JP5664625B2 - 半導体装置、セラミックス回路基板及び半導体装置の製造方法 - Google Patents
半導体装置、セラミックス回路基板及び半導体装置の製造方法 Download PDFInfo
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- JP5664625B2 JP5664625B2 JP2012224257A JP2012224257A JP5664625B2 JP 5664625 B2 JP5664625 B2 JP 5664625B2 JP 2012224257 A JP2012224257 A JP 2012224257A JP 2012224257 A JP2012224257 A JP 2012224257A JP 5664625 B2 JP5664625 B2 JP 5664625B2
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Description
例えば、風力発電、電気自動車等の電気車両などを制御するために用いられる大電力制御用のパワー半導体素子は、発熱量が多いことから、これを搭載する基板としては、例えばAlN(窒化アルミ)などからなるセラミックス基板上に導電性の優れた金属板を回路層として接合したセラミックス回路基板が、従来から広く用いられている。
例えば、特許文献1に示すパワーモジュールにおいては、セラミックス基板の一方の面に金属からなる回路層が形成されたセラミックス回路基板と、この回路層上に接合される半導体素子と、を備えた構造とされている。そして、セラミックス回路基板の他方側に放熱板が接合されており、半導体素子で発生した熱を、セラミックス回路基板側に伝達し、放熱板を介して外部へ放散する構成とされている。
特に、最近では、シリコン半導体からSiC又はGaNなど化合物半導体素子の実用化が期待されており、半導体素子自体の耐熱性の向上が見込まれるため、従来のようにはんだ材で接合した構造では対応が困難となってきている。
また、特許文献3、4には、金属酸化物粒子と有機物からなる還元剤とを含む酸化物ペーストを用いて、半導体素子等の電子部品を回路上に接合する技術が提案されている。
特許文献2に記載された金属ペーストにおいては、金属粒子と有機物とを含有しており、金属粒子が焼結することで、導電性の焼成体からなる接合層が形成され、この接合層を介して半導体素子等の電子部品が回路層上に接合されることになる。
一方、特許文献3,4に記載された酸化物ペーストにおいては、金属酸化物粒子が還元剤によって還元されることによって生成する金属粒子が焼結することで、導電性の焼成体からなる接合層が形成され、この接合層を介して半導体素子等の電子部品が回路層上に接合されることになる。
このように、金属粒子の焼成体によって接合層を形成した場合には、比較的低温条件で接合層を形成できるとともに、接合層自体の融点は高くなることから高温環境下においても接合強度が大きく低下しない。
また、特許文献3,4に記載されたように、金属酸化物粒子と有機物からなる還元剤とを含む酸化物ペーストを焼結する際には、有機物の分解反応に加えて、金属酸化物粒子の還元反応によってガスが発生する。
このような問題は、上述したパワーモジュールのみでなく、LED等の他の半導体装置においても同様である。
以上のことから、本発明においては、下地層の気孔率を5%以上55%未満の範囲内に設定している。
この構成の半導体装置によれば、発熱量の多いパワー半導体素子を用いた場合でも、効率的に熱を回路層へ伝達することができる。なお、パワー半導体としてはIGBT(Insulated Gate Bipolar Transistor)やMOSFET等があげられる。
このパワーモジュール1は、回路層12が配設されたセラミックス回路基板10と、回路層12の一方の面(図1において上面)に接合された半導体素子3と、セラミックス回路基板10の他方側に配設された冷却器40とを備えている。
なお、下地層31及び接合層38は、図1に示すように、回路層12の表面全体には形成されておらず、半導体素子3が配設される部分、すなわち、半導体素子3との接合面にのみ選択的に形成されている。
ガラス層32内部には、粒径が数ナノメートル程度の微細な導電性粒子が分散されている。なお、ガラス層32内の導電性粒子は、例えば透過型電子顕微鏡(TEM)を用いることで観察されるものである。
また、Ag層33の内部には、粒径が数マイクロメートル程度のガラス粒子が分散されている。
なお、この下地層31に形成された気孔は、外部に開口した連続気孔(open pore)とされており、下地層31の外周面(回路層12と半導体素子3の接合面の外周縁部分)に開口するように構成されている。
また、このガラス含有Agペーストは、その粘度が10Pa・s以上500Pa・s以下、より好ましくは50Pa・s以上300Pa・s以下に調整されている。
樹脂は、ガラス含有Agペーストの粘度を調整するものであり、500℃以上で分解されるものが適している。本実施形態では、エチルセルロースを用いている。なお。樹脂の含有量を増加させることにより、焼成後の下地層31の気孔率が高くなる傾向にある。
また、本実施形態では、ジカルボン酸系の分散剤を添加している。なお、分散剤を添加することなくガラス含有Agペーストを構成してもよい。
酸化銀粉末の含有量が酸化銀ペースト全体の60質量%以上92質量%以下とされ、還元剤の含有量が酸化銀ペースト全体の5質量%以上15質量%以下とされ、有機金属化合物粉末の含有量が酸化銀ペースト全体の0質量%以上10質量%以下とされており、残部が溶剤とされている。この酸化銀ペーストにおいては、焼結によって得られる接合層38に未反応の有機物が残存することを抑制するために、分散剤及び樹脂は添加しないことが望ましい。
