WO2017157486A1 - Semiconductor device - Google Patents

Semiconductor device Download PDF

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Publication number
WO2017157486A1
WO2017157486A1 PCT/EP2016/075970 EP2016075970W WO2017157486A1 WO 2017157486 A1 WO2017157486 A1 WO 2017157486A1 EP 2016075970 W EP2016075970 W EP 2016075970W WO 2017157486 A1 WO2017157486 A1 WO 2017157486A1
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WO
WIPO (PCT)
Prior art keywords
control electrode
electrode area
grooved
area
grooved plate
Prior art date
Application number
PCT/EP2016/075970
Other languages
French (fr)
Inventor
Chunlei Liu
Fabian MOHN
Franziska Brem
Original Assignee
Abb Schweiz Ag
Audi Ag
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 Abb Schweiz Ag, Audi Ag filed Critical Abb Schweiz Ag
Publication of WO2017157486A1 publication Critical patent/WO2017157486A1/en

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    • H—ELECTRICITY
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    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/48—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
    • H01L23/488—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of soldered or bonded constructions
    • H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
    • H01L23/49811—Additional leads joined to the metallisation on the insulating substrate, e.g. pins, bumps, wires, flat leads
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Definitions

  • the invention relates to the field of power semiconductors.
  • the invention relates to a semiconductor device, a semiconductor module and a method for manufacturing the semiconductor device and/or module.
  • a typical emitter contact area (for a bipolar transistor) or source contact area (for a field- effect transistor) of a power semiconductor device usually comprises a topside metallization onto which Al wire bonds are bonded.
  • a topside metallization onto which Al wire bonds are bonded.
  • the topside emitter/source contact area of fast IGBTs and wide bandgap semiconductor devices is usually split into multiple contact areas.
  • the gate/base structures between the different contact areas enable a fast and balanced gate signal to all contact areas.
  • This gate/base structure may be higher than the contact areas, since additional passivation material (such as polyimide) may cover the conducting parts of the gate/base structure between the contact areas and thus may provide a specific topology to active areas below the contact areas and the gate/base structure.
  • the separate contact areas may be very small and it may be very challenging and complicated to process such small top plates for each contact area. Also, costs may increase due to the higher part count and pick and place operations.
  • DE 10 2007 036 841 A1 shows a semiconductor component with a semiconductor chip, onto which a connection element with conducting layers is attached.
  • US 2009/0079006 A1 relates to a semiconductor apparatus with a conductive member having a recess on its lower surface above a metal gate interconnect. DESCRIPTION OF THE INVENTION
  • t e invention provides a cheap and easy to manufacture semiconductor device with high reliability and high current density. It is a further objective to enable a reliable top plate sintering process for a semiconductor device with split emitter/source contact areas, which does not cause damage to the gate/base structures on the chip topside.
  • a first aspect of the invention relates to a semiconductor device.
  • a semiconductor device may comprise one or more semiconductor chips and electrical connection elements such as an electrically conducting top plate. It has to be noted that the semiconductor device may be a power semiconductor device, i.e. adapted for processing currents of more than 10 A and/or voltages of more than 300 V.
  • the semiconductor device comprises: a semiconductor element with one or more power electrode areas, a control electrode area and an elevated control electrode structure on one side, wherein the elevated control electrode structure is interconnected with the control electrode area and protrudes the one or more power electrode areas; and a grooved plate, which is bonded with a grooved side to the power electrode area, wherein the grooved plate has at least one groove in the grooved side, in which at least a part of the control electrode structure is accommodated.
  • the semiconductor element may be or may comprise a semiconductor chip (for example based on Si or SiC), which provides several contact areas onto which a structured metallization layer is attached.
  • the structured metallization layer may be divided into several parts providing electrode areas.
  • the semiconductor element may be a semiconductor switch having two power electrodes (for example on opposite sides), through which the current to be switched flows, and a control electrode on one side, which may be supplied with a signal for switching the semiconductor switch.
  • the side of the semiconductor element with the power electrode area and the control electrode area may be seen as a top side and the opposite side may be seen as a bottom side of the semiconductor element. It has to be noted that the terms “top” and “bottom” only refers to opposite sides of a member but not with respect to a vertical orientation of the member.
  • the control electrode structure may be used for distributing a control signal uniformly via the top side of the semiconductor element.
  • the electrical conducting parts of the control electrode structure, which are connected with the control contact area, may be aligned besides and/or between the one or more power electrode areas on the top side. Electrical isolating parts of the control electrode structure, which cover the electrically conducting parts, may protrude the one or more power electrode areas.
  • the electrical isolating parts may be made from plastics, such as polyimide.
  • the one or more power electrode areas and the control electrode area may all have a surface on the same level, i.e. may define a common surface plane.
  • the control electrode structure may be higher than this level and/or surface plane.
  • the grooved plate which may be a one-piece metal plate, may be bonded (such as soldered or sintered) with its grooved bottom side to the one or more power electrode areas on the top side of the semiconductor element.
  • the bottom side of the grooved plate may have flat surfaces between the one or more grooves corresponding to the one or more contact areas.
  • the top side of the grooved plate may be flat, i.e. may have no grooves.
  • the top side may be adapted for bonding wire bonds to the top plate.
