WO2012014843A1 - パワー半導体ユニット、パワーモジュール、パワー半導体ユニットの製造方法およびパワーモジュールの製造方法 - Google Patents
パワー半導体ユニット、パワーモジュール、パワー半導体ユニットの製造方法およびパワーモジュールの製造方法 Download PDFInfo
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- WO2012014843A1 WO2012014843A1 PCT/JP2011/066854 JP2011066854W WO2012014843A1 WO 2012014843 A1 WO2012014843 A1 WO 2012014843A1 JP 2011066854 W JP2011066854 W JP 2011066854W WO 2012014843 A1 WO2012014843 A1 WO 2012014843A1
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- power semiconductor
- electrode lead
- lead frame
- semiconductor unit
- heat radiating
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- B60L1/00—Supplying electric power to auxiliary equipment of vehicles
- B60L1/003—Supplying electric power to auxiliary equipment of vehicles to auxiliary motors, e.g. for pumps, compressors
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Abstract
Description
本発明の第2の態様によると、第1の態様のパワー半導体ユニットにおいて、凹凸段差は、放熱面の一部がモールド材の表面よりも窪んでおり、傾斜面は、放熱面の周囲を囲むように突出したモールド材の縁に形成された傾斜加工面から成るのが好ましい。
本発明の第3の態様によると、第1の態様のパワー半導体ユニットにおいて、凹凸段差は、放熱面の全体が前記モールド材の表面よりも突出しており、傾斜面は、モールド材の表面から突出した放熱面の縁に形成された面取り加工面から成るのが好ましい。
本発明の第4の態様によると、第1乃至3のいずれか一の態様に記載のパワー半導体ユニットにおいて、傾斜面の角度は110度以上180度未満である。
本発明の第5の態様によると、第1乃至4のいずれか一の態様に記載のパワー半導体ユニットにおいて、パワー半導体素子は電極を表裏両面に有し、電極リードフレームは、パワー半導体素子の裏面側の電極面が接合される第1の電極リードフレームと、パワー半導体素子の表面側の電極面が接合される第2の電極リードフレームとを有し、第1および第2の電極リードフレームの少なくとも一方の電極リードフレームに対して、傾斜面を成す段差側面が形成された凹凸段差を有するのが好ましい。
本発明の第6の態様によると、第5の態様のパワー半導体ユニットにおいて、第1および第2の電極リードフレームの少なくとも一方に形成され、放熱面から接合面に貫通する貫通孔と、溶融状態で貫通孔から電極面と接合面との隙間に注入され、凝固することにより電極面と接合面とを金属接合する金属接合体と、貫通孔が形成された電極リードフレームの放熱面に形成され、該電極リードフレームの端部から貫通孔に連通する溝と、を備え、貫通孔および溝は、モールド材によって覆われているのが好ましい。
本発明の第7の態様によると、第6の態様のパワー半導体ユニットにおいて、貫通孔は、接合面の縁領域を貫通するように形成されているのが好ましい。
本発明の第8の態様によると、パワーモジュールは、第5乃至7のいずれか一の態様に記載のパワー半導体ユニットと、外周面に放熱フィンが形成された対向する第1および第2の放熱壁を有し、第1の放熱壁の内周面と第1の電極リードフレームの放熱面とが対向し、かつ、第2の放熱壁の内周面と第2の電極リードフレームの放熱面とが対向するようにパワー半導体ユニットが内挿される有底の金属筒と、第1の放熱壁の内周面と第1の電極リードフレームの放熱面との間に密着して配置される第1の熱伝導性絶縁シートと、第2の放熱壁の内周面と第2の電極リードフレームの放熱面との間に密着して配置される第2の熱伝導性絶縁シートと、を備える。
本発明の第9の態様によると、第8の態様のパワーモジュールにおいて、金属筒は、第1の放熱壁の周囲に形成されて該放熱壁よりも肉厚の薄い第1の薄肉部と、第2の放熱壁の周囲に形成されて該放熱壁よりも肉厚の薄い第2の薄肉部とを有し、第1および第2の薄肉部は、第1および第2の放熱壁によってパワー半導体ユニットが挟持されるように塑性変形しているのが好ましい。
本発明の第10の態様によると、第8または9の態様のパワーモジュールにおいて、第1および第2の熱伝導性絶縁シートが、熱硬化性樹脂に熱伝導率が5W/mK以上の絶縁性無機材料を体積分率50%以上90%以下充填した高熱伝導層と、熱硬化性樹脂から成り、高熱伝導層の表裏両面に形成された高密着化層と、を備えているのが好ましい。
