JP6550477B2 - 開気孔接触片のガルバニック接合による部品の電気接触方法およびそれに対応する部品モジュール - Google Patents

開気孔接触片のガルバニック接合による部品の電気接触方法およびそれに対応する部品モジュール Download PDF

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JP6550477B2
JP6550477B2 JP2017562693A JP2017562693A JP6550477B2 JP 6550477 B2 JP6550477 B2 JP 6550477B2 JP 2017562693 A JP2017562693 A JP 2017562693A JP 2017562693 A JP2017562693 A JP 2017562693A JP 6550477 B2 JP6550477 B2 JP 6550477B2
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contact
component
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contact piece
pored
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JP2018516464A (ja
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シュテグマイアー、シュテファン
バウエレッガー、フーベルト
ゾムマー、フォルクマー
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Siemens AG
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Description

本発明は、導電接触部を備えた部品の電気接触方法および少なくとも1つの導電接触部を備えた部品を有する部品モジュールに関する。
特にマイクロシステム技術およびパワーエレクトロニクスにおいては、例えば抵抗のような受動部品、例えばIGBT、ダイオード、MOSFET、LEDのような半導体部品、例えばFR4、DCB、ANMのような基板およびリードフレームの電気接触部が、構造技術および接続技術により互いに電気的に接続される。
基板への電気的な接触のために、導電接着剤による接着、いわゆるプリフォームのはんだ付け、はんだペーストによるはんだ付け、拡散はんだ付けならびに焼結のような方法が知られている。拡散はんだ付けおよび焼結の場合に、部品接触部も高温に耐える。
これに対して、基板から離れた接触は、通常、ワイヤボンディング技術(リボンボンディング技術も)や、例えばモリブデンの如き調整要素の助けを借りた加圧接触技術のような方法により実現されるか、又はプレーナ技術(例えば、SiPLIT、SkinおよびDirectFET)により実現される。しかし、加圧焼結又は低加圧焼結による接触の場合には、応力や破損に対して弱い電気接触部が生じる。さらに、このような焼結の方法は時間的および装置的に高価である。さらに、はんだ付けおよび焼結の方法は、接触させられるべき構成要素に高い温度を供給することを必要とし、従って熱に弱い部品には使用できないという欠点を有する。さらに、電気めっき、拡散はんだ付けおよび焼結は、非常に時間のかかる方法である。
これに対して、締付け接続又はばね接続又は押圧接続の場合に、必要不可欠の固定が、特に複数の接触部位の接触の際に、不利なことに著しい組立費用を必要とする。さらに、これらの接触方法は、不規則な加圧力に起因した部品破損のリスクがあるために、十分な信頼性がない。
これに対して、注入可能なはんだ材料(例えば、出願時点でIndium Cooperation社によって販売された「Heatspring」(登録商標))を用いた接触は、接触部の導電率が低いという結果に終わり、しかも複雑で高価である。
従って、これらの公知の方法には、基板への電気接触および基板から遠い電気接触を行うのに、次の必要条件を同時に満たすことが困難であるという欠点がある。
・複数の接触部を同時に形成すること。
・高い温度上昇なしに形成すること。
・高い圧力上昇なしに形成すること。
・数秒から数分までの時間範囲内で形成すること。
・接触部が大きな接触面を有すること。
・接触部が高い耐温性を有すること。
従って、本発明の課題は、少なくとも1つの導電接触部を有する部品の、上記欠点を持たない電気接触方法を提供することにある。特に、本発明による方法により、高い温度上昇又は圧力上昇なしに迅速に大きな平面と耐温性とを有する複数の接触部を同時に接触させることができなければならない。さらに、本発明の課題は、このように接触させられた電気接触部を有する部品モジュールを提供することにある。