  • the one or more grooves of the grooved plate may be adapted for accommodating at least a part of the control electrode structure and/or may be aligned with at least a part of the control electrode structure.
  • the grooves may be deeper than an elevation level of the control electrode structure.
  • a grooved (i.e. structured) metal plate may help to release an interface residual stress after its bonding to the semiconductor element, especially, when the grooved plate is made of a metal with high CTE (coefficient of thermal expansion), such as Cu or Al. This may increase the reliability of the interconnection between the grooved plate and the semiconductor element. Furthermore, the thickness of the grooved plate may be increased. A thick grooved plate also may be used as a spacer/post for implementing double side module packaging.
  • the semiconductor device facilitates the packaging and electrically contacting of wide bandgap semiconductor devices.
  • the elevated control electrode structure has one or more arms, each arm starting at the control electrode area and running besides parts of the power electrode area.
  • the control electrode area may be arranged between or besides two power electrode areas and the arms may extend between the two power electrode areas.
  • the arms may comprise an electrically conducting part/layer electrically connected with the control electrode area and an electrically isolating part covering the electrically conducting part.
  • the elevated control electrode structure comprises isolation material above an electrical conducting layer.
  • the isolating material may be made of plastics, such as polyimide.
  • the one or more power electrode areas and the control electrode area are provided by one or more metallization layers on a semiconductor substrate of the semiconductor element.
  • the one or more power electrode areas and the control electrode area may be provided by a structured metallization layer.
  • the electrically conducting parts of the control electrode structure may be made from this metallization layer.
  • the grooved plate is sintered with the grooved side to the power electrode area.
  • sintering material may be applied to the bottom side of the grooved plate and/or the power electrode areas and after that the grooved plate may be pressed against the semiconductor element, such that it is bonded with the power contact areas.
  • the grooved plate is sintered via a sintering preform interpositioned between the grooved plate and the semiconductor element with the power electrode area, such that the sintering preform covers the elevated control electrode structure.
  • a sintering preform may be a substrate into which sintering particles are included. After sintering, parts of the preform, which will extend before the sintering also over the control electrode structure, may remain between the control electrode structure and the grooved plate in the groove.
  • the grooved plate is a one piece metal plate.
  • a metal plate may be provided with one or more grooves corresponding to arms of the control electrode structure for manufacturing the grooved plate.
  • the grooved plate may be made from copper, aluminium, silver and/or molybdenum.
  • the semiconductor element comprises a bipolar transistor (such as an IGBT) with an emitter, collector and base, the power electrode area being an emitter area and the control electrode area being a base area.
  • the opposite side of the semiconductor element may provide a collector area.
  • the semiconductor element comprises a field effect transistor (such as a MOSFET) with a source, drain and gate, the power electrode area being a source area and the control electrode area being a gate area.
  • the opposite side of the semiconductor element may provide a drain area.
  • the MOSFET may be a wide bandgap device and/or based on SiC.
  • a further power electrode area is provided on an opposite side of the semiconductor element.
  • this power electrode area which may be a source area or drain area, may be provided by a metallization layer on the semiconductor element.
  • a further aspect of the invention relates to a semiconductor module with a semiconductor device as described in the above and in the following.
  • a semiconductor module may further comprise further electrical connection elements and mechanical supporting parts for the semiconductor device.
  • the semiconductor module further comprises: a substrate onto which the semiconductor device is attached (for example bonded or soldered) and at least one metal conductor interconnecting the grooved plate with the substrate.
  • the metal conductor may comprise at least one wire bond, ribbon bond and/or lead frame interconnecting the grooved plate with the substrate.
  • a wire bond may be a conductor with substantially round cross-section.
  • a ribbon bond may be a conductor with substantially longitudinal cross-section. Both a wire bond and a ribbon bond may comprise flexible parts that are deformed during attachment of the wire /ribbon bond with its ends to the semiconductor module.
  • a lead frame may be a stamped or etched part of a metal plate, which may have its final shape before bonding.
  • the grooved plate is integrated into the ribbon bond or the lead frame. It may be possible that the grooved plate is provided in one piece with the lead frame or the ribbon bond and/or that the grooved plate is made of the material of the ribbon bond or the lead frame. For example, an end of the ribbon bond or the lead frame (that may be thicker than a further part of the ribbon band or the lead frame) may be provided with a groove (for example by etching) and/or may be formed into the grooved plate (for example by stamping).
  • the ribbon bond with the integrated grooved plate may be directly bonded (soldered or sintered) to the power electrode area, for example with ultrasonic (ribbon) bonding.
  • the lead frame may be sintered or soldered to the power electrode area, for example with an additional bond layer.
  • the wire bond, the ribbon bond or lead frame are bonded to the grooved plate. It also may be possible that the grooved plate is provided as separate part and that the wire bond, the ribbon bond or lead frame are bonded to a top side of the grooved plate.
  • a wire bond and/or a ribbon bond may be bonded with ultrasonic wire/ribbon bonding.
  • the wire bond, the ribbon bond and/or the lead frame are made from copper and/or aluminium. It may be possible that the wire bond, the ribbon bond and/or the lead frame have Cu core surrounded by Al.
  • the one or more wire bond may have a diameter between 200 Mm and 400 Mm, for example about 300 Mm.
