WO2015107804A1 - 半導体モジュール - Google Patents

半導体モジュール Download PDF

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Publication number
WO2015107804A1
WO2015107804A1 PCT/JP2014/082632 JP2014082632W WO2015107804A1 WO 2015107804 A1 WO2015107804 A1 WO 2015107804A1 JP 2014082632 W JP2014082632 W JP 2014082632W WO 2015107804 A1 WO2015107804 A1 WO 2015107804A1
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WIPO (PCT)
Prior art keywords
resin frame
circuit board
crosspiece
circuit boards
outer edge
Prior art date
Application number
PCT/JP2014/082632
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English (en)
French (fr)
Inventor
力宏 丸山
孝仁 原田
Original Assignee
富士電機株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 富士電機株式会社 filed Critical 富士電機株式会社
Priority to CN201480038707.XA priority Critical patent/CN105940489B/zh
Priority to EP14879151.0A priority patent/EP3007219B1/en
Priority to JP2015557735A priority patent/JP6132034B2/ja
Publication of WO2015107804A1 publication Critical patent/WO2015107804A1/ja
Priority to US14/990,423 priority patent/US9673117B2/en

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    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04—Manufacture 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
    • H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
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    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
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Definitions

  • the present invention relates to a semiconductor module in which a circuit formed using a plurality of insulated circuit boards is accommodated in a case with a lid.
  • Patent Document 1 is known for a structure in which a shielding plate is provided at the center of one substrate housed in a case.
  • an optical receiver IC and an amplifier IC are mounted on a single substrate, and left and right cutouts are provided at the center of the substrate between the optical receiver IC and the amplifier IC.
  • a shielding plate is inserted so as to engage with the entire thickness portion of the board, and in order to avoid contact between the signal wiring provided on the board and the shielding plate, a portion of the lower surface of the shielding plate facing the signal wiring is cut. It is described that a notch is formed.
  • a lid is disposed on the case and the shielding plate.
  • Patent Document 2 a protrusion is provided on the back surface of the cover plate and the printed circuit board for control circuit is pressed from the upper side to suppress the upward displacement of the printed circuit board.
  • a power semiconductor module that relieves the stress generated in the above is described.
  • Patent Document 3 discloses a semiconductor including a plurality of semiconductor chips, bonding wires, a resin case, and an external lead-out metal terminal (hereinafter referred to as a metal terminal) that is insert-molded in the resin case. Modules are listed.
  • the metal case is inserted into the outer peripheral frame of the resin case to widen the space inside the case, and wiring between the insulating circuit board, semiconductor chip, and terminals is made only with bonding wires, and the metal terminal is directly on the insulating circuit board. This structure is not soldered.
  • the metal terminal is required to be securely fixed to the resin case. This is because if the metal terminal is floating from the resin case, there is a high possibility of causing a connection failure when wire bonding is performed on the metal terminal.
  • the metal terminal is bent in an L shape, and the resin case portion is stepped so that the lower end portion to be wire-bonded in the metal terminal can be reliably supported, and a convex portion protruding outward is provided at the lower end portion.
  • the fixing between the metal terminal and the resin case was strengthened.
  • the structure in which the insulated circuit board is further enlarged uses a structure in which the insulated circuit board is divided and assembled in order to reduce the influence of the warp of the insulated circuit board and improve the adhesion between the insulated circuit board and the heat sink. It is done.
  • the above document does not describe a semiconductor module in which a circuit formed using a plurality of insulated circuit boards is housed in a case with a lid and the entire periphery of each of the plurality of insulated circuit boards is pressed and fixed from above.
  • the wall 205c that suppresses the periphery of the insulating circuit board 201 is provided not only in the outer frame of the resin case 205a but also in the center portion, the wall 205c becomes an obstacle, and the gap between the insulating circuit boards 201 is reduced. There is a problem that the connection with the bonding wire cannot be performed.
  • the present invention has been made in view of the above-described points, and an object of the present invention is to facilitate electrical connection between insulating circuit boards even in a structure having a plurality of insulating circuit boards.
  • An object of the present invention is to provide a semiconductor module that can suppress warping deformation of a substrate and can radiate heat generated by a semiconductor chip satisfactorily.
  • a semiconductor module of the present invention includes a plurality of insulating circuit boards each including a semiconductor chip, and an adjacent insulating circuit board among outer edges of the insulating circuit board.
  • an upper lid having a partition wall portion in contact with.
  • the insulating circuit boards can be electrically connected by the conductive member straddling the crosspiece without being obstructed by the partition. Further, since the partition wall portion of the upper lid presses the crosspiece portion of the resin frame, and the crosspiece portion presses the first outer edge portion of the insulating circuit substrate, it is possible to suppress warping of the insulating circuit substrate.
  • the upper lid includes a columnar portion that protrudes from a surface of the lid facing the insulating circuit substrate and contacts the insulating circuit substrate.
  • the insulating circuit board can be prevented from warping.
  • the upper lid may be bonded to the resin frame. According to this structure, it becomes easy to attach an upper cover to a resin frame. Moreover, the structure provided with the engaging part which fixes the said upper cover to the said resin frame may be sufficient. According to this configuration, it is easier to attach the upper lid to the resin frame.
  • the resin frame includes a step portion disposed along the inner wall of the resin frame, and has a shaft portion, a leg portion, and a width narrower than the shaft portion or the leg portion.