還元剤は、還元性を有する有機物とされており、例えば、アルコール、有機酸を用いることができる。
有機金属化合物は、熱分解によって生成する有機酸によって酸化銀の還元反応や有機物の分解反応を促進させる作用を有するものであり、例えば蟻酸Ag、酢酸Ag、プロピオン酸Ag、安息香酸Ag、シュウ酸Agなどのカルボン酸系金属塩等が適用される。
なお、この酸化銀ペーストは、その粘度が10Pa・s以上100Pa・s以下、より好ましくは30Pa・s以上80Pa・s以下に調整されている。
まず、回路層12となるアルミニウム板及び金属層13となるアルミニウム板を準備し、これらのアルミニウム板を、セラミックス基板11の一方の面及び他方の面にそれぞれろう材を介して積層し、加圧・加熱後冷却することによって、前記アルミニウム板とセラミックス基板11とを接合する(回路層及び金属層形成工程S01)。なお、このろう付けの温度は、640℃〜650℃に設定されている。
なお、ガラス含有Agペーストを塗布する際には、スクリーン印刷法、オフセット印刷法、感光性プロセス等の種々の手段を採用することができる。本実施形態では、スクリーン印刷法によってガラス含有Agペーストを回路層12の半導体素子3が搭載される部分に形成した。
この下地層焼成工程S04により、回路層12の一方の面に、ガラス層32とAg層33とを備えた下地層31が形成される。このとき、ガラス層32によって、回路層12の表面に自然発生していたアルミニウム酸化皮膜が溶融除去されることになり、回路層12に直接ガラス層32が形成される。
さらに、Ag層33の内部に、粒径が数マイクロメートル程度のガラス粒子が分散されることになる。このガラス粒子は、Ag粒子の焼結が進行していく過程で、残存したガラス成分が凝集したものと推測される。
このようにして、図3に示すように、回路層12の一方の面に下地層31が形成された本実施形態であるセラミックス回路基板10が製造される。
なお、酸化銀ペーストを塗布する際には、スクリーン印刷法、オフセット印刷法、感光性プロセス等の種々の手段を採用することができる。本実施形態では、スクリーン印刷法によって酸化銀ペーストを印刷した。
そして、半導体素子3とセラミックス回路基板10とを積層した状態で加熱炉内に装入し、酸化銀ペーストの焼成を行う(接合層焼成工程S07)。このとき、荷重を0〜10MPaとし、焼成温度を150〜400℃とする。
また、望ましくは半導体素子3とセラミックス回路基板10とを積層方向に加圧した状態で加熱することによって、より確実に接合することができる。
しかも、本実施形態では、ガラス層32内部に、粒径が数ナノメートル程度とされた微細な導電性粒子が分散されていて、ガラス層32においても導電性が確保されており、具体的には、ガラス層32を含めた下地層31の厚さ方向の電気抵抗値Pが0.5Ω以下に設定されているので、下地層31及び接合層38を介して半導体素子3と回路層12との間で電気を確実に導通することが可能となり、信頼性の高いパワーモジュール1を構成することができる。
また、酸化銀ペーストの原料、配合量については、実施形態に記載されたものに限定されることはない。例えば有機金属化合物を含有しないものであってもよい。
また、このAg粒子の表層には、有機物を含んでいてもよい。この場合、有機物が分解する際の熱を利用して低温での焼結性を向上させることが可能となる。
さらに、下地層31におけるガラス層32とAg層33の厚さ、接合層38の厚さについても、本実施形態に限定されるものではない。
さらに、絶縁層としてAlNからなるセラミックス基板を用いたものとして説明したが、これに限定されることはなく、Si3N4やAl2O3等からなるセラミックス基板を用いてもよいし、絶縁樹脂によって絶縁層を構成してもよい。
なお、回路層及び金属層を構成する金属板を銅又は銅合金で構成した場合には、銅又は銅合金からなる金属板をセラミックス基板に接合する際に、直接接合法(DBC法)、活性金属ろう付け法、鋳造法等を適用することができる。
例えば、図5に示すように、LED素子(半導体素子)を搭載したLED装置(半導体装置)であってもよい。
このようなLED装置101においても、回路層112の一方の面には、気孔率が5%以上55%以下の範囲内とされた下地層131が設けられていることから、有機物の分解反応や金属酸化物粒子の還元反応によるガスを、下地層131の気孔を介して外部へと排出することができ、接合層138内にガスが残存することを抑制できる。
次に示すセラミックス回路基板を用いて、下地層の気孔率を変更し、各種半導体装置(パワーモジュール)を作製した。
ここで、ガラス含有Agペーストに含まれるAg粉末の形状、粒径、ガラス含有Agペーストの焼成条件を、表1に示すように調整した。
得られたセラミックス回路基板を切断し、下地層の断面を機械研磨した後、Arイオンエッチング(日本電子株式会社製クロスセクションポリッシャSM−09010)を行い、レーザ顕微鏡(株式会社キーエンス製VK X−200)を用いて断面観察を実施した。
そして、得られた画像を2値化処理し、白色部をAg及びガラス、黒色部を気孔とした。なお、本発明例1の断面観察写真を図6(a)に、この断面観察写真を2値化処理した画像を図6(b)に示す。2値化した画像から、黒色部の面積を求め、以下に示す式で気孔率を算出した。5箇所の断面で測定し、各断面の気孔率を算術平均して下地層の気孔率とした。結果を表1に示す。
気孔率=黒色部(気孔)面積/下地層の全体面積