  • a semiconductor module with a sintered grooved plate and rather thick Cu wire bonds, a ribbon bond or a lead frame may be adapted for operating under high temperature, may have a high reliability, a high current density and/or a high overload capability.
  • a further aspect of the invention relates to a method of manufacturing a semiconductor device and/or a semiconductor module, for example as described in the above and in the following. It has to be understood that features of the method as described in the above and in the following may be features of the semiconductor device and/or module as described in the above and in the following, and vice versa.
  • the method comprises: providing a semiconductor element with a power electrode area, a control electrode area and an elevated control electrode structure interconnected with the control electrode area and protruding the power electrode area; providing a grooved plate, which has at least one groove in a grooved side; and bonding the grooved plate with the grooved side to the power electrode area, such that at least a part of the control electrode structure is accommodated in the groove. It has to be noted that, when only one grooved plate is bonded to the semiconductor element, only one pick and place process and only one bonding process has to be performed.
  • the method further comprises: etching the at least one groove into the grooved plate.
  • the one or more grooves may be manufactured with a photochemical etching process, which also may be used to manufacture the grooved plate from a metal sheet (for example made form Cu, Al, Mo). An accuracy required for the groove structure may be easily achieved by the photochemical etching process.
  • a plurality of grooved plates may be produced in a large batch quantity from a large sheet.
  • the method further comprises: sintering the grooved plate to the power electrode area.
  • the sintering may be performed based on Ag particles. All other processes of bonding the grooved plate to the semiconductor element may be used, too. In these processes, solder or transient liquid phase preforms may be used, though the process pressure is not that high for those processes and less critical than for a sintering process.
  • the method further comprises: applying a sintering material on the grooved side of the grooved plate.
  • a sintering material on the grooved side of the grooved plate.
  • One method of topside emitter/source sintering may be applying Ag paste on the bottom side of the grooved plate or the transferring of an Ag sintering foil to the bottom side of the grooved plate.
  • the method further comprises: providing a sintering preform between the grooved plate and the semiconductor element.
  • the sintering preform may be plastics material tailored to cover all power electrode areas on the top side in which plastics material sintering particles are accommodated.
  • a sintering preform made from a dense Ag foil with pre-applied Ag nanoparticles on both sides may be used.
  • a dense sintering preform may have a less risk of sintering particle contamination.
  • FIG. 1 schematically shows a top view of a semiconductor element for a semiconductor device according to an embodiment of the invention.
  • Fig. 2 schematically shows a top view of a further semiconductor element for a semiconductor device according to an embodiment of the invention.
  • Fig. 3 schematically shows a cross-sectional view of a semiconductor device according to an embodiment of the invention during manufacturing.
  • Fig. 4 schematically shows a cross-sectional view of a semiconductor device according to a further embodiment of the invention during manufacturing.
  • Fig. 5 schematically shows a cross-sectional view of a semiconductor module according to an embodiment of the invention.
  • Fig. 6 schematically shows a cross-sectional view of a semiconductor module according to a further embodiment of the invention.
  • Fig. 7 schematically shows a cross-sectional view of a semiconductor module according to a further embodiment of the invention.
  • Fig. 8 schematically shows a cross-sectional view of a semiconductor module according to a further embodiment of the invention.
  • Fig. 1 and 2 show a semiconductor element 10 from above, whereas Fig. 3 shows a semiconductor element 10 in a cross-sectional view.
  • the semiconductor element 10 comprises a substrate or chip 12, in which a semiconductor switch is provided. On a top side, the semiconductor element 10 has a structured metallization layer 14, which provides several power electrode areas 16 and a control electrode area 18.
  • the control electrode area 18 is part of a control electrode structure 20 that has several arms 22 extending from the control electrode area 18.
  • the arms 22 are running between the power electrode areas 16 and/or besides of them.
  • the arms 22 comprise an electrically conducting part 24 (provided by the structured metallization layer 14) and an electrically isolating part 26, which covers the electrically conducting part 24.
  • the electrode areas 16, 18 all may provide surfaces on the same level, while the control electrode structure 20 may be elevated from these surfaces.
  • the semiconductor element 10 may comprise a further power contact area 17.
  • the semiconductor element 10 may be an IGBT and the power electrode areas 16 may be emitter areas, the power electrode area 17 may be a collector area, while the control electrode area 18 may be a base area.
  • the semiconductor element 10 may be a MOSFET based on SiC and the power electrode areas 16 may be source areas, the power electrode area 17 may be a drain area, while the control electrode area may be a gate area.
  • Fig. 3 and 4 show a semiconductor device 28 during manufacturing, which also comprises a grooved top plate 30.
  • the grooved top plate 30 comprises a substantially flat top side 32 and a grooved bottom side 34, with at least one groove 36 corresponding to the elevated parts 26 of the control electrode structure 20.
  • the groove 36 and/or the top plate 30 may be etched from a sheet of metal, such as Cu, Al, Mo.
  • the grooved top plate 30 may be one-piece and may be a metal plate.
  • a sintering material 38 such as sintering paste or a sintering foil, may be applied to the bottom side 34.
  • a sintering preform 40 which comprises sintering particles accommodated in a dense substrate material, which hinders the sintering particles from leaving the sintering preform, may be positioned between the grooved top plate 30 and the semiconductor element 10.