  • a metal terminal having a bent hinge portion connecting the shaft portion and the leg portion is provided, and the leg portion is disposed on the upper surface of the step portion.
  • the width of the hinge portion is narrower than at least one of the width of the shaft portion and the width of the leg portion, or both, and is engaged with the resin frame, and the leg portion bent from the hinge portion is stepped. Since it can fix on the upper stage surface, position shift with a metal terminal and a resin frame can be suppressed.
  • the hinge part that engages the resin frame of the metal terminal has a shape that is narrower than the full width of the metal terminal. The number of metal terminals manufactured per unit area can be increased.
  • the metal terminal is embedded in a frame portion of the resin frame body with a part of the shaft portion and a part of the leg portion exposed.
  • a method of manufacturing a semiconductor module according to the present invention includes a plurality of insulating circuit boards each including a semiconductor chip, a crosspiece that abuts a first outer edge portion facing an adjacent insulating circuit board among outer edge portions of the insulating circuit board, and A resin frame having a frame portion that comes into contact with a second outer edge portion excluding the first outer edge portion from an outer edge portion of the insulating circuit board, and the insulating circuit board are electrically connected across the crosspiece.
  • a method of manufacturing a semiconductor module wherein the insulating circuit board and the resin frame are configured such that the crosspiece is in contact with the first outer edge and the frame is in contact with the second outer edge.
  • a first step of disposing A second step of electrically connecting the circuit boards with the conductive member; the lid portion of the upper lid covers an opening in the upper part of the resin frame; and the partition portion of the upper lid contacts a part of the crosspiece.
  • the insulating circuit boards can be easily connected by the conductor straddling the crosspiece without being obstructed by the partition.
  • a semiconductor module can be provided.
  • FIG. 3 is a top view after a resin frame 5 is placed on an insulated circuit board on which a semiconductor chip is mounted as shown in FIG. 2 and bonding wires (conductive members) 7 are connected.
  • FIG. 4 is a schematic cross-sectional view in which a cross-sectional view of the upper lid 8 is added to the B1-B2 cross-sectional view of FIG. For ease of viewing, the semiconductor chip and the bonding wires 7a and 7b around the chip are omitted.
  • FIG. 5 is a schematic cross-sectional view of the B1-B2 cross section in a state where the upper lid 8 of FIG. 4 is set at an appropriate position. Similar to FIG. 4, the semiconductor chip and bonding wires 7a and 7b around the chip are omitted. It is a schematic cross section which shows schematic structure of the semiconductor module using the conventional several insulated circuit board.
  • FIG. 1 is an exploded perspective view of a semiconductor module before assembling a part of the semiconductor module according to an embodiment of the present invention.
  • FIG. 1A is a perspective view of the upper lid 8.
  • the upper lid 8 includes a partition wall portion 8b and a columnar portion 8a.
  • the partition wall portion 8b and the columnar portion 8a are disposed on the side of the upper lid 8 facing the insulating circuit board 9.
  • the partition wall portion 8b presses a part of the crosspiece portion 5a of the resin frame 5 shown in FIG.
  • the columnar portion 8a presses the central portion of each insulating circuit board 9 shown in FIG.
  • FIG. 1 (b) shows a resin frame 5 in which metal terminals 4a and 4b are insert-molded into a frame portion 5c.
  • the resin frame 5 includes a crosspiece 5a, a frame 5c, and a step 5e.
  • the opening 5b is a portion surrounded by the crosspiece 5a and the frame 5c, and a through hole is opened.
  • the step portion 5e is disposed along the inner wall of the resin frame 5, and the upper step surface of the step portion 5e is a surface on which the metal terminals 4a and 4b are installed.
  • the resin frame 5 includes a through hole 6 for fixing the semiconductor module to a heat sink (not shown).
  • FIG. 1C shows an insulated circuit board 9 drawn without a semiconductor chip and a bonding wire (conductive member).
  • a known insulating ceramic such as alumina, aluminum nitride, silicon nitride or the like is used.
  • a circuit pattern 9 a made of copper foil or the like is bonded to the front surface side of each insulating circuit board 9, and copper foil is bonded to the entire surface of the insulating circuit board 9, leaving the periphery.
  • semiconductor chips 2a and 2b such as IGBT (Insulated Gate Bipolar Transistor) and FWD (Free Wheeling Diode) are mounted on the circuit pattern 9a by solder bonding.
  • IGBT Insulated Gate Bipolar Transistor
  • FWD Free Wheeling Diode
  • FIG. 2 is a perspective view of a state in which the resin frame 5 of FIG. 1B is placed on the insulating circuit board 9 of FIG.
  • the metal terminals 4 a and 4 b are embedded in the resin frame 5.
  • the leg portion 4c of the metal terminal extends from the resin frame 5 and is disposed on the upper surface of the step portion 5e.
  • the upper surface of the stepped portion 5e may be flat, but may be provided with a recess that fits with the legs of the metal terminals 4a and 4b as shown. If it does in this way, metal terminal 4a, 4b will be stabilized and position shift can be prevented.
  • the resin frame 5 Since the opening 5b provided in the center of the resin frame 5 is slightly smaller than the size of the insulated circuit board, the resin frame 5 can be pressed and adhered evenly around the insulated circuit board 9. The crosspiece 5a of the resin frame 5 presses and adheres to the vicinity of the outer edge of the adjacent insulating circuit board 9.
