JP6366857B2 - 電力用半導体装置 - Google Patents
電力用半導体装置 Download PDFInfo
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- JP6366857B2 JP6366857B2 JP2017547681A JP2017547681A JP6366857B2 JP 6366857 B2 JP6366857 B2 JP 6366857B2 JP 2017547681 A JP2017547681 A JP 2017547681A JP 2017547681 A JP2017547681 A JP 2017547681A JP 6366857 B2 JP6366857 B2 JP 6366857B2
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- power semiconductor
- external wiring
- layer
- semiconductor device
- conductor layer
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
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Description
一方、半導体素子の上面電極における接続は、従来、Alワイヤボンド接合を用いることで必要な電流容量及び接続信頼性を確保してきた。しかしながら、半導体素子の小型化により、接続部の単位体積当たりの電流密度が増大し、その結果、接続信頼性の低下を招く恐れが懸念されている。
電力用半導体装置(パワー半導体モジュール)では、例えば上記特許文献1に記載するように、電力変換用途のスイッチングデバイスとして用いられる複数のIGBT(絶縁ゲートバイポーラトランジスタ)と、逆並列接続のフリーホイールダイオード(FWD)とを1セットとし、その複数セットが、例えばインバータ回路の半導体素子構成になるように、絶縁回路基板上に配置、配線されている。
ここでは金属基板上に固着された絶縁回路基板上に、IGBTの下面電極及び複数の外部端子の下端がそれぞれはんだ接合される。さらにIGBTの上面電極には、ワイヤボンディングによってAl線の配線が行なわれ、このAl線は、さらに外部端子に電気的に接続されている。
また、金属基板上の絶縁回路基板全体を取り囲むように金属基板の外周には、枠状の樹脂ケースが固着される。この樹脂ケースと金属基板上とで構成される、樹脂ケースの内側空間には、絶縁性の封止樹脂材が充填されて電力用半導体装置が形成される。
即ち、本発明の一態様における電力用半導体装置は、絶縁層における厚み方向の対向面に第1導体層及び第2導体層を有する絶縁基板と、上記第1導体層に第1固着層を介して接合した複数の半導体素子と、それぞれの上記半導体素子で共用する外部配線であり、当該外部配線と上記第1導体層との間に上記半導体素子が位置し上記第1導体層に沿って延在した状態で第2固着層を介して各半導体素子に接合する素子連結部、及びこの素子連結部の一端を上記厚み方向へ折り曲げた外部接続用端部を有する、外部配線と、上記第1導体層上の複数の半導体素子の周囲に第3固着層を介して上記第1導体層に接合された枠部材と、を備え、上記枠部材は、上記外部接続用端部と嵌合する嵌合部を有し、上記外部配線は、上記半導体素子側へ突出する、少なくとも2つの突起部を有する、ことを特徴とする。
図1は、本実施の形態の電力用半導体装置101の斜視図であり、図2はその断面図である。電力用半導体装置101は、基本的構成部分として、複数の半導体素子5と、外部配線7と、枠部材8と、絶縁基板10とを備える。これらの構成部分について、以下に順次説明を行う。
半導体素子5は、その厚み方向における2つの対向面のそれぞれに電極を有し、一方面、例えば下面、の電極が第1固着層4によって第1導体層1に接合される。第1固着層4としては、例えば、はんだ、Ag導体、Cu導体などの導電性を有し機械的な固着が可能な金属系の物質が用いられる。このときAgの層など高融点の材料を用いることで、電力用半導体素子5における動作温度が上昇したときの第1固着層4の信頼性を高めることができる。