  • the grooved top plate 30 then may be pressed with its bottom side 34 onto the power electrode areas 16 and sintered to them. Due to the groove 36, the control electrode structure 20 is not damaged, when the grooved top plate 30 is pressed onto the semiconductor element 10. In the case of Fig 4, a part 42 of the sintering preform 40 may stay inside the groove 36.
  • Fig. 5 shows a semiconductor module 43, which comprises a semiconductor device 28.
  • the semiconductor device 28 may be bonded with its bottom side to a substrate 44 (such as a metalized ceramics or plastics substrate).
  • the top side 32 of the grooved top plate 30 may be electrically interconnected with wire bonds 46 with other parts of the semiconductor module 43. Due to the mechanical properties of the grooved top plate 32 and its material, thick wire bonds 46 (about 300 Mm diameter) may be used.
  • Fig. 6 shows a semiconductor module 43, in which the grooved top plate 30 is integrated into a metal ribbon bond 48.
  • a metal ribbon bond 48 for example, an end of the ribbon bond 48, which may be thicker than the remaining part may be provided with a groove 36.
  • the grooved top plate integrated into the ribbon bond 48 may be directly bonded by ultrasonic ribbon bonding to the power electrode areas 16.
  • Fig. 7 shows a semiconductor module 43, in which a separate metal ribbon bond 48 is bonded to the grooved top plate 30.
  • the grooved top plate 30 may be bonded to the power electrode areas 16 as describe with respect to Fig. 3 and 4. After that or before, the ribbon bond 48 may be soldered or sintered to the top side 32 of the grooved top plate 30.
  • Fig. 8 shows a semiconductor module 43, in which the grooved top plate 30 is integrated into a pre-shaped lead frame 50.
  • the lead frame 50 may be etched and/or stamped from a metal plate, for example made of Ag, Cu, Al. During the etching, the groove 36 may be etched into an end of the lead frame 50 for producing the grooved plate 30.
  • the grooved lead frame 50 may be bonded by sintering or soldering to the power electrode areas 16.
  • the lead frame 50 may be provided with an additional bond layer 52 (of different material) on the grooved bottom side 34 and/or on the end to be bonded to the substrate 44.
  • the grooved top plate 30 in Fig. 6, 7 and 8 also may be sintered to the power electrode areas 16 as described with respect to Fig. 3 and 4 with sintering material 38 or a sintering preform 40. Furthermore, it may be possible that the grooved plates of Fig. 3 to 7 are provided with an additional bond layer 52.

Abstract

A semiconductor device (28) comprises a semiconductor element (10) with a power electrode area (16), a control electrode area (18) and an elevated control electrode structure (20) on one side, wherein the elevated control electrode structure (20) is interconnected with the control electrode area (18) and protrudes the power electrode area (16); and a grooved plate (30), which is bonded with a grooved side (34) to the power electrode area (16); wherein the grooved plate (30) has at least one groove (36) in the grooved side (34), in which at least a part of the control electrode structure (20) is accommodated, whereby the grooved plate (30) is sintered via a sintering preform (40) interpositioned between the grooved plate (30) and the semiconductor element (10) to the power electrode area (16), such that the sintering preform (40) covers the elevated control electrode structure (20).

Description

Semiconductor device
FIELD OF THE INVENTION
The invention relates to the field of power semiconductors. In particular, the invention relates to a semiconductor device, a semiconductor module and a method for manufacturing the semiconductor device and/or module. BACKGROUND OF THE INVENTION
A typical emitter contact area (for a bipolar transistor) or source contact area (for a field- effect transistor) of a power semiconductor device (such as an IGBT or MOSFET) usually comprises a topside metallization onto which Al wire bonds are bonded. In order to improve the reliability and to increase current density, it is possible to sinter an additional metal top plate onto the emitter/source contact metallization layer.
However, the topside emitter/source contact area of fast IGBTs and wide bandgap semiconductor devices (for example based on SiC) is usually split into multiple contact areas. The gate/base structures between the different contact areas enable a fast and balanced gate signal to all contact areas. This gate/base structure may be higher than the contact areas, since additional passivation material (such as polyimide) may cover the conducting parts of the gate/base structure between the contact areas and thus may provide a specific topology to active areas below the contact areas and the gate/base structure.
In such a case, it may be possible to use multiple top plates for each of the separate contact areas. However, the separate contact areas may be very small and it may be very challenging and complicated to process such small top plates for each contact area. Also, costs may increase due to the higher part count and pick and place operations.
DE 10 2007 036 841 A1 shows a semiconductor component with a semiconductor chip, onto which a connection element with conducting layers is attached.
US 2009/0079006 A1 relates to a semiconductor apparatus with a conductive member having a recess on its lower surface above a metal gate interconnect. DESCRIPTION OF THE INVENTION
It is an objective of t e invention to provide a cheap and easy to manufacture semiconductor device with high reliability and high current density. It is a further objective to enable a reliable top plate sintering process for a semiconductor device with split emitter/source contact areas, which does not cause damage to the gate/base structures on the chip topside.
These objectives are achieved by the subject-matter of the independent claims. Further exemplary embodiments are evident from the dependent claims and the following description.