この本発明の課題は、請求項1記載の特徴事項を有する方法と、請求項15記載の特徴事項を有する部品モジュールとによって解決される。本発明の好ましい発展形態は、従属請求項、以下の記載および図面からもたらされる。
本発明による方法は、少なくとも1つの電気接触部を有する部品を電気的に接触させるための方法である。本発明による方法では、少なくとも1つの接触部に少なくとも1つの開気孔接触片がガルバニック接合される。その接触片の開気孔性は、多数の電解液通路を提供し、従って、電解液は外側から接触片と部品の電気接触部との接触面に到達することができる。理想的には接触片の開気孔材料が連続気泡構造を有し、その連続気泡構造を貫通して電解液が格別に効率良く通過することができる。
本発明による方法は、少なくとも潜在的に熱に弱い被接触部品において大きな温度上昇なしに有利に実施することができる。というのは、ガルバニック法は、通常高々150℃の比較的低い温度で実施されるからである。
さらに、本発明による方法により、部品の高い加圧負担を容易に回避することもできる。というのは、ガルバニック法は、加圧力を全く又は場合によっては僅かしか必要としないからである。
本発明による方法により、持続弾性を有する弾力性のある接触を容易に実現することができる。というのは、まさに開気孔材料が通常、持続弾性を有する弾力性のある材料特性を有するからである。
この出願での「ガルバニック接合される」という言い回しは、特に「ガルバノ技術による接合」、又は「めっき法による接合」を意味する。このガルバニック接合は、好ましくは電解液により、特に電解浴により行われる。
好ましくは、本発明による方法では、電解液が開気孔接触片の開気孔内に導入される。
この出願での「開気孔接触片」という用語は、気孔が外側から接触片の内部に通じている接触片を意味する。
好ましくは、本発明による方法では、前記接触片がガルバニック接合され、その際に、前記接触片および/又は前記部品の電気接触部が形成されている材料と同じ材料が析出される。
本発明による方法では、前記少なくとも1つの接触部が少なくともそれ自体としては平らな部材である部品が使用されると有利である。その代替又は追加として、前記接触部が有する接触面の最大限の平面的広がりが、この接触面に対して垂直方向の当該接触部の広がりよりも大きいことが好ましい。
まさに面接触による接触の場合には、本発明による方法が格別に有利であることが分かった。というのは、この方法により平面的な接触が容易に実現できるからである。特に、このようにして熱分散する接触が容易に達成できる。というのは、平面的な接触が、既に空間的なジオメトリに基づいて、強い熱分散を生じさせるからである。通常は熱分散のために必要な熱伝導性も付与されている。というのは、接触に必要である良好な導電性と、熱分散にとって望ましい良好な熱伝導性とが、典型的な材料に関しては通常、互いに付随して現れるからである。
本発明による方法では、少なくとも1つの接触片として導電性の接触片を使用するのが好適である。本発明による方法のこの発展形態では、接触接続を非常に速やかに実現することができる。というのは、接触部位に析出された材料により導電接続を実現するだけでよいからである。本発明による方法のこの発展形態では、接触片自体が既に大きな面積の導電通路であるので、大量の材料を析出することは必要でない。
本発明による有利な発展形態では、前記少なくとも1つの開気孔接触片が多孔質材料から又は多孔質材料を含んで形成されている。
本発明による方法では、前記少なくとも1つの開気孔接触片が金属から又は金属を含んで形成されており、該金属がニッケルおよび/又は銀および/又は金および/又は錫および/又は銅であると有利である。
本発明による方法では、前記少なくとも1つの開気孔接触片が織物構造および/又は発泡構造および/又はメッシュ構造で形成されていると適切である。
本発明による方法の有利な発展形態では、前記少なくとも1つの開気孔接触片が、前記接触部に次の温度においてガルバニック接合される、すなわち高々100℃、好ましくは高々60℃、特に高々20℃、適切には高々5℃である温度、および/又は前記部品の動作温度から高々20℃だけ、好ましくは高々10℃だけ、特に高々5℃だけ、理想的には高々2℃だけずれた温度においてガルバニック接合される。低い温度で動作する場合には本発明による方法の実施時における部品の温度上昇を格別に少なく保つことができる。まさに温度に敏感な部品に対しては、本発明による方法のこの発展形態を選択するとよい。さらにガルバニック接合とその後の動作温度との温度差をできるだけ少なくするならば、前記部品は格別に少ない応力で接続されている。部品の予定動作温度が100℃よりも高い温度であるならば、ガルバニック接合は100℃よりも高い温度で行うのがよい。この場合には塩溶融に基づく金属析出法が有利に使用される。
