JPWO2015125352A1 - パワー半導体モジュールおよびパワーユニット - Google Patents
パワー半導体モジュールおよびパワーユニット Download PDFInfo
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Abstract
Description
図1は、本発明の実施の形態1によるパワー半導体モジュールの構成を示す断面図である。絶縁基板10は、窒化アルミニウムから成るセラミック板などの絶縁体の基板1の両面に、銅から成る表面電極2aおよび裏面電極2bが接合されている。この絶縁基板10が2枚1組で用意され、それぞれの絶縁基板10の表面電極2aの表面にSiのパワー半導体素子3であるIGBT(Insulated Gate Bipolar Transistor)およびFWD(Free Wheeling Diode)が接合されている。パワー半導体素子3が接合された絶縁基板10を半導体素子基板20と称することとする。図1に示すように、それぞれの半導体素子基板20は同一面上に配置されている。図1は断面図であるため、パワー半導体素子3としてはIGBTだけを図示している。なお本実施の形態1ではパワー半導体素子はSi半導体を例として示したが、パワー半導体素子はSiC(炭化ケイ素)、GaN(窒化ガリウム)系材料、ダイヤモンドなどの材料のワイドバンドギャップ半導体でも適用でき、パワー半導体素子の種類に制約は無い。ワイドバンドギャップ半導体はSi半導体よりも高温で動作が可能であるため、特に本発明を適用すると効果が大きい。配線部材5により一方の絶縁基板10の表面電極2aと他方の絶縁基板10上のIGBTが配線されて、すなわち半導体素子基板間が電気的に接続されてインバータ1相分の回路を構成する。
図3は、本発明の実施の形態2によるパワー半導体モジュールの構成を示す断面図である。図3に示すように、モールド樹脂6の配線部材5の上部となる部分にも第二の凹部70を設けてもよい。実施の形態1のように隣接する絶縁基板10間にのみ凹部7を形成すると配線部材上下部位の応力が不均衡になり、パワー半導体モジュールが反る恐れがある。この実施の形態2の構成によれば、配線部材5の上部となる部分に形成した第二の凹部70によって、隣接する絶縁基板10間に形成した凹部7に起因した配線部材5近傍の応力の不均衡を補正でき、パワー半導体モジュール100の反りを低減することができる。
図4は、本発明の実施の形態3によるパワー半導体モジュールの構成を示す断面図である。実施形態1において、パワー半導体モジュールに応力が加わった場合に、凹部の底面が角形状であるため角部に応力が集中し、凹部底面からのモールド樹脂6の割れが発生する問題がある。この場合、配線部材5がモールド樹脂6から露出する割れ、および表面電極2aが露出する割れが形成されると、凹部を介して配線部材5と表面電極2aとの間にモールド樹脂が無い領域が形成され、そこが電気的にリークパスとなり、パワー半導体モジュールの絶縁耐性が劣化する。
図5は、本発明の実施の形態4によるパワー半導体モジュールの構成を示す断面図である。実施の形態3において、非常に大きな応力がパワー半導体モジュールに加わる場合は、モールド樹脂に形成した凹部底面の角部における応力集中が無くとも凹部底面のモールドに割れが発生し、配線部材と表面電極を繋ぐリークパスが形成され、パワー半導体モジュールの絶縁性が低下する恐れがある。
図8(A)は、本発明の実施の形態5によるパワー半導体モジュールの底面を見た下面図、図8(B)は図8(A)のA−A部の断面図である。実施の形態1のパワー半導体モジュールでは図2のように1本のスリット形状で凹部7が形成されているが、このように1本のスリット形状の凹部7を形成した場合に、凹部7の部分は薄いモールド樹脂と配線部材だけの構造となり曲げ剛性が低くなり、この凹部7の部分の折れ曲がりによりパワー半導体モジュールの反りが大きくなる問題がある。
