US20170133316A1 - Semiconductor device with stacked terminals - Google Patents

Semiconductor device with stacked terminals Download PDF

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Publication number
US20170133316A1
US20170133316A1 US15/274,734 US201615274734A US2017133316A1 US 20170133316 A1 US20170133316 A1 US 20170133316A1 US 201615274734 A US201615274734 A US 201615274734A US 2017133316 A1 US2017133316 A1 US 2017133316A1
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United States
Prior art keywords
planar
semiconductor device
busbar
terminal
semiconductor
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Abandoned
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US15/274,734
Inventor
Wenjun Liu
Robert James Ramm
Colin Kenneth Campbell
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Tesla Inc
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Tesla Motor Inc
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Application filed by Tesla Motor Inc filed Critical Tesla Motor Inc
Priority to US15/274,734 priority Critical patent/US20170133316A1/en
Publication of US20170133316A1 publication Critical patent/US20170133316A1/en
Assigned to TESLA MOTORS, INC. reassignment TESLA MOTORS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RAMM, Robert James, CAMPBELL, COLIN KENNETH, LIU, WENJUN
Priority to US15/890,482 priority patent/US10304770B2/en
Abandoned legal-status Critical Current

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00Details of semiconductor or other solid state devices
    • H01L23/48Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
    • H01L23/50Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor for integrated circuit devices, e.g. power bus, number of leads
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    • H01L23/00Details of semiconductor or other solid state devices
    • H01L23/34Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
    • H01L23/36Selection of materials, or shaping, to facilitate cooling or heating, e.g. heatsinks
    • H01L23/373Cooling facilitated by selection of materials for the device or materials for thermal expansion adaptation, e.g. carbon
    • H01L23/3735Laminates or multilayers, e.g. direct bond copper ceramic substrates
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01GCAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G4/00Fixed capacitors; Processes of their manufacture
    • H01G4/002Details
    • H01G4/018Dielectrics
    • H01G4/06Solid dielectrics
    • H01G4/08Inorganic dielectrics
    • H01G4/12Ceramic dielectrics
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    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/48Manufacture or treatment of parts, e.g. containers, prior to assembly of the devices, using processes not provided for in a single one of the subgroups H01L21/06 - H01L21/326
    • H01L21/4814Conductive parts
    • H01L21/4821Flat leads, e.g. lead frames with or without insulating supports
    • H01L21/4825Connection or disconnection of other leads to or from flat leads, e.g. wires, bumps, other flat leads
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    • H01L23/053Containers; Seals characterised by the shape of the container or parts, e.g. caps, walls the container being a hollow construction and having an insulating or insulated base as a mounting for the semiconductor body
    • H01L23/057Containers; Seals characterised by the shape of the container or parts, e.g. caps, walls the container being a hollow construction and having an insulating or insulated base as a mounting for the semiconductor body the leads being parallel to the base
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    • H01L23/49534Multi-layer
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    • H01L23/49541Geometry of the lead-frame
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    • H01L2224/291Material with a principal constituent of the material being a metal or a metalloid, e.g. boron [B], silicon [Si], germanium [Ge], arsenic [As], antimony [Sb], tellurium [Te] and polonium [Po], and alloys thereof
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    • H01L2224/321Disposition
    • H01L2224/32151Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/32221Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/32245Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic
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    • H01L2224/34Strap connectors, e.g. copper straps for grounding power devices; Manufacturing methods related thereto
    • H01L2224/36Structure, shape, material or disposition of the strap connectors prior to the connecting process
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    • H01L2224/34Strap connectors, e.g. copper straps for grounding power devices; Manufacturing methods related thereto
    • H01L2224/39Structure, shape, material or disposition of the strap connectors after the connecting process
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    • H01L25/00Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
    • H01L25/03Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
    • H01L25/04Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
    • H01L25/07Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L29/00
    • H01L25/072Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L29/00 the devices being arranged next to each other
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    • H01L2924/0001Technical content checked by a classifier
    • H01L2924/00014Technical content checked by a classifier the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
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    • H01L2924/102Material of the semiconductor or solid state bodies
    • H01L2924/1025Semiconducting materials
    • H01L2924/10251Elemental semiconductors, i.e. Group IV
    • H01L2924/10253Silicon [Si]
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    • H01L2924/10Details of semiconductor or other solid state devices to be connected
    • H01L2924/11Device type
    • H01L2924/13Discrete devices, e.g. 3 terminal devices
    • H01L2924/1304Transistor
    • H01L2924/1305Bipolar Junction Transistor [BJT]
    • H01L2924/13055Insulated gate bipolar transistor [IGBT]

Definitions

  • a housing with thin leads extending from it can be in form of a solid rectangle that serves to enclose and protect the circuitry on the inside. Protruding through the housing are the leads which are used to electrically connect the device to other components or circuits. For example, this form factor is used for some types of insulated-gate bipolar transistor (IGBT).
  • IGBT insulated-gate bipolar transistor
  • a power inverter a converter of direct current (DC) to alternating current (AC)—depends on the efficiency of the semiconductors devices in its circuits.
  • the efficiency of the apparatus can affect the performance of some larger system. For example, in an electric vehicle (e.g., a plug-in electric vehicle or a hybrid vehicle) the range of travel by electric power before one has to recharge the battery is an important characteristic. Therefore, an improved semiconductor device can improve the performance and efficiency of electric vehicles and other systems.
  • a semiconductor device comprises: a housing; a substrate inside the housing; a semiconductor circuit on the substrate; and first and second planar busbars electrically connected to the semiconductor circuit, the first and second planar busbars being parallel to each other and extending away from the semiconductor circuit in opposite directions through respective openings in the housing.
  • the second planar busbar is in a different plane than the first planar busbar such that there is an offset between the first and second planar busbars.
  • the semiconductor circuit is positioned between the second planar busbar and the substrate. The offset accommodates attachment of a distal end of the second planar busbar to a corresponding first planar busbar from an adjacent semiconductor device.
  • the first planar busbar is configured to have a planar terminal attached to it such that the planar terminal is on a same side of the first planar busbar as the semiconductor circuit.
  • the second planar busbar is configured to have an attachment to a planar terminal such that the planar terminal is positioned on an opposite side of the second planar busbar than the semiconductor circuit.
  • the housing is configured so that the planar terminal extends across the housing toward the attachment.
  • the planar terminal contains a contact portion offset from a main portion thereof by an offsetting portion, and wherein the contact portion abuts the second planar busbar at the attachment, and wherein the main portion extends along the housing.
  • the substrate includes a direct bonded copper structure.
