JP6444537B2 - 半導体装置及びその製造方法 - Google Patents
半導体装置及びその製造方法 Download PDFInfo
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- JP6444537B2 JP6444537B2 JP2017555999A JP2017555999A JP6444537B2 JP 6444537 B2 JP6444537 B2 JP 6444537B2 JP 2017555999 A JP2017555999 A JP 2017555999A JP 2017555999 A JP2017555999 A JP 2017555999A JP 6444537 B2 JP6444537 B2 JP 6444537B2
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Description
また、動作温度が高く、変換効率に優れている点で、今後の主流となる可能性の高いSiC半導体に適用できるパッケージ形態であることも、パワーモジュールには求められている。
即ち、本発明の一態様における半導体装置は、板状電極及び半導体素子を備え、上記半導体素子における表面電極と上記板状電極とを接合材にて接合した接合部を有する半導体装置において、上記板状電極は、上記半導体素子に対向する対向面に、上記接合部を囲み上記接合材に対して耐熱性を有する枠状部材を備えたことを特徴とする。
図1Aから図1H(総称して図1と記す場合もある)は、実施の形態1によるパワーモジュール100の概略構成を示す概念図である。パワーモジュール100の概略構成を説明すると、パワーモジュール100は、板状電極61、及び、半導体素子の一例に相当するパワー半導体素子(下記のIGBT22等)を有し、パワー半導体素子における表面電極と板状電極61とが接合材にて接合された接合部を有する。さらに、板状電極61は、枠状部材52を有する。このようなパワーモジュール100について、更に詳しく以下に説明する。
図1Aに示すように、このようなセラミック基板10の表面導体層13に、接合材の一例に相当するはんだ(融点219℃)31を用いて、ダイオード21及びIGBT22における各裏面電極がダイボンドされる。はんだ31として、例えばSn−Ag−Cuのはんだが用いられる。
ケース51は、PPS(Poly Phenylene Sulfide Resin)の樹脂製であり、ケース51には、以下に詳しく説明する板状電極61及び信号電極62等がインサートモールド形成され保持されている。
さらにまた板状電極61は、当該板状電極61を貫通する貫通部612を2つ有する。貫通部612は、IGBT22及びダイオード21の各表面主電極221、211と、板状電極61とが接合される際に、本実施形態では溶融したはんだが通過可能な穴であり、IGBT22の表面主電極221(サイズ:12mm×12mm)及びダイオード21の表面主電極211(サイズ:12mm×12mm)における、それぞれのほぼ中心に対応して位置する。本実施形態では、貫通部612は、一例として直径2.5mmの大きさを有する。尚、貫通部612のサイズは、IGBT22等のパワー半導体素子における表面主電極のサイズに応じて決定することができる。
枠状部材52及び補助枠状部材53は、図2A及び図2B(総称して図2と記す場合もある。)に示すように、板状電極61をその厚み方向から挟みケース51に連接した連接部530を有する。よって枠状部材52及び補助枠状部材53は、連接部530を介してケース51と同一の材料で、ケース51を成型し板状電極61がインサートモールド形成される工程と同じ工程にてケース51と一体形成される。尚、枠状部材52及び補助枠状部材53の形状等については、以下で詳しく説明する。
即ち、板状電極61が有する枠状部材52は、図1B及び図2Bに示すように、IGBT22及びダイオード21における表面主電極221、211に接する面における第1開口部521と、板状電極61に接する面における第2開口部522とを有する。ここで第1開口部521及び第2開口部522は、共に、板状電極61における貫通部612がそれぞれの中央部分に位置する開口部である。
第1開口部521は、一例として11mm×11mmの大きさであり、例えば半径3mmの円弧形状の四隅を有した大略方形状であり、第2開口部522は一例として8mm×8mmの大きさであり、例えば半径2mmの円弧形状の四隅を有した大略方形状を有する。よって枠状部材52は、すり鉢形状部523を有する。このすり鉢形状部523における深さは、一例として0.5mmである。このすり鉢形状部523の内側に、はんだ32が注入され、はんだ接合部32A(図1Cから図1F)が形成される。このように枠状部材52は、はんだ32による接合部32Aを囲む部材であり、また、はんだ32に対して耐熱性を有する部材である。
したがって、IGBT22及びダイオード21の各表面主電極221、211と、板状電極61とを接合する際に、枠状部材52が各表面主電極221、211に密接している場合には、溶融したはんだは、表面主電極221、211の端部まで濡れ広がることはできない。
そのため、はんだ32の接合部32Aの端部に集中する接合応力が、剥離の生じやすい表面主電極221、211の端部に重なることを防止することが可能となり、接合信頼性、ひいてはパワーモジュール100の信頼性を確保しやすくなる。さらにまた、はんだ32の接合部32Aを確実に形成することができオープン不良の発生を防止することができる。その結果、パワーモジュール100における不具合の発生が低減でき、従来に比べてパワーモジュールの生産性及び品質向上を図ることが可能となる。
即ち、板状電極61の背面615に備わる補助枠状部材53は、図1B及び図2Aに示すように、板状電極61に接する面における第3開口部531と、補助枠状部材53の表面における第4開口部532とを有する。第3開口部531及び第4開口部532は、共に、板状電極61における貫通部612と同心状に位置する。