A first aspect of the invention relates to a semiconductor device. A semiconductor device may comprise one or more semiconductor chips and electrical connection elements such as an electrically conducting top plate. It has to be noted that the semiconductor device may be a power semiconductor device, i.e. adapted for processing currents of more than 10 A and/or voltages of more than 300 V.
According to an embodiment of the invention, the semiconductor device comprises: a semiconductor element with one or more power electrode areas, a control electrode area and an elevated control electrode structure on one side, wherein the elevated control electrode structure is interconnected with the control electrode area and protrudes the one or more power electrode areas; and a grooved plate, which is bonded with a grooved side to the power electrode area, wherein the grooved plate has at least one groove in the grooved side, in which at least a part of the control electrode structure is accommodated.
The semiconductor element may be or may comprise a semiconductor chip (for example based on Si or SiC), which provides several contact areas onto which a structured metallization layer is attached. The structured metallization layer may be divided into several parts providing electrode areas.
For example, the semiconductor element may be a semiconductor switch having two power electrodes (for example on opposite sides), through which the current to be switched flows, and a control electrode on one side, which may be supplied with a signal for switching the semiconductor switch.
The side of the semiconductor element with the power electrode area and the control electrode area may be seen as a top side and the opposite side may be seen as a bottom side of the semiconductor element. It has to be noted that the terms "top" and "bottom" only refers to opposite sides of a member but not with respect to a vertical orientation of the member. The control electrode structure may be used for distributing a control signal uniformly via the top side of the semiconductor element. The electrical conducting parts of the control electrode structure, which are connected with the control contact area, may be aligned besides and/or between the one or more power electrode areas on the top side. Electrical isolating parts of the control electrode structure, which cover the electrically conducting parts, may protrude the one or more power electrode areas. The electrical isolating parts may be made from plastics, such as polyimide.
The one or more power electrode areas and the control electrode area may all have a surface on the same level, i.e. may define a common surface plane. The control electrode structure may be higher than this level and/or surface plane.
The grooved plate, which may be a one-piece metal plate, may be bonded (such as soldered or sintered) with its grooved bottom side to the one or more power electrode areas on the top side of the semiconductor element. The bottom side of the grooved plate may have flat surfaces between the one or more grooves corresponding to the one or more contact areas. The top side of the grooved plate may be flat, i.e. may have no grooves. The top side may be adapted for bonding wire bonds to the top plate.
The one or more grooves of the grooved plate may be adapted for accommodating at least a part of the control electrode structure and/or may be aligned with at least a part of the control electrode structure. Thus, the grooves may be deeper than an elevation level of the control electrode structure.
With the grooved top plate, excessive pressure on the control electrode structure between split power electrode areas may be avoided. In particular, a sintering process of the grooved plate onto the semiconductor element (in which high pressure may be exerted on the semiconductor element) may be simplified.
Furthermore, a grooved (i.e. structured) metal plate may help to release an interface residual stress after its bonding to the semiconductor element, especially, when the grooved plate is made of a metal with high CTE (coefficient of thermal expansion), such as Cu or Al. This may increase the reliability of the interconnection between the grooved plate and the semiconductor element. Furthermore, the thickness of the grooved plate may be increased. A thick grooved plate also may be used as a spacer/post for implementing double side module packaging.
Since in particular wide bandgap semiconductor elements, which have comparable small power electrodes, may be provided with a single top plate, the semiconductor device facilitates the packaging and electrically contacting of wide bandgap semiconductor devices. According to an embodiment of the invention, the elevated control electrode structure has one or more arms, each arm starting at the control electrode area and running besides parts of the power electrode area. For example, the control electrode area may be arranged between or besides two power electrode areas and the arms may extend between the two power electrode areas. The arms may comprise an electrically conducting part/layer electrically connected with the control electrode area and an electrically isolating part covering the electrically conducting part.
According to an embodiment of the invention, the elevated control electrode structure comprises isolation material above an electrical conducting layer. The isolating material may be made of plastics, such as polyimide.
According to an embodiment of the invention, the one or more power electrode areas and the control electrode area are provided by one or more metallization layers on a semiconductor substrate of the semiconductor element. For example, the one or more power electrode areas and the control electrode area may be provided by a structured metallization layer. Also the electrically conducting parts of the control electrode structure may be made from this metallization layer.
According to the invention, the grooved plate is sintered with the grooved side to the power electrode area. For example, sintering material may be applied to the bottom side of the grooved plate and/or the power electrode areas and after that the grooved plate may be pressed against the semiconductor element, such that it is bonded with the power contact areas. The grooved plate is sintered via a sintering preform interpositioned between the grooved plate and the semiconductor element with the power electrode area, such that the sintering preform covers the elevated control electrode structure. Another possibility is to use a sintering preform for the sintering process. A sintering preform may be a substrate into which sintering particles are included. After sintering, parts of the preform, which will extend before the sintering also over the control electrode structure, may remain between the control electrode structure and the grooved plate in the groove.
According to an embodiment of the invention, the grooved plate is a one piece metal plate. For example, a metal plate may be provided with one or more grooves corresponding to arms of the control electrode structure for manufacturing the grooved plate. For example, the grooved plate may be made from copper, aluminium, silver and/or molybdenum.
