WO2021111563A1 - 半導体装置、電力変換装置および半導体装置の製造方法 - Google Patents

半導体装置、電力変換装置および半導体装置の製造方法 Download PDF

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Publication number
WO2021111563A1
WO2021111563A1 PCT/JP2019/047510 JP2019047510W WO2021111563A1 WO 2021111563 A1 WO2021111563 A1 WO 2021111563A1 JP 2019047510 W JP2019047510 W JP 2019047510W WO 2021111563 A1 WO2021111563 A1 WO 2021111563A1
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Prior art keywords
resin member
semiconductor device
conductive wire
adjacent
convex portion
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PCT/JP2019/047510
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English (en)
French (fr)
Inventor
晴子 人見
耕三 原田
坂本　健
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三菱電機株式会社
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Priority to CN201980102607.1A priority Critical patent/CN114747000A/zh
Priority to PCT/JP2019/047510 priority patent/WO2021111563A1/ja
Priority to JP2021562266A priority patent/JP7270772B2/ja
Priority to DE112019007938.7T priority patent/DE112019007938T5/de
Priority to US17/765,439 priority patent/US20220336402A1/en
Publication of WO2021111563A1 publication Critical patent/WO2021111563A1/ja

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Definitions

  • the present invention relates to a semiconductor device, a power conversion device, and a method for manufacturing the semiconductor device.
  • a semiconductor device including a semiconductor element, a conductive wire bonded to the electrode of the semiconductor element at the joint portion, and a first resin member covering the joint portion of the conductive wire and the electrode.
  • the first resin member arranged on the electrode can be spread to the end of the joint portion of the conductive wire.
  • the viscosity of the first resin member is low enough to allow the first resin member to flow on the electrodes. Therefore, in order to prevent the first resin member from flowing out from above the electrode, it is necessary to further provide a second resin film having a film thickness thicker than that of the first resin member on the peripheral edge of the electrode. Therefore, there is a problem that the structure of the semiconductor device becomes complicated.
  • the present invention has been made in view of the above problems, and an object of the present invention is to allow the first resin member to be spread between the conductive wire and the electrode to the end of the joint portion of the conductive wire, and to have a simple structure. It is an object of the present invention to provide a semiconductor device, a power conversion device, and a method for manufacturing the semiconductor device.
  • the semiconductor device of the present invention includes a semiconductor element, at least one first resin member, and at least one conductive wire.
  • the semiconductor element includes a main body portion and a surface electrode.
  • the surface electrode has a first surface and a second surface. The first surface is joined to the main body. The second surface faces the first surface.
  • At least one first resin member is arranged on the second surface of the surface electrode.
  • At least one conductive wire includes a joint. The joint is adjacent to at least one first resin member. The joint portion is joined to the second surface.
  • At least one first resin member includes a convex portion. The convex portion projects on the side opposite to the main body portion with respect to the surface electrode.
  • At least one conductive wire includes a recess. The recess is adjacent to the joint. The recess extends along the protrusion. The concave portion is fitted to the convex portion.
  • At least one recess of the conductive wire is adjacent to the joint.
  • the concave portion is fitted to the convex portion of at least one first resin member. Therefore, the convex portion of the first resin member can be spread to the end portion of the joint portion. Further, the concave portion of at least one conductive wire is fitted to the convex portion of the first resin portion. Therefore, it is possible to provide a semiconductor device having a simple structure.
  • FIG. 5 is an enlarged cross-sectional view of region II of FIG. 1 schematically showing a configuration of a semiconductor device according to a first embodiment. The dimensions of the first resin member and the conductive wire are shown, and it is an enlarged cross-sectional view corresponding to FIG.
  • FIG. 5 is an enlarged cross-sectional view of a region II of FIG. 1 schematically showing another configuration of the semiconductor device according to the first embodiment. It is sectional drawing along the VI-VI line of FIG. FIG.
  • FIG. 3 is a cross-sectional view taken along the line VII-VII of FIG.
  • FIG. 3 is a cross-sectional view taken along the line VIII-VIII of FIG.
  • FIG. 3 is a cross-sectional view taken along the line IX-IX of FIG.
  • the configuration of the semiconductor device according to the first modification of the first embodiment is schematically shown, and it is an enlarged top view corresponding to the II region of FIG.
  • the configuration of the semiconductor device according to the second modification of the first embodiment is schematically shown, and it is an enlarged top view corresponding to the II region of FIG.
  • the configuration of the semiconductor device according to the second modification of the first embodiment is schematically shown, and it is an enlarged cross-sectional view corresponding to the II region of FIG.
  • FIG. 5 is a cross-sectional view schematically showing a dispenser, a first resin member, and a first electrode in the method for manufacturing a semiconductor device according to the first embodiment. It is a flowchart which shows roughly the other manufacturing method of the semiconductor device which concerns on Embodiment 1.
  • FIG. 6 is an enlarged cross-sectional view of an XVIII region of FIG.
  • FIG. 17 which schematically shows a configuration of a semiconductor device according to a second embodiment. It is an enlarged top view of the XVIII region of FIG. 17 which schematically shows the structure of the semiconductor device which concerns on Embodiment 2.
  • FIG. The configuration of the semiconductor device according to the modified example of the second embodiment is schematically shown, and is an enlarged top view corresponding to FIG.
  • It is a flowchart which shows roughly the manufacturing method of the semiconductor device which concerns on Embodiment 2.
  • It is a block diagram which shows schematic structure of the power conversion system which concerns on Embodiment 3.
  • the semiconductor device 50 includes a semiconductor element 1, at least one first resin member 2, at least one conductive wire 3, a circuit board 5, and a case 6.
  • the semiconductor device 50 may include a sealing resin member 4.
  • the semiconductor device 50 is a power semiconductor device for electric power.
  • the semiconductor element 1 includes a front surface electrode 10, a main body portion 11, and a back surface electrode 12.
  • the surface electrode 10 has a first surface 10b and a second surface 10t.
  • the first surface 10b is joined to the main body portion 11.
  • the second surface 10t faces the first surface 10b.
  • the direction in which the second surface 10t faces the first surface 10b of the surface electrode 10 is defined as the first direction (Z-axis direction).
  • the semiconductor element 1 is a power semiconductor element for electric power.
  • the semiconductor element 1 may be, for example, a switching element such as an insulated gate bipolar transistor (IGBT: Insulated Gate Bipolar Transistor) and a metal oxide semiconductor field effect transistor (MOSFET: Metal Oxide Semiconductor Field Effect Transistor), or a shot. It may be a rectifying element such as a key barrier diode.
  • the material of the semiconductor element 1 is, for example, silicon (Si).
  • the material of the semiconductor element 1 may include, for example, a wide bandgap semiconductor material such as silicon carbide (SiC), gallium nitride (GaN), or diamond.
  • At least one conductive wire 3 is bonded to the surface electrode 10.
  • the second surface 10t of the surface electrode 10 faces at least one conductive wire 3.
  • the back surface electrode 12 is bonded to the circuit board 5.
  • the front electrode 10 and the back electrode 12 sandwich the main body 11.
  • the material of the front electrode 10 and the back electrode 12 is, for example, an aluminum (Al) alloy containing silicon (Si).
  • the front electrode 10 and the back electrode 12 may be covered with at least one coating layer (not shown).
  • the material of at least one coating layer (not shown) is, for example, nickel (Ni) or gold (Au).
  • At least one coating layer (not shown) may include a plurality of coating layers (not shown). A plurality of coating layers (not shown) may be laminated.
  • FIG. 1 the configuration of the first resin member 2 according to the first embodiment will be described with reference to FIGS. 1 to 5.
  • the sealing resin member 4 (see FIG. 1) is not shown in FIGS. 2 to 5 for convenience of explanation.
  • at least one first resin member 2 is arranged on the second surface 10t of the surface electrode 10.
  • at least one first resin member 2 intersects with at least one conductive wire 3 in top view.
  • the shape of at least one first resin member 2 when viewed from the third direction (Y-axis direction) is a chevron shape due to a curved structure.
  • At least one first resin member 2 is arranged between the second surface 10t of the surface electrode 10 and at least one conductive wire 3.
  • At least one first resin member 2 includes a convex portion 20.
  • the convex portion 20 projects on the side opposite to the main body portion 11 with respect to the surface electrode 10.
  • the convex portion 20 is a convex surface along the concave portion 31 described later.
  • the convex portion 20 includes the convex portion inner end 2i and the convex portion outer end 2o.
  • the convex portion inner end 2i is adjacent to the joint portion 30 and the concave portion 31, which will be described later.
  • the convex outer end 2o is provided on the side opposite to the joint 30 with respect to the convex inner end 2i.
  • At least one first resin member 2 includes one first resin member 2a and the other first resin member 2b.
  • the first resin member 2a is arranged with a gap from the other first resin member 2b.
  • the first resin member 2a includes the convex portion 20a included in the convex portion 20.
  • the convex portion 20a includes a one-sided convex portion inner end 2ai included in the convex portion inner end 2i and a one-sided convex portion outer end 2ao included in the convex portion outer end 2o.
  • the first resin member 2b includes the other convex portion 20b included in the convex portion 20.
  • the other convex portion 20b includes the other convex portion inner end 2bi included in the convex portion inner end 2i and the other convex portion outer end 2bo included in the convex portion outer end 2o.
  • the dimension H2 in the first direction (Z-axis direction) of at least one first resin member 2 is the first direction (Z-axis direction) of at least one conductive wire 3 in the portion where the joint portion 30 is provided.
  • the dimension H3 in the Z-axis direction is 0.2 times or more and less than 1 time.
  • the dimension of each of the at least one first resin member 2 in the first direction (Z-axis direction) is the dimension from the second surface 10t of the surface electrode 10 to the top of the convex portion 20.
  • the dimension W2 in the second direction (X-axis direction) of at least one first resin member 2 is, for example, 0.5 times or more and 10 times or less the dimension in the third direction (Y-axis direction) of the joint portion 30.
  • the dimension of the first resin member 2 in the second direction (X-axis direction) is the dimension from the convex inner end 2i of the convex portion 20 to the convex outer end 2o.
  • Each of the at least one first resin member 2 contains at least one of a polyimide resin and a polyamide resin.
  • the material of at least one first resin member 2 is a resin having high heat resistance.
  • the viscosity of at least one first resin member 2 is, for example, 50 Pa ⁇ s or more and 150 Pa ⁇ s or less. In this embodiment, the viscosity is measured by the cone-plate viscometer method defined in JIS standard 5600-2-3.
  • the thixotropy index of at least one first resin member 2 is, for example, 1.1 or more.
  • the thixotropy index of at least one first resin member 2 may be, for example, 2.5 or more.
  • the thixotropy index is a thixotropy index defined in JIS standard K6833-1.
  • the first resin member 2 may have a glass transition temperature higher than the maximum operating temperature of the semiconductor device 50.
  • the glass transition temperature of the first resin member 2 may be, for example, 150 ° C. or higher.
  • the first resin member 2 may contain a filler (not shown).
  • the material of the filler (not shown) contained in the first resin member 2 is, for example, metal or rubber.
  • the convex portion 20 may include a hem portion 204 and a protruding portion 205.
  • the hem portion 204 is in contact with the second surface 10t.
