JP4764983B2 - 半導体装置の製造方法 - Google Patents
半導体装置の製造方法 Download PDFInfo
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- JP4764983B2 JP4764983B2 JP2006201588A JP2006201588A JP4764983B2 JP 4764983 B2 JP4764983 B2 JP 4764983B2 JP 2006201588 A JP2006201588 A JP 2006201588A JP 2006201588 A JP2006201588 A JP 2006201588A JP 4764983 B2 JP4764983 B2 JP 4764983B2
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- 239000010410 layer Substances 0.000 description 30
- 239000010949 copper Substances 0.000 description 15
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 12
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
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Description
図7において、1は放熱用銅ベース、2A,2Bは左右に並べて銅ベース1に搭載した絶縁基板(セラミックス基板表,裏両面に銅箔を直接接合して導体パターンを形成したDCB(Direct Copper Bonding)基板)、2a〜2eは絶縁基板2A,2Bの上面に形成した導体パターン、3は絶縁基板2A,2Bの導体パターン2a,2dにマウントしたIGBTチップ、4はFWD(Free Wheel Diode)、5はIGBTチップ3およびFWD4の上面電極に重ねて接合した銅,アルミ板,あるいはMo,W等の焼結体に銅を含浸させた複合材で作られたヒートスプレッダ、6はヒートスプレッダ5の上面と絶縁基板2の導体パターン2b,2eとの間に配線したリードフレーム(Cu,Cu合金箔)、7は絶縁基板2Aと2Bの間に跨がって導体パターン2cと2d,および2bと2eとの間に配線したリードフレーム、8(+),8(-),8(o)は入力,出力端子として導体パターン2b,2c,2eの端部から引出したリードフレームである。
これに対して、リードフレーム6,7,8を接合相手部材であるヒートスプレッダ5の上面,絶縁基板2A,2Bの各導体パターンに接合する方法として、次記のようにレーザ溶接法により重ね溶接するようにしており、その溶接部を符号10で示す。
本発明は上記の点に鑑みなされたものであり、前述したレーザ溶接の検証,考察結果を基に、配線部材であるリードフレームの接合部を接合相手部材であるヒートスプレッダ,絶縁基板の導体パターンの上に重ねてレーザ溶接する際に、低パワーのレーザ光照射で、溶接バラツキの少ない溶接が高い再現性で実現できるように改良した半導体装置の製造方法を提供することを目的とする。
(1)母材表面にNiまたはSnのメッキを施し、メッキ層のレーザ光照射面を粗面化したリードフレームを用意し、前記リードフレームの接合部を、接合相手部材として用意した半導体チップの上面電極に接合されたヒートスプレッダもしくは半導体チップをマウントする絶縁基板の導体パターンに布設して重ね合わせ、この状態で前記接合部の上面にレーザ光を照射して前記リードフレームと前記接合相手部材とを溶接する(請求項1)。
(2)母材表面にNiまたはSnのメッキを施し、レーザ光照射面とは反対側のメッキ層表面を粗面化したリードフレームを用意し、前記リードフレームの接合部を、接合相手部材として用意した半導体チップの上面電極に接合されたヒートスプレッダもしくは半導体チップをマウントする絶縁基板の導体パターンに布設して重ね合わせ、この状態で前記接合部の上面にレーザ光を照射して前記リードフレームと前記接合相手部材とを溶接する(請求項2)。
(3)前項(2)により裏面側の粗面化と併せて、レーザ光が照射されるリードフレームの接合部上面も粗面化する(請求項3)。
(4)リードフレームの接合部上面,ないし裏面に形成した粗面の表面粗さは、パラメータRa(算術平均粗さ)を0.1〜10μm、Ry(最大高さ)をリードフレームのメッキ層厚さ以下に設定する(請求項4)。
(5)リードフレームの接合部裏面および該接合部裏面と対峙する接合相手部材の接合面の双方を粗面化する場合には、その表面粗さはパラメータRa(算術平均粗さ)を0.05〜5μm、Ry(最大高さ)をリードフレームのメッキ層厚さ以下に設定する(請求項5)。
(6)前記の各項において、リードフレームの接合部に照射するレーザ光は、波長が0.19〜10.6μmのレーザを使用する(請求項6)。
(1)リードフレームの接合部上面を粗面化してここに照射したレーザ光を粗面上で乱反射させることにより、全反射の割合を低く抑えてレーザ光の吸収率を高めることができ、これによりレーザ光エネルギー/熱エネルギーの変換効率が向上して低パワーでのレーザ溶接が可能となる。