また外部配線7の厚みは、例えば0.2mm〜1mm程度が用いられる。厚みが大きいほど電力用半導体素子5への熱応力が大きくなることから自ずと制限があり、また薄すぎると通電時におけるオーム抵抗による発熱が大きくなるため、適切な厚み選択が必要である。
また外部配線7は、素子連結部7aにおいて、半導体素子5側へ突出する少なくとも2つの突起部7bを有する。この点については後述する。
枠部材8の材料としては、射出成型可能で耐熱性の高い樹脂材料が用いられる。例えばPPS(ポリフェニレンサルファイド)あるいは液晶樹脂、フッ素系樹脂などが好適である。尚、半導体素子5及び外部配線7等が配置されている、枠部材8の内側には封止材が注入され封止が行われる。該封止により、半導体素子5におけるコレクタ〜エミッタ間、絶縁基板10の沿面周辺のコレクタ〜ヒートシンク間の絶縁性が確保される。
一方、従来の電力用半導体装置からもそうであるように、モーターの負荷の増減による半導体素子等の温度変化により、電力用半導体装置内部の接合部には熱応力が発生し、繰り返される温度変化によって接合部が劣化することが懸念される。即ち、長期使用に対して寿命が存在する。よって安全に使用できる期間を保証するために寿命設計を行う必要がある。
即ち、外部配線の重心が複数の電力用半導体素子間における重心からオフセットしてしまう。その結果、外部配線の姿勢が不安定になり第2固着層で接合する際に、ある半導体素子に対して配置されている第2固着層の厚みと、別の半導体素子に対して配置されている第2固着層の厚みとのバラツキが非常に大きくなる。最悪の場合には、外部配線が転倒してしまう懸念もある。
このような各第2固着層における厚みのバラツキは、以下の問題を招く。即ち、第2固着層の厚みが非常に大きい場合、第2固着層に作用する熱応力は小さくなるが、一方、電力用半導体素子の上面電極に作用する熱応力は大きくなってしまう。その結果、上面電極の亀裂進展が早くなる。一方、第2固着層の厚みが非常に小さい場合には、第2固着層に作用する熱応力が非常に大きくなり、第2固着層の亀裂進展が非常に早くなる。
以上の説明から判るように、半導体素子の電極と外部配線との接合部信頼性を得るには、第2固着層の最小厚み及び最大厚みを厳密に規定しなければならない。
即ち、嵌合部8bは、外部配線7の転倒防止を図るための構成部分であり、外部配線7の外部接続用端部7dと嵌合して外部配線7の位置ずれを規制する。ここで嵌合部8bと外部配線7との嵌合は、嵌合部8bにおいて外部配線7の接触面の全面で接触してもよいし、上記接触面の一部で接触している状態でもよく、共に同様の効果を発揮出来る。
また、外部配線7の外部接続用端部7dは、絶縁基板10の厚み方向11に沿って延在し当該電力用半導体装置101の表面(上面)から取り出されることから、電力用半導体装置101の小型化を実現し、さらに、外部配線7は、複数の半導体素子5に対して設置されることから、生産性及びコスト面での有益性も同時に確保することができる。
図3に示す本実施の形態2の電力用半導体装置102は、上述した実施の形態1における外部配線7にさらに工夫を加えた外部配線7−2を有する構成を備える。電力用半導体装置102は、外部配線7−2の構成以外、実施の形態1と同じ構成を備えることから、以下では主に外部配線7−2について説明を行う。尚、図4は本実施の形態2における電力用半導体装置102の断面図である。
この凹部7cは、素子連結部7aにおける第2固着層6との接触面7eに設けられる。また凹部7cは、図3及び図4に示すように外部配線7−2を貫通したものでもよいし、図7に示すように非貫通のものでもよい。また凹部7cの形状は、図示する円形に限定されず、任意の形状を採用することができる。例えば溝状であってもよい。
図5に示す本実施の形態3の電力用半導体装置103は、上述した実施の形態1又は2における枠部材8にさらに工夫を加えた枠部材8−2を有した構成を備える。電力用半導体装置103は、枠部材8−2の構成以外、実施の形態1又は2と同じ構成を備えることから、以下では主に枠部材8−2について説明を行う。