  • the protruding portion 205 protrudes from the hem portion 204 on the side opposite to the second surface 10t.
  • the dimension of the convex portion 20 in the first direction is the dimension from the second surface 10t to the top of the convex portion 20.
  • At least one conductive wire 3 includes a junction 30.
  • the joint portion 30 is adjacent to at least one first resin member 2.
  • the joint portion 30 is joined to the second surface 10t.
  • At least one conductive wire 3 includes a recess 31.
  • the recess 31 is adjacent to the joint 30.
  • the concave portion 31 extends along the convex portion 20.
  • the concave portion 31 is fitted to the convex portion 20.
  • the direction from the joint portion 30 toward the recess 31 along the second surface 10t is defined as the second direction (X-axis direction).
  • the second direction (X-axis direction) is the same as the longitudinal direction of the joint portion 30.
  • the direction orthogonal to both the first direction (Z-axis direction) and the second direction (X-axis direction) is defined as the third direction (Y-axis direction).
  • the third direction (Y-axis direction) is the same as the width direction of the joint portion 30.
  • the joint portion 30 is sandwiched between the one convex portion 20a and the other convex portion 20b along the second surface 10t.
  • the joint portion 30 includes one end 30a of the joint portion and the other end 30b of the joint portion.
  • One end 30a of the joint portion is adjacent to the inner end 2ai of the one convex portion.
  • the other end 30b of the joint portion is adjacent to the inner end 2bi of the other convex portion.
  • the dimension of the joint portion 30 in the second direction (X-axis direction) is the dimension along the second surface 10t of the surface electrode 10 from one end 30a of the joint portion to the other end 30b of the joint portion.
  • the joint portion 30 is in contact with the first resin member 2 only at one end 30a of the joint portion and the other end 30b of the joint portion.
  • the joint portion 30 is not surrounded by the first resin member 2.
  • the one end 30a of the joint portion is in contact with the first resin member 2a extending from the one end 30a side of the joint portion to the other end 30b side of the joint portion.
  • the other end 30b of the joint portion is in contact with the other first resin member 2b extending from the other end 30b side of the joint portion to the one end 30a side of the joint portion.
  • the concave portion 31 is adjacent to the convex portion 20 and the joint portion 30.
  • the concave portion 31 is a concave surface along the convex portion 20.
  • the concave portion 31 overlaps the convex portion 20 when viewed from above.
  • the recess 31 includes one recess 31a and the other recess 31b.
  • the recess 31a sandwiches the joint portion 30 with the other recess 31b.
  • the concave portion 31a is fitted to the one convex portion 20a of the first resin member 2a.
  • the recess 31a is adjacent to the joint 30 and the first resin member 2a at one end 30a of the joint.
  • the other concave portion 31b is fitted to the other convex portion 20b of the other first resin member 2b.
  • the other recess 31b is adjacent to the joint 30 and the other first resin member 2b at the other end 30b of the joint.
  • At least one conductive wire 3 is joined to the conductive circuit pattern 51 of the circuit board 5.
  • At least one conductive wire 3 may be bonded to the surface electrode 10 and the conductive circuit pattern 51 by, for example, a wire bonder.
  • At least one conductive wire 3 is bonded by, for example, a wedge tool.
  • the cross-sectional shape of the joint portion 30 is substantially triangular.
  • the cross-sectional shape of the recess 31 is substantially triangular.
  • the stretched portion extending to the side opposite to the joint portion 30 with respect to the recess 31 is separated from the second surface 10t and at least one first resin member 2.
  • At least one conductive wire 3 includes a wire upper surface 3t and a wire lower surface 3b.
  • the lower surface 3b of the wire faces the second surface 10t of the surface electrode 10.
  • the upper surface 3t of the wire faces the lower surface 3b of the wire.
  • the material of at least one conductive wire 3 is, for example, a metal such as gold (Au), aluminum (Al) or copper (Cu).
  • the sealing resin member 4 seals the semiconductor element 1, at least one first resin member 2, and at least one conductive wire 3.
  • the sealing resin member 4 may seal at least a part of the conductive wire 3 or may seal the entire conductive wire 3.
  • the material of the sealing resin member 4 is, for example, an insulating resin material.
  • the semiconductor device 50 may or may not include the sealing resin member 4.
  • the circuit board 5 includes a conductive circuit pattern 51, an insulating substrate 52, and a conductive plate 53.
  • the conductive circuit pattern 51, the insulating substrate 52, and the conductive plate 53 are laminated in the order of the conductive circuit pattern 51, the insulating substrate 52, and the conductive plate 53.
  • the insulating substrate 52 extends in the XY plane.
  • the material of the insulating substrate 52 is, for example, an inorganic material (ceramic material) such as aluminum oxide (Al 2 O 3 ), aluminum nitride (Al N) or silicon nitride (Si 3 N 4).
  • the insulating substrate 52 includes an upper surface of the insulating substrate and a lower surface of the insulating substrate facing the upper surface of the insulating substrate.
  • the conductive circuit pattern 51 is provided on the upper surface of the insulating substrate.
  • the conductive plate 53 is provided on the lower surface of the insulating substrate.
  • the material of the conductive circuit pattern 51 and the conductive plate 53 is, for example, a metal such as copper (Cu) or aluminum (Al).
  • the back electrode 12 of the semiconductor element 1 is bonded to the conductive circuit pattern 51.
  • the back surface electrode 12 is joined to the conductive circuit pattern 51 by, for example, solder or a metal fine particle sintered body (not shown).
  • the case 6 includes a heat sink 61 and an enclosure 62.
  • the semiconductor device 50 is configured as a case-type module by the case 6.
  • the sealing resin member 4 is at least partially filled in the internal space of the case 6.
  • a circuit board 5 is attached to the heat sink 61.
  • the conductive plate 53 of the circuit board 5 is joined to the heat sink 61 by a joining member (not shown) such as electric heating grease.
  • the heat generated from the semiconductor element 1 is transferred to the heat sink 61 through the circuit board 5.
  • the heat transferred to the heat sink 61 is diffused to the outside of the semiconductor device 50.
  • the material of the heat sink 61 is, for example, a metal such as aluminum (Al).
  • the outer enclosure 62 surrounds the semiconductor element 1, at least one first resin member 2, at least one conductive wire 3, the circuit board 5, and the sealing resin member 4.
  • the outer enclosure 62 is attached to the peripheral edge of the heat sink 61.
  • the material of the enclosure 62 is, for example, an insulating resin such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT).
  • At least one conductive wire 3 includes a plurality of conductive wires 3.
  • Each of the concave portions 31 of the plurality of conductive wires 3 is fitted to the convex portion 20.
  • at least one first resin member 2 is formed across a plurality of conductive wires 3.
  • Each of at least one first resin member 2 intersects a plurality of conductive wires 3.
  • the first modification of the first embodiment is different from the first embodiment in that at least one conductive wire 3 in the modification of the first embodiment includes a plurality of conductive wires 3.
  • At least one first resin member 2 is composed of one first resin member 2.
  • At least one conductive wire 3 is composed of one conductive wire 3.
  • the convex portion 20 of one first resin member 2 is fitted into one concave portion 31 of one conductive wire 3.
  • the convex portion 20 is in contact with either one end 30a of the joint portion 30a or the other end 30b of the joint portion 30 of the joint portion 30.
  • the manufacturing method of the semiconductor device 50 includes a step S1 in which the semiconductor element 1 is prepared, a step S2 in which the convex portion 20 is formed, and a step in which the concave portion 31 is fitted into the convex portion 20. Includes S3.
  • the semiconductor element 1 is prepared in the step S1 in which the semiconductor element 1 is prepared. As shown in FIG. 1, the semiconductor element 1 is bonded to the circuit board 5.
  • At least one first resin member 2 is applied to the second surface 10t of the surface electrode 10 so that at least one first resin member 2 is formed.
  • a convex portion 20 is formed on 2.
  • the first resin member 2 is applied to the surface electrode 10 by the dispenser 8.
  • the distance HD between the surface electrode 10 and the dispenser nozzle when the first resin member 2 is dispensed is the thixotropy of the first resin member when the thixotropy index of the first resin member 2 is larger than 1.1. It is smaller than when the index is 1.1 or less.
  • the convex portion 20 is formed of one end 30a of the joint portion and the other end 30b of the joint portion. It is pre-applied so that it is placed adjacent to at least one of them.
  • the first resin member 2 is arranged at a position where one convex portion 20a is adjacent to one end 30a of the joint portion in step S3 in which the concave portion 31 (see FIG. 3) is fitted to the convex portion 20. Is applied in advance.
  • the first resin member 2 is arranged at a position where the other convex portion 20b is adjacent to the other end 30b of the joint portion in the step S3 in which the concave portion 31 (see FIG. 3) is fitted to the convex portion 20. Is applied in advance.
  • the applied first resin member 2 is heated. Since the solvent contained in the first resin member 2 evaporates as the first resin member 2 is heated, the shape of the convex portion 20 of the first resin member 2 is maintained when the conductive wire 3 is joined. It becomes hard to the extent. In the present embodiment, when the first resin member 2 becomes hard enough to maintain the shape of the convex portion 20 when the conductive wire 3 is joined, it is called temporary curing.
  • step S2 in which the convex portion 20 is formed at least one first resin member 2 is temporarily cured so that the convex portion 20 of at least one first resin member 2 is held.
  • the first resin member 2 is temporarily cured by heating it on a hot plate at 100 ° C. for 1 minute, for example. As shown in FIG. 14, the temporarily cured first resin member 2 can be adhered to the conductive wire 3.
  • step S3 in which the concave portion 31 is fitted to the convex portion 20, the surface electrode 10 so that the joint portion 30 of at least one conductive wire 3 is adjacent to at least one first resin member 2. It is joined to the second surface 10t of.
  • the conductive wire 3 is deformed along the convex portion 20, the concave portion 31 is formed in the conductive wire 3.
  • the conductive wire 3 is pressed against the temporarily cured first resin member 2, the conductive wire 3 is recessed, so that the recess 31 is formed in the conductive wire 3.
  • the concave portion 31 is fitted to the convex portion 20 while the conductive wire 3 is joined to the second surface 10t.
  • the circuit board 5 is joined to the heat sink 61.
  • the outer enclosure 62 is joined to the heat sink 61.
  • the first resin member 2 is finally cured.
  • the solvent of the first resin member 2 is sufficiently volatilized, the first resin member 2 is finally cured.
  • the first resin member 2 contains a polyimide resin, the imide precursor undergoes a ring closure reaction, so that the first resin member 2 is finally cured.
  • the first resin member 2 is finally cured, the first resin member 2 is heated at 200 ° C. for 3 hours in, for example, a low oxygen oven.
  • the semiconductor element 1, at least one first resin member 2, and the conductive wire 3 are sealed after the step S3 in which the concave portion 31 is fitted to the convex portion 20.
  • the step S4 sealed by the stop resin member 4 may be included.
  • the liquid sealing resin member 4 is supplied on the semiconductor element 1, at least one first resin member 2, and the conductive wire 3.
  • the supplied sealing resin member 4 is cured.
  • the recess 31 of at least one conductive wire 3 is adjacent to the joint portion 30, it is in contact with the end portion of the joint portion 30. ing.