好適には、本発明による方法では、前記少なくとも1つの開気孔接触片が、電気化学的めっき法によりガルバニック接合される。
本発明による方法のこの発展形態では、有利には導電接触片が使用され、電気化学的めっき法により金属がその接触片上に析出される。本発明による方法では、該方法において接触片上に析出されるべき金属を含んで形成されている陽極が使用されると有利である。この金属が銅であると有利である。代替としてかつ同様に有利には、金属としてニッケルおよび/又は銀および/又は金および/又は錫が使用される。
代替としてかつ同様に好ましくは、本発明による方法において、前記少なくとも1つの開気孔接触片が、外部電流のない方法により、特に置換メタライゼーションおよび/又は還元メタライゼーションおよび/又は接触メタライゼーションによりガルバニック接合される。外部電流のないめっき法の場合には、金属の析出が、その後の前記部品の動作温度にほぼ等しい動作温度で行われると有利である。それによって機械的応力が低減又は回避される。さらに同様に腐食保護を、特にニッケルのめっき、又はニッケルおよび金のめっきによって実現することができる。外部電流のない方法の他の利点は、前記部品自体が電気接触される必要がないことにある。従って、高価なシード層(英語の「Seed layers」)の析出および接触手段が必要でない。
本発明による方法の有利な発展形態では、当初それ自体は通り抜けのできない導電通路を形成している接触片、つまり厳密に言えば巨視的には導電性でない接触片が使用される。もっと正確に言うならば、その接触片は多数の金属島を有し、これらの金属島が、いわばメタライゼーション島として、(有利には外部電流のない)めっき法の経過中に初めて通り抜けのできる導電通路を形成する。
好ましくは、本発明による方法において、前記部品が、前記接触片により他の構成素子および/又は電流導体に、および/又は基板に接触させられ、その後に前記接触片および/又は前記部品および/又は前記他の構成素子および/又は電流導体および/又は基板が電気絶縁層を施される。
本発明による方法において、前記絶縁層が、キャスティングおよび/又はモールドにより、および/又はシロキサンおよび/又はポリマーで成形されると有利である。
本発明による方法の有利な発展形態では、部品としてパワー部品が使用される。
本発明による方法において、部品として少なくとも1つのトランジスタ、特に絶縁ゲート電極を有するバイポーラトランジスタ(絶縁ゲートバイポーラトランジスタ:IGBT)を有する部品が使用されると適切である。
本発明による方法では、2つの接触部を有する部品が使用され、好ましくは2つの接触部が該部品の互いに反対の方を向いている側面、特に平らな側面にあって、接触部ごとに該接触部に少なくとも1つの開気孔接触片が、好ましくはそれぞれ本発明による方法に従って既述のようにガルバニック接合されるとよい。
本発明による部品モジュールは、少なくとも1つの電気接触部を備えた部品を有する。その電気接触部には本発明に従って少なくとも1つの開気孔接触片がガルバニック接合されている。
本発明による部品モジュールが上述の如く本発明による方法により構築されていると格別に有利である。
本発明による部品モジュールの発展形態では、部品モジュールが積み重ねたスタックの様式で実現され、このスタックの複数の平面は、プリント板および/又は基板により形成されており、そのプリント板および/又は基板には部品が接触片により接合されている。さらに全ての平面の部品の接触部が同時に本発明による方法により接触させられると有利である。
本発明による部品モジュールの他の発展形態では、複数の部品が共通に1つの基板又は1つのプリント板の平坦面において、該基板又は該プリント板に接合されている。この発展形態においても、複数の部品が同時に本発明による方法により接触させられるとよい。
以下において、図面に示す実施例に基づいて本発明をさらに詳細に説明する。
図1は、本発明による部品モジュールの第1実施例を製造するための本発明による方法の第1実施例を実施する前におけるセラミック基板へのパワー部品の配置を示す原理的な断面図である。 図2は、本発明による方法の第1ステップの実施時における図1によるパワー部品の配置を示す原理的断面図である。 図3は、本発明による方法の第1ステップの実施後における図1によるパワー部品の配置を示す原理的断面図である。 図4は、図3からの部分拡大図(A)およびこの部分拡大図からの部分詳細図(B)である。 図5は、図1乃至4による方法ステップ後における本発明による部品モジュールを示す原理的断面図である。 図6は、本発明による部分モジュールの他の実施例を製造するための本発明による方法の他の実施例を実施する前におけるセラミック基板へのパワー部品の配置を示す原理的断面図である。 図7は、本発明による方法の他の実施例の第1ステップの実施時における図6によるパワー部品の配置を示す原理的断面図である。 図8は、図6および7による方法ステップ後の本発明による部分モジュールの他の実施例を示す原理的断面図である。