  • a semiconductor assembly comprises: a first semiconductor device comprising: a first housing; a first substrate inside the first housing; a first semiconductor circuit on the first substrate; and first and second planar busbars electrically connected to the first semiconductor circuit, the first and second planar busbars being parallel to each other and extending away from the first semiconductor circuit in opposite directions through respective openings in the first housing; a second semiconductor device comprising: a second housing; a second substrate inside the second housing; a second semiconductor circuit on the second substrate; and third and fourth planar busbars electrically connected to the second semiconductor circuit, the third and fourth planar busbars being parallel to each other and extending away from the second semiconductor circuit in opposite directions through respective openings in the second housing, wherein the second planar busbar of the first semiconductor device is attached to the third planar busbar of the second semiconductor device; a first planar terminal attached to the first planar busbar of the first semiconductor device; and a second planar terminal attached to the fourth planar busbar of the second semiconductor device.
  • Implementations can include any or all of the following features.
  • Each of the second and fourth planar busbars is in a different plane than a corresponding one of the first and third planar busbars such that their offsets exists between respective planar busbars.
  • the offsets accommodate attachment of the second planar busbar to the third planar busbar.
  • the first planar busbar is configured to have the first planar terminal attached to it such that the first planar terminal is on a same side of the first planar busbar as the first semiconductor circuit.
  • the fourth planar busbar is configured to have an attachment to the second planar terminal such that the second planar terminal is positioned on an opposite side of the fourth planar busbar than the second semiconductor circuit.
  • the first and second housings are configured so that the second planar terminal extends across the first and second housings toward the attachment.
  • the second planar terminal contains a contact portion offset from a main portion thereof by an offsetting portion, and wherein the contact portion abuts the fourth planar busbar at the attachment, and wherein the main portion extends along the first and second housings.
  • the semiconductor device further comprises a capacitor, wherein the first and second planar terminals connect the capacitor to the first and second semiconductor devices.
  • a method comprises: positioning a first semiconductor device near a second semiconductor device, the first semiconductor device having first and second planar busbars parallel to each other and extending in opposite directions through respective openings in a first housing, the second semiconductor device having third and fourth planar busbars parallel to each other and extending in opposite directions through respective openings in a second housing; attaching the second planar busbar of the first semiconductor device to the third planar busbar of the second semiconductor device; positioning a first planar terminal adjacent the first planar busbar of the first semiconductor device, and positioning a second planar terminal adjacent the fourth planar busbar of the second semiconductor device; and attaching the first planar terminal to the first planar busbar, and attaching the second planar terminal to the fourth planar busbar.
  • Attaching the first planar terminal to the first planar busbar comprises accessing the first planar terminal from a same side of the first planar busbar as where a semiconductor circuit of the first semiconductor device is located.
  • Attaching the second planar terminal to the fourth planar busbar comprises accessing the second planar terminal from an opposite side of the fourth planar busbar than where a semiconductor circuit of the second semiconductor device is located.
  • FIG. 1 shows a cross section of an example of a semiconductor device having stacked planar terminals.
  • FIG. 2 shows a top view of the semiconductor device in FIG. 1 .
  • FIG. 3 shows a cross section of another example of a semiconductor device having stacked planar terminals.
  • FIG. 4 shows a perspective view of an assembly of semiconductor devices and capacitors.
  • FIG. 5 shows a cross section of the assembly in FIG. 4 .
  • FIG. 6 shows another example of a semiconductor assembly configured to have stacked terminals.
  • a semiconductor device has relatively large and planar high-voltage terminals and/or busbars that are stacked on top of each other. These planar terminals/busbars and their arrangement with regard to the device as a whole can allow more efficient semiconductor operation and provide a convenient manufacturing process. For example, some parts of systems that are traditionally arranged around the device can instead be integrated into the same package as the device. This can improve the device's electrical and thermal performance, reduce its inductance, and lower the manufacturing and assembly costs.
  • Some implementations feature a co-pack design where one die (e.g., an IGBT and a diode) is included in a separate housing to form an individual device. Such devices can then be paired with each other to form the intended circuit, for example an inverter or other power electronics component. This can reduce the number of manufacturing steps, for example so that sintering is only performed on top and bottom sides of the co-pack with two step sintering. This can significantly simplify the manufacturing process and improve the yield rate. As another example, reliability validation testing can be simplified.
  • one die e.g., an IGBT and a diode
  • IGBTs or power inverters. This is for illustrative purposes only and other implementations include transistors other than an IGBT and/or an apparatus other than an inverter.
  • the module essentially consists of a substrate with four semiconductor circuits (also referred to as silicon dies) positioned in a generally rectangular arrangement on its surface.
  • the module then has two busbars soldered to the silicon dies so that they extend away from the module. That is, each of the busbars is positioned on top of two of the silicon dies so that one busbar end is on the substrate and the other end extends beyond the edge of the substrate.
  • These busbars are usually parallel to each other and spaced apart some distance that essentially corresponds to the positioning of the silicon dies on the substrate. In operation, current flows into the semiconductor device through one of the busbars, passes through the silicon dies, and flows out of the device through the other busbar.
  • the inductance is proportional to the area between the busbars.
  • the individual silicon dies are connected to each other by bond wires that also connect them to one or more of the three leads extending from the housing.
  • the bond wires often loop up in between two silicon dies, or between a die and the lead.
  • the inductance is proportional to the area under the loop of the bond wire. As such, the efficiency of the semiconductor device can be improved by reducing the area between busbars or the area under bond wire loops.
  • FIG. 1 shows a cross section of an example of a semiconductor device 100 having stacked planar terminals 102 A-B.
  • the device is implemented using a substrate 104 .
  • the substrate can serve to direct heat away from the device while electrically insulating high-voltage components.
  • the substrate includes a direct bonded copper (DBC) structure.
  • DBC direct bonded copper
  • the DBC structure can include a ceramic layer sandwiched between copper layers as illustrated.
  • silicon dies 106 A-B are shown. These silicon dies contain the circuitry that defines the particular mode(s) of operation of the overall semiconductor assembly. In some implementations, the silicon dies define an IGBT device. For example, the silicon dies can be manufactured as chips (sometimes referred to as silicon chips) that are then mounted onto the top surface of the substrate.
  • the semiconductor device has the stacked planar terminals 102 A-B that abut the silicon dies 106 A-B, respectively.
  • the stacked planar terminals have an arbitrary length extending toward the left in the figure.
  • Each of the terminals forms a complete plane, can be made of any conductive material, and can be soldered to its respective silicon die(s).
  • the planar terminal 102 A here abuts the silicon die 106 A and is labeled positive (+) for reference.
  • the planar terminal 102 B here abuts the silicon die 106 B and is labeled negative ( ⁇ ) for reference. That is, the terminals are stacked on top of each other and in this example the negative terminal overlaps the positive one.
  • a separation 108 is here formed between the planar terminals.
  • the planar terminal 102 B has an offsetting portion 110 along the entire width of the plane so as to provide a contact portion 112 that abuts the silicon die 106 B.