第3開口部531は、一例として直径2.2mmの大きさであり、第4開口部532は一例として直径5.0mmの大きさであり、よって補助枠状部材53は、円すい台形状部533を有する。この円すい台形状部533における深さは、一例として0.5mmである。
また、溶融したはんだを流し込むことで接合部32Aを形成する場合にも、円すい台形状部533は、ガイドとしても機能することができる。
セラミック基板10について、本実施の形態ではアルミナセラミック基板を用いたが、チッ化アルミニウム、あるいはチッ化シリコンなどのセラミック基板でもよく、上述と同様の効果が得られる。また、表面導体層13及び裏面導体層12として銅を用いたが、アルミニウム導体層を用いてもよく、上述と同様の効果が得られる。
このような手法を採ることで、例えばケースの寸法が大型化してインサートモールド成型が困難な場合でも、枠状部材52及び補助枠状部材53をそれぞれ形成することが可能になるという利点がある。
図3Aから図3D(総称して図3と記す場合もある。)を参照して、実施の形態2によるパワーモジュール102について説明する。
本実施の形態2におけるパワーモジュール102は、上述の実施の形態1におけるパワーモジュール100と基本的に同様の構成を有する。パワーモジュール102とパワーモジュール100との主な相違点は、板状電極61がさらにスペーサ54を有する点、はんだ接合がリフロー炉を用いて行われる点などである。
したがって以下では、両者で相違する構成部分について主に説明を行い、共通する構成部分についてはその説明を省略する。尚、図3Aから図3Cでは、図1B及び図1Cにおける図示の上下を反転させた表示になっている。
また、実施の形態2のパワーモジュール102では、図3Aに示すように、枠状部材52のすり鉢形状部523には、板はんだ320が載置される。板はんだ320は、例えば直径8mm、厚さ0.5mmである。
さらに、板はんだ310に面して、セラミック基板10における表面導体層13を配置して、セラミック基板10は、ケース51に形成した突起511に載置される。このとき、板状電極61のスペーサ54、本実施の形態では枠状部材52と共に形成されたスペーサ54、の先端は、セラミック基板10に当接する。また、セラミック基板10の周囲は、接着剤8にてケース51に固定される。
図4を参照して、実施の形態3によるパワーモジュール103について説明する。
本実施の形態3におけるパワーモジュール103は、上述の実施の形態1,2におけるパワーモジュール100、102と基本的に同様の構成を有する。パワーモジュール103とパワーモジュール102との主な相違点は、リフロー炉によるはんだ接合ではなく、溶融したはんだの注入による点、及び、ケース51を用いることなくトランスファーモールドにて成型される点などである。このため、板状電極61とは異なる形状を有する板状電極66を用いる。
したがって以下では、相違する構成部分について主に説明を行い、共通する構成部分についてはその説明を省略する。
また、板状電極66は、スペーサ54を有することから、実施の形態2におけるパワーモジュール102が奏する効果と同様の効果を得ることができる。
又、2015年12月16日に出願された、日本国特許出願No.特願2015−245191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。
32 はんだ、32A 接合部、51 ケース、52 枠状部材、
53 補助枠状部材、54 スペーサ、61,66 板状電極、
100,102、103 パワーモジュール、
211,221 表面主電極、
521 第1開口部、531 第3開口部、
612 貫通部。
Claims (9)
- 板状電極及び半導体素子を備え、上記半導体素子における表面電極と上記板状電極とを接合材にて接合した接合部を有する半導体装置において、
上記板状電極は、上記半導体素子に対向する対向面に、上記接合部を囲み上記接合材に対して耐熱性を有する枠状部材を備え、
上記枠状部材は、上記半導体素子に面し上記表面電極よりも小さいサイズの開口部を有し、上記開口部はすり鉢状形状である、
ことを特徴とする半導体装置。 - 上記開口部は、大略方形状である、請求項1に記載の半導体装置。
- 上記開口部は、円弧形状の四隅を有する、請求項1又は2に記載の半導体装置。
- 上記板状電極を保持するケースをさらに有し、
上記枠状部材は、上記ケースと一体形成するためケースに連接した連接部を有する、請求項1から3のいずれか1項に記載の半導体装置。 - 上記半導体素子を実装した基板をさらに有し、
上記板状電極は、上記基板に当接するスペーサを有する、請求項1から4のいずれか1項に記載の半導体装置。 - 上記板状電極は、上記枠状部材で囲まれる上記接合材が通過する、当該板状電極を貫通した貫通部と、上記対向面と反対側の背面に設けられ上記貫通部よりも小さい開口部を有する補助枠状部材と、をさらに有する、請求項1から5のいずれか1項に記載の半導体装置。
- 請求項1から6のいずれか1項に記載の半導体装置の製造方法であって、
板状電極に備わる枠状部材は、半導体素子における表面電極よりも小さいサイズの開口部を有し、上記開口部に接合材を載置するように上記板状電極を配向し、
上記枠状部材における上記接合材に表面電極を対向させて半導体素子を上記枠状部材に載置し、
上記半導体素子と絶縁基板における導体層との間に接合材を配置して上記絶縁基板をケースに保持し、
上記接合材を溶融させて、上記板状電極、上記半導体素子、及び上記絶縁基板を接合する、
製造方法。 - 上記枠状部材は、上記ケースを成型する際にケースと共に上記板状電極に形成される、請求項7に記載の半導体装置の製造方法。
- 上記枠状部材は、別途作製した独立部品であり、上記ケースへの固定により上記板状電極に形成される、請求項7に記載の半導体装置の製造方法。
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