According to an embodiment of the invention, the semiconductor element comprises a bipolar transistor (such as an IGBT) with an emitter, collector and base, the power electrode area being an emitter area and the control electrode area being a base area. The opposite side of the semiconductor element may provide a collector area. According to an embodiment of the invention, the semiconductor element comprises a field effect transistor (such as a MOSFET) with a source, drain and gate, the power electrode area being a source area and the control electrode area being a gate area. The opposite side of the semiconductor element may provide a drain area. The MOSFET may be a wide bandgap device and/or based on SiC.
According to an embodiment of the invention, a further power electrode area is provided on an opposite side of the semiconductor element. Also this power electrode area, which may be a source area or drain area, may be provided by a metallization layer on the semiconductor element.
A further aspect of the invention relates to a semiconductor module with a semiconductor device as described in the above and in the following. A semiconductor module may further comprise further electrical connection elements and mechanical supporting parts for the semiconductor device.
According to an embodiment of the invention, the semiconductor module further comprises: a substrate onto which the semiconductor device is attached (for example bonded or soldered) and at least one metal conductor interconnecting the grooved plate with the substrate. For example, the metal conductor may comprise at least one wire bond, ribbon bond and/or lead frame interconnecting the grooved plate with the substrate.
A wire bond may be a conductor with substantially round cross-section. A ribbon bond may be a conductor with substantially longitudinal cross-section. Both a wire bond and a ribbon bond may comprise flexible parts that are deformed during attachment of the wire /ribbon bond with its ends to the semiconductor module.
A lead frame may be a stamped or etched part of a metal plate, which may have its final shape before bonding.
According to an embodiment of the invention, the grooved plate is integrated into the ribbon bond or the lead frame. It may be possible that the grooved plate is provided in one piece with the lead frame or the ribbon bond and/or that the grooved plate is made of the material of the ribbon bond or the lead frame. For example, an end of the ribbon bond or the lead frame (that may be thicker than a further part of the ribbon band or the lead frame) may be provided with a groove (for example by etching) and/or may be formed into the grooved plate (for example by stamping).
The ribbon bond with the integrated grooved plate may be directly bonded (soldered or sintered) to the power electrode area, for example with ultrasonic (ribbon) bonding.
The lead frame may be sintered or soldered to the power electrode area, for example with an additional bond layer. According to an embodiment of the invention, the wire bond, the ribbon bond or lead frame are bonded to the grooved plate. It also may be possible that the grooved plate is provided as separate part and that the wire bond, the ribbon bond or lead frame are bonded to a top side of the grooved plate. For example, a wire bond and/or a ribbon bond may be bonded with ultrasonic wire/ribbon bonding.
According to an embodiment of the invention, the wire bond, the ribbon bond and/or the lead frame are made from copper and/or aluminium. It may be possible that the wire bond, the ribbon bond and/or the lead frame have Cu core surrounded by Al.
The one or more wire bond may have a diameter between 200 Mm and 400 Mm, for example about 300 Mm. A semiconductor module with a sintered grooved plate and rather thick Cu wire bonds, a ribbon bond or a lead frame may be adapted for operating under high temperature, may have a high reliability, a high current density and/or a high overload capability.
A further aspect of the invention relates to a method of manufacturing a semiconductor device and/or a semiconductor module, for example as described in the above and in the following. It has to be understood that features of the method as described in the above and in the following may be features of the semiconductor device and/or module as described in the above and in the following, and vice versa.
According to an embodiment of the invention, the method comprises: providing a semiconductor element with a power electrode area, a control electrode area and an elevated control electrode structure interconnected with the control electrode area and protruding the power electrode area; providing a grooved plate, which has at least one groove in a grooved side; and bonding the grooved plate with the grooved side to the power electrode area, such that at least a part of the control electrode structure is accommodated in the groove. It has to be noted that, when only one grooved plate is bonded to the semiconductor element, only one pick and place process and only one bonding process has to be performed.
According to an embodiment of the invention, the method further comprises: etching the at least one groove into the grooved plate. For example, the one or more grooves may be manufactured with a photochemical etching process, which also may be used to manufacture the grooved plate from a metal sheet (for example made form Cu, Al, Mo). An accuracy required for the groove structure may be easily achieved by the photochemical etching process.
For example, a plurality of grooved plates may be produced in a large batch quantity from a large sheet. According to an embodiment of the invention, the method further comprises: sintering the grooved plate to the power electrode area. The sintering may be performed based on Ag particles. All other processes of bonding the grooved plate to the semiconductor element may be used, too. In these processes, solder or transient liquid phase preforms may be used, though the process pressure is not that high for those processes and less critical than for a sintering process.
According to an embodiment of the invention, the method further comprises: applying a sintering material on the grooved side of the grooved plate. One method of topside emitter/source sintering may be applying Ag paste on the bottom side of the grooved plate or the transferring of an Ag sintering foil to the bottom side of the grooved plate.