本発明の第11の態様によると、第10の態様のパワーモジュールにおいて、高密着化層は、熱硬化性樹脂としてエポキシ変性ポリアミドイミド樹脂を体積分率50%よりも多く含み、マトリクス樹脂としてのエポキシ変性ポリアミドイミド樹脂に平均粒径5μm以下のシリコーン樹脂がミクロ相分離された構造を有するのが好ましい。
本発明の第12の態様によると、パワー半導体ユニットの製造方法は、第2の態様に記載のパワー半導体ユニットの放熱面の周囲を囲むように突出したモールド材の縁領域をレーザー加工することにより、傾斜面を形成する。
本発明の第13の態様によると、パワー半導体ユニットの製造方法は、第3の態様に記載のパワー半導体ユニットに設けられた電極リードフレームの接合面に、パワー半導体素子の電極面を金属接合する第1の工程と、電極リードフレームの放熱面とトランスファーモールド金型との間に柔軟性離型シートを配置する第2の工程と、トランスファーモールド金型を電極リードフレームの放熱面に押圧して、放熱面を柔軟性離型シートに沈み込ませた状態でトランスファーモールドを行う第3の工程と、を有する。
本発明の第14の態様によると、パワーモジュールの製造方法は、温度140℃以下、加圧力2MPa以下、気圧10kPa以下および圧着時間15分以内という圧着条件で、第10または11の態様に記載のパワーモジュールに設けられたパワー半導体ユニットの第1および第2の電極リードフレームの放熱面に、第1および第2の熱伝導性絶縁シートを圧着する第1の圧着工程と、パワー半導体ユニットに圧着された第1および第2の熱伝導性絶縁シートに、温度130℃以上、加圧力5MPa以下、気圧10kPa以下およびの圧着時間5分以上という圧着条件で、第1および第2の放熱壁の各内周面を圧着する第2の圧着工程と、を有する。
-第1の実施の形態-
図1は、本発明によるパワーモジュールの外観を示す図である。パワーモジュール300は、スイッチング素子を含むようにトランスファーモールドされたパワー半導体ユニットを、金属筒1内に収納したものである。パワーモジュール300は、例えば、電気自動車やハイブリッド自動車等の電気車両に搭載される電力変換装置に用いられる。
度或いは過電圧から保護する。
図21は、パワーモジュールの製造方法を説明する図である。まず、図21(a)に示すように、トランスファーモールドによって形成されたパワー半導体ユニット6の表裏両面に、すなわち、電極リードフレーム316,319の放熱面316s、319sおよび封止材13の表面に、絶縁シート10を圧着する。なお、図20に示した絶縁シート10の表裏両面には、作業性の観点から離型シートが貼られているが、圧着をする際には、絶縁シート10の片面側(パワー半導体ユニット6に対向しない方の面)の離型シートは残したままとする。その状態で、真空プレス機を用いて、温度130℃、加圧力1MPa、気圧10kPaの条件で1分間圧着する。
図22~図25を参照して本発明の第2の実施の形態について説明する。図22は、第2の実施の形態におけるパワーモジュール300Bの断面を模式的に示した図である。パワーモジュール300Bはと図12に示したパワーモジュール300との相違点は、電極リードフレーム7の形状が異なる点にある。以下では異なる点を中心に説明する。
(3)一方、図13(a)に示すように、放熱面7bの全体が封止材13の表面よりも突出している凹凸段差の場合には、傾斜面は、封止材13の表面13bから突出した放熱面7bの縁に形成された面取り加工面7aとされる。
日本国特許出願2010年第166705号(2010年7月26日出願)
Claims (14)
- パワー半導体素子と、
板状導電性部材で形成され、該板状導電性部材の表裏面の一方の面に、前記パワー半導体素子の電極面が金属接合される接合面が形成されるとともに、前記表裏面の他方の面に放熱面が形成されている電極リードフレームと、
前記放熱面の少なくとも一部が露出するように前記パワー半導体素子をモールドするモールド材と、を備えるパワー半導体ユニットであって、
絶縁シートを介して前記放熱面が放熱部材に熱接触して前記パワー半導体素子の熱が前記放熱部材へ放熱され、
前記放熱面の露出領域と該露出領域に隣接する前記モールド材の表面とは、いずれか一方が突出した凹凸段差を成し、
前記凹凸段差の凸側の面と凹側の面との間に形成された段差側面は、前記凸側の面との間の角度および前記凹側の面との間の角度がそれぞれ鈍角となるような傾斜面で構成されているパワー半導体ユニット。 - 請求項1に記載のパワー半導体ユニットにおいて、
前記凹凸段差は、前記放熱面の一部が前記モールド材の表面よりも窪んでおり、
前記傾斜面は、前記放熱面の周囲を囲むように突出した前記モールド材の縁に形成された傾斜加工面から成るパワー半導体ユニット。 - 請求項1に記載のパワー半導体ユニットにおいて、
前記凹凸段差は、前記放熱面の全体が前記モールド材の表面よりも突出しており、
前記傾斜面は、前記モールド材の表面から突出した前記放熱面の縁に形成された面取り加工面から成るパワー半導体ユニット。 - 請求項1乃至3のいずれか一項に記載のパワー半導体ユニットにおいて、
前記傾斜面の前記角度は110度以上180度未満であるパワー半導体ユニット。 - 請求項1乃至4のいずれか一項に記載のパワー半導体ユニットにおいて、
前記パワー半導体素子は前記電極を表裏両面に有し、
前記電極リードフレームは、前記パワー半導体素子の裏面側の電極面が接合される第1の電極リードフレームと、前記パワー半導体素子の表面側の電極面が接合される第2の電極リードフレームとを有し、