図1に示されている部品10は、絶縁ゲート電極を有するバイポーラトランジスタ(英語の「insulated-gate bipolar transistor」:IGBT)であり、互いに反対の方を向いている第1の平らな側面20および第2の平らな側面30を有する。第1の平らな側面20および第2の平らな側面30に沿って、パワー部品10の薄膜状の面接触部40,50が延びており、これらの面接触部は平面状のチップメタライゼーションとして形成されている。図示の実施例では、パワー部品10の図1において上側に配置された面接触部40が銅からなるのに対し、パワー部品10の下側に配置された面接触部50が銀からなる。基本的には、上側の面接触部も、銀から、又は銀を含んで形成されていてもよいし、あるいはAlSiCu、その他の金属又はその他の導電材料から、又はAlSiCu、その他の金属又はその他の導電材料を含んで形成されていてもよい。これに対して、下側の面接触部は、金又はその他の金属又はその他の導電材料から、又は金又はその他の金属又はその他の導電材料を含んで形成されていてもよい。
これらの面接触部40,50の接触のために、面接触部40,50には開気孔材料の接触片60,70が配置され、これらの接触片60,70は、面接触部40,50に沿ってほぼ平面状に延びている。図示の実施例では、接触片60,70は導電性に形成されており、かつ銅スポンジとして実現されている。特に図示されていないがその他の点では図に基づいて説明されている実施例に相当する他の実施例において、開気孔接触片60,70は、その他の開気孔導電材料からなっていてもよく、例えばメッシュ構造又は織物構造又はその他の多孔質構造として形成されたアルミニウムの接触片又はチタンの接触片、又はその他の金属から又はその他の金属を含んで形成された接触片であってよい。例えば、導電材料により特定範囲を被覆されたポリマースポンジ又は導電粒子を混合されたポリマースポンジも、接触片として使用することができる。
パワー部品10の一方の面接触部50は、窒化アルミニウム(AlN)からなるセラミックコア100を有するセラミック基板90の他の面接触部80の方を向いている。基本的にはセラミックコア100は、特に図示されていない他の実施例において、異なるセラミック材料からなっていてよいし、あるいはシリコンおよび/又はエポキシ樹脂からなるFR4又はその他の基材のようなプリント基板材料からなっていてよい。セラミック基板90の他の面接触部80は、表面的な基板メタライゼーションとして、図示の実施例では銅の基板メタライゼーションとして形成されている。パワー部品10におけるセラミック基板90の方を向いている面接触部50と、他の面接触部80とは、互いに平行に延びており、従って平らな間隙を形成している。セラミック基板90の方を向いているその面接触部50に配置された接触片70は、この平らな間隙を完全に埋めており、全体にわたって、パワー部品10のこの面接触部50とセラミック基板90の他の面接触部80とに接触している。それゆえ、接触片70は、パワー部品10とセラミック基板90との接触のために配置されている。
開気孔接触片60,70は、他の方法ステップにおいて、電極110,120に接触させられる(図2)。そのために一方では、第1の電極110が、セラミック基板90と反対の方を向いている面接触部40上に配置されている接触片60の(パワー部品10から遠い方の)外側面130に電気的に接触させられる。他の電極、すなわち第2の電極120は、パワー部品10とセラミック基板90との間にある接触片に接している銅の面接触部80に電気的に接触させられる。第1の電極110は同時に固定要素として作用し、この固定要素は、本発明の方法の経過中、パワー部品10、セラミック基板90および接触片60,70からなるパワーモジュールの固定を保証する。そのために、第1の電極110は、詳しく示されていない締付け装置によりセラミック基板90の方向に力を加えられる。その代わりに、その他の点では図示の実施例に相当する他の実施例では、電極110が固定要素として形成されずに、接触片60,70の固定が導電接着剤により行われる。その接着剤の導電性によって、接触片60,70における電気的接触を簡単に行うことができる。