  • the concave portion 31 is fitted to the convex portion 20 of at least one first resin member 2.
  • the convex portion 20 of the first resin member 2 fitted in the concave portion 31 can be spread to the end portion of the joint portion 30.
  • the first resin member 2a can be arranged so that the first resin member 2a is adjacent to one recess 31a of at least one conductive wire 3 and one end 30a of the joint portion. As a result, the first resin member 2a can be spread to one end 30a of the joint portion.
  • the other first resin member 2b can be arranged so that the other first resin member 2b is adjacent to the other recess 31b of at least one conductive wire 3 and the other end 30b of the joint portion. As a result, the other first resin member 2b can be spread to the other end 30b of the joint portion.
  • the first resin member 2 is placed between the surface electrode 10 and the conductive wire 3. Can be provided without gaps. Thereby, the shape of the first resin member 2 can be stabilized. Therefore, even when the semiconductor device 50 is applied in the power cycle test, the first resin member 2 can be continuously fixed between at least one conductive wire 3 and the surface electrode 10. As a result, it is possible to suppress the occurrence of cracks in the joint portion 30. Therefore, the reliability of the semiconductor device 50 can be improved.
  • the concave portion 31 of at least one conductive wire 3 is fitted to the convex portion 20 of the first resin member 2.
  • the first resin member 2 is fitted in the concave portion 31 while the convex portion 20 is maintained. Therefore, it is possible to provide the semiconductor device 50 having a simple structure.
  • the viscosity of the first resin member 2 is 50 Pa ⁇ s or more and 150 Pa ⁇ s or less, the first resin member 2 can be held on the surface electrode 10. As a result, there is no possibility that the first resin member 2 will flow out from above the surface electrode 10. Therefore, it is not necessary to provide a structure for suppressing the first resin member 2 from flowing out from above the surface electrode 10. Therefore, it is possible to provide the semiconductor device 50 having a simple structure.
  • the first resin member 2 contains at least one of a polyimide resin and a polyamide resin, it has higher heat resistance than the first resin member 2 which does not contain either a polyimide resin or a polyamide resin. There is. Thereby, the semiconductor device 50 having high reliability can be provided.
  • the dimension H2 in the first direction (Z-axis direction) of at least one first resin member 2 is the first direction (Z-axis direction) of at least one conductive wire 3 in the portion where the joint portion 30 is provided.
  • the dimension H3 in the Z-axis direction is 0.2 times or more and less than 1 times
  • the dimension W2 in the second direction (X-axis direction) of at least one first resin member 2 is the third direction (Y-axis) of the joint portion 30. It is 0.5 times or more and 10 times or less the dimension of the direction).
  • the first resin member 2 can be arranged between the conductive wire 3 and the surface electrode 10 so as not to protrude from the conductive wire 3 and the surface electrode 10. As a result, the amount of the first resin member 2 used can be reduced. Further, since the first resin member 2 is efficiently provided, the conductive wire 3 can be efficiently reinforced by the first resin member 2.
  • first resin member 2 is filled between the conductive wire 3 and the surface electrode 10 due to the surface tension of the first resin member 2, it is difficult to make the dimensions of the first resin member 2 the above dimensions. It is difficult to efficiently provide the first resin member 2.
  • the dimension H2 in the first direction (Z-axis direction) of at least one first resin member 2 is at least one of the portions where the joint portion 30 is provided.
  • the dimension W2 in the first direction (Z-axis direction) of the one conductive wire 3 can be 0.2 times or more and less than 1 times the dimension H3 in the first direction (Z-axis direction), and the dimension W2 in the second direction (X-axis direction) of at least one first resin member 2 is joined.
  • the dimension of the portion 30 in the third direction (Y-axis direction) can be 0.5 times or more and 10 times or less. As a result, the first resin member 2 can be efficiently provided.
  • the joint portion 30 is in contact with the first resin member 2 only at one end 30a of the joint portion and the other end 30b of the joint portion.
  • the amount of the first resin member 2 used can be reduced as compared with the case where the entire circumference of the joint portion 30 is in contact with the first resin member 2.
  • each concave portion 31 of the plurality of conductive wires 3 is fitted to the convex portion 20. Therefore, a plurality of conductive wires 3 are bonded to each of the first resin members 2. Therefore, the working time in manufacturing the semiconductor device 50 can be shortened as compared with the case where the plurality of first resin members 2 are dispensed.
  • At least one first resin member 2 may be composed of one first resin member 2.
  • the amount of the first resin member 2 used can be reduced as compared with the case where at least one first resin member 2 includes the plurality of first resin members 2. Therefore, the manufacturing cost of the semiconductor device 50 can be reduced.
  • the concave portion 31 of the conductive wire 3 is fitted to the convex portion 20 of the first resin member 2.
  • the step S3 to be performed is included.
  • the first resin member 2 can be arranged without a gap between the conductive wire 3 and the surface electrode 10.
  • the method for manufacturing the semiconductor device 50 includes a step S3 in which the concave portion 31 of the conductive wire 3 is fitted into the convex portion 20 of the first resin member 2. As a result, the first resin member 2 fits into the concave portion 31 while the convex portion 20 is maintained. Therefore, it is possible to provide the semiconductor device 50 having a simple structure.
  • the concave portion 31 of the conductive wire 3 is adhered to the convex portion 20 of the first resin member 2, so that the first resin member 2 is attached to the conductive wire. It can be arranged without a gap between 3 and the surface electrode 10.
  • step S2 in which the convex portion 20 is formed at least one first resin member 2 is temporarily cured so that the convex portion 20 of at least one first resin member 2 is held. As a result, the shape of the convex portion 20 can be maintained. Further, at least one conductive wire 3 is dented by pressing the at least one conductive wire 3 against at least one temporarily cured first resin member 2. As a result, the recess 31 can be formed in at least one conductive wire 3.
  • the first resin member 2 After the step S3 in which the concave portion 31 is fitted to the convex portion 20, the first resin member 2 is finally cured. Therefore, the first resin member 2 can be sufficiently adhered to the conductive wire 3.
  • the semiconductor element 1, at least one first resin member 2, and the conductive wire 3 are sealed by the sealing resin member 4.
  • the semiconductor element 1, at least one first resin member 2, and the conductive wire 3 are reinforced by the sealing resin member 4, so that the reliability of the semiconductor device 50 can be improved.
  • Embodiment 2 Unless otherwise specified, the second embodiment has the same configuration, manufacturing method, and action and effect as those of the first embodiment. Therefore, the same components as those in the first embodiment are designated by the same reference numerals, and the description will not be repeated.
  • the semiconductor device 50 further includes a second resin member 7.
  • the semiconductor device 50 according to the present embodiment is different from the semiconductor device 50 according to the first embodiment in that the second resin member 7 is further included.
  • At least one conductive wire 3 includes an adjacent portion 32 and a rising portion 33.
  • the adjacent portion 32 is adjacent to the joint portion 30.
  • the rising portion 33 rises from the adjacent portion 32 on the side opposite to the main body portion 11 (see FIG. 1) with respect to the surface electrode 10.
  • At least one conductive wire 3 is bent at the joint portion 30, the adjacent portion 32, and the rising portion 33.
  • the joint portion 30, the adjacent portion 32, and the rising portion 33 form a neck portion of at least one conductive wire 3.
  • the second resin member 7 covers at least one conductive wire 3 from the rising portion 33 to the joining portion 30 via the adjacent portion 32 on the opposite side of the surface electrode 10.
  • the second resin member 7 covers at least a part of the joint portion 30, the adjacent portion 32, and at least a part of the rising portion 33. As shown in FIG. 19, in the top view, the second resin member 7 overlaps the boundary between at least one first resin member 2 and the joint portion 30.
  • the second resin member 7 contains at least one of a polyimide resin and a polyamide resin.
  • the second resin member 7 may be a resin having high heat resistance.
  • the thixotropy index of the second resin member 7 is, for example, 1.1 or more.
  • the thixotropy index of the second resin member 7 may be, for example, 2.5 or more.
  • the second resin member 7 may contain a filler (not shown).
  • the material of the filler (not shown) contained in the second resin member 7 is, for example, ceramic, metal or rubber.
  • the second resin member 7 may have a glass transition temperature higher than the maximum operating temperature of the semiconductor device 50.
  • the glass transition temperature of the second resin member 7 may be, for example, 150 ° C. or higher.
  • At least one conductive wire 3 includes a plurality of conductive wires 3.
  • the second resin member 7 straddles a plurality of conductive wires 3.
  • the second resin member 7 intersects a plurality of conductive wires 3.
  • the step S5 coated with the second resin member 7 is further included.
  • the solvent of the second resin member 7 may be volatilized to temporarily cure the second resin member 7.
  • the second resin member 7 is temporarily cured by heating it on a hot plate at 100 ° C. for 1 minute, for example.
  • the second resin member 7 is finally cured.
  • the solvent of the second resin member 7 is sufficiently volatilized, the second resin member 7 is finally cured.
  • the second resin member 7 contains a polyimide resin, the imide precursor undergoes a ring closure reaction, so that the second resin member 7 is finally cured.
  • the second resin member 7 is finally cured, the second resin member 7 is heated at 200 ° C. for 3 hours in, for example, a low oxygen oven.
  • the semiconductor element 1 As shown in FIG. 21, after the step S5 coated by the second resin member 7, the semiconductor element 1, at least one first resin member 2, the second resin member 7, and the conductive wire 3 are sealed resin member 4. It may further include step S4 sealed by.
  • the rising portion 33 rises from the adjacent portion 32 on the side opposite to the main body portion 11 with respect to the surface electrode 10.
  • the second resin member 7 covers from the rising portion 33 to the joint portion 30 via the adjacent portion 32.
  • the joint portion 30, the adjacent portion 32, and the rising portion 33 can be reinforced. Therefore, even when the semiconductor device 50 is applied in the power cycle test, it is possible to suppress the occurrence of cracks in the joint portion 30, the adjacent portion 32, and the rising portion 33. Therefore, the reliability of the semiconductor device 50 can be improved.
  • the second resin member 7 contains at least one of the polyimide resin and the polyamide resin, it has higher heat resistance than the second resin member 7 which does not contain either the polyimide resin or the polyamide resin. There is. Thereby, the semiconductor device 50 having high reliability can be provided.
  • the joint portion 30, the adjacent portion 32, and the rising portion 33 can be covered with the second resin member 7 having a sufficient thickness.
  • the thickness of the second resin member 7 is, for example, 10 ⁇ m or more and 100 ⁇ m or less. As a result, it is possible to prevent cracks from occurring in the joint portion 30, the adjacent portion 32, and the rising portion 33.
  • the second resin member 7 straddles a plurality of conductive wires 3. Therefore, in the manufacturing process of the semiconductor device 50, when the second resin member 7 is dispensed, the second resin member 7 can be continuously applied. As a result, the working time in manufacturing the semiconductor device 50 can be shortened.
  • the surface of the semiconductor device 50 is surfaced with respect to at least one conductive wire 3.
  • a step S5 is further included in which the rising portion 33 of at least one conductive wire 3 to the joining portion 30 via the adjacent portion 32 is covered with the second resin member 7. Therefore, the adjacent portion 32 can be reinforced.