According to an embodiment of the invention, the method further comprises: providing a sintering preform between the grooved plate and the semiconductor element. The sintering preform may be plastics material tailored to cover all power electrode areas on the top side in which plastics material sintering particles are accommodated. For example, a sintering preform made from a dense Ag foil with pre-applied Ag nanoparticles on both sides may be used. Compared with a silver paste or silver foil onto which the sintering particles are provided, a dense sintering preform may have a less risk of sintering particle contamination.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject-matter of the invention will be explained in more detail in the following text with reference to exemplary embodiments which are illustrated in the attached drawings. Fig. 1 schematically shows a top view of a semiconductor element for a semiconductor device according to an embodiment of the invention.
Fig. 2 schematically shows a top view of a further semiconductor element for a semiconductor device according to an embodiment of the invention.
Fig. 3 schematically shows a cross-sectional view of a semiconductor device according to an embodiment of the invention during manufacturing.
Fig. 4 schematically shows a cross-sectional view of a semiconductor device according to a further embodiment of the invention during manufacturing.
Fig. 5 schematically shows a cross-sectional view of a semiconductor module according to an embodiment of the invention. Fig. 6 schematically shows a cross-sectional view of a semiconductor module according to a further embodiment of the invention.
Fig. 7 schematically shows a cross-sectional view of a semiconductor module according to a further embodiment of the invention.
Fig. 8 schematically shows a cross-sectional view of a semiconductor module according to a further embodiment of the invention.
The reference symbols used in the drawings, and their meanings, are listed in summary form in the list of reference symbols. In principle, identical parts are provided with the same reference symbols in the figures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Fig. 1 and 2 show a semiconductor element 10 from above, whereas Fig. 3 shows a semiconductor element 10 in a cross-sectional view.
The semiconductor element 10 comprises a substrate or chip 12, in which a semiconductor switch is provided. On a top side, the semiconductor element 10 has a structured metallization layer 14, which provides several power electrode areas 16 and a control electrode area 18.
The control electrode area 18 is part of a control electrode structure 20 that has several arms 22 extending from the control electrode area 18. The arms 22 are running between the power electrode areas 16 and/or besides of them. The arms 22 comprise an electrically conducting part 24 (provided by the structured metallization layer 14) and an electrically isolating part 26, which covers the electrically conducting part 24.
The electrically isolating part 26 and therefore the control electrode structure 20 protrudes the substantially flat electrode areas 16, 18. The electrode areas 16, 18 all may provide surfaces on the same level, while the control electrode structure 20 may be elevated from these surfaces.
On the opposite side, the semiconductor element 10 may comprise a further power contact area 17.
In Fig. 1 , the semiconductor element 10 may be an IGBT and the power electrode areas 16 may be emitter areas, the power electrode area 17 may be a collector area, while the control electrode area 18 may be a base area. In Fig. 2, the semiconductor element 10 may be a MOSFET based on SiC and the power electrode areas 16 may be source areas, the power electrode area 17 may be a drain area, while the control electrode area may be a gate area. Fig. 3 and 4 show a semiconductor device 28 during manufacturing, which also comprises a grooved top plate 30.
The grooved top plate 30 comprises a substantially flat top side 32 and a grooved bottom side 34, with at least one groove 36 corresponding to the elevated parts 26 of the control electrode structure 20. For example, the groove 36 and/or the top plate 30 may be etched from a sheet of metal, such as Cu, Al, Mo. In particular, the grooved top plate 30 may be one-piece and may be a metal plate.
As shown in Fig. 3, before a sintering process of the grooved top plate to the semiconductor element 12, a sintering material 38, such as sintering paste or a sintering foil, may be applied to the bottom side 34.
Alternatively, as shown in Fig. 4, a sintering preform 40, which comprises sintering particles accommodated in a dense substrate material, which hinders the sintering particles from leaving the sintering preform, may be positioned between the grooved top plate 30 and the semiconductor element 10.
The grooved top plate 30 then may be pressed with its bottom side 34 onto the power electrode areas 16 and sintered to them. Due to the groove 36, the control electrode structure 20 is not damaged, when the grooved top plate 30 is pressed onto the semiconductor element 10. In the case of Fig 4, a part 42 of the sintering preform 40 may stay inside the groove 36.
Fig. 5 shows a semiconductor module 43, which comprises a semiconductor device 28.
As shown in Fig. 5, after the sintering, parts of the control electrode structure 20 are accommodated in the groove 36.
The semiconductor device 28 may be bonded with its bottom side to a substrate 44 (such as a metalized ceramics or plastics substrate). The top side 32 of the grooved top plate 30 may be electrically interconnected with wire bonds 46 with other parts of the semiconductor module 43. Due to the mechanical properties of the grooved top plate 32 and its material, thick wire bonds 46 (about 300 Mm diameter) may be used.
Fig. 6 shows a semiconductor module 43, in which the grooved top plate 30 is integrated into a metal ribbon bond 48. For example, an end of the ribbon bond 48, which may be thicker than the remaining part may be provided with a groove 36. The grooved top plate integrated into the ribbon bond 48 may be directly bonded by ultrasonic ribbon bonding to the power electrode areas 16.