  • the contact portion forms a plane that is parallel to, and offset from, the plane of the main portion of the planar terminal 102 B.
  • the offsetting portion can be formed using any suitable technique, such as by stamping or bending.
  • a housing 114 encloses at least part of the semiconductor device.
  • the housing can have one or more openings.
  • the housing has a common opening 116 through which the planar terminals 102 A-B extend. For example, after the substrate, the silicon dies and the planar terminals are assembled, the housing can be overmolded on that assembly so that the terminals extend from the enclosed structure.
  • An electric insulator 118 can be provided in the separation between the planar terminals.
  • the insulator provides electric insulation across the entire width of the conductive sheets that form the respective planar terminals.
  • insulating paper is used.
  • a semiconductor device 100 that includes a housing 114 , a substrate 104 inside the housing, semiconductor circuits 106 A-B on the substrate, and planar terminals 102 A-B that extend away from the housing and are electrically connected to the first and second semiconductor circuits, respectively.
  • the planar terminals are stacked on top of each other.
  • the inductance is now proportional to the area between the planar terminals 102 A-B plus the area between the terminal 102 B and the substrate 104 where the negative terminal overlaps the positive one.
  • This can allow for a significant reduction of inductance compared to traditional device designs.
  • the busbar structure can be considered (at least partially) integrated within the housing.
  • FIG. 2 shows a top view of the semiconductor device 100 in FIG. 1 .
  • the terminal 102 A is here shown as narrower that the terminal 102 B only to clarify the illustration. This arrangement provides an increased busbar width per die area which improves performance.
  • the planar terminals overlap each other for most of their respective surface areas. Also shown are additional semiconductor circuits.
  • these include further silicon dies 200 A-B that are also part of the semiconductor device.
  • the planar terminals are attached to the respective silicon die(s) 106 A-B and 200 A-B by any suitable technique, including, but not limited to, soldering.
  • FIG. 3 shows a cross section of another example of a semiconductor device 300 having stacked planar terminals 302 A-B.
  • the silicon dies and the substrate can be essentially the same as above.
  • busbars 304 A-B that abut the respective silicon dies here extend in a common plane, not stacked on top of each other.
  • the busbars 304 A-B can be essentially planar conductors that provide high voltage connection to the silicon dies.
  • Some or all of the busbar 304 A is exposed to the outside through an opening 306 in a housing 308 that encloses at least part of the semiconductor device.
  • some or all of the busbar 304 B is exposed to the outside through an opening 310 in the housing.
  • the openings can be formed as part of an overmolding process that encapsulates the device into an enclosed structure.
  • planar terminal 302 A abuts the busbar 304 A outside the housing.
  • planar terminal 302 B abuts the busbar 304 B, at least the part thereof that is exposed through the opening 310 .
  • the planar terminal and the busbar can be welded together.
  • this approach can lead to a simplified manufacturing process in that the planar terminals—which can be sheets wide enough to span several IGBTs—can easily be aligned with and attached to the busbars of the device(s).
  • both of the busbars can be exposed through holes in a similar way as shown for the busbar 304 B.
  • planar terminal 302 B can have an offsetting portion that provides a contact portion—parallel with and offset from the main portion of the planar terminal—so as to reach at least a portion of its busbar.
  • Electric insulation 312 can be provided in the separation between the planar terminals 302 A-B.
  • the stacked structure of these planar terminals (with insulation) can be assembled in advance and then this assembly can be brought to the rest of the semiconductor device for making the electrical connections.
  • the current example can be considered as having the stacking done outside the semiconductor package instead of inside it which can simplify the manufacture.
  • FIG. 4 shows a perspective view of an assembly 400 of semiconductor devices 402 and capacitors 404 .
  • FIG. 5 shows a cross section of the assembly in FIG. 4 .
  • capacitors are coupled to the semiconductor devices in order to protect against transients, and to help maintain a voltage on a DC bus.
  • the capacitors can serve as DC link capacitors.
  • Any form of capacitor conductors can be used, including, but not limited to, films or foils (e.g., folded or rolled into a compact structure).
  • a set of six semiconductor devices 402 are shown but in other implementations more or fewer can be used.
  • the semiconductor housings are here omitted for clarity.
  • the semiconductor devices are arranged next to each other in a row.
  • Each device has a substrate 406 and busbars 408 A-B.
  • the busbars are connected to respective semiconductor circuits on the substrates (e.g., silicon dies) which are not visible in this illustration.
  • the silicon dies would be positioned between the respective busbars 408 A-B and the substrate 406 .
  • Planar terminals 410 A-B are here comprised of conductive sheets that connect the capacitors 404 to each of the semiconductor devices via the busbars.
  • the planar terminals are stacked on top of each other so that the planar terminal 410 A abuts the busbar 408 A and the planar terminal 410 B abuts the busbar 408 B.
  • they connect to respective conductors of the capacitors. That is, each planar terminal connects multiple semiconductor devices to each of the several capacitors.
  • FIG. 4 also illustrates that the busbars can have a significant width compared to the semiconductor device as a whole (essentially the substrate width). For example, each of the busbars can be at least 70% of the width of the semiconductor device.
  • planar terminals 410 A-B can have a step shape when viewed in profile.
  • the planar terminals are essentially flat planes in the area near the semiconductor devices.
  • the planar terminal 410 B (the “lower” of the terminals in this example) makes turns 412 A-B so as to provide a contact plane 414 B for (in this example) the bottom conductor of the capacitor.
  • the planar terminal 410 A can make corresponding turns to form a contact plane 414 A for the opposite capacitor conductor.
  • planar terminals provide a continuous conductive plane for current traveling to and from the capacitors. That is, because there are no holes in these sheets or pins at their edge where they electrically connect to the semiconductor devices, there are fewer or no “necks” that impede the flow of current.
  • the assembly 400 can form part of a power inverter.
  • the inverter can include two (or more) of the assembly 400 where the semiconductor devices (e.g., IGBTs) are jointly controlled so as to perform the DC-to-AC conversion.
  • the semiconductor devices e.g., IGBTs
  • two such assemblies can be oriented so that their respective semiconductor devices are near each other, which can simplify the placement and operation of cooling systems (e.g., liquid-based heatsinks).
  • Semiconductor devices e.g., 402 are positioned in a row. Each of the semiconductor devices comprises a substrate (e.g., 406 ), first and second semiconductor circuits (e.g., 106 A-B) on the substrate, and first and second busbars (e.g., 408 A-B) abutting the first and second semiconductor circuits, respectively.
  • a substrate e.g., 406
  • first and second semiconductor circuits e.g., 106 A-B
  • first and second busbars e.g., 408 A-B
  • An assembly is formed by placing a first planar terminal (e.g., 410 A) in contact with the first busbar (e.g., 408 A) of each of the plurality of semiconductor devices, and a second planar terminal (e.g., 410 B) in contact with the second busbar (e.g., 408 B) of each of the plurality of semiconductor devices.
