JP2022045072A - 半導体装置 - Google Patents

半導体装置 Download PDF

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Publication number
JP2022045072A
JP2022045072A JP2020150569A JP2020150569A JP2022045072A JP 2022045072 A JP2022045072 A JP 2022045072A JP 2020150569 A JP2020150569 A JP 2020150569A JP 2020150569 A JP2020150569 A JP 2020150569A JP 2022045072 A JP2022045072 A JP 2022045072A
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JP
Japan
Prior art keywords
porous body
connector
semiconductor device
semiconductor element
base frame
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Pending
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JP2020150569A
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English (en)
Inventor
譽寧 蔡
Yu-Ning Tsai
英敏 倉谷
Hidetoshi Kuratani
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toshiba Corp
Toshiba Electronic Devices and Storage Corp
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Toshiba Corp
Toshiba Electronic Devices and Storage Corp
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Application filed by Toshiba Corp, Toshiba Electronic Devices and Storage Corp filed Critical Toshiba Corp
Priority to JP2020150569A priority Critical patent/JP2022045072A/ja
Priority to CN202110861495.7A priority patent/CN114156250A/zh
Priority to US17/468,595 priority patent/US11776884B2/en
Publication of JP2022045072A publication Critical patent/JP2022045072A/ja
Pending legal-status Critical Current

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Abstract

Figure 2022045072000001
【課題】信頼性の高い半導体装置を提供する。
【解決手段】実施形態の半導体装置は、ベースフレームと、ベースフレームの上に設けられた半導体素子と、半導体素子の上に設けられ、上面と、側面と、少なくとも側面に設けられ複数の細孔を有する多孔質体と、を有するコネクタと、半導体素子の周囲及び少なくともコネクタの側面に設けられたモールド樹脂と、を備え、コネクタの上面は露出している。
【選択図】図1

Description

本発明の実施形態は、半導体装置に関する。
発電や送電、ポンプやブロアなどの回転機、通信システムや工場などの電源装置、交流モータによる鉄道、電気自動車、家庭用電化製品等の幅広い分野に向けた、MOSFET(Metal-Oxide-Semiconductor Field-Effect-Transistor)やIGBT(Insulated Gate Bipolar Transistor)等の、電力制御用に設計されたパワー半導体素子の開発が行われている。
また、かかるパワー半導体素子を用いた、パワーモジュールとしての半導体装置の開発が行われている。このような半導体装置には、高電流密度化、低損失化、高放熱化等のスペックが要求されている。
特許第5807340号公報
本発明が解決しようとする課題は、信頼性の高い半導体装置を提供することである。
実施形態の半導体装置は、ベースフレームと、ベースフレームの上に設けられた半導体素子と、半導体素子の上に設けられ、上面と、側面と、少なくとも側面に設けられ複数の細孔を有する多孔質体と、を有するコネクタと、半導体素子の周囲及び少なくともコネクタの側面に設けられたモールド樹脂と、を備え、コネクタの上面は露出している。