  • FIG. 3 is a top view after the resin frame 5 is placed on the insulating circuit board on which the semiconductor chip is mounted as shown in FIG. 2 and the bonding wires (conductive members) 7 are connected.
  • Semiconductor chips 2a and 2b such as IGBT and FWD are connected to the circuit pattern 9a through solder.
  • wire bonding wirings 7a and 7b for constituting a required inverter circuit and the like are provided between the semiconductor chips 2a and 2b, between the insulating circuit boards, and between the leg portions 4c of the metal terminals.
  • a bonding wire 7 is provided between the surface of the circuit pattern 9a of the insulating circuit board 9 adjacent over the crosspiece 5a of the resin frame 5, and is electrically connected.
  • the conductive member is not limited to the bonding wire, and may be a flat plate material.
  • FIG. 4 is a schematic cross-sectional view obtained by adding a cross-sectional view of the upper lid 8 to the B1-B2 cross-sectional view of FIG.
  • the metal terminals 4a and 4b include a shaft portion 4d, a leg portion 4c, and a hinge portion 4e that is bent by connecting the shaft portion 4d and the leg portion 4c.
  • the hinge part 4e is narrower than the shaft part 4d or the leg part 4c and is engaged with the resin frame, and the leg part 4c bent from the hinge part 4e is fixed to the step part 5e. The positional deviation between 4a, 4b and the resin frame 5 can be suppressed.
  • the metal terminals 4a and 4b of the present invention have a shape in which the hinge portion 4e engaged with the resin frame 5 is narrower than the shaft portion 4d or the leg portion 4c. Can be laid out at a narrow pitch, reducing the amount of mill ends and increasing the number of manufactured metal terminals per unit area.
  • the metal terminals 4a and 4b are held by integral molding in a state in which the portion is led out.
  • the metal terminals 4 a and 4 b do not necessarily have to be integrally molded with the resin frame 5.
  • Metal terminals may be integrated by fitting into a molded resin frame. In this way, the metal terminals 4a and 4b are collected in the resin frame 5 outside the wire bonding wiring region, and only the leg portion 4c bent in an L shape at the hinge portion is exposed on the step portion 5e inside the resin frame 5. By doing so, the shaft portion 4d of the metal terminal is embedded in the resin frame 5, and only the leg portion of the metal terminal that becomes the connection point of the bonding wire is exposed, so that the wire bonding work becomes easy, and A highly reliable connection can be achieved.
  • FIG. 5 is a schematic cross-sectional view of the B1-B2 cross section in a state where the upper lid 8 of FIG. 4 is set at an appropriate position. Similar to FIG. 4, the semiconductor chip and bonding wires 7a and 7b around the chip are omitted.
  • the upper lid 8 includes a partition wall portion 8b and a columnar portion 8a on the lower side.
  • the partition wall portion 8 b is arranged so as to press the upper surface of the crosspiece portion 5 a of the resin frame body 5 when the upper lid 8 is put on the upper opening of the resin frame body 5.
  • the columnar portion 8 a is disposed so as to press the vicinity of the center of the insulated circuit board 9.
  • the present invention is characterized in that the partition wall portion 8b provided in the upper lid 8 is shaped so as not to interfere with the bonding wire 7.
  • the partition wall portion 8b provided in the upper lid 8 is shaped so as not to interfere with the bonding wire 7.
  • the partition wall 8 b does not contact the bonding wire 7.
  • the part 8 b is shaped to contact only the upper surface of the crosspiece 5 a between the bonding wires 7.
  • the partition wall portion 8b presses the insulating circuit substrate 9 through the beam portion 5a.
  • the plurality of insulated circuit boards 9 are evenly brought into contact with the peripheral edges of the insulated circuit boards 9 by the frame portions 5c and the crosspieces 5a that are the outer periphery of the resin frame body 5.
  • An equal pressing force can be applied.
  • the plurality of insulated circuit boards 9 are bonded to the lower surface of the frame portion 5c of the resin frame 5 and the lower surface of the crosspiece portion 5a with an adhesive.
  • the semiconductor module 1 can suppress warping deformation of the insulating circuit board 9.
  • the heat sink has a flat surface facing the back surface of the insulating circuit board 9 and is in contact with the copper foil on the back surface of the plurality of insulating circuit boards 9.
  • a screw groove is formed on the flat surface, and the resin frame 5 is fixed to the heat sink with a screw through the through hole 6. Therefore, the heat generated by the semiconductor chips 2a and 2b can be radiated to a heat sink (not shown).
  • the upper lid 8 since the partition wall portion 8b presses the insulating circuit board 9 through the crosspiece 5a, the length from the upper lid 8 of the partition wall portion 8b is shorter than the length from the upper lid 8 of the columnar portion 8a. Become. This is also a structural feature of an example of the above embodiment.
  • the semiconductor module 1 includes a plurality of insulated circuit boards 9 juxtaposed with each other, and the insulated circuit boards 9.
  • a resin frame 5 to be adhered on the periphery and an upper lid 8 for closing the upper opening of the resin frame 5 are provided.
  • the method of covering the upper lid 8 with the upper opening of the resin frame 5 may be a method of adhering to the resin frame 5 with an adhesive.
  • the engaging portion has a structure such as fitting, screwing, and meshing. The pressing force against the insulating circuit board 9 by the columnar portion 8a and the partition wall portion 8b of the upper lid 8 can be ensured.