  • the first and second planar terminals are stacked on top of each other. For example, the terminals can first be stacked and then (as an assembled stack) be placed in contact with the respective busbars.
  • the first planar terminal is welded to the first busbar of each of the plurality of semiconductor devices. Such welding can be performed from one side of the assembly.
  • a weld 416 A from above the assembly is here schematically illustrated.
  • the second planar terminal is welded to the second busbar of each of the plurality of semiconductor devices. Such welding can be performed from the opposite side of the assembly.
  • a weld 416 B from below the assembly is here schematically illustrated. For example, laser welding can be used.
  • An electrical insulation layer (e.g., 118 ) can be included between the first and second planar terminals.
  • an insulating paper can be inserted before the terminals are stacked on top of each other.
  • Each of the first and second planar terminals can be electrically connected to a plurality of capacitors (e.g., 404 ).
  • respective contact planes of the terminals can be connected (e.g., welded) to respective capacitor terminals.
  • More or fewer steps can be performed in some assembly processes. Also, two or more steps can be performed in a different order.
  • FIG. 6 shows another example of a semiconductor assembly 600 configured to have stacked terminals.
  • This example uses a co-pack design where a pair of individual devices 602 and 604 make use of terminals 606 and 608 that are planar and stacked.
  • the semiconductor devices can also have planar busbars.
  • the device 602 has busbars 610 and 612
  • the device 604 has busbars 614 and 616 .
  • the shown polarities (+ and ⁇ ) are for illustrative purposes only. These busbars facilitate positioning of the terminals 606 and 608 in a stacked fashion, as well as can simplify the assembly technique.
  • Each device has a substrate 618 on which a corresponding silicon die 620 is positioned.
  • the substrate and/or the die can be similar or identical to those described elsewhere herein.
  • the die 620 can include both one or more switching devices (e.g., an IGBT) and one or more other semiconductor devices (e.g., a diode).
  • the assembly 600 which includes the two devices 602 and 604 —can then be used in one of the half bridges in a power inverter.
  • the busbars 612 and 616 are here positioned on top of the corresponding silicon die and are electrically connected to it.
  • the other busbars 610 and 614 are also electrically connected, for example by one or more wire bonds (not shown) to the die.
  • the busbars for the individual device e.g., busbars 610 and 612
  • the busbars for the individual device can be configured so that they facilitate good performance characteristics (e.g., reduced inductance) and a simplified assembly process.
  • These busbars can be positioned in opposite directions from the silicon die.
  • one of the planar busbars can extend in a plane that is parallel to and offset from the plane of the other busbar.
  • the busbar 612 sits higher above the substrate than the busbar 610 so that there is an offset between them.
  • the busbars can be located in a common plane.
  • the devices 602 and 604 are enclosed in respective housings 622 and 624 .
  • One advantage of a co-pack design can be that the individual die within its housing is easy to handle and install.
  • the busbar geometries of the respective individual devices can facilitate direct connection between the devices, and with other components such as terminals.
  • the planar busbars can extend from the respective housing in essentially opposing directions.
  • the busbar 610 has an opening 626 that allows connection with the terminal 608 .
  • the busbar 612 has an opening 628 that allows connection with the busbar 614 from the device 604 .
  • the attachment between the busbar 616 and the terminal 606 can be facilitated by a contact portion 630 that is offset from a main part of the terminal 606 by an offsetting portion 632 . For example, this can facilitate a close spacing (here in a vertical direction) between the terminal 606 and the busbar 616 , which can help avoid significant inductance.
  • the assembly 600 can be used in any or all contexts described above. Some examples will be provided. With reference again to FIG. 4 , the capacitors 404 shown there can be connected to the assembly 600 .
  • the planar terminal 410 A can serve as the terminal 606
  • the planar terminal 410 B can serve as the terminal 608 .
  • this can allow advantageous simplified connection to the semiconductor devices, while allowing the terminals to be planar and have relatively large surface areas.
  • the assembly 600 can be assembled using any or all approaches described above.
  • the busbars 612 and 614 are attached to each other before the terminals (e.g., 606 , 608 ) are put in place.
  • Any suitable joining technique can be used, including, but not limited to, laser welding, ultrasonic welding, sintering or soldering.
  • the planar terminals 606 and 608 can be attached to the respective devices 602 and 604 in analogy with examples described herein.
  • the planar terminal 410 A shown there can serve as the terminal 606
  • the planar terminal 410 B shown there can serve as the terminal 608 .
  • the weld 416 A can be applied to create attachment between the terminal 606 and the busbar 616 .
  • the weld is applied from above the terminal 606 .
  • the weld 416 B can be applied to create attachment between the terminal 608 and the busbar 610 .
  • the weld is applied from below the terminal 608 .
  • This can provide an efficient manufacturing process where sintering (as an example of a joining technique) need only be performed on a top and bottom of an individual co-packed device. For example, two-step sintering can be used.
  • a first semiconductor device can be positioned near a second semiconductor device, the first semiconductor device having first and second planar busbars parallel to each other and extending in opposite directions through respective openings in a first housing.
  • the second semiconductor device can have third and fourth planar busbars parallel to each other and extending in opposite directions through respective openings in a second housing.
  • the second planar busbar of the first semiconductor device can be attached to the third planar busbar of the second semiconductor device.
  • a first planar terminal can be positioned adjacent the first planar busbar of the first semiconductor device, and a second planar terminal can be positioned adjacent the fourth planar busbar of the second semiconductor device.
  • the first planar terminal can be attached to the first planar busbar, and the second planar terminal can be attached to the fourth planar busbar.

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Abstract

A semiconductor device includes: a housing; a substrate inside the housing; first and second semiconductor circuits on the substrate; and first and second planar terminals electrically connected to the first and second semiconductor circuits, respectively, the first and second planar terminals stacked on top of each other, wherein each of the first and second planar terminals extends away from the housing.

Description

    CROSS-REFERENCE TO RELATED APPLICATION
  • The present U.S. Utility Patent Application claims priority pursuant to 35 U.S.C. §119(e) to U.S. Provisional Application No. 62/233,178, entitled “SEMICONDUCTOR DEVICE WITH STACKED TERMINALS”, filed Sep. 25, 2015, which is hereby incorporated herein by reference in its entirety and made part of the present U.S. Utility Patent Application for all purposes.
  • BACKGROUND
  • Many traditional semiconductor devices have essentially similar shapes: a housing with thin leads extending from it. The housing can be in form of a solid rectangle that serves to enclose and protect the circuitry on the inside. Protruding through the housing are the leads which are used to electrically connect the device to other components or circuits. For example, this form factor is used for some types of insulated-gate bipolar transistor (IGBT).