  • the semiconductor element 1 As shown in FIG. 21, after the step S5 coated by the second resin member 7, the semiconductor element 1, at least one first resin member 2, the second resin member 7, and the conductive wire 3 are sealed resin member 4. Further includes step S4 sealed by. Therefore, since the semiconductor element 1, at least one first resin member 2, the second resin member 7, and the conductive wire 3 are reinforced by the sealing resin member 4, the reliability of the semiconductor device 50 can be improved.
  • Embodiment 3 the semiconductor device according to the first and second embodiments described above is applied to a power conversion device.
  • the present disclosure is not limited to a specific power conversion device, the case where the present disclosure is applied to a three-phase inverter will be described below as the third embodiment.
  • FIG. 22 is a block diagram showing a configuration of a power conversion system to which the power conversion device according to the present embodiment is applied.
  • the power conversion system shown in FIG. 22 includes a power supply 100, a power conversion device 200, and a load 300.
  • the power supply 100 is a DC power supply, and supplies DC power to the power converter 200.
  • the power supply 100 can be composed of various things, for example, a DC system, a solar cell, a storage battery, a rectifier circuit connected to an AC system, or an AC / DC converter. May be good. Further, the power supply 100 may be configured by a DC / DC converter that converts the DC power output from the DC system into a predetermined power.
  • the power conversion device 200 is a three-phase inverter connected between the power supply 100 and the load 300, converts the DC power supplied from the power supply 100 into AC power, and supplies the AC power to the load 300. As shown in FIG. 22, the power conversion device 200 has a main conversion circuit 201 that converts DC power into AC power and outputs it, and a control circuit 203 that outputs a control signal for controlling the main conversion circuit 201 to the main conversion circuit 201. And have.
  • the load 300 is a three-phase electric motor driven by AC power supplied from the power converter 200.
  • the load 300 is not limited to a specific application, and is an electric motor mounted on various electric devices.
  • the load 300 is used as an electric motor for a hybrid vehicle, an electric vehicle, a railroad vehicle, an elevator, or an air conditioner.
  • the main conversion circuit 201 includes a switching element and a freewheeling diode (not shown), and when the switching element switches, the DC power supplied from the power supply 100 is converted into AC power and supplied to the load 300.
  • the main conversion circuit 201 is a two-level three-phase full bridge circuit, and has six switching elements and each switching element. It can consist of six anti-parallel freewheeling diodes.
  • each switching element and each freewheeling diode of the main conversion circuit 201 is a switching element or freewheeling diode included in the semiconductor device 202 corresponding to the semiconductor device according to any one of the above-described first and second embodiments. ..
  • the six switching elements are connected in series for each of the two switching elements to form an upper and lower arm, and each upper and lower arm constitutes each phase (U phase, V phase, W phase) of the full bridge circuit. Then, the output terminals of the upper and lower arms, that is, the three output terminals of the main conversion circuit 201 are connected to the load 300.
  • the main conversion circuit 201 includes a drive circuit (not shown) for driving each switching element
  • the drive circuit may be built in the semiconductor device 202, or a drive circuit may be provided separately from the semiconductor device 202. It may be provided.
  • the drive circuit generates a drive signal for driving the switching element of the main conversion circuit 201 and supplies the drive signal to the control electrode of the switching element of the main conversion circuit 201.
  • a drive signal for turning on the switching element and a drive signal for turning off the switching element are output to the control electrodes of each switching element.
  • the drive signal When the switching element is kept on, the drive signal is a voltage signal (on signal) equal to or higher than the threshold voltage of the switching element, and when the switching element is kept off, the drive signal is a voltage equal to or lower than the threshold voltage of the switching element. It becomes a signal (off signal).
  • the control circuit 203 controls the switching element of the main conversion circuit 201 so that the desired power is supplied to the load 300. Specifically, the time (on time) at which each switching element of the main conversion circuit 201 should be in the on state is calculated based on the power to be supplied to the load 300.
  • the main conversion circuit 201 can be controlled by PWM control that modulates the on-time of the switching element according to the voltage to be output. Then, a control command (control signal) is output to the drive circuit included in the main conversion circuit 201 so that an on signal is output to the switching element that should be turned on at each time point and an off signal is output to the switching element that should be turned off. Is output.