開気孔接触片60,70と電極110,120との接触によって、(公知の)電気化学的めっき法により、金属が、図示の実施例では銅が、開気孔接触片60,70と面接触部40,50,80との間の領域に析出する(図3)。図示の実施例では、その析出された材料が、チップメタリゼーション又はセラミック基板メタリゼーションと接触片60,70とに沿って平面状に延びている層132,134,136を形成する。この析出の結果、同時に開気孔接触片60,70のそれぞれがパワー部品10と結合する。その際に、全ての接触片60,70が、同時に、該接触片が接している各接触部40,50,80と結合する。
パワー部品10、接触片70およびセラミック基板90の上記の実施例に基づいて実現された部品接触部が、図4Aに現実的な部分拡大図で示されている。この部分拡大図は、パワー部品10とセラミック基板90との間にある接触片70の接合を示す。図4Bの詳細図はパワー部品10への接触片70の接合を示す。接触片70の一側面すなわちパワー部品10の方を向いた側面140と、パワー部品10のチップメタライゼーションの一側面すなわち接触面70の方を向いた側面150との間において、ガルバニック接合の過程で、介在する銅の粒成長が起こり、その粒成長によって介在領域160が金属で埋められたことが認識できる。
後続の処理ステップでは、セラミック基板90と接触させられたパワー部品10とからなる本発明によるパワーモジュールが、絶縁材料170で、図示の例ではシロキサンで被覆される(図5)。特に図示されていないがその他の点では図示の実施例に相当する他の実施例では、それとは異なる絶縁材料170、例えばポリマーが使用される。
図6乃至8に示された他の実施例では、電気化学的めっき法の代わりに、外部電流のない(無電解)めっき法が使用される。それに応じて、この実施例は次の点で図1〜5に示された実施例と異なる。すなわち、公知の如く、外部電流のないめっき法にとって、電極110,120を用いた接触は必要でない。従って、第1の電極110の代わりに、固定要素180だけが存在する(図6)。固定要素180は、詳しく図示されていない締付け装置によりセラミック基板90の方向に力を加えられ、それによってパワーモジュールが本発明による方法の経過中、一体に保持される。それの代替として、その他の点では図示の実施例に相当する他の実施例では、固定要素180が設けられず、その代わりに接触片60’,70’の固定が接着剤により(例えば、小さな接着点により)行われる。
外部電流のないめっき法により、公知の方法で金属が、図示の実施例では銅が、開気孔接触片60’,70’とパワー部品10との間の領域に析出する(図7)。図示の実施例では、析出材料が、チップメタライゼーション又はセラミック基板メタライゼーションと接触片60’,70’とに沿って平面的に延びている層を形成している。この析出によって、同時にそれぞれ開気孔接触片60’,70’がパワー部品10と結合する。
その他の点では図6乃至8に基づいて説明した実施例に相当する他の実施例では、当初それ自体は通り抜けのできない導電通路を形成する接触片が使用される。その接触片は、もっと正確に言えば、多数の銅の金属島を有し、これらの金属島は、いわばメタライゼーション島として外部電流のないめっき法の経過中に、上述のように最初のうちは通り抜けのできない導電通路を形成している。
後続の処理ステップにおいて、セラミック基板90と接触させられたパワー部品10とからなる本発明によるパワーモジュールが、絶縁材料170、図示の例ではシロキサンで被覆される(図8)。その他の点では図示の実施例に相当する特に図示されていない他の実施例では、異なる絶縁材料170、例えばポリマーが使用される。
上述の実施例と同様に、他の実施例では、めっきされる金属は銅の代わりにその他の金属であってもよい。
特に図示されていない他の実施例では、本発明によるパワーモジュールが、複数のセラミック基板又はその他の基板を積み重ねたスタックの様式で実現されているとよい。電子的な接触が、複数の平面で同時に本発明による方法により行われるとよい。代替として、付加的に1つの個別平面において複数の部品が、本発明による方法により同時に接触させられてもよい。
10 部品
40 接触部
50 接触部
60,60’ 開気孔接触片
80 面接触部
90 セラミック基板
70,70’ 開気孔接触片
100 セラミックコア
110 電極
120 電極
130 外側面
140 側面
150 側面
160 介在領域
170 絶縁材料
180 固定要素

Claims (15)

  1. 少なくとも1つの電気接触部(40,50)を有する部品(10)の電気接触のための方法であって、
    前記少なくとも1つの接触部(40,50)に少なくとも1つの開気孔接触片(60,70,60’,70’)がガルバニック接合され、
    前記少なくとも1つの開気孔接触片(60,70,60’,70’)が、多孔質材料又は多孔質材料を含む材料から形成されている、方法。