  • the crosspieces 5a are arranged on the first outer edges facing each other between the insulating circuit boards 9, and the frame parts 5c of the resin frame 5 are the second of the plurality of insulating circuit boards 9.
  • the upper lid 8 is fixed to the resin frame 5 such that the lid portion 8c of the upper lid 8 covers the opening at the top of the resin frame, and the partition wall portion 8b of the upper lid 8 is in contact with a part of the crosspiece 5a.
  • a third step More preferably, a fourth step of injecting silicone gel or the like into the space surrounded by the resin frame 5 and the insulating circuit board 9 before sealing the upper lid 8 on the resin frame 5 in the third step is included. preferable.
  • the semiconductor module according to the embodiment described above even if the structure has a plurality of insulated circuit boards, electrical connection between the insulated circuit boards can be facilitated, and warping deformation of the insulated circuit boards can be suppressed. It is possible to provide a semiconductor module capable of radiating heat generated from a semiconductor chip satisfactorily.

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Abstract

　複数の絶縁回路基板を有する構造であっても、絶縁回路基板間の電気的な接続を容易にし、絶縁回路基板の反り変形を抑制でき半導体チップの発熱を良好に放熱することのできる半導体モジュールを提供する。　半導体モジュールは、半導体チップを備えた複数の絶縁回路基板９と、絶縁回路基板９間の対向する第１外縁部に接触する桟部５ａ、および第１外縁部を除いた複数の絶縁回路基板９の第２外縁部に接触する枠部５ｃを持った樹脂枠体５と、桟部５ａを跨いで絶縁回路基板９間を電気的に接続する導電部材７と、樹脂枠体５の上部の開口を覆う蓋部８ｃ、および桟部５ａの一部と突き合わされる隔壁部８ｂを持った上蓋８とを備える。

Description

半導体モジュール
　本発明は、複数の絶縁回路基板を用いて形成した回路を、蓋付きケースに収容した半導体モジュールに関する。
　ケースに収容された１つの基板の中央部に遮蔽板を設ける構造は、特許文献１が知られている。特許文献１には、１つの基板上に光受信ＩＣと増幅器ＩＣが搭載されており、光受信ＩＣと増幅器ＩＣとの間の基板中央部に左右の切り欠きが設けられ、この切り欠き部分で基板の全厚み部分と係合するように遮蔽板が挿入され、基板上に設けられた信号配線と遮蔽板との当接を避けるべく、遮蔽板の下面の信号配線に対向する部分には切り欠きが形成されていることが記載されている。ケースと遮蔽板の上には、蓋が配置されている。
　また、特許文献２には、蓋板の裏面に突起を設けて制御回路用プリント基板を上側から押さえつけることにより、前記プリント基板の上方向の変位を抑制し、このプリント基板とリードピンのはんだ接合部に生じる応力を緩和するパワー半導体モジュールが記載されている。
　また、端子に関する文献として、特許文献３には、複数の半導体チップと、ボンディングワイヤと、樹脂ケースと、樹脂ケース内にインサート成型された外部導出用金属端子（以降、金属端子）とを備える半導体モジュールが記載されている。樹脂ケースの外周枠に金属端子をインサート成型することによりケース内側の空間を広くして、ボンディングワイヤだけで絶縁回路基板や半導体チップや端子間の配線を行い、金属端子を絶縁回路基板上に直接はんだ接合しない構造である。この構造では、金属端子が樹脂ケースに確実に固定されていることが求められる。金属端子が樹脂ケースから浮いていると、金属端子に対してワイヤボンディングを行う際に、接続不良を起こす可能性が高くなるからである。そこで従来は、金属端子をＬ字状に曲げ、金属端子におけるワイヤボンディングすべき下端部を確実に支持できるように、樹脂ケース部分を階段状にし、下端部に外側に突出する凸部を設けることで、金属端子と樹脂ケースとの固定を強化していた。