  • the drive circuit outputs an on signal or an off signal as a drive signal to the control electrode of each switching element according to this control signal.
  • the semiconductor device according to the first embodiment and the second embodiment is applied as the semiconductor device 202 constituting the main conversion circuit 201, it has high reliability and is simple. A power conversion device having a structure can be realized.
  • the present disclosure is not limited to this, and can be applied to various power conversion devices.
  • a two-level power conversion device is used, but a three-level or multi-level power conversion device may be used, and when power is supplied to a single-phase load, the present disclosure is provided to a single-phase inverter. You may apply it.
  • the present disclosure can be applied to a DC / DC converter or an AC / DC converter.
  • the power conversion device to which the present disclosure is applied is not limited to the case where the above-mentioned load is an electric motor. It can also be used as a power conditioner for a photovoltaic power generation system, a power storage system, or the like.

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Abstract

半導体装置（５０）は、半導体素子（１）と、少なくとも１つの第１樹脂部材（２）と、少なくとも１つの導電ワイヤ（３）とを備えている。半導体素子（１）は、表面電極（１０）と本体部（１１）とを含んでいる。少なくとも１つの第１樹脂部材（２）は、表面電極（１０）の第２面（１０ｔ）に配置されている。少なくとも１つの導電ワイヤ（３）は、接合部（３０）を含んでいる。少なくとも１つの第１樹脂部材（２）は、凸部（２０）を含んでいる。凸部（２０）は、表面電極（１０）に対して本体部（１１）とは反対側に突出している。少なくとも１つの導電ワイヤ（３）は、凹部（３１）を含んでいる。凹部（３１）は、接合部（３０）に隣り合っている。凹部（３１）は、凸部（２０）に沿って延びている。凹部（３１）は、凸部（２０）に嵌合している。

Description

半導体装置、電力変換装置および半導体装置の製造方法
　本発明は、半導体装置、電力変換装置および半導体装置の製造方法に関するものである。
　従来、半導体素子と、接合部において半導体素子の電極に接合された導電ワイヤと、導電ワイヤの接合部と電極とを覆う第１樹脂部材とを備えた半導体装置がある。例えば、ＷＯ２０１６／０１６９７０号公報（特許文献１）に記載された半導体装置では、電極の上に配置された第１樹脂部材は、導電ワイヤの接合部の端部まで行き渡らせることが可能である。
ＷＯ２０１６／０１６９７０号公報
　上記公報に掲載された半導体装置では、第１樹脂部材の粘度は、第１樹脂部材が電極の上を流動できる程度に低い。このため、第１樹脂部材が電極の上から流出することを抑制するために、第１樹脂部材よりも厚い膜厚を有する第２の樹脂膜を電極の周縁にさらに設ける必要がある。したがって、半導体装置の構造が複雑になるという問題がある。
　本発明は上記課題に鑑みてなされたものであり、その目的は、導電ワイヤと電極との間において導電ワイヤの接合部の端部まで第１樹脂部材を行き渡らせることができ、かつ簡易な構造を有する半導体装置、電力変換装置および半導体装置の製造方法を提供することである。
　本発明の半導体装置は、半導体素子と、少なくとも１つの第１樹脂部材と、少なくとも１つの導電ワイヤとを備えている。半導体素子は、本体部と、表面電極とを含んでいる。表面電極は、第１面および第２面を有している。第１面は、本体部に接合されている。第２面は、第１面に対向している。少なくとも１つの第１樹脂部材は、表面電極の第２面に配置されている。少なくとも１つの導電ワイヤは、接合部を含んでいる。接合部は、少なくとも１つの第１樹脂部材に隣り合っている。接合部は、第２面に接合されている。少なくとも１つの第１樹脂部材は、凸部を含んでいる。凸部は、表面電極に対して本体部とは反対側に突出している。少なくとも１つの導電ワイヤは、凹部を含んでいる。凹部は、接合部に隣り合っている。凹部は、凸部に沿って延びている。凹部は、凸部に嵌合している。
　本発明の半導体装置によれば、少なくとも１つの導電ワイヤの凹部は、接合部に隣り合っている。凹部は、少なくとも１つの第１樹脂部材の凸部に嵌合している。このため、第１樹脂部材の凸部を接合部の端部まで行き渡らせることができる。また、少なくとも１つの導電ワイヤの凹部は、第１樹脂部の凸部に嵌合している。このため、簡易な構造を有する半導体装置を提供することができる。
実施の形態１に係る半導体装置の構成を概略的に示す断面図である。 実施の形態１に係る半導体装置の構成を概略的に示す図１のＩＩ領域の拡大上面図である。 実施の形態１に係る半導体装置の構成を概略的に示す図１のＩＩ領域の拡大断面図である。 第１樹脂部材および導電ワイヤの寸法を示し、図３に対応する拡大断面図である。 実施の形態１に係る半導体装置の他の構成を概略的に示す図１のＩＩ領域の拡大断面図である。 図３のＶＩ－ＶＩ線に沿った断面図である。 図３のＶＩＩ－ＶＩＩ線に沿った断面図である。 図３のＶＩＩＩ－ＶＩＩＩ線に沿った断面図である。 図３のＩＸ－ＩＸ線に沿った断面図である。 実施の形態１の第１の変形例に係る半導体装置の構成を概略的に示し、図１のＩＩ領域に対応する拡大上面図である。 実施の形態１の第２の変形例に係る半導体装置の構成を概略的に示し、図１のＩＩ領域に対応する拡大上面図である。 実施の形態１の第２の変形例に係る半導体装置の構成を概略的に示し、図１のＩＩ領域に対応する拡大断面図である。 実施の形態１に係る半導体装置の製造方法を概略的に示すフローチャートである。 実施の形態１に係る半導体装置の製造方法における第１樹脂部材および第１電極を概略的に示す断面図である。 実施の形態１に係る半導体装置の製造方法におけるディスペンサ、第１樹脂部材および第１電極を概略的に示す断面図である。 実施の形態１に係る半導体装置の他の製造方法を概略的に示すフローチャートである。 実施の形態２に係る半導体装置の構成を概略的に示す断面図である。 実施の形態２に係る半導体装置の構成を概略的に示す図１７のＸＶＩＩＩ領域の拡大断面図である。 実施の形態２に係る半導体装置の構成を概略的に示す図１７のＸＶＩＩＩ領域の拡大上面図である。 実施の形態２の変形例に係る半導体装置の構成を概略的に示し、図１９に対応する拡大上面図である。 実施の形態２に係る半導体装置の製造方法を概略的に示すフローチャートである。 実施の形態３に係る電力変換システムの構成を概略的に示すブロック図である。
　以下、実施の形態について図に基づいて説明する。なお、以下では、同一または相当する部分に同一の符号を付すものとし、重複する説明は繰り返さない。
　実施の形態１．
　＜半導体装置５０の構成について＞
　図１を用いて、実施の形態１に係る半導体装置５０の構成を説明する。図１に示されるように、半導体装置５０は、半導体素子１と、少なくとも１つの第１樹脂部材２と、少なくとも１つの導電ワイヤ３と、回路基板５と、ケース６とを含んでいる。半導体装置５０は、封止樹脂部材４を含んでいてもよい。半導体装置５０は、電力用のパワー半導体装置である。
　＜半導体素子１の構成について＞
　次に、図１を用いて、実施の形態１に係る半導体素子１の構成を説明する。図１に示されるように、半導体素子１は、表面電極１０と、本体部１１と、裏面電極１２とを含んでいる。表面電極１０は、第１面１０ｂおよび第２面１０ｔを有している。第１面１０ｂは、本体部１１に接合されている。第２面１０ｔは、第１面１０ｂに対向している。本実施の形態において、表面電極１０の第１面１０ｂに第２面１０ｔが対向する方向を第１方向（Ｚ軸方向）とする。
　半導体素子１は、電力用のパワー半導体素子である。半導体素子１は、例えば、絶縁ゲート型バイポーラトランジスタ（ＩＧＢＴ：Insulated　Gate　Bipolar　Transistor）および金属酸化物半導体電界効果トランジスタ（ＭＯＳＦＥＴ：Metal　Oxide　Semiconductor　Field　Effect　Transistor）などのスイッチング素子であってもよいし、ショットキーバリアダイオードなどの整流素子であってもよい。半導体素子１の材料は、例えば、珪素（Ｓｉ）である。半導体素子１の材料は、例えば、炭化珪素（ＳｉＣ）、窒化ガリウム（ＧａＮ）またはダイヤモンドなどのワイドバンドギャップ半導体材料を含んでいてもよい。
　表面電極１０には、少なくとも１つの導電ワイヤ３が接合されている。表面電極１０の第２面１０ｔは、少なくとも１つの導電ワイヤ３に向かい合っている。裏面電極１２は、回路基板５に接合されている。表面電極１０および裏面電極１２は、本体部１１を挟み込んでいる。
　表面電極１０および裏面電極１２の材料は、例えば、珪素（Ｓｉ）を含むアルミニウム（Ａｌ）合金である。表面電極１０および裏面電極１２は、図示されない少なくとも１つの被覆層で覆われていてもよい。図示されない少なくとも１つの被覆層の材料は、例えば、ニッケル（Ｎｉ）または金（Ａｕ）である。図示されない少なくとも１つの被覆層は、図示されない複数の被覆層を含んでいてもよい。図示されない複数の被覆層は、積層されていてもよい。
　＜第１樹脂部材２の構成について＞
　次に、図１～図５を用いて、実施の形態１に係る第１樹脂部材２の構成を説明する。なお、図２～図５には封止樹脂部材４（図１参照）は説明の便宜のため図示されていない。図１に示されるように、少なくとも１つの第１樹脂部材２は、表面電極１０の第２面１０ｔに配置されている。図２に示されるように、少なくとも１つの第１樹脂部材２は、上面視において、少なくとも１つの導電ワイヤ３と交差している。図３に示されるように、少なくとも１つの第１樹脂部材２の各々の第３方向（Ｙ軸方向）から見たときの形状は、曲線構成による山形の形状である。少なくとも１つの第１樹脂部材２は、表面電極１０の第２面１０ｔと少なくとも１つの導電ワイヤ３との間に配置されている。
　図３に示されるように、少なくとも１つの第１樹脂部材２は、凸部２０を含んでいる。凸部２０は、表面電極１０に対して本体部１１とは反対側に突出している。凸部２０は、後述される凹部３１に沿った凸面である。凸部２０は、凸部内側端２ｉおよび凸部外側端２ｏを含んでいる。凸部内側端２ｉは、後述される接合部３０および凹部３１に隣り合っている。凸部外側端２ｏは、凸部内側端２ｉに対して接合部３０とは反対側に設けられている。
　図３に示されるように、本実施の形態において、少なくとも１つの第１樹脂部材２は、一方第１樹脂部材２ａおよび他方第１樹脂部材２ｂを含んでいる。一方第１樹脂部材２ａは、他方第１樹脂部材２ｂから間を空けて配置されている。一方第１樹脂部材２ａは、凸部２０に含まれる一方凸部２０ａを含んでいる。一方凸部２０ａは、凸部内側端２ｉに含まれる一方凸部内側端２ａｉと、凸部外側端２ｏに含まれる一方凸部外側端２ａｏとを含んでいる。