  2. 少なくとも1つの電気接触部(40,50)を有する部品(10)の電気接触のための方法であって、
    前記少なくとも1つの接触部(40,50)に少なくとも1つの開気孔接触片(60,70,60’,70’)がガルバニック接合され、
    前記少なくとも1つの開気孔接触片(60,70,60’,70’)が、織物構造、発泡構造およびメッシュ構造の少なくとも1つで形成されている、方法。
  3. 前記少なくとも1つの接触部(40,50)が、少なくともそれ自体としては平らな部材である部品(10)、および前記少なくとも1つの接触部(40,50)が有する接触面の最大限の平面的広がりがその接触面に対して垂直方向の当該接触部の広がりよりも大きい部品(10)の少なくとも一方が使用される、請求項1または2記載の方法。
  4. 前記少なくとも1つの接触片(60,70,60’,70’)として、導電性の開気孔接触片(60,70,60’,70’)が使用される、請求項1または2記載の方法。
  5. 前記少なくとも1つの開気孔接触片(60,70,60’,70’)が、金属又は金属を含む材料から形成されている、請求項1乃至4の1つに記載の方法。
  6. 高々100℃である温度、および、前記部品の動作温度から高々20℃だけ偏差を有する温度の少なくとも一方において、前記少なくとも1つの開気孔接触片(60,70,60’,70’)が前記接触部(40,50)にガルバニック接合される、請求項1乃至の1つに記載の方法。
  7. 前記少なくとも1つの開気孔接触片(60,70,60’,70’)が、電気化学的めっき法によりガルバニック接合される、請求項1乃至の1つに記載の方法。
  8. 前記少なくとも1つの開気孔接触片(60,70,60’,70’)が、外部電流のない方法によりガルバニック接合される、請求項1乃至の1つに記載の方法。
  9. 前記部品(10)が、前記接触片(60,70,60’,70’)により、
    他の構成素子および電流導体の少なくとも一方に接触させられるか、
    基板(90)に接触させられるか、
    または、他の構成素子および電流導体の少なくとも一方と基板(90)に接触させられ、
    その後に前記接触片(60,70,60’,70’)、前記部品(10)、前記他の構成素子、電流導体および基板(90)の少なくとも1つが電気絶縁層(170)を施される、請求項1乃至の1つに記載の方法。
  10. 前記絶縁層(170)が、
    キャスティングおよびモールドの少なくとも一方により形成されるか、
    シロキサンおよびポリマーの少なくとも一方から形成されるか、またはシロキサンおよびポリマーの少なくとも一方を含んで形成されるか、
    または、キャスティングおよびモールドの少なくとも一方により形成されるとともに、シロキサンおよびポリマーの少なくとも一方から形成されるか、またはシロキサンおよびポリマーの少なくとも一方を含んで形成される、
    請求項記載の方法。
  11. 前記部品(10)としてパワー部品が使用される、請求項1乃至10の1つに記載の方法。
  12. 前記部品(10)として、少なくとも1つのトランジスタを有する部品が使用される、請求項1乃至11の1つに記載の方法。
  13. 2つの接触部(40,50)を有する部品(10)が使用され、接触部(40,50)ごとに少なくとも1つの開気孔接触片(60,70,60’,70’)が該接触部にガルバニック接合される、請求項1乃至12の1つに記載の方法。
  14. 少なくとも1つの開気孔接触片(60,70,60’,70’)がガルバニック接合されている少なくとも1つの電気接触部(40,50)を有する部品を備えた部品モジュールであって、
    前記少なくとも1つの開気孔接触片(60,70,60’,70’)が、多孔質材料又は多孔質材料を含む材料から形成されているか、又は、織物構造、発泡構造およびメッシュ構造の少なくとも1つで形成されている、部品モジュール。
  15. 請求項1乃至13の1つに記載の方法により形成されている請求項14記載の部品モジュール。
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KR20180014081A (ko) 2018-02-07
CN107660308A (zh) 2018-02-02
WO2016193038A1 (de) 2016-12-08
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US11037862B2 (en) 2021-06-15
EP3281218A1 (de) 2018-02-14

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