  • Because semiconductor devices are used for controlling electric current, their efficiency in doing so play an important role in the efficiency of the overall apparatus where they are being used. For instance, the performance and efficiency of a power inverter—a converter of direct current (DC) to alternating current (AC)—depends on the efficiency of the semiconductors devices in its circuits. The efficiency of the apparatus, in turn, can affect the performance of some larger system. For example, in an electric vehicle (e.g., a plug-in electric vehicle or a hybrid vehicle) the range of travel by electric power before one has to recharge the battery is an important characteristic. Therefore, an improved semiconductor device can improve the performance and efficiency of electric vehicles and other systems.
  • SUMMARY
  • In a first aspect, a semiconductor device comprises: a housing; a substrate inside the housing; a semiconductor circuit on the substrate; and first and second planar busbars electrically connected to the semiconductor circuit, the first and second planar busbars being parallel to each other and extending away from the semiconductor circuit in opposite directions through respective openings in the housing.
  • Implementations can include any or all of the following features. The second planar busbar is in a different plane than the first planar busbar such that there is an offset between the first and second planar busbars. The semiconductor circuit is positioned between the second planar busbar and the substrate. The offset accommodates attachment of a distal end of the second planar busbar to a corresponding first planar busbar from an adjacent semiconductor device. The first planar busbar is configured to have a planar terminal attached to it such that the planar terminal is on a same side of the first planar busbar as the semiconductor circuit. The second planar busbar is configured to have an attachment to a planar terminal such that the planar terminal is positioned on an opposite side of the second planar busbar than the semiconductor circuit. The housing is configured so that the planar terminal extends across the housing toward the attachment. The planar terminal contains a contact portion offset from a main portion thereof by an offsetting portion, and wherein the contact portion abuts the second planar busbar at the attachment, and wherein the main portion extends along the housing. The substrate includes a direct bonded copper structure.
  • In a second aspect, a semiconductor assembly comprises: a first semiconductor device comprising: a first housing; a first substrate inside the first housing; a first semiconductor circuit on the first substrate; and first and second planar busbars electrically connected to the first semiconductor circuit, the first and second planar busbars being parallel to each other and extending away from the first semiconductor circuit in opposite directions through respective openings in the first housing; a second semiconductor device comprising: a second housing; a second substrate inside the second housing; a second semiconductor circuit on the second substrate; and third and fourth planar busbars electrically connected to the second semiconductor circuit, the third and fourth planar busbars being parallel to each other and extending away from the second semiconductor circuit in opposite directions through respective openings in the second housing, wherein the second planar busbar of the first semiconductor device is attached to the third planar busbar of the second semiconductor device; a first planar terminal attached to the first planar busbar of the first semiconductor device; and a second planar terminal attached to the fourth planar busbar of the second semiconductor device.
  • Implementations can include any or all of the following features. Each of the second and fourth planar busbars is in a different plane than a corresponding one of the first and third planar busbars such that their offsets exists between respective planar busbars. The offsets accommodate attachment of the second planar busbar to the third planar busbar. The first planar busbar is configured to have the first planar terminal attached to it such that the first planar terminal is on a same side of the first planar busbar as the first semiconductor circuit. The fourth planar busbar is configured to have an attachment to the second planar terminal such that the second planar terminal is positioned on an opposite side of the fourth planar busbar than the second semiconductor circuit. The first and second housings are configured so that the second planar terminal extends across the first and second housings toward the attachment. The second planar terminal contains a contact portion offset from a main portion thereof by an offsetting portion, and wherein the contact portion abuts the fourth planar busbar at the attachment, and wherein the main portion extends along the first and second housings. The semiconductor device further comprises a capacitor, wherein the first and second planar terminals connect the capacitor to the first and second semiconductor devices.
  • In a third aspect, a method comprises: positioning a first semiconductor device near a second semiconductor device, the first semiconductor device having first and second planar busbars parallel to each other and extending in opposite directions through respective openings in a first housing, the second semiconductor device having third and fourth planar busbars parallel to each other and extending in opposite directions through respective openings in a second housing; attaching the second planar busbar of the first semiconductor device to the third planar busbar of the second semiconductor device; positioning a first planar terminal adjacent the first planar busbar of the first semiconductor device, and positioning a second planar terminal adjacent the fourth planar busbar of the second semiconductor device; and attaching the first planar terminal to the first planar busbar, and attaching the second planar terminal to the fourth planar busbar. Attaching the first planar terminal to the first planar busbar comprises accessing the first planar terminal from a same side of the first planar busbar as where a semiconductor circuit of the first semiconductor device is located. Attaching the second planar terminal to the fourth planar busbar comprises accessing the second planar terminal from an opposite side of the fourth planar busbar than where a semiconductor circuit of the second semiconductor device is located.
  • BRIEF DESCRIPTION OF DRAWINGS
  • FIG. 1 shows a cross section of an example of a semiconductor device having stacked planar terminals.
  • FIG. 2 shows a top view of the semiconductor device in FIG. 1.
  • FIG. 3 shows a cross section of another example of a semiconductor device having stacked planar terminals.
  • FIG. 4 shows a perspective view of an assembly of semiconductor devices and capacitors.
  • FIG. 5 shows a cross section of the assembly in FIG. 4.
  • FIG. 6 shows another example of a semiconductor assembly configured to have stacked terminals.
  • DETAILED DESCRIPTION
  • This document describes examples of systems and techniques relating to improved semiconductor devices. In some implementations, a semiconductor device has relatively large and planar high-voltage terminals and/or busbars that are stacked on top of each other. These planar terminals/busbars and their arrangement with regard to the device as a whole can allow more efficient semiconductor operation and provide a convenient manufacturing process. For example, some parts of systems that are traditionally arranged around the device can instead be integrated into the same package as the device. This can improve the device's electrical and thermal performance, reduce its inductance, and lower the manufacturing and assembly costs.
  • Some implementations feature a co-pack design where one die (e.g., an IGBT and a diode) is included in a separate housing to form an individual device. Such devices can then be paired with each other to form the intended circuit, for example an inverter or other power electronics component. This can reduce the number of manufacturing steps, for example so that sintering is only performed on top and bottom sides of the co-pack with two step sintering. This can significantly simplify the manufacturing process and improve the yield rate. As another example, reliability validation testing can be simplified.
  • Some examples herein mention IGBTs or power inverters. This is for illustrative purposes only and other implementations include transistors other than an IGBT and/or an apparatus other than an inverter.
  • In a conventional IGBT, the module essentially consists of a substrate with four semiconductor circuits (also referred to as silicon dies) positioned in a generally rectangular arrangement on its surface. The module then has two busbars soldered to the silicon dies so that they extend away from the module. That is, each of the busbars is positioned on top of two of the silicon dies so that one busbar end is on the substrate and the other end extends beyond the edge of the substrate. These busbars are usually parallel to each other and spaced apart some distance that essentially corresponds to the positioning of the silicon dies on the substrate. In operation, current flows into the semiconductor device through one of the busbars, passes through the silicon dies, and flows out of the device through the other busbar.