既に説明した外部配線7における突起部7b、並びに、枠部材8−2において嵌合部8b及び凸部8cを設けたことで、第2固着層6の最小厚み及び最大厚みを、ジグの使用無しに厳密に規定することが可能になる。その結果、各半導体素子5の電極と外部配線7との接合部信頼性を従来に比べて向上させることができる。
図6を参照して本実施の形態4の電力用半導体装置104について説明する。この電力用半導体装置104も実施の形態3で説明した枠部材8−2を有する。尚、図6は、実施の形態2の電力用半導体装置102つまり外部配線7−2を有する構成において、枠部材8を枠部材8−2に換えた構成を示しているが、実施の形態1の電力用半導体装置101において、枠部材8を枠部材8−2に換えた構成を採ることもできる。
また、枠部材8の形状において全体で反り等の歪みがある場合、及び、第1導体層1の形状においても反り等の歪みがある場合でも、第3固着層9量を適正化することが可能となる。よって、電力用半導体装置104の生産性を飛躍的に向上させることが可能となる。
本実施の形態5における電力用半導体装置は、上述した実施の形態1から4における外部配線7あるいは外部配線7−2に関して工夫を施した電力用半導体装置である。よって以下では、主に外部配線7あるいは外部配線7−2に関して説明を行う。
例えば自動車用の駆動モーターは、モーター1台あるいは2台とエンジンとのハイブリッドシステム用のもの、又は、モーターのみの電気自動車用のもの等、多種多様化しており、このモーターを駆動するインバータに求められる信頼性スペックもそれぞれのシステムに応じて多種多様化している。そして、小型化という課題に合わせて、様々な信頼性スペックに応じて安価で高品質なインバータが求められている。
又、2015年10月28日に出願された、日本国特許出願No.特願2015−211583号の明細書、図面、特許請求の範囲、及び要約書の開示内容の全ては、参考として本明細書中に編入されるものである。
6 第2固着層、7 外部配線、7a 素子連結部、7b 突起部、7c 凹部、
7d 外部接続用端部、7e 接触面、7−2 外部配線、
8 枠部材、8b 嵌合部、8c 凸部、8d 凹部、8e 接触面、
8−2 枠部材、9 第3固着層、10 絶縁基板、
101〜104 電力用半導体装置。
Claims (5)
- 絶縁層における厚み方向の対向面に第1導体層及び第2導体層を有する絶縁基板と、
上記第1導体層に第1固着層を介して接合した複数の半導体素子と、
それぞれの上記半導体素子で共用する外部配線であり、当該外部配線と上記第1導体層との間に上記半導体素子が位置し上記第1導体層に沿って延在した状態で第2固着層を介して各半導体素子に接合する素子連結部、及びこの素子連結部の一端を上記厚み方向へ折り曲げた外部接続用端部を有する、外部配線と、
上記第1導体層上の複数の半導体素子の周囲に第3固着層を介して上記第1導体層に接合された枠部材と、を備え、
上記枠部材は、上記外部接続用端部と嵌合する嵌合部を有し、
上記外部配線は、上記半導体素子側へ突出する、少なくとも2つの突起部を有する、
ことを特徴とする電力用半導体装置。 - 上記素子連結部は、上記第2固着層との接触面に凹部を有する、請求項1に記載の電力用半導体装置。
- 上記枠部材は、上記第3固着層との接触面に上記第1導体層側へ突出する凸部をさらに有する、請求項1又は2に記載の電力用半導体装置。
- 上記枠部材は、上記第3固着層との接触面に凹部をさらに有する、請求項1から3のいずれか1項に記載の電力用半導体装置。
- 上記外部配線は、Cu合金における線膨張係数よりも小さく半導体素子における線膨張係数よりも大きい線膨張係数を有する、請求項1から4のいずれか1項に記載の電力用半導体装置。
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DE112016004980T5 (de) | 2018-07-19 |
WO2017073233A1 (ja) | 2017-05-04 |
JPWO2017073233A1 (ja) | 2018-04-19 |
CN107851639B (zh) | 2020-08-25 |
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