特開２００５－５０９７４号公報 特開２０００－６８４４６号公報 特開２０００－２０８６５５号公報
　一枚の絶縁回路基板を用いる半導体モジュールは、半導体チップサイズやチップ数がさらに増加すると、絶縁回路基板に必要な面積が増大する。絶縁回路基板の面積が大きくなりすぎると、熱膨張係数の違いに起因する応力により絶縁回路基板の反りや割れが生じるおそれがある。従って、絶縁回路基板がさらに大きくなる構造では、絶縁回路基板の反りの影響を低減して絶縁回路基板とヒートシンクとの密着性を向上するため、絶縁回路基板を複数に分割して組み立てる構造が用いられる。しかしながら、複数の絶縁回路基板を用いて形成した回路を、蓋付きケースに収容し、複数の絶縁回路基板のそれぞれの全周辺を上から押さえて固定する半導体モジュールに関する記載は上記文献には無い。図６のように、単に、樹脂ケース２０５aの外枠だけでなく中央部にも絶縁回路基板２０１の周辺を抑える壁２０５cを設ける構造では、この壁２０５ｃが障害となって、絶縁回路基板２０１間のボンディングワイヤによる接続ができないという問題点があった。
　また、上記特許文献３のように金属端子の外側に凸部を備えていると、原材料である金属板から金属端子を製造する際、金属板の単位面積当たりの金属端子の製造個数が少なくなるという問題点があった。
　本発明は、前述した点を鑑みてなされたものであり、本発明の目的は、複数の絶縁回路基板を有する構造であっても、絶縁回路基板間の電気的な接続を容易にし、絶縁回路基板の反り変形を抑制でき、半導体チップの発熱を良好に放熱することのできる半導体モジュールを提供することにある。
　前記課題を解消して、発明の目的を達成するために、本発明の半導体モジュールは、半導体チップを備えた複数の絶縁回路基板と、前記絶縁回路基板の外縁部のうち隣接する絶縁回路基板と対向する第１外縁部に当接する桟部、および前記絶縁回路基板の外縁部から前記第１外縁部を除いた第２外縁部に当接する枠部を持った樹脂枠体と、前記桟部を跨いで前記絶縁回路基板間を電気的に接続する導電部材と、前記樹脂枠体の上部の開口を覆う蓋部、および前記蓋部の前記回路基板と対向する面から突出し前記桟部の一部に当接する隔壁部を持った上蓋とを備えることを特徴とする。
　本発明の半導体モジュールによれば、隔壁部に邪魔されることなく、桟部を跨ぐ導電部材によって絶縁回路基板間を電気的に接続できる。また、上蓋の隔壁部が樹脂枠体の桟部を押圧し、さらに桟部が絶縁回路基板の第１外縁部を押圧するので、絶縁回路基板が反ることを抑制できる。
　本発明の半導体モジュールにおいて、前記上蓋が、前記蓋部の前記絶縁回路基板と対向する面から突出して絶縁回路基板に当接する柱状部を備えることが好ましい。
　この構成によれば、上蓋の柱状部が絶縁回路基板の中央部分を押圧するので、絶縁回路基板が反ることを抑制できる。なお、前記上蓋は、前記樹脂枠体に接着されていてもよい。この構成によれば、上蓋を樹脂枠体に取り付けることが容易になる。また、前記上蓋を前記樹脂枠体に固定させる係合部を備える構成でもよい。この構成によれば、上蓋を樹脂枠体に取り付けることがより容易になる。
　本発明の半導体モジュールにおいて、前記樹脂枠体は、該樹脂枠体の内壁に沿って配設された段差部を備え、軸部と、脚部と、前記軸部又は前記脚部よりも狭い幅で前記軸部と前記脚部を連結する屈曲されたヒンジ部とを持った金属端子を備え、前記脚部が前記段差部の上段面上に配置されていることが好ましい。
　この構成によれば、ヒンジ部の幅が、軸部の幅と脚部の幅の少なくとも一方もしくはその両方より狭くされて樹脂枠体に係合され、ヒンジ部から折り曲げられた脚部を段差部の上段面上に固定できるので、金属端子と樹脂枠体との位置ずれを抑制できる。また、金属端子の樹脂枠体と係合するヒンジ部分は、金属端子の全幅より狭くした形状であるために、プレス加工で製造する際には、狭ピッチでレイアウトして、端材の量を減らし、単位面積当たりの金属端子の製造個数を増加できる。
　本発明の半導体モジュールにおいて、前記金属端子が、前記軸部の一部と前記脚部の一部とを露出した状態で、前記樹脂枠体の枠部に埋設されていることが好ましい。
　この構成によれば、金属端子の軸部は樹脂枠体に埋設されており、ボンディングワイヤの接続点となる金属端子の脚部のみが露出しているので、ワイヤボンディング作業が容易になり、且つ高信頼性の接続とすることができる。