実施形態の半導体装置の模式断面図である。 実施形態の多孔質体及びソースコネクタの断面の顕微鏡写真である。
以下、図面を参照しつつ本発明の実施形態を説明する。なお、以下の説明では、同一又は類似の部材には同一の符号を付す場合がある。また、一度説明した部材等については適宜その説明を省略する場合がある。
本明細書中、部品等の位置関係を示すために、図面の上方向を「上」、図面の下方向を「下」と記述する。本明細書中、「上」、「下」の概念は、必ずしも重力の向きとの関係を示す用語ではない。
(実施形態)
実施形態の半導体装置は、ベースフレームと、ベースフレームの上に設けられた半導体素子と、半導体素子の上に設けられ、上面と、側面と、少なくとも側面に設けられ複数の細孔を有する多孔質体と、を有するコネクタと、半導体素子の周囲及び少なくともコネクタの側面に設けられたモールド樹脂と、を備え、コネクタの上面は露出している。
図1は、本実施形態の半導体装置100の模式断面図である。
半導体装置100は、ベースフレーム2と、第1接合材4と、半導体素子6と、第2接合材8と、ソースコネクタ(コネクタの一例)10と、ゲートコネクタ20と、コネクタ22と、第3接合材24と、第4接合材26と、モールド樹脂30と、を備える。
ベースフレーム2は、半導体素子6と、図示しない外部電気回路との接続に用いられている。ベースフレーム2は、例えば電気導電性の板状部材である。
半導体素子6は、ベースフレーム2の上に設けられている。半導体素子6は、例えば縦型のMOSFETであるが、これに限定されるものではない。例えば半導体素子6がMOSFETである場合、半導体素子6の底面に設けられた図示しないドレイン電極は、半導体素子6とベースフレーム2の間に設けられた第1接合材4により、ベースフレーム2と電気的に接続されている。
ソースコネクタ10は、半導体素子6の上に設けられている。ソースコネクタ10は、底面10aと、側面10bと、上面10cと、側面10dと、面10eと、側面10fと、を有している。例えば半導体素子6がMOSFETである場合、半導体素子6の上面に設けられた、図示しないソース電極は、半導体素子6とソースコネクタ10の間に設けられた第2接合材8により、ソースコネクタ10と電気的に接続されている。ソースコネクタ10は、例えば、半導体素子6のソース電極と、図示しない外部電気回路の電気的接続に用いられている。
ソースコネクタ10は、多孔質体12を有する。具体的には、ソースコネクタ10の、少なくとも側面10bには、複数の細孔を有する多孔質体12が設けられている。半導体装置100においては、多孔質体12としての多孔質体12a、12b、12c、12d、12e及び12fが、それぞれソースコネクタの底面10a、側面10b、上面10c、側面10d、面10e及び側面10fに設けられている。なお、多孔質体12a、12c、12d、12e及び12fは、設けられていなくてもかまわない。
ゲートコネクタ20の一端は、半導体素子6の上面に設けられた図示しないゲート電極と、第3接合材24により、電気的に接続されている。ゲートコネクタ20の他端は、第4接合材26を介して、コネクタ22に電気的に接続されている。ゲートコネクタ20及びコネクタ22は、半導体素子6のゲート電極と、図示しない外部電気回路の電気的接続に用いられている。なお、半導体素子6のゲート電極と外部電気回路の電気的接続には、ボンディングワイヤ等のワイヤを用いてもかまわない。
モールド樹脂30は、ベースフレーム2の上面、第1接合材4の周囲、半導体素子6の周囲、ゲートコネクタ20の周囲、第3接合材24の周囲及び第4接合材26の周囲に設けられている。また、モールド樹脂30は、多孔質体12a、12b、12d、12e及び12fの表面に設けられている。多孔質体12c、ベースフレーム2の底面及びコネクタ22の一部は、露出している。なお、多孔質体12cが設けられていないソースコネクタ10の場合には、ソースコネクタ10の上面10cが露出している。
ベースフレーム2、ソースコネクタ10、ゲートコネクタ20及びコネクタ22は、例えばCu(銅)等の金属又は合金を含む。なお、ベースフレーム2、ソースコネクタ10、ゲートコネクタ20及びコネクタ22の表面には、例えば、Au(金)、Pt(白金)、Pd(パラジウム)、Ag(銀)、Cu(銅)、Sn(錫)又はNi(ニッケル)等を含む薄膜が設けられていても良い。
第1接合材4、第2接合材8、第3接合材24及び第4接合材26としては、はんだや銀の微粒子を含む導電性樹脂等が用いられる。
多孔質体12は、例えば、Al(アルミニウム)、Zn(亜鉛)、Mg(マグネシウム)、Ni(ニッケル)、Co(コバルト)、Fe(鉄)、Cr(クロム)、Ti(チタン)、Zr(ジルコニウム)、Cu(銅)を含む。また、多孔質体12は、上記の元素を含む合金であっても良い。多孔質体12は、Niを含むことが好ましい。
モールド樹脂30は、例えば、シリカ(SiO)粒子等のフィラーを含むエポキシ樹脂等である。