　他方第１樹脂部材２ｂは、凸部２０に含まれる他方凸部２０ｂを含んでいる。他方凸部２０ｂは、凸部内側端２ｉに含まれる他方凸部内側端２ｂｉと、凸部外側端２ｏに含まれる他方凸部外側端２ｂｏとを含んでいる。
　図４に示されるように、少なくとも１つの第１樹脂部材２の第１方向（Ｚ軸方向）の寸法Ｈ２は、接合部３０が設けられた部分の少なくとも１つの導電ワイヤ３の第１方向（Ｚ軸方向）の寸法Ｈ３の例えば、０．２倍以上１倍未満である。少なくとも１つの第１樹脂部材２の各々の第１方向（Ｚ軸方向）の寸法は、表面電極１０の第２面１０ｔから凸部２０の頂部までの寸法である。
　少なくとも１つの第１樹脂部材２の第２方向（Ｘ軸方向）の寸法Ｗ２は、接合部３０の第３方向（Ｙ軸方向）の寸法の例えば、０．５倍以上１０倍以下である。第１樹脂部材２の第２方向（Ｘ軸方向）の寸法は、凸部２０の凸部内側端２ｉから凸部外側端２ｏまでの寸法である。
　少なくとも１つの第１樹脂部材２の各々は、ポリイミド系樹脂およびポリアミド系樹脂の少なくともいずれかを含んでいる。少なくとも１つの第１樹脂部材２の材料は、高い耐熱性を有する樹脂である。
　少なくとも１つの第１樹脂部材２の粘度は、例えば、５０Ｐａ・ｓ以上１５０Ｐａ・ｓ以下である。なお、本実施の形態において、粘度は、ＪＩＳ規格５６００－２－３に定められるコーン・プレート粘度計法によって計測される。
　少なくとも１つの第１樹脂部材２のチクソトロピー・インデックスは、例えば、１．１以上である。少なくとも１つの第１樹脂部材２のチクソトロピー・インデックスは、例えば、２．５以上であってもよい。なお、本実施の形態において、チクソトロピー・インデックスは、ＪＩＳ規格Ｋ６８３３－１に定められるチクソトロピー・インデックスである。
　第１樹脂部材２は、半導体装置５０の最高使用温度よりも高いガラス転移温度を有していてもよい。第１樹脂部材２のガラス転移温度は、例えば、１５０℃以上であってもよい。第１樹脂部材２は、図示されないフィラーを含んでいてもよい。第１樹脂部材２に含まれる図示されないフィラーの材料は、例えば、金属またはゴムである。
　図５に示されるように、凸部２０は、裾部２０４と突出部２０５とを含んでいてもよい。裾部２０４は、第２面１０ｔに接している。突出部２０５は、裾部２０４に対して第２面１０ｔとは反対側に突出している。凸部２０が裾部２０４と突出部２０５とを含む場合、凸部２０の第１方向（Ｚ軸方向）の寸法は、第２面１０ｔから凸部２０の頂部までの寸法である。
　＜導電ワイヤ３の構成について＞
　次に、図３～図９を用いて、実施の形態１に係る導電ワイヤ３の構成を説明する。なお、図３～図９には封止樹脂部材４（図１参照）は説明の便宜のため図示されていない。図３に示されるように、少なくとも１つの導電ワイヤ３は、接合部３０を含んでいる。接合部３０は、少なくとも１つの第１樹脂部材２に隣り合っている。接合部３０は、第２面１０ｔに接合されている。少なくとも１つの導電ワイヤ３は、凹部３１を含んでいる。凹部３１は、接合部３０に隣り合っている。凹部３１は、凸部２０に沿って延びている。凹部３１は、凸部２０に嵌合している。
　本実施の形態において、第２面１０ｔに沿って接合部３０から凹部３１に向かう方向を第２方向（Ｘ軸方向）とする。第２方向（Ｘ軸方向）は、接合部３０の長手方向と同じである。第１方向（Ｚ軸方向）および第２方向（Ｘ軸方向）の両方に直交する方向を第３方向（Ｙ軸方向）とする。第３方向（Ｙ軸方向）は、接合部３０の幅方向と同じである。
　図３に示されるように、接合部３０は、第２面１０ｔに沿って一方凸部２０ａと他方凸部２０ｂとに挟み込まれている。接合部３０は、接合部一方端３０ａおよび接合部他方端３０ｂを含んでいる。接合部一方端３０ａは、一方凸部内側端２ａｉと隣り合っている。接合部他方端３０ｂは、他方凸部内側端２ｂｉと隣り合っている。接合部３０の第２方向（Ｘ軸方向）の寸法は、接合部一方端３０ａから接合部他方端３０ｂまでの表面電極１０の第２面１０ｔに沿った寸法である。
　本実施の形態において、接合部３０は、接合部一方端３０ａおよび接合部他方端３０ｂにおいてのみ第１樹脂部材２に接している。接合部３０は、第１樹脂部材２に取り囲まれていない。接合部一方端３０ａは、接合部一方端３０ａ側から接合部他方端３０ｂ側に延びている一方第１樹脂部材２ａに接している。接合部他方端３０ｂは、接合部他方端３０ｂ側から接合部一方端３０ａ側に延びている他方第１樹脂部材２ｂに接している。
　図３に示されるように、凹部３１は、凸部２０および接合部３０に隣り合っている。凹部３１は、凸部２０に沿った凹面である。凹部３１は、上面視において凸部２０に重なっている。本実施の形態において、凹部３１は、一方凹部３１ａおよび他方凹部３１ｂを含んでいる。一方凹部３１ａは、他方凹部３１ｂとで接合部３０を挟み込んでいる。一方凹部３１ａは、一方第１樹脂部材２ａの一方凸部２０ａに嵌合している。一方凹部３１ａは、接合部一方端３０ａにおいて、接合部３０および一方第１樹脂部材２ａに隣り合っている。他方凹部３１ｂは、他方第１樹脂部材２ｂの他方凸部２０ｂに嵌合している。他方凹部３１ｂは、接合部他方端３０ｂにおいて、接合部３０および他方第１樹脂部材２ｂに隣り合っている。
　図１に示されるように、少なくとも１つの導電ワイヤ３は、回路基板５の導電回路パターン５１に接合されている。少なくとも１つの導電ワイヤ３は、例えば、ワイヤボンダーによって、表面電極１０および導電回路パターン５１にボンディングされてもよい。
　少なくとも１つの導電ワイヤ３は、例えば、ウェッジツールによってボンディングされる。図６に示されるように、少なくとも１つの導電ワイヤ３がウェッジツールによってボンディングされた場合、接合部３０の断面形状は略三角形である。図７に示されるように、少なくとも１つの導電ワイヤ３がウェッジツールによってボンディングされた場合、凹部３１の断面形状は略三角形である。図８および図９に示されるように、凹部３１に対して接合部３０とは反対側に延びている延伸部は、第２面１０ｔおよび少なくとも１つの第１樹脂部材２から離れている。
　図３に示されるように、少なくとも１つの導電ワイヤ３は、ワイヤ上面３ｔおよびワイヤ下面３ｂを含んでいる。ワイヤ下面３ｂは、表面電極１０の第２面１０ｔと向かい合っている。ワイヤ上面３ｔは、ワイヤ下面３ｂに対向している。
　少なくとも１つの導電ワイヤ３の材料は、例えば、金（Ａｕ）、アルミニウム（Ａｌ）または銅（Ｃｕ）などの金属である。
　＜封止樹脂部材４の構成について＞
　次に、図１を用いて、実施の形態１に係る封止樹脂部材４の構成を説明する。図１に示されるように、封止樹脂部材４は、半導体素子１と、少なくとも１つの第１樹脂部材２と、少なくとも１つの導電ワイヤ３とを封止している。封止樹脂部材４は、導電ワイヤ３の少なくとも一部を封止していてもよいし、導電ワイヤ３の全体を封止していてもよい。封止樹脂部材４の材料は、例えば、絶縁樹脂材料である。半導体装置５０は封止樹脂部材４を含んでいてもよいし、封止樹脂部材４を含んでいなくてもよい。
　＜回路基板５の構成について＞
　次に、図１を用いて、実施の形態１に係る回路基板５の構成を説明する。図１に示されるように、回路基板５は、導電回路パターン５１と、絶縁基板５２と、導電板５３とを含んでいる。導電回路パターン５１と、絶縁基板５２と、導電板５３とは、導電回路パターン５１、絶縁基板５２、導電板５３の順に積層されている。絶縁基板５２は、Ｘ－Ｙ平面に延在している。絶縁基板５２の材料は、例えば、酸化アルミニウム（Ａｌ２Ｏ３）、窒化アルミニウム（ＡｌＮ）または窒化珪素（Ｓｉ３Ｎ４）などの無機材料（セラミックス材料）などである。絶縁基板５２は、絶縁基板上面と、絶縁基板上面に対向する絶縁基板下面とを含んでいる。導電回路パターン５１は、絶縁基板上面に設けられている。導電板５３は、絶縁基板下面に設けられている。導電回路パターン５１および導電板５３の材料は、例えば、銅（Ｃｕ）またはアルミニウム（Ａｌ）などの金属である。
　導電回路パターン５１には、半導体素子１の裏面電極１２が接合されている。裏面電極１２は、例えば、図示されないはんだまたは金属微粒子焼結体などによって、導電回路パターン５１に接合されている。
　＜ケース６について＞
　次に、図１を用いて、実施の形態１に係るケース６の構成を説明する。図１に示されるように、ケース６は、ヒートシンク６１および外囲体６２を含んでいる。半導体装置５０は、ケース６によって、ケースタイプのモジュールとして構成される。封止樹脂部材４は、少なくとも部分的に、ケース６の内部空間に充填されている。
　ヒートシンク６１には、回路基板５が取り付けられている。ヒートシンク６１には、回路基板５の導電板５３が、例えば、電熱グリースなどの図示されない接合部材によって接合されている。半導体素子１から発生した熱は、回路基板５を通って、ヒートシンク６１に伝達される。ヒートシンク６１に伝達された熱は、半導体装置５０の外部に拡散される。ヒートシンク６１の材料は、例えば、アルミニウム（Ａｌ）などの金属である。
　外囲体６２は、半導体素子１、少なくとも１つの第１樹脂部材２、少なくとも１つの導電ワイヤ３、回路基板５、および封止樹脂部材４を囲んでいる。外囲体６２は、ヒートシンク６１の周縁に取り付けられている。外囲体６２の材料は、例えば、ポリフェニレンサルファイド（ＰＰＳ）またはポリブチレンテレフタレート（ＰＢＴ）などの絶縁樹脂である。
　＜第１の変形例の構成について＞
　以下、実施の形態１の第１の変形例について図１０に基づいて説明する。なお、以下では、同一または相当する部分に同一の符号を付すものとし、重複する説明は繰り返さない。
　図１０に示されるように、実施の形態１の第１の変形例において、少なくとも１つの導電ワイヤ３は、複数の導電ワイヤ３を含んでいる。複数の導電ワイヤ３の各々の凹部３１は、凸部２０に嵌合している。本実施の形態において、少なくとも１つの第１樹脂部材２は、複数の導電ワイヤ３にまたがって形成されている。少なくとも１つの第１樹脂部材２の各々は、複数の導電ワイヤ３に交差している。実施の形態１の変形例における少なくとも１つの導電ワイヤ３が複数の導電ワイヤ３を含んでいる点において、実施の形態１の第１の変形例は、実施の形態１と異なっている。
　＜第２の変形例の構成について＞
　以下、実施の形態１の第２の変形例について図１１および図１２に基づいて説明する。なお、以下では、同一または相当する部分に同一の符号を付すものとし、重複する説明は繰り返さない。
　図１１に示されるように、実施の形態１の第２の変形例において、少なくとも１つの第１樹脂部材２は、１つの第１樹脂部材２からなる。少なくとも１つの導電ワイヤ３は、１つの導電ワイヤ３からなる。図１２に示されるように、１つの第１樹脂部材２の凸部２０は、１つの導電ワイヤ３の１つの凹部３１に嵌合している。凸部２０は、接合部３０の接合部一方端３０ａおよび接合部他方端３０ｂのいずれかに接している。
＜半導体装置５０の製造方法について＞
　次に、主に図１３～１６を用いて、実施の形態１に係る半導体装置５０の製造方法を説明する。
　図１３に示されるように、半導体装置５０の製造方法は、半導体素子１が準備される工程Ｓ１と、凸部２０が形成される工程Ｓ２と、凹部３１が凸部２０に嵌合される工程Ｓ３とを含んでいる。
　半導体素子１が準備される工程Ｓ１において、半導体素子１が準備される。図１に示されるように、半導体素子１は、回路基板５に接合される。
　図１４に示されるように、凸部２０が形成される工程Ｓ２において、少なくとも１つの第１樹脂部材２が表面電極１０の第２面１０ｔに塗布されることによって、少なくとも１つの第１樹脂部材２に凸部２０が形成される。
　図１５に示されるように、第１樹脂部材２は、ディスペンサ８によって、表面電極１０に塗布される。第１樹脂部材２がディスペンスされる際における表面電極１０とディスペンサノズルとの間の距離ＨＤは、第１樹脂部材２のチクソトロピー・インデックスが１．１よりも大きい場合、第１樹脂部材のチクソトロピー・インデックスが１．１以下である場合よりも、小さくなる。
　図１４に示されるように、第１樹脂部材２は、凹部３１（図３参照）が凸部２０に嵌合される工程Ｓ３において凸部２０が接合部一方端３０ａおよび接合部他方端３０ｂの少なくともいずれかに隣り合う位置に配置されるように、あらかじめ塗布される。具体的には、第１樹脂部材２は、凹部３１（図３参照）が凸部２０に嵌合される工程Ｓ３において一方凸部２０ａが接合部一方端３０ａに隣り合う位置に配置されるように、あらかじめ塗布される。具体的には、第１樹脂部材２は、凹部３１（図３参照）が凸部２０に嵌合される工程Ｓ３において他方凸部２０ｂが接合部他方端３０ｂに隣り合う位置に配置されるように、あらかじめ塗布される。