Fig. 7 shows a semiconductor module 43, in which a separate metal ribbon bond 48 is bonded to the grooved top plate 30. The grooved top plate 30 may be bonded to the power electrode areas 16 as describe with respect to Fig. 3 and 4. After that or before, the ribbon bond 48 may be soldered or sintered to the top side 32 of the grooved top plate 30. Fig. 8 shows a semiconductor module 43, in which the grooved top plate 30 is integrated into a pre-shaped lead frame 50. The lead frame 50 may be etched and/or stamped from a metal plate, for example made of Ag, Cu, Al. During the etching, the groove 36 may be etched into an end of the lead frame 50 for producing the grooved plate 30. The grooved lead frame 50 may be bonded by sintering or soldering to the power electrode areas 16. For example, the lead frame 50 may be provided with an additional bond layer 52 (of different material) on the grooved bottom side 34 and/or on the end to be bonded to the substrate 44.
It has to be noted that the grooved top plate 30 in Fig. 6, 7 and 8 also may be sintered to the power electrode areas 16 as described with respect to Fig. 3 and 4 with sintering material 38 or a sintering preform 40. Furthermore, it may be possible that the grooved plates of Fig. 3 to 7 are provided with an additional bond layer 52.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art and practising the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. A single processor or controller or other unit may fulfil the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.
LIST OF REFERENCE SYMBOLS
10 semiconductor element
12 substrate/chip
14 metallization layer
16 power electrode area
17 power electrode area
18 control electrode area
20 control electrode structure
22 arm
24 electrically conducting part
26 electrically isolating part
28 semiconductor device
30 grooved top plate
32 top side
34 grooved bottom side
36 groove
38 sintering material
40 sintering preform
42 part of sintering preform
43 semiconductor module
44 substrate of semiconductor module
46 wire bond
48 ribbon bond
50 lead frame
52 bond layer

Claims

A semiconductor device (28), comprising:
a semiconductor element (10) with a power electrode area (16), a control electrode area (18) and an elevated control electrode structure (20) on one side, wherein the elevated control electrode structure (20) is interconnected with the control electrode area (18) and protrudes the power electrode area (16); and
a grooved plate (30), which is bonded with a grooved side (34) to the power electrode area (16);
wherein the grooved plate (30) has at least one groove (36) in the grooved side (34), in which at least a part of the control electrode structure (20) is
accommodated; wherein the grooved plate (30) is sintered via a sintering preform (40) interpositioned between the grooved plate (30) and the semiconductor element (10) to the power electrode area (16), such that the sintering preform (40) covers the elevated control electrode structure (20).
The semiconductor device (28) of claim 1 ,
wherein the elevated control electrode structure (20) has one or more arms (22), each arm (22) starting at the control electrode area (18) and running besides parts of the power electrode area (16).
The semiconductor device (28) of claim 1 or 2,
wherein the elevated control electrode structure (20) comprises isolation material (26) above an electrical conducting layer (24).
The semiconductor device (28) of one of the preceding claims,
wherein the power electrode area (16) and/or the control electrode area (18) are provided by one or more metallization layers (14) on a semiconductor substrate (12) of the semiconductor element (10).
The semiconductor device (28) of one of the preceding claims,
wherein the grooved plate (30) is a one piece metal plate; and/or
wherein the grooved plate (30) is made from copper, aluminium, silver and/or molybdenum.
The semiconductor device (28) of one of the preceding claims, wherein t e semiconductor element (10) comprises a bipolar transistor with an emitter, collector and base, the power electrode area (16) being an emitter area and the control electrode area (18) being a base area; or
wherein the semiconductor element (10) comprises a field effect transistor with a source, drain and gate, the power electrode area (16) being a source area and the control electrode area (18) being a gate area.
The semiconductor device (28) of one of the preceding claims,
wherein a further power electrode area (17) is provided on an opposite side semiconductor element (10).
A semiconductor module (43), comprising:
a semiconductor device (28) according to one of the claims 1 to 7;
a substrate (44) onto which the semiconductor device (28) is attached;
at least one wire bond (46), ribbon bond (48) and/or lead frame (52)
interconnecting the grooved plate (30) with the substrate (44).
The semiconductor module (43) of claim 8,
wherein the grooved plate (30) is integrated into the ribbon bond (48) or the leadframe (50); or
wherein the wire bond (46), the ribbon bond (48) or lead frame (50) are bonded to the grooved plate (30).
10. The semiconductor module (43) of claim 8 or 9,
wherein the wire bond (46), the ribbon bond (48) and/or the lead frame (50) are made from copper and/or aluminium; and/or
wherein the wire bond (46) has a diameter between 200 Mm and 400 Mm.
A method of manufacturing a semiconductor device (28), the method comprising: providing a semiconductor element (10) with a power electrode area (16), a control electrode area (18) and an elevated control electrode structure (20) interconnected with the control electrode area (18) and protruding the power electrode area (16); providing a grooved plate (30), which has at least one groove (36) in a grooved side (34); bonding t e grooved plate (30) with the grooved side (34) to the power electrode area (16), such that at least a part of the control electrode structure (20) is accommodated in the groove (36) by:
providing a sintering preform (40) between the grooved plate (30) and the semiconductor element (10); and
sintering the grooved plate (30) to the power electrode area (16) , such that the sintering preform (40) covers the elevated control electrode structure (20).
The method of claim 1 1 , further comprising:
etching the at least one groove (36) into the grooved plate (30).
PCT/EP2016/075970 2016-03-16 2016-10-27 Semiconductor device WO2017157486A1 (en)

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