して様々な実験，検証を行ったところ、従来のリフロー半田付けと同様な手法で部品の接合面に塗布したナノ金属ペーストに接合相手の部品を重ね合わせた上で軽く加圧力を加えて仮組み立てし、この仮組立状態でリフロー炉に搬入して接合を行った場合には接合面の中央部分に未接合の欠陥が多く発生することが知見された。
そこで、発明者等はこの接合欠陥の発生原因について究明した結果、その発生要因が次の点にあることが明らかになった。すなわち、金属ナノ粒子の粒子間，および金属ナノ粒子と被接合金属部材(図３における絶縁基板の導体パターン，半導体チップ，ヒートスプレッダ)との間で融着／焼結を適正に進めるには、金属ナノ粒子を独立分散状態に保持している分散材と分散材捕捉材との反応促進に加えて、この反応物質を捕捉した揮発性物質を蒸散させて接合面域から排除し、金属ナノ粒子を裸の状態にしてその表面活性を高めるようにすることが必須条件となる。
しかしながら、接合面に塗布したナノ金属ペーストを挟んで両側から半導体チップ３，絶縁基板２，ヒートスプレッダ４などの被接合部品を重ねて加圧力を加えた状態で加熱すると、特に接合面の中央面域におけるナノ金属ペーストが部品の間に封じ込められているために、加熱分解した有機成分の周囲への自由な蒸散（脱ガス）が阻害されることになる。このために接合面の中央面域では金属ナノ粒子の融着／焼結が十分に進行せず、結果として接合部に未接合部分が残るようになるものと推測される。
本発明は上記の点に鑑みなされたものであり、図３のように半導体チップの両主面に絶縁基板，ヒートスプレッダなどの部品を重ねてその相互間を面接合した半導体デバイスなどを対象に、ナノ金属ペーストを用いて部品間を接合させる際に、接合層内に未接合部分を残すことなく接合面全域で適正に接合できるように改良した半導体装置の部品間接合方法を提供することを目的とする。
上記目的を達成するために、本発明によれば、金属ナノ粒子，金属ナノ粒子の常温での凝集を抑制する有機分散材，加熱により有機分散材と反応する分散材捕捉材および前記分散材と分散材捕捉材との反応物質を捕捉して揮散させる揮発性有機成分を含む金属ペーストを用いた半導体装置の部品間接合方法であって、表面が金属母材である被接合部品の接合面域に前記金属ペーストを塗布して被接合部品を重ね合わせた状態で加熱し、この加熱により金属ナノ粒子を低温焼結させて部品間を導電，伝熱接合するようにした接合方法において、
前記の金属ペーストを被接合部品の接合面に塗布した状態で、部品の対向面間に金属コア材を分散介挿して重ね合わせ、続く加熱工程を経て接合するものとする（請求項１）。
ここで、前記の金属ペーストに含まれる金属ナノ粒子は、Ａｇナノ粒子もしくはＣｕナノ粒子であり（請求項２）、また金属コア材は、被接合部品間の接合層厚さに対応した線径の円柱状銅材である（請求項３）。
また、本発明では、半導体装置の絶縁基板とその導体パターンに接合する半導体チップ、ないしは半導体チップとその上面に接合するヒートスプレッダを被接合部品として、前記した接合方法を適用して半導体装置を組み立てるようにする（請求項４）。
上記接合方法のように、被接合部品の接合面にナノ金属ペーストを塗布し、さらにその塗布面に金属コア材を分散配置した上で部品を重ねて加圧した仮組立状態では、金属コア材をスペーサとして部品相互間に間隔が保持され、続く加熱工程で加熱分解する揮発性有機成分の周囲への蒸散経路が確保されることになる。なお、金属ナノ粒子を低温焼結させる金属ペーストのキュア条件は２００℃前後であることから、加熱工程で金属コア材（銅材）が溶融することはない。
したがって、加熱による接合反応の進行に伴って加熱分解するナノ金属ペーストの揮発性有機成分は部品の間に封じ込められたままになることなく、前記金属コアの介挿により確保された蒸散経路を通じて周囲に蒸散する。これにより、接合面に塗布したナノ金属ペーストの全域で金属ナノ粒子の分散材と分散材捕捉材との反応促進，およびその熱分解ガスの蒸散が被接合部品に阻害されることなく進行し。その結果として金属ナノ粒子の表面活性が高まり、接合面全域で未接合（欠陥）のない部品間の接合が達成される。
しかも、前記の金属コア材として、接合層厚に対応した線径の円柱状銅材を用いたことにより、被接合部品を重ね合わせる仮組立の過程でコア材が転がったり動いたりして介挿位置が多少変位しても部品相互間の間隔，平行度を安定保持できる。
以下、本発明の実施の形態を図１，図２に示す実施例に基づいて説明する。なお、図１は本発明の接合方法を適用して組立てた半導体デバイスの組立構造図、図２は被接合部品の接合面域に分散配置した金属コアを表した模式図であり、図中で図３に対応する部材には同じ符号を付してその説明は省略する。