  • One of the electrical characteristics that negatively affect semiconductor device performance is its inductance. It is therefore desirable to lower the inductance of a device without diminishing its ability to conduct and convert current. In the IGBT describe above, the inductance is proportional to the area between the busbars. Looking at the IGBT at a higher level, the individual silicon dies are connected to each other by bond wires that also connect them to one or more of the three leads extending from the housing. The bond wires often loop up in between two silicon dies, or between a die and the lead. In that context, the inductance is proportional to the area under the loop of the bond wire. As such, the efficiency of the semiconductor device can be improved by reducing the area between busbars or the area under bond wire loops.
  • FIG. 1 shows a cross section of an example of a semiconductor device 100 having stacked planar terminals 102A-B. The device is implemented using a substrate 104. The substrate can serve to direct heat away from the device while electrically insulating high-voltage components. In some implementations, the substrate includes a direct bonded copper (DBC) structure. For example, the DBC structure can include a ceramic layer sandwiched between copper layers as illustrated.
  • Semiconductor circuits are implemented on top of the substrate. Here, silicon dies 106A-B are shown. These silicon dies contain the circuitry that defines the particular mode(s) of operation of the overall semiconductor assembly. In some implementations, the silicon dies define an IGBT device. For example, the silicon dies can be manufactured as chips (sometimes referred to as silicon chips) that are then mounted onto the top surface of the substrate.
  • In this example, the semiconductor device has the stacked planar terminals 102A-B that abut the silicon dies 106A-B, respectively. The stacked planar terminals have an arbitrary length extending toward the left in the figure. Each of the terminals forms a complete plane, can be made of any conductive material, and can be soldered to its respective silicon die(s). The planar terminal 102A here abuts the silicon die 106A and is labeled positive (+) for reference. The planar terminal 102B here abuts the silicon die 106B and is labeled negative (−) for reference. That is, the terminals are stacked on top of each other and in this example the negative terminal overlaps the positive one. A separation 108 is here formed between the planar terminals.
  • Particularly, because the silicon dies 106A-B are in a common plane (on top of the substrate) the planar terminal 102B has an offsetting portion 110 along the entire width of the plane so as to provide a contact portion 112 that abuts the silicon die 106B. In some implementations, the contact portion forms a plane that is parallel to, and offset from, the plane of the main portion of the planar terminal 102B. The offsetting portion can be formed using any suitable technique, such as by stamping or bending.
  • A housing 114 encloses at least part of the semiconductor device. The housing can have one or more openings. In some implementations, the housing has a common opening 116 through which the planar terminals 102A-B extend. For example, after the substrate, the silicon dies and the planar terminals are assembled, the housing can be overmolded on that assembly so that the terminals extend from the enclosed structure.
  • An electric insulator 118 can be provided in the separation between the planar terminals. The insulator provides electric insulation across the entire width of the conductive sheets that form the respective planar terminals. In some implementations insulating paper is used.
  • That is, the above describes an example of a semiconductor device 100 that includes a housing 114, a substrate 104 inside the housing, semiconductor circuits 106A-B on the substrate, and planar terminals 102A-B that extend away from the housing and are electrically connected to the first and second semiconductor circuits, respectively. In particular, the planar terminals are stacked on top of each other.
  • As a result, the inductance is now proportional to the area between the planar terminals 102A-B plus the area between the terminal 102B and the substrate 104 where the negative terminal overlaps the positive one. This can allow for a significant reduction of inductance compared to traditional device designs. For example, because the planar terminals abut the silicon dies and also extend outside the housing, the busbar structure can be considered (at least partially) integrated within the housing. Some of the present implementations can avoid attaching IGBT leads to an external busbar layer and thereby eliminate the need to form holes in such busbar layer, which could otherwise increase the inductance.
  • FIG. 2 shows a top view of the semiconductor device 100 in FIG. 1. This illustrates how the planar terminal 102A abuts the silicon die 106A and the planar terminal 102B abuts the silicon die 106B. Because the planar terminals are stacked on top of each other and one of them partially overlaps the other, the terminal 102A and the dies 106A-B are shown in phantom. The terminal 102A is here shown as narrower that the terminal 102B only to clarify the illustration. This arrangement provides an increased busbar width per die area which improves performance. In some implementations, the planar terminals overlap each other for most of their respective surface areas. Also shown are additional semiconductor circuits. In some implementations, these include further silicon dies 200A-B that are also part of the semiconductor device. The planar terminals are attached to the respective silicon die(s) 106A-B and 200A-B by any suitable technique, including, but not limited to, soldering.
  • FIG. 3 shows a cross section of another example of a semiconductor device 300 having stacked planar terminals 302A-B. The silicon dies and the substrate can be essentially the same as above. However, busbars 304A-B that abut the respective silicon dies here extend in a common plane, not stacked on top of each other. The busbars 304A-B can be essentially planar conductors that provide high voltage connection to the silicon dies. Some or all of the busbar 304A is exposed to the outside through an opening 306 in a housing 308 that encloses at least part of the semiconductor device. Also, some or all of the busbar 304B is exposed to the outside through an opening 310 in the housing. For example, the openings can be formed as part of an overmolding process that encapsulates the device into an enclosed structure.
  • Here, the planar terminal 302A abuts the busbar 304A outside the housing. Also, the planar terminal 302B abuts the busbar 304B, at least the part thereof that is exposed through the opening 310. For example, the planar terminal and the busbar can be welded together. In some implementations, this approach can lead to a simplified manufacturing process in that the planar terminals—which can be sheets wide enough to span several IGBTs—can easily be aligned with and attached to the busbars of the device(s). In some implementations, both of the busbars can be exposed through holes in a similar way as shown for the busbar 304B.
  • Similar to the previous example, the planar terminal 302B can have an offsetting portion that provides a contact portion—parallel with and offset from the main portion of the planar terminal—so as to reach at least a portion of its busbar.
  • Electric insulation 312 can be provided in the separation between the planar terminals 302A-B. In some implementations, the stacked structure of these planar terminals (with insulation) can be assembled in advance and then this assembly can be brought to the rest of the semiconductor device for making the electrical connections. As such, the current example can be considered as having the stacking done outside the semiconductor package instead of inside it which can simplify the manufacture.
  • FIG. 4 shows a perspective view of an assembly 400 of semiconductor devices 402 and capacitors 404. FIG. 5 shows a cross section of the assembly in FIG. 4. In some implementations, capacitors are coupled to the semiconductor devices in order to protect against transients, and to help maintain a voltage on a DC bus. For example, the capacitors can serve as DC link capacitors. Any form of capacitor conductors can be used, including, but not limited to, films or foils (e.g., folded or rolled into a compact structure).