図9は、本発明の実施の形態6によるパワー半導体モジュールの底面を見た下面図である。図9に示すように、断面が円形の複数の穴を一列に配置して凹部7を形成してもよい。さらに、図10に示すように、スリット状の凹部7の端部側面が円弧形状であってもよい。また実施の形態5で説明した図8の各スリットの端部の側面を円弧形状としてもよい。穴の断面形状やスリット端部の円弧形状は真円に近くなくてもよく、穴やスリット端部の側面の形状が角が無い曲面であればよい。
図11は、本発明の実施の形態7によるパワー半導体モジュールの底面を見た下面図である。絶縁基板は2枚に限らず3枚以上であってもよい。例えば、図11に示すように6in1型パワー半導体モジュールが構成できるように6枚の絶縁基板が配列され、それぞれの絶縁基板間に凹部7が形成されていてもよい。凹部7の大きさは均一または一直線状でなくてもよく、個々の絶縁基板の形状が異なれば、隣接する絶縁基板間の形状に従って凹部7が形成されるようにモールド金型を設計する。
図12は、本発明の実施の形態8によるパワーユニットの構成を示す断面図である。本発明のパワー半導体モジュール100は、図12のように、パワー半導体モジュール100で発生する熱を放熱させるように、裏面電極2b側に接触部材40を介してヒートシンク30を設けてパワーユニットとして応用することができる。このようなパワーユニットを複数個用いて鉄道車両やハイブリッド自動車のインバータ装置等に適用することができる。
Claims (12)
- 絶縁体の基板の片面に表面電極が、他の面に裏面電極がそれぞれ形成された絶縁基板と、前記表面電極の表面に固着されたパワー半導体素子と、を有する半導体素子基板が同一面上に複数配置されるとともに、隣接する前記半導体素子基板の間を電気的に接続する配線部材を備え、前記半導体素子基板および前記配線部材を、少なくとも配置されている複数の前記裏面電極が全て露出するようにモールド樹脂によりモールドしたパワー半導体モジュールにおいて、
前記モールド樹脂は、隣接する前記絶縁基板間に前記裏面電極側から所定深さで前記モールド樹脂を構成する樹脂が充填されていない凹部を有することを特徴とするパワー半導体モジュール。 - 前記所定深さは前記絶縁基板の厚さ以上であることを特徴とする請求項1に記載のパワー半導体モジュール。
- スリットにより前記凹部を形成したことを特徴とする請求項1または2に記載のパワー半導体モジュール。
- 複数のスリットを一列に配置して前記凹部を形成したことを特徴とする請求項1または2に記載のパワー半導体モジュール。
- 前記スリットの端部の側面が曲面形状であることを特徴とする請求項3または4に記載のパワー半導体モジュール。
- 側面が曲面形状である複数の穴を配置して前記凹部を形成したことを特徴とする請求項1または2に記載のパワー半導体モジュール。
- 前記凹部の側面と底面の接続部が曲面形状であることを特徴とする請求項1から6のいずれか1項に記載のパワー半導体モジュール。
- 前記凹部の底面にさらに凹んだ尖頭部を設けたことを特徴とする請求項1から7のいずれか1項に記載のパワー半導体モジュール。
- 前記モールド樹脂の前記裏面電極側とは反対側の面から裏面電極側に向けて第二の凹部を設けたことを特徴とする請求項1から8のいずれか1項に記載のパワー半導体モジュール。
- 前記パワー半導体素子がワイドバンドギャップ半導体により形成されていることを特徴とする請求項1から9のいずれか1項に記載のパワー半導体モジュール。
- 前記ワイドバンドギャップ半導体は、炭化ケイ素、窒化ガリウム系材料またはダイヤモンドの半導体であることを特徴とする請求項10に記載のパワー半導体モジュール。
- 請求項1から11のいずれか1項に記載のパワー半導体モジュールの前記裏面電極側にヒートシンクを設けたことを特徴とするパワーユニット。
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