(2)一方、リードフレームの接合部裏面,ないし接合相手部材の接合面を粗面化してリードフレームを重ね合わせると、その重なり面には表面粗さに相応した空隙が生成して接合界面の伝熱抵抗が増す。したがって、この部分が熱溜まりとなってリードフレームの溶融部から伝熱してきた熱エネルギーが十分に蓄積されるようになる。これにより、リードフレームに生じた溶融領域の深さが接合相手部材との接合界面まで十分に成長してリードフレーム/接合相手部材間に強固な溶接部を形成することができる。
これにより、レーザ溶接工程でリードフレーム6の接合部上面にレーザ光13を照射した際には、実施例1で述べたレーザ光の吸収率が向上する効果と実施例2で述べた熱溜まり効果が相乗的に加わり、低パワーで溶接バラツキの少ないレーザ溶接が可能となる。
上記のようにリードフレーム6の母材表面にNiメッキを施した上で、このNiメッキ層14に粗面14aを形成することにより、レーザ光13の吸収率が図1と比べて大幅に向上するようになる。すなわち、リードフレーム6の母材であるCuに照射したレーザ光13(半導体レーザ(波長0.808μm))の吸収率は高々約15%であるのに対して、Niの吸収率は約30%である。したがって、リードフレーム6の表面にNiメッキを施した上で、このNiメッキ層14(メッキ層厚:10μm)に対して接合部上面を粗面化して粗面14aを形成することにより、図1で述べたリードフレーム表面の粗面化とNiメッキのレーザ吸収率との相乗効果でリードフレーム6へのレーザ光13の吸収率が格段に向上し、これにより図1の場合より低パワーでのレーザ溶接が可能となる。なお、表面粗さのパラメータRyをNiメッキ層厚以下に設定することで、粗面化処理によりリードフレーム6の母材下地がレーザ照射面に露呈することがなくなる。また、Niメッキ層14はリードフレーム6の母材が酸化,腐食するのを防ぐ保護層の役目も兼ねている。
レーザ溶接を行うようにしている。また、図5(b)では、前記の粗面14bに加えてヒートスプレッダ5の上面も粗面化し、図示のように粗面14bと粗面5aを上下に重ねてレーザ溶接するようにしている。
なお、前記の各実施例ではリードフレーム6/ヒートスプレッダ5間の溶接について述べたが、リードフレーム6の接合相手部材が図7に示した絶縁基板2A,2Bの導体パターンであっても同様な効果を奏することは勿論である。
2a〜2e 導体パターン
3 IGBTチップ(半導体チップ)
4 FWD(半導体チップ)
5 ヒートスプレッダ
5a 粗面(上面)
6〜8 リードフレーム
10 溶接部
13 レーザ光
14 Niメッキ層
14a 粗面(上面)
14b 粗面(裏面)
Claims (6)
- 半導体装置の内部配線用リード材としてのリードフレームの接合部を接合相手部材の上に重ね合わせ、この状態で前記接合部の上面にレーザ光を照射して前記リードフレームと前記接合相手部材とを重ね溶接してなる半導体装置の製造方法において、
母材表面にNiまたはSnのメッキを施し、メッキ層のレーザ光照射面を粗面化したリードフレームを用意し、前記リードフレームの接合部を、接合相手部材として用意した半導体チップの上面電極に接合されたヒートスプレッダもしくは半導体チップをマウントする絶縁基板の導体パターンに布設して重ね合わせ、この状態で前記接合部の上面にレーザ光を照射して前記リードフレームと前記接合相手部材とを溶接することを特徴とする半導体装置の製造方法。 - 半導体装置の内部配線用リード材としてのリードフレームの接合部を接合相手部材の上に重ね合わせ、この状態で前記接合部の上面にレーザ光を照射して前記リードフレームと前記接合相手部材とを重ね溶接してなる半導体装置の製造方法において、
母材表面にNiまたはSnのメッキを施し、レーザ光照射面とは反対側のメッキ層表面を粗面化したリードフレームを用意し、前記リードフレームの接合部を、接合相手部材として用意した半導体チップの上面電極に接合されたヒートスプレッダもしくは半導体チップをマウントする絶縁基板の導体パターンに布設して重ね合わせ、この状態で前記接合部の上面にレーザ光を照射して前記リードフレームと前記接合相手部材とを溶接することを特徴とする半導体装置の製造方法。 - 請求項2に記載の製造方法において、レーザ光が照射されるリードフレームの接合部上面を粗面化したことを特徴とする半導体装置の製造方法。
- 請求項1ないし3のいずれかの項に記載の製造方法において、リードフレームの接合部表面に形成した粗面の表面粗さは、パラメータRaが0.1〜10μm、Ryがリードフレームのメッキ層厚さ以下であることを特徴とする半導体装置の製造方法。
- 請求項2に記載の製造方法において、リードフレームの接合部裏面および該接合部裏面と対峙する接合相手部材の接合面の双方に形成した粗面の表面粗さは、パラメータRaが0.05〜5μm、Ryがリードフレームのメッキ層厚さ以下であることを特徴とする半導体装置の製造方法。
- 請求項1ないし5のいずれかの項に記載の製造方法において、リードフレームの接合部に照射するレーザ光の波長が0.19〜10.6μmであることを特徴とする半導体装置の製造方法。
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