  • Here, a set of six semiconductor devices 402 are shown but in other implementations more or fewer can be used. The semiconductor housings are here omitted for clarity. The semiconductor devices are arranged next to each other in a row. Each device has a substrate 406 and busbars 408A-B. The busbars are connected to respective semiconductor circuits on the substrates (e.g., silicon dies) which are not visible in this illustration. In particular, the silicon dies would be positioned between the respective busbars 408A-B and the substrate 406.
  • Planar terminals 410A-B are here comprised of conductive sheets that connect the capacitors 404 to each of the semiconductor devices via the busbars. The planar terminals are stacked on top of each other so that the planar terminal 410A abuts the busbar 408A and the planar terminal 410B abuts the busbar 408B. At the other end of the planar terminals, they connect to respective conductors of the capacitors. That is, each planar terminal connects multiple semiconductor devices to each of the several capacitors. FIG. 4 also illustrates that the busbars can have a significant width compared to the semiconductor device as a whole (essentially the substrate width). For example, each of the busbars can be at least 70% of the width of the semiconductor device.
  • One or more of the planar terminals 410A-B can have a step shape when viewed in profile. Here, the planar terminals are essentially flat planes in the area near the semiconductor devices. To accommodate the relative position of the capacitors and the semiconductor devices, the planar terminal 410B (the “lower” of the terminals in this example) makes turns 412A-B so as to provide a contact plane 414B for (in this example) the bottom conductor of the capacitor. The planar terminal 410A can make corresponding turns to form a contact plane 414A for the opposite capacitor conductor.
  • The planar terminals provide a continuous conductive plane for current traveling to and from the capacitors. That is, because there are no holes in these sheets or pins at their edge where they electrically connect to the semiconductor devices, there are fewer or no “necks” that impede the flow of current.
  • The assembly 400 can form part of a power inverter. In some implementations, the inverter can include two (or more) of the assembly 400 where the semiconductor devices (e.g., IGBTs) are jointly controlled so as to perform the DC-to-AC conversion. For example, two such assemblies can be oriented so that their respective semiconductor devices are near each other, which can simplify the placement and operation of cooling systems (e.g., liquid-based heatsinks).
  • An example of assembling an apparatus will now be described. This description will refer to some examples of components mentioned above for illustrative purposes. However, other components can be used instead of or in addition to these.
  • Semiconductor devices (e.g., 402) are positioned in a row. Each of the semiconductor devices comprises a substrate (e.g., 406), first and second semiconductor circuits (e.g., 106A-B) on the substrate, and first and second busbars (e.g., 408A-B) abutting the first and second semiconductor circuits, respectively.
  • An assembly is formed by placing a first planar terminal (e.g., 410A) in contact with the first busbar (e.g., 408A) of each of the plurality of semiconductor devices, and a second planar terminal (e.g., 410B) in contact with the second busbar (e.g., 408B) of each of the plurality of semiconductor devices. The first and second planar terminals are stacked on top of each other. For example, the terminals can first be stacked and then (as an assembled stack) be placed in contact with the respective busbars.
  • The first planar terminal is welded to the first busbar of each of the plurality of semiconductor devices. Such welding can be performed from one side of the assembly. A weld 416A from above the assembly is here schematically illustrated. Similarly, the second planar terminal is welded to the second busbar of each of the plurality of semiconductor devices. Such welding can be performed from the opposite side of the assembly. A weld 416B from below the assembly is here schematically illustrated. For example, laser welding can be used.
  • An electrical insulation layer (e.g., 118) can be included between the first and second planar terminals. For example, an insulating paper can be inserted before the terminals are stacked on top of each other.
  • Each of the first and second planar terminals can be electrically connected to a plurality of capacitors (e.g., 404). For example, respective contact planes of the terminals can be connected (e.g., welded) to respective capacitor terminals.
  • More or fewer steps can be performed in some assembly processes. Also, two or more steps can be performed in a different order.
  • FIG. 6 shows another example of a semiconductor assembly 600 configured to have stacked terminals. This example uses a co-pack design where a pair of individual devices 602 and 604 make use of terminals 606 and 608 that are planar and stacked. The semiconductor devices can also have planar busbars. Here, the device 602 has busbars 610 and 612, and the device 604 has busbars 614 and 616. The shown polarities (+ and −) are for illustrative purposes only. These busbars facilitate positioning of the terminals 606 and 608 in a stacked fashion, as well as can simplify the assembly technique.
  • Each device has a substrate 618 on which a corresponding silicon die 620 is positioned. The substrate and/or the die can be similar or identical to those described elsewhere herein. In some implementations that have a co-pack design, the die 620 can include both one or more switching devices (e.g., an IGBT) and one or more other semiconductor devices (e.g., a diode). For example, the assembly 600—which includes the two devices 602 and 604—can then be used in one of the half bridges in a power inverter.
  • The busbars 612 and 616 are here positioned on top of the corresponding silicon die and are electrically connected to it. The other busbars 610 and 614 are also electrically connected, for example by one or more wire bonds (not shown) to the die. The busbars for the individual device (e.g., busbars 610 and 612) can be configured so that they facilitate good performance characteristics (e.g., reduced inductance) and a simplified assembly process. These busbars can be positioned in opposite directions from the silicon die. In some implementations, one of the planar busbars can extend in a plane that is parallel to and offset from the plane of the other busbar. For example, here the busbar 612 sits higher above the substrate than the busbar 610 so that there is an offset between them. In other implementations, the busbars can be located in a common plane.
  • The devices 602 and 604 are enclosed in respective housings 622 and 624. One advantage of a co-pack design can be that the individual die within its housing is easy to handle and install. For example, the busbar geometries of the respective individual devices can facilitate direct connection between the devices, and with other components such as terminals.
  • The planar busbars can extend from the respective housing in essentially opposing directions. Here, for example, the busbar 610 has an opening 626 that allows connection with the terminal 608. The busbar 612 has an opening 628 that allows connection with the busbar 614 from the device 604. The attachment between the busbar 616 and the terminal 606 can be facilitated by a contact portion 630 that is offset from a main part of the terminal 606 by an offsetting portion 632. For example, this can facilitate a close spacing (here in a vertical direction) between the terminal 606 and the busbar 616, which can help avoid significant inductance.
  • The assembly 600 can be used in any or all contexts described above. Some examples will be provided. With reference again to FIG. 4, the capacitors 404 shown there can be connected to the assembly 600. In some implementations, the planar terminal 410A can serve as the terminal 606, and/or the planar terminal 410B can serve as the terminal 608. For example, this can allow advantageous simplified connection to the semiconductor devices, while allowing the terminals to be planar and have relatively large surface areas.