　本発明の半導体モジュールの製造方法は、半導体チップを備えた複数の絶縁回路基板と、前記絶縁回路基板の外縁部のうち隣接する絶縁回路基板と対向する第１外縁部に当接する桟部、および前記絶縁回路基板の外縁部から前記第１外縁部を除いた第２外縁部に当接する枠部を持った樹脂枠体と、前記桟部を跨いで前記絶縁回路基板間を電気的に接続する導電部材と、前記樹脂枠体の上部の開口を覆う蓋部、および前記蓋部の前記絶縁回路基板と対向する面から突出し前記桟部の一部に当接する隔壁部を持った上蓋とを備えた半導体モジュールの製造方法であって、前記桟部が前記第１外縁部に当接され、前記枠部が前記第２外縁部に当接されるように、前記絶縁回路基板と前記樹脂枠体とを配置する第１工程と、前記桟部を跨いで前記絶縁回路基板間を前記導電部材で電気的に接続する第２工程と、前記上蓋の前記蓋部が前記樹脂枠体上部の開口を覆い、前記上蓋の前記隔壁部が前記桟部の一部に当接するように、前記上蓋を前記樹脂枠体に固定する第３工程とを備える。
　本発明の半導体モジュールの製造方法によれば、隔壁部に妨げられることなく、桟部を跨ぐ導体によって絶縁回路基板間を容易に接続することができる。
　本発明によれば、複数の絶縁回路基板を有する構造であっても、絶縁回路基板間の電気的な接続を容易にし、絶縁回路基板の反り変形を抑制でき半導体チップの発熱を良好に放熱できる半導体モジュールを提供することができる。
本発明の一実施形態の半導体モジュールについて、組み立てる前の半導体モジュールの分解斜視図である。 図１（ｃ）の絶縁回路基板９上に、図１（ｂ）の樹脂枠体５を載せた状態の斜視図である。 半導体チップが搭載された絶縁回路基板に樹脂枠体５を図２のように載せ、ボンディングワイヤ（導電部材）７を接続した後の上面図である。 図３のＢ１－Ｂ２断面図に上蓋８の断面図を追加して示した概略断面図である。見易くするために、半導体チップおよびチップ周辺のボンディングワイヤ７ａ，７ｂ等を省略して記載している。 図４の上蓋８を適正な位置にセットした状態のＢ１－Ｂ２断面の概略断面図である。図４と同様に、半導体チップおよびチップ周辺のボンディングワイヤ７ａ，７ｂ等を省略して記載している。 従来の複数の絶縁回路基板を用いる半導体モジュールの概略構造を示す模式断面図である。
　以下、本発明の半導体モジュールにかかる実施形態について、図面を参照して詳細に説明する。なお、以下の実施形態の説明および添付図面において、同様の構成には同一の符号を付し、重複する説明を省略する。また、以下の説明に用いられる添付図面は、見易くまたは理解し易くするために正確なスケール、寸法比で描かれていない。また、本発明はその要旨を超えない限り、以下に説明する実施形態の記載に限定されるものではない。
　図１は、本発明の一実施形態にかかる半導体モジュールの一部について、組み立てる前の半導体モジュールの分解斜視図である。
　図１（ａ）は、上蓋８の斜視図である。上蓋８は、隔壁部８ｂと、柱状部８ａを備えている。隔壁部８ｂと柱状部８ａは、上蓋８の絶縁回路基板９に面する側に配置されている。隔壁部８ｂは、図１（ｂ）に示した樹脂枠体５の桟部５ａの一部を押圧する。柱状部８ａは、図１（ｃ）に示した各絶縁回路基板９の中央部分をそれぞれ押圧する。
　図１（ｂ）は、金属端子４ａ，４ｂを枠部５ｃにインサート成型した樹脂枠体５である。樹脂枠体５は、桟部５ａと枠部５ｃと段差部５ｅを備えている。開口部５ｂは、桟部５ａと枠部５ｃで囲まれた部分であり、貫通孔が開いている。段差部５ｅは、樹脂枠体５の内壁に沿って配設され、段差部５ｅの上段面は金属端子４ａ，４ｂを設置する面になっている。樹脂枠体５は、図示しないヒートシンクに半導体モジュールを固定するための貫通孔６を備えている。樹脂枠体５および上蓋８の材料としては、ポリフェニレンサルファイド樹脂（ＰＰＳ樹脂）、ポリアミド樹脂（ＰＡ樹脂）、アクリロニトリルブタジエンスチレン樹脂（ＡＢＳ樹脂）、ポリブチレンテレフタレート樹脂（ＰＢＴ樹脂）などから選ばれる樹脂が好ましい。
　図１（ｃ）は、半導体チップとボンディングワイヤ（導電部材）を省いて描いた絶縁回路基板９である。絶縁回路基板９としては、アルミナ、窒化アルミニウム、窒化珪素などの公知の絶縁性セラミックスが用いられる。各絶縁回路基板９のおもて面側には銅箔などからなる回路パターン９ａが接合され、各絶縁回路基板９の裏面側には周辺を残して全面に銅箔が接合されている。後述の図３に示すように、回路パターン９ａ上には、ＩＧＢＴ（Ｉｎｓｕｌａｔｅｄ　Ｇａｔｅ　Ｂｉｐｏｌａｒ　Ｔｒａｎｓｉｓｔｏｒ）やＦＷＤ（Ｆｒｅｅ　Ｗｈｅｅｌｉｎｇ　Ｄｉｏｄｅ）などの半導体チップ２ａ、２ｂがはんだ接合により搭載される。
　図２は、図１（ｃ）の絶縁回路基板９上に、図１（ｂ）の樹脂枠体５を載せた状態の斜視図である。金属端子４ａ，４ｂは、樹脂枠体５に埋め込まれている。金属端子の脚部４ｃは、樹脂枠体５から延出されて、段差部５ｅの上段面に配置されている。段差部５ｅの上段面は平坦でもよいが、図示されるように金属端子４ａ，４ｂの脚部と嵌合する凹部を備えてもよい。このようにすると、金属端子４ａ，４ｂが安定し、位置ずれを防ぐことができる。樹脂枠体５の中央に設けられる開口部５ｂは絶縁回路基板の大きさより少し小さくされているので、樹脂枠体５は絶縁回路基板９の周辺を均等に押圧し接着することができる。樹脂枠体５の桟部５ａは隣接する絶縁回路基板９の外縁近傍を押圧し接着する。