図2は、実施形態の多孔質体12及びソースコネクタ10の断面の顕微鏡(走査型電子顕微鏡(Scanning Electron Microscope)SEM)写真である。なお、図2に示した顕微鏡写真は、倍率を500倍として撮影されたものである。ソースコネクタ10の上に、多孔質体12が形成されている。そして、多孔質体12は、複数の細孔14を有している。図2には、複数の細孔14としての、細孔14a、14b、14c及び14dが示されている。なお、図2に示した多孔質体12は、Niにより形成されたものである。
複数の細孔14の平均めっき深さ(平均深さの一例)は、3μm以上20μm以下であることが好ましい。
複数の細孔14の平均孔ピッチは、1μm以上20μm以下であることが好ましい。
複数の細孔14の平均めっき深さ及び平均孔ピッチの測定方法について説明する。JIS B 0601:2013(ISO4287:1997)に基づき、多孔質体12の断面において、測定断面曲線に所定のカットオフ値λsの低域フィルタを適用して、断面曲線(primary profile)を得る。次に、カットオフ値λcの高域フィルタによって、断面曲線から長波長成分を遮断して輪郭曲線を得る。この輪郭曲線のことを、粗さ曲線(roughness profile)と呼ぶ。なお、λs及びλcの標準的な関係は、例えば、JIS B 0651による。
また、基準面(粗さ曲線の底面)を決定する。基準面とは、例えばソースコネクタ10がCuで形成され、多孔質体12がNiで形成されている場合には、CuとNiの界面である。
平均めっき深さとは、上記の粗さ曲線において、頂点(最大高さ)の部分と、基準面との距離を、合計20個分測定して、平均を取ったものである。なお、めっき深さは、JIS B 0601:2013(ISO4287:1997)のZt(最大断面高さ、又は輪郭曲線要素の高さ(Zt:profile element height)に相当している。
平均孔ピッチとは、上記の粗さ曲線において、基準面に平行な面内において、隣接する頂点同士の距離を、合計20個分測定して、平均を取ったものである。
多孔質体12の表面粗さについては、線粗さ(JIS B 0601の最大高さ粗さ)Rzは、3μm以上20μm以下であることが好ましい。また、面粗さSz(ISO25178)は、5μm以上30μm以下であることが好ましい。なお、線粗さRz及び面粗さSzについては、市販の粗さ計測器を用いて測定を行う。
多孔質体12の表面の濡れ性は、38dyne/cm以上であることが好ましい。
また、多孔質体12とモールド樹脂30の間のシェア強度が高いことが好ましい。なお、シェア強度は、例えば、市販のボンドテスターを用いて測定することが出来る。
次に、実施形態の半導体装置100の製造方法について説明する。
多孔質体12の製造方法について説明する、例えば、まず、電解めっきプロセスにおいて、ソースコネクタ10の表面に微細な水素(H)の泡を発生させる。次に、この水素の泡を取り込むように、めっき層を成長させる。これにより、多孔質体12として用いられるめっき層を形成することが出来る。ここで、ソースコネクタ10のすべての表面に多孔質体12を形成することも可能である。また、特定の表面に覆い(カバー)をすることにより、その特定の表面に多孔質体12を形成しないようにすることも可能である。なお、実施形態の多孔質体12の製造方法は、これに限定されるものではない。
多孔質体12が形成されたソースコネクタ10を用いた半導体装置100の製造は、公知の方法により好ましく行うことが出来る。
次に、実施形態の半導体装置の作用効果を記載する。
半導体素子6は、光・熱・湿度及び外部の不純物等からの保護のために、モールド樹脂30により封止されている。ここで、このように封止された半導体素子6と外部電気回路の電気的接続を、どのように行うかが問題となる。
まず、半導体素子6のゲート電極には、半導体素子6を制御する信号が入力される。このような制御信号の電流や電圧は、一般に、大きなものではない。そこで、半導体素子6のゲート電極と外部電気回路との電気接続は、例えば半導体装置100のように、配線抵抗が大きくなるものの、ゲートコネクタ20とコネクタ22という2個のコネクタを介して行い、ゲートコネクタ20がモールド樹脂30により全体が修正された形で行われてもかまわない。1個のコネクタを使って外部電気回路と接続する場合と比較すると、2個のコネクタを介して接続を行う場合においては、モールド樹脂30の外部から半導体素子6へ外部の不純物が侵入することが、起こりづらくなるためである。
しかし、ソース電極と外部電気回路の電気的接続については、配線のオーム損失を少なくするために、ゲート電極の場合のように複数のコネクタを用いたりせずに、ソースコネクタ10の上面をモールド樹脂30から露出させることにより行っている。この場合、ソースコネクタ10の、特に側面10b及び側面10dと、モールド樹脂30との界面においては、実装時の熱ストレス又は半導体素子6を駆動する際の加熱・冷却サイクルのため、モールド樹脂30の剥離が発生しやすい。これにより、モールド樹脂30が剥離した箇所から、外部の不純物等が半導体素子6の表面まで侵入して、半導体素子6の電極を腐食させて導通不良をおこしてしまうという問題があった。また、この問題は、側面10d、面10e及び側面10fのような、沿面距離が長い部分よりも、側面10bのような、沿面距離が短い部分において、外部の不純物等が侵入する経路が短くなるため、深刻なものとなっていた。なお、モールド樹脂30とベースフレーム2の界面にも、同様の問題があった。