すなわち、図示実施例の半導体デバイスでは、絶縁基板２の導体パターン２ｂと半導体チップ３との間、および半導体チップ２とその上面側に積層したヒートスプレッダ４との間が先記したナノ金属ペーストを用いて接合されており、その接合層を符号５で、また後記のように被接合部品間の接合面域に分散介挿した金属コアを符号６で表している。
ここで、図示の半導体チップ３は、例えば一辺の長さが７．５mm角のＩＧＢＴチップである。また、ナノ金属ペーストとしては、Ａｇナノ粒子，あるいはＣｕナノ粒子を主要成分として、これに有機分散材，分散材捕捉材，揮発性有機成分（溶剤），および銀粉，銅粉などの骨材を加えて混練したナノ金属ペースト（例えば、非特許文献１に開示されているナノペースト（商品名）：ハリマ化成（株））を用い、さらに前記した金属コア６には、接合層５の層厚に対応した線径１００μｍ，長さ２mmの円柱状銅材を使用している。
次に、図１に示した半導体デバイスの組立て、およびナノ金属ペーストを用いた部品間の接合方法を説明する。まず、絶縁基板２に対し、その導体パターン２ｂの接合面域に前記のナノ金属ペーストをスクリーン印刷法により均等な厚さに塗布する。次いで、棒状の金属コア６を接合面域の周囲４辺に分散してここに塗布したナノ金属ペーストの上に載せ、この状態で次に上方から半導体チップ３を接合位置に合わせて重ね合わせる。そして、上方から軽く加圧力を加えて金属コア６が絶縁基板２の導体パターン２ｂと当接するようにナノ金属ペーストの塗装面に押し込む。また、同様な方法で半導体チップ３の上面にナノ金属ペーストを均一に塗布し、さらに金属コア６を載せた状態でヒートスプレッダ４を重ね合わせ、軽く加圧力を加えて金属コア６をナノ金属ペーストの塗装面に押し込んで仮組立てする。これにより、絶縁基板２／半導体チップ３，半導体チップ３／ヒートスプレッダ４の部品相互間には前記の金属コア６をスペーサ部材として接合層５の層厚に対応した間隔が確保されることになる。
しかる後に、前記の仮組立体をリフロー炉に搬入し、ナノ金属ペーストの指定されたキュア条件（加熱温度１８０〜２２０℃，３０〜６０min）で加熱して各部品の間を導電，伝熱的に接合する。
この加熱工程では、先述のように有機分散材と分散材捕捉材との反応により裸になって活性化した金属ナノ粒子同士，および金属ナノ粒子と金属粉，被接合部品との間で溶着，焼結（架橋）が進行し、最終的には絶縁基板２／半導体チップ３／ヒートスプレッダ４の部品相互間に、金属コア６の線径に対応する厚さでマトリックス構造の接合層５が形成される。しかも、この接合過程では前記金属コア６の介在によって部品相互間には周囲に通じる蒸散経路が確保されている。これにより、金属ナノ粒子の溶着，焼結が進行する過程で熱分解した有機成分は、特に接合面の中央面域においても被接合部品の間に封じ込められることなく、前記の蒸散経路を通じて周囲に蒸散するようになる。その結果として、接合層５には層中に未接合部分を残すことなく、接合面の全域で部品間を適正に接合することができて半導体デバイスの信頼性が向上する。
本発明の接合方法を適用して組立てた半導体装置の組立構造図 図１における被接合部品間に介挿した金属コアの分散配置を模式的に表した平面図 部品相互間を半田接合した従来における半導体装置の組立構造図
符号の説明
２ 絶縁基板
２ｂ 導体パターン
３ 半導体チップ
４ ヒートスプレッダ
５ 接合層（ナノ金属ペースト）
６ 金属コア

Claims (4)

  1. 金属ナノ粒子，金属ナノ粒子の常温での凝集を抑制する有機分散材，加熱により有機分散材と反応する分散材捕捉材および前記分散材と分散材捕捉材との反応物質を捕捉して揮散させる揮発性有機成分を含む金属ペーストを用いた半導体装置の部品間接合方法であって、表面が金属母材である被接合部品の接合面域に前記金属ペーストを塗布して被接合部品を重ね合わせた状態で加熱し、この加熱により金属ナノ粒子を低温焼結させて部品間を導電，伝熱接合するようにした接合方法において、
    前記金属ペーストを被接合部品の接合面に塗布した状態で、部品の対向面間に金属コア材を分散介挿して重ね合わせ、続く加熱工程を経て接合することを特徴とする半導体装置の部品間接合方法。
  2. 請求項１に記載の接合方法において、金属ペーストの成分である金属ナノ粒子がＡｇナノ粒子，もしくはＣｕナノ粒子であることを特徴とする半導体装置の部品間接合方法。
  3. 請求項１に記載の接合方法において、金属コア材が、被接合部品間の接合層厚さに対応した線径の円柱状銅材であることを特徴とする半導体装置の部品間接合方法。
  4. 請求項１ないし３のいずれかの項に記載の接合方法において、金属ペーストを介して面接合される被接合部品が、絶縁基板とその導体パターンに接合する半導体チップ、ないしは半導体チップとその上面に接合するヒートスプレッダであることを特徴とする半導体装置の部品間接合方法。
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