　塗布された第１樹脂部材２は、加熱される。第１樹脂部材２が加熱されることによって第１樹脂部材２に含まれる溶媒が蒸発するため、第１樹脂部材２は、導電ワイヤ３が接合される際に凸部２０の形状が保持される程度に硬くなる。本実施の形態において、第１樹脂部材２が導電ワイヤ３が接合される際に凸部２０の形状が保持される程度に硬くなることを、仮硬化と呼ぶ。
　凸部２０が形成される工程Ｓ２において、少なくとも１つの第１樹脂部材２の凸部２０が保持される状態に少なくとも１つの第１樹脂部材２が仮硬化される。第１樹脂部材２は、例えば、ホットプレート上において１００℃で１分間加熱されることによって、仮硬化される。図１４に示されるように、仮硬化された第１樹脂部材２は、導電ワイヤ３に接着され得る。
　図３に示されるように、凹部３１が凸部２０に嵌合される工程Ｓ３において、少なくとも１つの導電ワイヤ３の接合部３０が少なくとも１つの第１樹脂部材２に隣り合うように表面電極１０の第２面１０ｔに接合される。凹部３１が凸部２０に嵌合される工程Ｓ３において、凹部３１が形成され、かつ凹部３１が凸部２０に嵌合される。導電ワイヤ３が凸部２０に沿って変形することによって、導電ワイヤ３に凹部３１が形成される。具体的には、仮硬化された第１樹脂部材２に導電ワイヤ３が押しつけられることによって、導電ワイヤ３が凹むため、導電ワイヤ３に凹部３１が形成される。第１樹脂部材２が表面電極１０の第２面１０ｔに塗布された後に、導電ワイヤ３が第２面１０ｔに接合されつつ、凹部３１が凸部２０に嵌合される。
　また、凹部３１が凸部２０に嵌合される工程Ｓ３において、回路基板５は、ヒートシンク６１に接合される。外囲体６２は、ヒートシンク６１に接合される。
　凹部３１が凸部２０に嵌合される工程Ｓ３の後に、第１樹脂部材２が本硬化される。第１樹脂部材２の溶媒が十分に揮発されることによって、第１樹脂部材２が本硬化される。また、第１樹脂部材２がポリイミド系樹脂を含む場合、イミド前駆体に閉環反応が生じることによって、第１樹脂部材２は本硬化される。第１樹脂部材２が本硬化される際に、第１樹脂部材２は、例えば、低酸素オーブン内において２００℃で３時間加熱される。
　図１６に示されるように、半導体装置５０の製造方法は、凹部３１が凸部２０に嵌合される工程Ｓ３の後に、半導体素子１、少なくとも１つの第１樹脂部材２および導電ワイヤ３が封止樹脂部材４によって封止される工程Ｓ４を含んでいてもよい。液状の封止樹脂部材４が半導体素子１、少なくとも１つの第１樹脂部材２および導電ワイヤ３の上に供給される。供給された封止樹脂部材４は、硬化される。
　＜作用効果について＞
　続いて、本実施の形態の作用効果を説明する。
　本実施の形態に係る半導体装置５０によれば、図３に示されるように、少なくとも１つの導電ワイヤ３の凹部３１は、接合部３０に隣り合っているため、接合部３０の端部に接している。凹部３１は、少なくとも１つの第１樹脂部材２の凸部２０に嵌合している。これにより、凹部３１に嵌合された第１樹脂部材２の凸部２０を接合部３０の端部まで行き渡らせることができる。
　具体的には、一方第１樹脂部材２ａが少なくとも１つの導電ワイヤ３の一方凹部３１ａおよび接合部一方端３０ａに隣り合うように、一方第１樹脂部材２ａを配置できる。これにより、一方第１樹脂部材２ａを接合部一方端３０ａまで行き渡らせることができる。また、他方第１樹脂部材２ｂが少なくとも１つの導電ワイヤ３の他方凹部３１ｂおよび接合部他方端３０ｂに隣り合うように、他方第１樹脂部材２ｂを配置することができる。これにより、他方第１樹脂部材２ｂを接合部他方端３０ｂまで行き渡らせることができる。
　図３に示されるように、少なくとも１つの凹部３１が少なくとも１つの第１樹脂部材２の凸部２０に嵌合しているため、第１樹脂部材２を表面電極１０と導電ワイヤ３との間に隙間なく設けることができる。これにより、第１樹脂部材２の形状を安定させることができる。このため、パワーサイクル試験において半導体装置５０に印可された場合でも、第１樹脂部材２を少なくとも１つの導電ワイヤ３と表面電極１０との間に固定し続けることができる。これにより、接合部３０にクラックが発生することを抑制できる。したがって、半導体装置５０の信頼性を向上することができる。
　図３に示されるように、少なくとも１つの導電ワイヤ３の凹部３１は、第１樹脂部材２の凸部２０に嵌合している。第１樹脂部材２は、凸部２０が維持されている状態で、凹部３１に嵌合している。このため、簡易な構造を有する半導体装置５０を提供することができる。
　第１樹脂部材２の粘度が５０Ｐａ・ｓ以上１５０Ｐａ・ｓ以下であるため、第１樹脂部材２が表面電極１０の上に保持され得る。これにより、第１樹脂部材２が表面電極１０の上から流出するおそれがない。よって、第１樹脂部材２が表面電極１０の上から流出することを抑制するための構造を設ける必要がない。したがって、簡易な構造を有する半導体装置５０を提供することができる。
　第１樹脂部材２がポリイミド系樹脂およびポリアミド系樹脂の少なくともいずれかを含んでいるため、ポリイミド系樹脂およびポリアミド系樹脂のいずれも含まない第１樹脂部材２よりも、高い耐熱性を有している。これにより、高い信頼性を有する半導体装置５０を提供できる。
　図４に示されるように、少なくとも１つの第１樹脂部材２の第１方向（Ｚ軸方向）の寸法Ｈ２が、接合部３０が設けられた部分の少なくとも１つの導電ワイヤ３の第１方向（Ｚ軸方向）の寸法Ｈ３の０．２倍以上１倍未満であり、少なくとも１つの第１樹脂部材２の第２方向（Ｘ軸方向）の寸法Ｗ２が接合部３０の第３方向（Ｙ軸方向）の寸法の０．５倍以上１０倍以下である。これにより、少なくとも１つの第１樹脂部材２を少なくとも１つの導電ワイヤ３と表面電極１０との間に効率良く配置することができる。具体的には、第１樹脂部材２を導電ワイヤ３と表面電極１０との間に配置しつつ、導電ワイヤ３と表面電極１０との間からはみ出さないようにすることができる。これにより、第１樹脂部材２の使用量を減らすことができる。また、第１樹脂部材２が効率良く設けられることによって、導電ワイヤ３を第１樹脂部材２によって効率良く補強できる。
　仮に第１樹脂部材２の表面張力によって導電ワイヤ３と表面電極１０との間に第１樹脂部材２が充填される場合、第１樹脂部材２の寸法を上記の寸法にすることは難しいため、第１樹脂部材２を効率良く設けることは難しい。
　第１樹脂部材２のチクソトロピー・インデックスが１．１以上であるため、少なくとも１つの第１樹脂部材２の第１方向（Ｚ軸方向）の寸法Ｈ２を接合部３０が設けられた部分の少なくとも１つの導電ワイヤ３の第１方向（Ｚ軸方向）の寸法Ｈ３の０．２倍以上１倍未満にでき、少なくとも１つの第１樹脂部材２の第２方向（Ｘ軸方向）の寸法Ｗ２を接合部３０の第３方向（Ｙ軸方向）の寸法の０．５倍以上１０倍以下にできる。これにより、第１樹脂部材２を効率良く設けることができる。
　図３に示されるように、接合部３０は、接合部一方端３０ａおよび接合部他方端３０ｂにおいてのみ第１樹脂部材２に接している。接合部３０の全周が第１樹脂部材２に接している場合よりも、第１樹脂部材２の使用量を小さくすることができる。
　本実施の形態の第１の変形例によれば、図１０に示されるように、複数の導電ワイヤ３の各々の凹部３１は、凸部２０に嵌合されている。このため、１つの第１樹脂部材２の各々に、複数の導電ワイヤ３が接合されている。よって、半導体装置５０の製造における作業時間を、複数の第１樹脂部材２がディスペンスされている場合よりも、短縮できる。
　本実施の形態の第２の変形例によれば、図１２に示されるように、少なくとも１つの第１樹脂部材２は、１つの第１樹脂部材２からなっていてもよい。これにより、少なくとも１つの第１樹脂部材２が複数の第１樹脂部材２を含んでいる場合よりも、第１樹脂部材２の使用量を減らすことができる。よって、半導体装置５０の製造コストを小さくすることができる。
　本実施の形態の半導体装置５０の製造方法によれば、図１３に示されるように、半導体装置５０の製造方法は、導電ワイヤ３の凹部３１が第１樹脂部材２の凸部２０に嵌合される工程Ｓ３を含んでいる。これにより、第１樹脂部材２を導電ワイヤ３と表面電極１０との間に隙間なく配置することができる。
　半導体装置５０の製造方法は、導電ワイヤ３の凹部３１が第１樹脂部材２の凸部２０に嵌合される工程Ｓ３を含んでいる。これにより、第１樹脂部材２は、凸部２０が維持されている状態で、凹部３１に嵌合する。よって、簡易な構造を有する半導体装置５０を提供することができる。
　第１樹脂部材２が表面電極１０の第２面１０ｔに塗布された後に、導電ワイヤ３の凹部３１が第１樹脂部材２の凸部２０に接着されるため、第１樹脂部材２を導電ワイヤ３と表面電極１０との間に隙間なく配置することができる。
　凸部２０が形成される工程Ｓ２において、少なくとも１つの第１樹脂部材２の凸部２０が保持される状態に少なくとも１つの第１樹脂部材２が仮硬化される。これにより、凸部２０の形状が保持され得る。また、仮硬化された少なくとも１つの第１樹脂部材２に少なくとも１つの導電ワイヤ３が押し当てられることによって、少なくとも１つの導電ワイヤ３が凹む。これによって、少なくとも１つの導電ワイヤ３に凹部３１が形成され得る。
　凹部３１が凸部２０に嵌合される工程Ｓ３の後に、第１樹脂部材２が本硬化される。このため、第１樹脂部材２が導電ワイヤ３に十分に接着され得る。
　図１６に示されるように、凹部３１が凸部２０に嵌合される工程Ｓ３の後に、半導体素子１、少なくとも１つの第１樹脂部材２および導電ワイヤ３が封止樹脂部材４によって封止される。これにより、半導体素子１、少なくとも１つの第１樹脂部材２および導電ワイヤ３が封止樹脂部材４によって補強されるため、半導体装置５０の信頼性を向上することができる。
　実施の形態２．
　実施の形態２は、特に説明しない限り、上記の実施の形態１と同一の構成、製造方法および作用効果を有している。したがって、上記の実施の形態１と同一の構成には同一の符号を付し、説明を繰り返さない。
　図１７～図１９を用いて、実施の形態２に係る半導体装置５０の構成を説明する。図１７に示されるように、本実施の形態において、半導体装置５０は、第２樹脂部材７をさらに含んでいる。本実施の形態に係る半導体装置５０は、第２樹脂部材７をさらに含んでいる点において、実施の形態１に係る半導体装置５０と異なっている。
　図１８に示されるように、本実施の形態において、少なくとも１つの導電ワイヤ３は、隣接部３２と立ち上がり部３３とを含んでいる。隣接部３２は、接合部３０に隣り合っている。立ち上がり部３３は、表面電極１０に対して本体部１１（図１参照）とは反対側に隣接部３２から立ち上がっている。少なくとも１つの導電ワイヤ３は、接合部３０、隣接部３２および立ち上がり部３３において屈曲されている。接合部３０、隣接部３２および立ち上がり部３３は、少なくとも１つの導電ワイヤ３のネック部を構成している。
　第２樹脂部材７は、少なくとも１つの導電ワイヤ３に対して表面電極１０の反対側において、立ち上がり部３３から隣接部３２を経由して接合部３０まで覆っている。第２樹脂部材７は、接合部３０の少なくとも一部と、隣接部３２と、立ち上がり部３３の少なくとも一部とを覆っている。図１９に示されるように、上面視において、第２樹脂部材７は、少なくとも１つの第１樹脂部材２と接合部３０との境界と重なっている。
　第２樹脂部材７は、ポリイミド系樹脂およびポリアミド系樹脂の少なくともいずれかを含んでいる。第２樹脂部材７は、高い耐熱性を有する樹脂であってもよい。第２樹脂部材７のチクソトロピー・インデックスは、例えば、１．１以上である。第２樹脂部材７のチクソトロピー・インデックスは、例えば、２．５以上であってもよい。
　第２樹脂部材７は、図示されないフィラーを含んでいてもよい。第２樹脂部材７に含まれる図示されないフィラーの材料は、例えば、セラミック、金属またはゴムである。第２樹脂部材７は、半導体装置５０の最高使用温度よりも高いガラス転移温度を有していてもよい。第２樹脂部材７のガラス転移温度は、例えば、１５０℃以上であってもよい。
　以下、実施の形態２の変形例について図１９および図２０に基づいて説明する。なお、以下では、同一または相当する部分に同一の符号を付すものとし、重複する説明は繰り返さない。
　図２０に示されるように、実施の形態２の変形例において、少なくとも１つの導電ワイヤ３は、複数の導電ワイヤ３を含んでいる。第２樹脂部材７は、複数の導電ワイヤ３にまたがっている。本実施の形態において、第２樹脂部材７は、複数の導電ワイヤ３に交差している。
　次に、図２１を用いて、実施の形態２に係る半導体装置５０の製造方法を説明する。