モールド樹脂30の剥離を抑制するために、ソースコネクタ10の表面やベースフレーム2の表面についてエッチング処理を行い、モールド樹脂30とソースコネクタ10の表面又はベースフレーム2の表面との密着性を向上させる(アンカー効果)ことが考えられる。しかし、ソースコネクタ10やベースフレーム2に好ましく用いられるCuは、表面酸化が発生しやすく、耐腐食性も高くない。そのため、エッチング処理では十分にモールド樹脂30の剥離の問題を解決することが出来なかった。
耐腐食性を向上させるために、ソースコネクタ10の表面やベースフレーム2の表面を、Ni等のめっきで保護する手法が考えられる。しかし、Ni等のめっきで保護されたソースコネクタ10の表面やベースフレーム2の表面と、モールド樹脂30の密着性は良くない。そのため、モールド樹脂30の剥離の問題を解決することが出来なかった。
実施形態の半導体装置100は、ベースフレーム2と、ベースフレーム2の上に設けられた半導体素子6と、半導体素子6の上に設けられ、上面10cと、側面10bと、少なくとも側面10bに設けられ複数の細孔14を有する多孔質体12と、を有するソースコネクタ10と、半導体素子6の周囲及び少なくともソースコネクタの側面10bに設けられたモールド樹脂と、を備え、ソースコネクタの上面10cは露出している。
多孔質体12がソースコネクタ10の側面10bに設けられることにより、モールド樹脂30が多孔質体12の細孔14に食い込んで密着性が向上し、剥離が起こりづらくなる。また、多孔質体12が設けられることにより、ソースコネクタ10の耐腐食性が向上する。そのため、信頼性の高い半導体装置の提供が可能となる。
多孔質体12とモールド樹脂30の密着性を向上させるためには、複数の細孔14の平均めっき深さは3μm以上20μm以下であることが好ましい。3μmより小さい場合には、十分な密着性が得られない。一方、20μmより大きくなると、製造時に多くのめっき屑が発生し、うまく多孔質体12を形成することが出来ない。
また、複数の細孔の平均孔ピッチは1μm以上20μm以下であることが好ましい。1μmより小さい場合には、十分な密着性が得られない。一方、20μmより大きくなると、製造時に多くのめっき屑が発生し、うまく多孔質体12を形成することが出来ない。
また、多孔質体の線粗さRzは3μm以上20μm以下であることが好ましい。3μmより小さい場合には、十分な密着性が得られない。一方、20μmより大きくなると、製造時に多くのめっき屑が発生し、うまく多孔質体12を形成することが出来ない。
また、多孔質体の線粗さRzは3μm以上20μm以下であることが好ましい。3μmより小さい場合には、十分な密着性が得られない。一方、20μmより大きくなると、製造時に多くのめっき屑が発生し、うまく多孔質体12を形成することが出来ない。
多孔質体12は、Niを含むことが好ましい。上記の特性を有する多孔質体12を容易に形成することが出来るためである。
なお、多孔質体12は、さらにソースコネクタの上面10cに設けられていても良い。半導体装置100の実装の際に用いられる、例えばSn(スズ)を含むめっき層が、多孔質体12を設けることにより、良好に形成されるためである。
以下に、実施例1及び実施例2を、比較例1及び比較例2と対比しながら説明する。
(実施例1)
電解めっきプロセスを用いて、ソースコネクタ10の表面に微細な水素(H)の泡を発生させた。次に、この水素の泡を取り込むように、Niめっき層を成長させ、多孔質体12が全ての面に膜厚10μmで形成されたソースコネクタ10を製造した。そして、このソースコネクタを用いて、半導体装置を製造した。
(実施例2)
実施例1と同様の方法で半導体装置を製造した。ただし、半導体装置の製造にあたり、多孔質体12が全ての面に膜厚20μmで形成されたソースコネクタ10を用いた。
(比較例1)
多孔質体12を有しないソースコネクタ10を用いて、半導体装置を製造した。
(比較例2)
実施例1と同様の方法で半導体装置を製造した。ただし、半導体装置の製造にあたり、多孔質体が全ての面に膜厚3μmで形成されたソースコネクタ10を用いた。
次に、実施例1、実施例2、比較例1及び比較例2について、以下の方法で、平均めっき深さ、平均孔ピッチ、線粗さRz、面粗さSz、表面張力濡れ判断、及びシェア強度比を評価した。
平均めっき深さは、多孔質体12の断面SEM観察に基づき評価した。
平均孔ピッチは、多孔質体12の断面SEM観察に基づき評価した。
線粗さRz及び面粗さSzは、多孔質体12の表面を、レーザー顕微鏡(Olympus社製OLS4100)を用いて測定することにより行った。