　図３は、半導体チップが搭載された絶縁回路基板に樹脂枠体５を図２のように載せ、ボンディングワイヤ（導電部材）７を接続した後の上面図である。ＩＧＢＴやＦＷＤのような半導体チップ２ａ，２ｂは、ハンダを介して回路パターン９ａに接続される。次いで、所要のインバータ回路などを構成するためのワイヤボンディング配線７ａ，７ｂが、半導体チップ２ａ、２ｂ間、絶縁回路基板間および金属端子の脚部４ｃとの間などに施される。さらに、ボンディングワイヤ７が、樹脂枠体５の桟部５ａの上を跨いで隣接する絶縁回路基板９の回路パターン９ａ面間に施され、電気的に接続している。なお、導電部材は、上記ボンディングワイヤに限定されず、扁平な板材であってもよい。
　図４は、図３のＢ１－Ｂ２断面図に上蓋８の断面図を追加して示した概略断面図である。見易くするために、半導体チップおよびチップ周辺のボンディングワイヤ７ａ，７ｂ等を省略して記載している。金属端子４ａ，４ｂは、軸部４ｄと、脚部４ｃと、前記軸部４ｄと前記脚部４ｃを連結して屈曲されたヒンジ部４ｅと備えている。ヒンジ部４ｅは、前記軸部４ｄまたは前記脚部４ｃより幅が狭くされて樹脂枠体に係合され、ヒンジ部４ｅから折り曲げられた脚部４ｃは段差部５ｅに固定されるので、金属端子４ａ，４ｂと樹脂枠体５との位置ずれを抑制できる。
　なお、本発明の金属端子４ａ，４ｂは、樹脂枠体５と係合するヒンジ部分４ｅを軸部４ｄまたは脚部４ｃよりも幅を狭くした形状であるために、プレス加工で製造する際には、狭ピッチでレイアウトして、端材の量を減らし、単位面積当たりの金属端子の製造個数を増加できる。
　図４の断面図に示した半導体モジュールは、金属端子４ａ，４ｂの脚部４ｃの一部を樹脂枠体５の内側の段差部５ｅの平坦な上段面上に露出させ、軸部４ｄの一部を外部に導出させた状態で、金属端子４ａ，４ｂを一体モールド成型により保持している。ただし、金属端子４ａ，４ｂは、樹脂枠体５に必ずしも一体モールド成型しなくともよい。モールド成型した樹脂枠体に金属端子を嵌め込みにより一体化してもよい。このように金属端子４ａ，４ｂをワイヤボンディング配線領域外の樹脂枠体５に集め、ヒンジ部でＬ字状に折り曲げられた脚部４ｃのみを樹脂枠体５の内側の段差部５ｅ上に露出させることにより、金属端子の軸部４ｄは樹脂枠体５に埋設されており、ボンディングワイヤの接続点となる金属端子の脚部のみが露出しているので、ワイヤボンディング作業が容易になり、且つ高信頼性の接続とすることができる。
　図５は、図４の上蓋８を適正な位置にセットした状態のＢ１－Ｂ２断面の概略断面図である。図４と同様に、半導体チップおよびチップ周辺のボンディングワイヤ７ａ，７ｂ等を省略して記載している。図１（ａ）に破線で示したように、上蓋８は、下側に隔壁部８ｂと柱状部８ａを備えている。図４、図５に示すように、隔壁部８ｂは、上蓋８を樹脂枠体５の上部の開口に被せたときに、樹脂枠体５の桟部５ａの上面を押圧するように配置されている。柱状部８ａは、絶縁回路基板９の中央近辺を押圧するように配置されている。
　しかし、前述したように、ボンディングワイヤ７が樹脂枠体５の桟部５ａを跨いで接続されている箇所が存在するので、隔壁部８ｂの下端面を桟部５ａの上面と同寸法にすると、隔壁部８ｂがボンディングワイヤ７と干渉することになる。そこで本発明では、上蓋８に設けられている隔壁部８ｂがボンディングワイヤ７と干渉しない形状にされていることを特徴とする。例えば、図３に示したボンディングワイヤ７のように、ボンディングワイヤ７が絶縁回路基板９の両端近辺の位置に設けられている場合には、隔壁部８ｂがボンディングワイヤ７に接触しないように、隔壁部８ｂは、ボンディングワイヤ７の間の桟部５ａの上面のみに接触する形状にされている。このように隔壁部８ｂの寸法をボンディングワイヤ７に接触しないように下側の桟部５ａより短い形状にしても、隔壁部８ｂが桟部５ａを介して絶縁回路基板９を押圧する。そのため、複数の絶縁回路基板９は、樹脂枠体５の外周である枠部５ｃおよび桟部５ａによって、各絶縁回路基板９の周縁を均等に接触されるので、絶縁回路基板９に対してほぼ均等な押圧力を与えることができる。複数の絶縁回路基板９は、樹脂枠体５の枠部５ｃの下面や桟部５ａの下面と接着剤で接着されている。その結果、半導体モジュール１は、絶縁回路基板９の反り変形を抑制することができる。ヒートシンクは、絶縁回路基板９の裏面と対向する面が平坦面に成形されており、複数の絶縁回路基板９の裏面の銅箔に接触されている。前記平坦面には、ネジ溝が形成されており、樹脂枠体５は、貫通孔６を通したネジでヒートシンクに固定される。従って、半導体チップ２ａ，２ｂの発熱を、図示しないヒートシンクに放熱することができる。また、上蓋８に関して、隔壁部８ｂは桟部５ａを介して絶縁回路基板９を押圧するので、隔壁部８ｂの上蓋８からの長さは、柱状部８ａの上蓋８からの長さよりも、短くなる。このことも上記実施の形態の一例の構造的な特徴である。
　本発明にかかる半導体モジュール１は、図１、図２の斜視図、図３の上面図に示すように、相互に近接して併置された複数の絶縁回路基板９と、この絶縁回路基板９の周辺上に接着させる樹脂枠体５と、この樹脂枠体５の上側の開口を閉じる上蓋８を備える。この上蓋８を樹脂枠体５の上側の開口に被せる方法は、樹脂枠体５へ接着剤で接着させる方法でもよい。また、上蓋８を樹脂枠体５に固定させる係合部を備えてもよい。係合部は、例えば、嵌合、ネジ止め、かみ合わせなどの構造にする。上蓋８の柱状部８ａ、隔壁部８ｂによる絶縁回路基板９に対する押圧力を確実にすることができる。