接合率は、超音波探傷装置を用いて評価し、以下の式から算出した。ここで、初期接合面積とは、接合前における接合すべき面積、すなわち半導体素子面積とした。超音波探傷像において非接合部分は接合部内の白色部で示されることから、この白色部の面積を非接合面積とした。
接合率 = (初期接合面積−非接合面積)/初期接合面積
なお、下地層の気孔率が2%とされた従来例を基準として1とし、この従来例との比率で評価した。評価結果を表1に示す。
一方、下地層の気孔率が68%とされた比較例においては、初期接合率は88%と従来例に比べ高くなっていたが、熱抵抗が従来例に比べて高くなっている。これは、下地層に気孔が多く存在することにより、半導体素子からの熱を回路層側へと効率よく伝達できていないためと推測される。
以上のことから、本発明例によれば、回路層と半導体素子とが確実に接合され、半導体素子からの熱を回路層側へと効率よく伝達することができる半導体装置が得られることが確認された。
3 半導体素子
10 セラミックス回路基板
11 セラミックス基板(絶縁層)
12 回路層
31 下地層
38 接合層
101 LED装置(半導体装置)
103 発光素子(半導体素子)
112 回路層
131 下地層
138 接合層
Claims (4)
- 導電性を有するアルミニウム又はアルミニウム合金からなる回路層と、前記回路層上に搭載される半導体素子と、を備えた半導体装置であって、
前記回路層の一方の面には、気孔率が5%以上55%以下の範囲内とされた下地層が形成され、前記下地層は、前記回路層側に形成されたガラス層と、このガラス層上に形成されたAg層とを備えており、
この下地層の上に、金属粒子及び金属酸化物粒子の少なくとも一方または両方と有機物とを含む接合材の焼成体からなる接合層が形成されており、
前記回路層と前記半導体素子とが、前記下地層及び前記接合層を介して接合されていることを特徴とする半導体装置。 - 前記回路層と、前記回路層の他方の面に配設されたセラミックス基板と、を有するセラミックス回路基板を備え、
前記半導体素子は、パワー半導体素子とされていることを特徴とする請求項1に記載の半導体装置。 - 請求項2に記載された半導体装置に用いられるセラミックス回路基板であって、
導電性を有するアルミニウム又はアルミニウム合金からなる回路層と、前記回路層の一方の面に形成された下地層と、前記回路層の他方の面に配設されたセラミックス基板と、を有し、
前記下地層は、前記回路層側に形成されたガラス層と、このガラス層上に形成されたAg層とを備えており、気孔率が5%以上55%以下の範囲内とされていることを特徴とするセラミックス回路基板。 - 請求項1又は請求項2に記載された半導体装置の製造方法であって、
前記回路層の一方の面に、ガラス成分を含むガラス含有Agペーストを塗布して焼成することにより、前記回路層側に形成されたガラス層と、このガラス層上に形成されたAg層とを備え、気孔率が5%以上55%以下の範囲内とされた下地層を形成する下地層形成工程と、
前記下地層の上に、金属粒子及び金属酸化物粒子の少なくとも一方または両方と有機物とを含む接合材を配設する接合材配設工程と、
前記接合材の上に前記半導体素子を積層する半導体素子積層工程と、
前記半導体素子と前記接合材と前記下地層と前記回路層とを積層した状態で加熱して、前記下地層の上に、金属粒子及び金属酸化物粒子の少なくとも一方または両方と有機物とを含む接合材の焼成体からなる接合層を形成する焼成工程と、を備え、
前記回路層と前記半導体素子とを、前記下地層及び前記接合層を介して接合することを特徴とする半導体装置の製造方法。
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US11349049B2 (en) | 2016-05-11 | 2022-05-31 | Nichia Corporation | Semiconductor element, semiconductor device, and method for manufacturing semiconductor element |
US10249804B2 (en) | 2016-07-19 | 2019-04-02 | Nichia Corporation | Semiconductor device, base, and method for manufacturing same |
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CN104704618A (zh) | 2015-06-10 |
TWI609462B (zh) | 2017-12-21 |
US9401340B2 (en) | 2016-07-26 |
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US20150255419A1 (en) | 2015-09-10 |
TW201421618A (zh) | 2014-06-01 |
IN2015DN02878A (ja) | 2015-09-11 |
WO2014057902A1 (ja) | 2014-04-17 |
JP2014078558A (ja) | 2014-05-01 |
CN104704618B (zh) | 2017-08-08 |
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EP2908333A4 (en) | 2016-06-08 |
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