  • The assembly 600 can be assembled using any or all approaches described above. First, in some implementations, the busbars 612 and 614 are attached to each other before the terminals (e.g., 606, 608) are put in place. Any suitable joining technique can be used, including, but not limited to, laser welding, ultrasonic welding, sintering or soldering.
  • Second, the planar terminals 606 and 608 can be attached to the respective devices 602 and 604 in analogy with examples described herein. With reference to FIG. 5, the planar terminal 410A shown there can serve as the terminal 606, and/or the planar terminal 410B shown there can serve as the terminal 608. This can simplify the stage of creating connections to/from the devices. In some implementations, the weld 416A can be applied to create attachment between the terminal 606 and the busbar 616. For example, the weld is applied from above the terminal 606. In some implementations, the weld 416B can be applied to create attachment between the terminal 608 and the busbar 610. For example, the weld is applied from below the terminal 608. This can provide an efficient manufacturing process where sintering (as an example of a joining technique) need only be performed on a top and bottom of an individual co-packed device. For example, two-step sintering can be used.
  • That is, the above exemplifies a manufacturing process where a first semiconductor device can be positioned near a second semiconductor device, the first semiconductor device having first and second planar busbars parallel to each other and extending in opposite directions through respective openings in a first housing. The second semiconductor device can have third and fourth planar busbars parallel to each other and extending in opposite directions through respective openings in a second housing. The second planar busbar of the first semiconductor device can be attached to the third planar busbar of the second semiconductor device. A first planar terminal can be positioned adjacent the first planar busbar of the first semiconductor device, and a second planar terminal can be positioned adjacent the fourth planar busbar of the second semiconductor device. The first planar terminal can be attached to the first planar busbar, and the second planar terminal can be attached to the fourth planar busbar.
  • A number of implementations have been described as examples. Nevertheless, other implementations are covered by the following claims.

Claims (20)

What is claimed is:
1. A semiconductor device comprising:
a housing;
a substrate inside the housing;
a semiconductor circuit on the substrate; and
first and second planar busbars electrically connected to the semiconductor circuit, the first and second planar busbars being parallel to each other and extending away from the semiconductor circuit in opposite directions through respective openings in the housing.
2. The semiconductor device of claim 1, wherein the second planar busbar is in a different plane than the first planar busbar such that there is an offset between the first and second planar busbars.
3. The semiconductor device of claim 2, wherein the semiconductor circuit is positioned between the second planar busbar and the substrate.
4. The semiconductor device of claim 2, wherein the offset accommodates attachment of a distal end of the second planar busbar to a corresponding first planar busbar from an adjacent semiconductor device.
5. The semiconductor device of claim 1, wherein the first planar busbar is configured to have a planar terminal attached to it such that the planar terminal is on a same side of the first planar busbar as the semiconductor circuit.
6. The semiconductor device of claim 1, wherein the second planar busbar is configured to have an attachment to a planar terminal such that the planar terminal is positioned on an opposite side of the second planar busbar than the semiconductor circuit.
7. The semiconductor device of claim 6, wherein the housing is configured so that the planar terminal extends across the housing toward the attachment.
8. The semiconductor device of claim 7, wherein the planar terminal contains a contact portion offset from a main portion thereof by an offsetting portion, and wherein the contact portion abuts the second planar busbar at the attachment, and wherein the main portion extends along the housing.
9. The semiconductor device of claim 1, wherein the substrate includes a direct bonded copper structure.
10. A semiconductor assembly comprising:
a first semiconductor device comprising:
a first housing;
a first substrate inside the first housing;
a first semiconductor circuit on the first substrate; and
first and second planar busbars electrically connected to the first semiconductor circuit, the first and second planar busbars being parallel to each other and extending away from the first semiconductor circuit in opposite directions through respective openings in the first housing;
a second semiconductor device comprising:
a second housing;
a second substrate inside the second housing;
a second semiconductor circuit on the second substrate; and
third and fourth planar busbars electrically connected to the second semiconductor circuit, the third and fourth planar busbars being parallel to each other and extending away from the second semiconductor circuit in opposite directions through respective openings in the second housing, wherein the second planar busbar of the first semiconductor device is attached to the third planar busbar of the second semiconductor device;
a first planar terminal attached to the first planar busbar of the first semiconductor device; and
a second planar terminal attached to the fourth planar busbar of the second semiconductor device.
11. The semiconductor device of claim 10, wherein each of the second and fourth planar busbars is in a different plane than a corresponding one of the first and third planar busbars such that their offsets exists between respective planar busbars.
12. The semiconductor device of claim 11, wherein the offsets accommodate attachment of the second planar busbar to the third planar busbar.
13. The semiconductor device of claim 10, wherein the first planar busbar is configured to have the first planar terminal attached to it such that the first planar terminal is on a same side of the first planar busbar as the first semiconductor circuit.
14. The semiconductor device of claim 10, wherein the fourth planar busbar is configured to have an attachment to the second planar terminal such that the second planar terminal is positioned on an opposite side of the fourth planar busbar than the second semiconductor circuit.
15. The semiconductor device of claim 14, wherein the first and second housings are configured so that the second planar terminal extends across the first and second housings toward the attachment.
16. The semiconductor device of claim 15, wherein the second planar terminal contains a contact portion offset from a main portion thereof by an offsetting portion, and wherein the contact portion abuts the fourth planar busbar at the attachment, and wherein the main portion extends along the first and second housings.
17. The semiconductor device of claim 10, further comprising a capacitor, wherein the first and second planar terminals connect the capacitor to the first and second semiconductor devices.
18. A method comprising:
positioning a first semiconductor device near a second semiconductor device, the first semiconductor device having first and second planar busbars parallel to each other and extending in opposite directions through respective openings in a first housing, the second semiconductor device having third and fourth planar busbars parallel to each other and extending in opposite directions through respective openings in a second housing;
attaching the second planar busbar of the first semiconductor device to the third planar busbar of the second semiconductor device;
positioning a first planar terminal adjacent the first planar busbar of the first semiconductor device, and positioning a second planar terminal adjacent the fourth planar busbar of the second semiconductor device; and
attaching the first planar terminal to the first planar busbar, and attaching the second planar terminal to the fourth planar busbar.
19. The method of claim 18, wherein attaching the first planar terminal to the first planar busbar comprises accessing the first planar terminal from a same side of the first planar busbar as where a semiconductor circuit of the first semiconductor device is located.
20. The method of claim 18, wherein attaching the second planar terminal to the fourth planar busbar comprises accessing the second planar terminal from an opposite side of the fourth planar busbar than where a semiconductor circuit of the second semiconductor device is located.
US15/274,734 2015-09-25 2016-09-23 Semiconductor device with stacked terminals Abandoned US20170133316A1 (en)

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