　本発明の半導体モジュール１の製造方法は、桟部５ａが絶縁回路基板９間の対向する第１外縁部上に配置され、樹脂枠体５の枠部５ｃが複数の絶縁回路基板９の第２外縁部上に配置されるように絶縁回路基板９と樹脂枠体５とを配置する第１工程と、桟部５ａを跨いで絶縁回路基板９間を導電部材７で電気的に接続する第２工程と、上蓋８の蓋部８ｃが樹脂枠体上部の開口を覆い、上蓋８の隔壁部８ｂが桟部５ａの一部に突き合わせた状態になるように上蓋８が樹脂枠体５に固定される第３工程とを備える。第３工程で樹脂枠体５に上蓋８を被せる前に、樹脂枠体５と絶縁回路基板９とで囲まれる空間内部にシリコーンゲルなどを注入し封止する第４工程が含まれることがより好ましい。
　以上、説明した実施の形態にかかる半導体モジュールによれば、複数の絶縁回路基板を有する構造であっても、絶縁回路基板間の電気的な接続を容易にし、絶縁回路基板の反り変形を抑制でき半導体チップの発熱を良好に放熱できる半導体モジュールを提供できる。
１　半導体モジュール
２ａ、２ｂ　半導体チップ
４ａ、４ｂ　金属端子
４ｃ　金属端子の脚部
４ｄ　金属端子の軸部
４ｅ　金属端子のヒンジ部
５　樹脂枠体
５ａ　桟部
５ｂ　開口部
５ｃ　枠部
５ｄ　樹脂枠体側の係合部
５ｅ　段差部
６　貫通孔
７、７ａ　ボンディングワイヤ（導電部材）
８　上蓋
８ａ　柱状部
８ｂ　隔壁部
８ｃ　蓋部
８ｄ　上蓋側の係合部
９　絶縁回路基板
９ａ　回路パターン
２００　半導体モジュール
２０１　絶縁回路基板
２０３　半導体チップ
２０４　外部導出金属端子
２０５ａ　樹脂ケース
２０５ｂ　上蓋
２０５ｃ　壁

Claims (5)

  1. 　半導体チップを備えた複数の絶縁回路基板と、
    　前記絶縁回路基板の外縁部のうち隣接する絶縁回路基板と対向する第１外縁部に当接する桟部、および前記絶縁回路基板の外縁部から前記第１外縁部を除いた第２外縁部に当接する枠部を持った樹脂枠体と、
    　前記桟部を跨いで前記絶縁回路基板間を電気的に接続する導電部材と、
    　前記樹脂枠体の上部の開口を覆う蓋部、および前記蓋部の前記回路基板と対向する面から突出し前記桟部の一部に当接する隔壁部を持った上蓋と、
    　を備えることを特徴とする半導体モジュール。
  2. 　前記上蓋が、前記蓋部の前記絶縁回路基板と対向する面から突出して絶縁回路基板に当接する柱状部を備えることを特徴とする請求項１に記載の半導体モジュール。
  3. 　前記樹脂枠体は、
    　該樹脂枠体の内壁に沿って配設された段差部を備え、
    　軸部と、脚部と、前記軸部又は前記脚部よりも狭い幅で前記軸部と前記脚部を連結する屈曲されたヒンジ部とを持った金属端子を備え、
    　前記脚部が前記段差部の上段面上に配置されていることを特徴とする請求項１または２に記載の半導体モジュール。
  4. 　前記金属端子が、前記軸部の一部と前記脚部の一部とを露出した状態で、前記樹脂枠体の枠部に埋設されていることを特徴とする請求項１から３のいずれか一項に記載の半導体モジュール。
  5. 　半導体チップを備えた複数の絶縁回路基板と、前記絶縁回路基板の外縁部のうち隣接する絶縁回路基板と対向する第１外縁部に当接する桟部、および前記絶縁回路基板の外縁部から前記第１外縁部を除いた第２外縁部に当接する枠部を持った樹脂枠体と、前記桟部を跨いで前記絶縁回路基板間を電気的に接続する導電部材と、前記樹脂枠体の上部の開口を覆う蓋部、および前記蓋部の前記絶縁回路基板と対向する面から突出し前記桟部の一部に当接する隔壁部を持った上蓋とを備えた半導体モジュールの製造方法であって、
    　前記桟部が前記第１外縁部に当接され、前記枠部が前記第２外縁部に当接されるように、前記絶縁回路基板と前記樹脂枠体とを配置する第１工程と、
    　前記桟部を跨いで前記絶縁回路基板間を前記導電部材で電気的に接続する第２工程と、
    　前記上蓋の前記蓋部が前記樹脂枠体上部の開口を覆い、前記上蓋の前記隔壁部が前記桟部の一部に当接するように、前記上蓋を前記樹脂枠体に固定する第３工程と、
    を備えることを特徴とする半導体モジュールの製造方法。
PCT/JP2014/082632 2014-01-17 2014-12-10 半導体モジュール WO2015107804A1 (ja)

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JP2017126682A (ja) * 2016-01-15 2017-07-20 京セラ株式会社 半導体装置
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CN105940489A (zh) 2016-09-14
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US20160118310A1 (en) 2016-04-28
US9673117B2 (en) 2017-06-06

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