前記第1および第2の電極リードフレームの少なくとも一方の電極リードフレームに対して、前記傾斜面を成す段差側面が形成された凹凸段差を有するパワー半導体ユニット。 - 請求項5に記載のパワー半導体ユニットにおいて、
前記第1および第2の電極リードフレームの少なくとも一方に形成され、前記放熱面から前記接合面に貫通する貫通孔と、
溶融状態で前記貫通孔から前記電極面と前記接合面との隙間に注入され、凝固することにより電極面と接合面とを金属接合する金属接合体と、
前記貫通孔が形成された電極リードフレームの放熱面に形成され、該電極リードフレームの端部から前記貫通孔に連通する溝と、を備え、
前記貫通孔および溝は、前記モールド材によって覆われているパワー半導体ユニット。 - 請求項6に記載のパワー半導体ユニットにおいて、
前記貫通孔は、前記接合面の縁領域を貫通するように形成されているパワー半導体ユニット。 - 請求項5乃至7のいずれか一項に記載のパワー半導体ユニットと、
外周面に放熱フィンが形成された対向する第1および第2の放熱壁を有し、前記第1の放熱壁の内周面と前記第1の電極リードフレームの放熱面とが対向し、かつ、前記第2の放熱壁の内周面と前記第2の電極リードフレームの放熱面とが対向するように前記パワー半導体ユニットが内挿される有底の金属筒と、
前記第1の放熱壁の内周面と前記第1の電極リードフレームの放熱面との間に密着して配置される第1の熱伝導性絶縁シートと、
前記第2の放熱壁の内周面と前記第2の電極リードフレームの放熱面との間に密着して配置される第2の熱伝導性絶縁シートと、を備えたパワーモジュール。 - 請求項8に記載のパワーモジュールにおいて、
前記金属筒は、前記第1の放熱壁の周囲に形成されて該放熱壁よりも肉厚の薄い第1の薄肉部と、前記第2の放熱壁の周囲に形成されて該放熱壁よりも肉厚の薄い第2の薄肉部とを有し、
前記第1および第2の薄肉部は、前記第1および第2の放熱壁によって前記パワー半導体ユニットが挟持されるように塑性変形しているパワーモジュール。 - 請求項8または9に記載のパワーモジュールにおいて、
前記第1および第2の熱伝導性絶縁シートが、
熱硬化性樹脂に熱伝導率が5W/mK以上の絶縁性無機材料を体積分率50%以上90%以下充填した高熱伝導層と、
前記熱硬化性樹脂から成り、前記高熱伝導層の表裏両面に形成された高密着化層と、を備えているパワーモジュール。 - 請求項10に記載のパワーモジュールにおいて、
前記高密着化層は、前記熱硬化性樹脂としてエポキシ変性ポリアミドイミド樹脂を体積分率50%よりも多く含み、マトリクス樹脂としての前記エポキシ変性ポリアミドイミド樹脂に平均粒径5μm以下のシリコーン樹脂がミクロ相分離された構造を有するパワーモジュール。 - パワー半導体ユニットの製造方法であって、
請求項2に記載のパワー半導体ユニットの前記放熱面の周囲を囲むように突出した前記モールド材の縁領域をレーザー加工することにより、前記傾斜面を形成するパワー半導体ユニットの製造方法。 - パワー半導体ユニットの製造方法であって、
請求項3に記載のパワー半導体ユニットに設けられた前記電極リードフレームの前記接合面に、前記パワー半導体素子の電極面を金属接合する第1の工程と、
前記電極リードフレームの前記放熱面とトランスファーモールド金型との間に柔軟性離型シートを配置する第2の工程と、
前記トランスファーモールド金型を前記電極リードフレームの前記放熱面に押圧して、前記放熱面を前記柔軟性離型シートに沈み込ませた状態でトランスファーモールドを行う第3の工程と、を有するパワー半導体ユニットの製造方法。 - パワーモジュールの製造方法であって、
温度140℃以下、加圧力2MPa以下、気圧10kPa以下および圧着時間15分以内という圧着条件で、請求項10または11に記載のパワーモジュールに設けられた前記パワー半導体ユニットの前記第1および第2の電極リードフレームの放熱面に、前記第1および第2の熱伝導性絶縁シートを圧着する第1の圧着工程と、
前記パワー半導体ユニットに圧着された前記第1および第2の熱伝導性絶縁シートに、温度130℃以上、加圧力5MPa以下、気圧10kPa以下およびの圧着時間5分以上という圧着条件で、前記第1および第2の放熱壁の各内周面を圧着する第2の圧着工程と、を有するパワーモジュールの製造方法。
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Also Published As
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US20130119525A1 (en) | 2013-05-16 |
EP2600398A4 (en) | 2015-08-05 |
CN103069935A (zh) | 2013-04-24 |
CN103069935B (zh) | 2015-07-22 |
EP2600398A1 (en) | 2013-06-05 |
JP5437943B2 (ja) | 2014-03-12 |
EP2600398B1 (en) | 2016-11-23 |
US8723306B2 (en) | 2014-05-13 |
JP2012028595A (ja) | 2012-02-09 |
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