表面張力濡れ判断は、アルコテスト社製の各表面張力のテストペンを用いて、多孔質体12の表面に直線を書くことにより行った。ここで、直線を書いた後、直線状態が変わらない場合には、濡れていると判定する。例えば、30dyne/cmのテストペンを用いて多孔質体12の表面に書いた直線の状態が変わらない場合、その多孔質体12の表面の濡れ性は、少なくとも30dyne/cm以上であると判定する。この場合、後述する表1において、「○」と記載している。一方、30dyne/cmのテストペンを用いて直線を書いた後、5分以内に水滴状になる場合には、濡れ性は、30dyne/cmについては「△」と記載している。また、30dyne/cmのテストペンを用いて直線を書いた後、5秒以内で水滴状になる場合には、濡れ性は、30dyne/cmについては「×」と記載している。そして、濡れ性の高いものは、多孔質体12に対するモールド樹脂30の濡れ性が高く、多孔質体12とモールド樹脂30の密着性が向上していると判断した。
シェア強度比は、ボンドテスター(Nordoson Dage社 Dage-4000)を用いて測定した。ここで、2種類の樹脂(樹脂1、樹脂2)を用いて製造した半導体装置について、シェア強度比を測定した。樹脂1は、線膨張係数α=14(ppm/℃)、ガラス転移温度T=135℃である。樹脂2は、線膨張係数α=21(ppm/℃)、ガラス転移温度T=165℃である。ここで、シェア強度比は、比較例1の半導体装置の強度に対する比をとっている。
Figure 2022045072000002
表1から明らかなように、実施例1及び実施例2においては、測定する場所によって差はあるものの、平均めっき深さは3μm以上20μm以下の範囲にあり、平均孔ピッチは1μm以上20μm以下の範囲にあり、線粗さRzは3μm以上20μm以下の範囲にあり、面粗さSzは5μm以上30μm以下の範囲にある。表面張力濡れ判断は、44dyne/cmの判断も「○」であり、比較例1に対して高い濡れ性を示した。そして、シェア強度比も、樹脂1・樹脂2いずれの場合においても高いため、モールド樹脂30と多孔質体12の密着性が高くなっているものと判断した。
比較例1においては、表面張力濡れ判断(40dyne/cm)及び表面張力濡れ判断(44dyne/cm)の結果が「△」であった。
比較例2においては、平均めっき深さ、平均孔ピッチ、線粗さRz及び面粗さSzのいずれも、好ましい範囲のものではなかった。そして、表面張力濡れ判断(38dyne/cm)の結果が「△」であり、表面張力濡れ判断(40dyne/cm)及び表面張力濡れ判断(44dyne/cm)の結果が「×」であったため、モールド樹脂30と多孔質体12の密着性が低いと判断した。
本発明のいくつかの実施形態及び実施例を説明したが、これらの実施形態及び実施例は、例として提示したものであり、発明の範囲を限定することは意図していない。これら新規な実施形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略、置き換え、変更を行うことが出来る。これら実施形態やその変形は、発明の範囲や要旨に含まれると共に、特許請求の範囲に記載された発明とその均等の範囲に含まれる。
2 ベースフレーム
4 第1接合材
6 半導体素子
8 第2接合材
10 ソースコネクタ(コネクタ)
10b ソースコネクタの側面
10c ソースコネクタの上面
12 多孔質体
14 細孔
20 ゲートコネクタ
22 コネクタ
24 第3接合材
26 第4接合材
30 モールド樹脂
100 半導体装置

Claims (7)

  1. ベースフレームと、
    前記ベースフレームの上に設けられた半導体素子と、
    前記半導体素子の上に設けられ、上面と、側面と、少なくとも前記側面に設けられ複数の細孔を有する多孔質体と、を有するコネクタと、
    前記半導体素子の周囲及び少なくとも前記コネクタの前記側面に設けられたモールド樹脂と、
    を備え、
    前記コネクタの上面は露出している、
    半導体装置。
  2. 前記複数の細孔の平均深さは3μm以上20μm以下である請求項1記載の半導体装置。
  3. 前記複数の細孔の平均孔ピッチは1μm以上20μm以下である請求項1又は請求項2記載の半導体装置。
  4. 前記多孔質体の線粗さRzは3μm以上20μm以下である請求項1乃至請求項3いずれか一項記載の半導体装置。
  5. 前記多孔質体の面粗さSzは5μm以上30μm以下である請求項1乃至請求項4いずれか一項記載の半導体装置。
  6. 前記多孔質体は、Ni(ニッケル)を含む請求項1乃至請求項5いずれか一項記載の半導体装置。
  7. 前記多孔質体は、さらに前記上面に設けられ、前記上面に設けられた前記多孔質体は露出している請求項1乃至請求項6いずれか一項記載の半導体装置。
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JP2002151632A (ja) * 2000-11-14 2002-05-24 Toshiba Corp 樹脂封止型半導体装置の製造方法
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