　図２１に示されるように、本実施の形態において、少なくとも１つの導電ワイヤ３の立ち上がり部３３から隣接部３２を経由して接合部３０までが、少なくとも１つの導電ワイヤ３に対して表面電極１０とは反対側において、第２樹脂部材７によって被覆される工程Ｓ５をさらに含んでいる。
　接合部３０、隣接部３２および立ち上がり部３３が第２樹脂部材７によって被覆された後に、第２樹脂部材７の溶媒が揮発されることによって、第２樹脂部材７が仮硬化されてもよい。第２樹脂部材７は、例えば、ホットプレート上において１００℃で１分間加熱されることによって、仮硬化される。
　凹部３１が凸部２０に嵌合される工程Ｓ３の後に、第２樹脂部材７が本硬化される。第２樹脂部材７の溶媒が十分に揮発されることによって、第２樹脂部材７は本硬化される。また、第２樹脂部材７がポリイミド系樹脂を含む場合、イミド前駆体に閉環反応が生じることによって、第２樹脂部材７は本硬化される。第２樹脂部材７が本硬化される際に、第２樹脂部材７は、例えば、低酸素オーブン内において２００℃で３時間加熱される。
　図２１に示されるように、第２樹脂部材７によって被覆される工程Ｓ５の後に、半導体素子１、少なくとも１つの第１樹脂部材２、第２樹脂部材７および導電ワイヤ３が封止樹脂部材４によって封止される工程Ｓ４をさらに含んでいてもよい。
　続いて、本実施の形態の作用効果を説明する。
　本実施の形態に係る半導体装置５０によれば、図１８に示されるように、立ち上がり部３３が表面電極１０に対して本体部１１とは反対側に隣接部３２から立ち上がっている。本実施の形態において、第２樹脂部材７は、立ち上がり部３３から隣接部３２を経由して接合部３０まで覆っている。これにより、接合部３０、隣接部３２および立ち上がり部３３を補強できる。よって、パワーサイクル試験において半導体装置５０に印可された場合でも、接合部３０、隣接部３２および立ち上がり部３３にクラックが発生することを抑制できる。したがって、半導体装置５０の信頼性を向上することができる。また、少なくとも１つの導電ワイヤ３が隣接部３２において破断することを抑制できる。
　第２樹脂部材７がポリイミド系樹脂およびポリアミド系樹脂の少なくともいずれかを含んでいるため、ポリイミド系樹脂およびポリアミド系樹脂のいずれも含まない第２樹脂部材７よりも、高い耐熱性を有している。これにより、高い信頼性を有する半導体装置５０を提供できる。
　第２樹脂部材７のチクソトロピー・インデックスが１．１以上であるため、接合部３０、隣接部３２および立ち上がり部３３を十分な厚みを有する第２樹脂部材７によって被覆することができる。第２樹脂部材７の厚みは、例えば、１０μｍ以上１００μｍ以下である。これにより、接合部３０、隣接部３２および立ち上がり部３３にクラックが生じることを抑制できる。
　本実施の形態の変形例に係る半導体装置５０によれば、図２０に示されるように、第２樹脂部材７は、複数の導電ワイヤ３にまたがっている。このため、半導体装置５０の製造工程において、第２樹脂部材７をディスペンスする際に、第２樹脂部材７を連続的に塗布できる。これにより、半導体装置５０の製造における作業時間を短くすることができる。
　本実施の形態に係る半導体装置５０の製造方法によれば、図２１に示されるように、凹部３１が凸部２０に嵌合される工程Ｓ３の後に、少なくとも１つの導電ワイヤ３に対して表面電極１０の反対側において、少なくとも１つの導電ワイヤ３の立ち上がり部３３から隣接部３２を経由して接合部３０までが第２樹脂部材７によって被覆される工程Ｓ５をさらに含んでいる。このため、隣接部３２が補強され得る。
　図２１に示されるように、第２樹脂部材７によって被覆される工程Ｓ５の後に、半導体素子１、少なくとも１つの第１樹脂部材２、第２樹脂部材７および導電ワイヤ３が封止樹脂部材４によって封止される工程Ｓ４をさらに含んでいる。このため、半導体素子１、少なくとも１つの第１樹脂部材２、第２樹脂部材７および導電ワイヤ３が封止樹脂部材４によって補強されるため、半導体装置５０の信頼性を向上することができる。
　実施の形態３．
　本実施の形態は、上述した実施の形態１および実施の形態２にかかる半導体装置を電力変換装置に適用したものである。本開示は特定の電力変換置に限定されるものではないが、以下、実施の形態３として、三相のインバータに本開示を適用した場合について説明する。
　図２２は、本実施の形態にかかる電力変換装置を適用した電力変換システムの構成を示すブロック図である。
　図２２に示す電力変換システムは、電源１００、電力変換装置２００、負荷３００から構成される。電源１００は、直流電源であり、電力変換装置２００に直流電力を供給する。電源１００は種々のもので構成することが可能であり、例えば、直流系統、太陽電池、蓄電池で構成することができるし、交流系統に接続された整流回路やＡＣ／ＤＣコンバータで構成することとしてもよい。また、電源１００を、直流系統から出力される直流電力を所定の電力に変換するＤＣ／ＤＣコンバータによって構成することとしてもよい。
　電力変換装置２００は、電源１００と負荷３００の間に接続された三相のインバータであり、電源１００から供給された直流電力を交流電力に変換し、負荷３００に交流電力を供給する。電力変換装置２００は、図２２に示すように、直流電力を交流電力に変換して出力する主変換回路２０１と、主変換回路２０１を制御する制御信号を主変換回路２０１に出力する制御回路２０３とを備えている。
　負荷３００は、電力変換装置２００から供給された交流電力によって駆動される三相の電動機である。なお、負荷３００は特定の用途に限られるものではなく、各種電気機器に搭載された電動機であり、例えば、ハイブリッド自動車や電気自動車、鉄道車両、エレベーター、もしくは、空調機器向けの電動機として用いられる。
　以下、電力変換装置２００の詳細を説明する。主変換回路２０１は、スイッチング素子と還流ダイオードを備えており（図示せず）、スイッチング素子がスイッチングすることによって、電源１００から供給される直流電力を交流電力に変換し、負荷３００に供給する。主変換回路２０１の具体的な回路構成は種々のものがあるが、本実施の形態にかかる主変換回路２０１は２レベルの三相フルブリッジ回路であり、６つのスイッチング素子とそれぞれのスイッチング素子に逆並列された６つの還流ダイオードから構成することができる。主変換回路２０１の各スイッチング素子および各還流ダイオードの少なくともいずれかは、上述した実施の形態１および実施の形態２のいずれかの半導体装置に相当する半導体装置２０２が有するスイッチング素子又は還流ダイオードである。６つのスイッチング素子は２つのスイッチング素子ごとに直列接続され上下アームを構成し、各上下アームはフルブリッジ回路の各相（Ｕ相、Ｖ相、Ｗ相）を構成する。そして、各上下アームの出力端子、すなわち主変換回路２０１の３つの出力端子は、負荷３００に接続される。
　また、主変換回路２０１は、各スイッチング素子を駆動する駆動回路（図示なし）を備えているが、駆動回路は半導体装置２０２に内蔵されていてもよいし、半導体装置２０２とは別に駆動回路を備える構成であってもよい。駆動回路は、主変換回路２０１のスイッチング素子を駆動する駆動信号を生成し、主変換回路２０１のスイッチング素子の制御電極に供給する。具体的には、後述する制御回路２０３からの制御信号に従い、スイッチング素子をオン状態にする駆動信号とスイッチング素子をオフ状態にする駆動信号とを各スイッチング素子の制御電極に出力する。スイッチング素子をオン状態に維持する場合、駆動信号はスイッチング素子の閾値電圧以上の電圧信号（オン信号）であり、スイッチング素子をオフ状態に維持する場合、駆動信号はスイッチング素子の閾値電圧以下の電圧信号（オフ信号）となる。
　制御回路２０３は、負荷３００に所望の電力が供給されるよう主変換回路２０１のスイッチング素子を制御する。具体的には、負荷３００に供給すべき電力に基づいて主変換回路２０１の各スイッチング素子がオン状態となるべき時間（オン時間）を算出する。例えば、出力すべき電圧に応じてスイッチング素子のオン時間を変調するＰＷＭ制御によって主変換回路２０１を制御することができる。そして、各時点においてオン状態となるべきスイッチング素子にはオン信号を、オフ状態となるべきスイッチング素子にはオフ信号が出力されるよう、主変換回路２０１が備える駆動回路に制御指令（制御信号）を出力する。駆動回路は、この制御信号に従い、各スイッチング素子の制御電極にオン信号又はオフ信号を駆動信号として出力する。
　本実施の形態に係る電力変換装置では、主変換回路２０１を構成する半導体装置２０２として実施の形態１および実施の形態２にかかる半導体装置を適用するため、高い信頼性を有し、かつ簡易な構造を有する電力変換装置を実現することができる。
　本実施の形態では、２レベルの三相インバータに本開示を適用する例を説明したが、本開示は、これに限られるものではなく、種々の電力変換装置に適用することができる。本実施の形態では、２レベルの電力変換装置としたが３レベルやマルチレベルの電力変換装置であっても構わないし、単相負荷に電力を供給する場合には単相のインバータに本開示を適用しても構わない。また、直流負荷等に電力を供給する場合にはＤＣ／ＤＣコンバータやＡＣ／ＤＣコンバータに本開示を適用することも可能である。
　また、本開示を適用した電力変換装置は、上述した負荷が電動機の場合に限定されるものではなく、例えば、放電加工機やレーザー加工機、又は誘導加熱調理器や非接触給電システムの電源装置として用いることもでき、さらには太陽光発電システムや蓄電システム等のパワーコンディショナーとして用いることも可能である。
　今回開示された実施の形態はすべての点で例示であって制限的なものではないと考えられるべきである。本発明の範囲は上記した説明ではなくて請求の範囲によって示され、請求の範囲と均等の意味および範囲内でのすべての変更が含まれることが意図される。
　１　半導体素子、２　第１樹脂部材、３　ワイヤ、４　第２樹脂部材、７　第３樹脂、１０　表面電極、１０ｔ　第１面、１０ｂ　第２面、１１　本体部、２０　凸部、３０　接合部、３１　凹部、３２　立ち上がり部、３３　立ち上がり部、５０　半導体装置、１００　電源、２００　電力変換装置、２０１　主変換回路、２０２　半導体装置、２０３　制御回路、３００　負荷。

Claims (16)

  1. 　本体部と、前記本体部に接合された第１面および前記第１面に対向する第２面を有する表面電極とを含む半導体素子と、
    　前記表面電極の前記第２面に配置された少なくとも１つの第１樹脂部材と、
    　前記少なくとも１つの第１樹脂部材に隣り合いかつ前記第２面に接合された接合部を含む少なくとも１つの導電ワイヤとを備え、
    　前記少なくとも１つの第１樹脂部材は、前記表面電極に対して前記本体部とは反対側に突出している凸部を含み、
    　前記少なくとも１つの導電ワイヤは、前記接合部に隣り合いかつ前記凸部に沿って延びる凹部を含み、
    　前記凹部は、前記凸部に嵌合している、半導体装置。
  2. 　前記少なくとも１つの第１樹脂部材の粘度は、５０Ｐａ・ｓ以上１５０Ｐａ・ｓ以下である、請求項１に記載の半導体装置。
  3. 　前記表面電極の前記第１面に前記第２面が対向する方向を第１方向とし、
    　前記第２面に沿って前記接合部から前記凹部に向かう方向を第２方向とし、
    　前記第１方向および前記第２方向の両方に直交する方向を第３方向としたときに、
    　前記少なくとも１つの第１樹脂部材の前記第１方向の寸法は、前記接合部が設けられた部分の前記少なくとも１つの導電ワイヤの前記第１方向の寸法の０．２倍以上１倍未満であり、
    　前記少なくとも１つの第１樹脂部材の前記第２方向の寸法は、前記接合部の前記第３方向の寸法の０．５倍以上１０倍以下である、請求項１または２に記載の半導体装置。
  4. 　前記少なくとも１つの第１樹脂部材は、ポリイミド系樹脂およびポリアミド系樹脂の少なくともいずれかを含む、請求項１～３のいずれか１項に記載の半導体装置。
  5. 　前記少なくとも１つの第１樹脂部材のチクソトロピー・インデックスは、１．１以上である、請求項１～４のいずれか１項に記載の半導体装置。
  6. 　第２樹脂部材をさらに備え、
    　前記少なくとも１つの導電ワイヤは、前記接合部に隣り合う隣接部と、前記表面電極に対して前記本体部とは反対側に前記隣接部から立ち上がっている立ち上がり部とを含み、
    　前記第２樹脂部材は、前記少なくとも１つの導電ワイヤに対して前記表面電極とは反対側において、前記立ち上がり部から前記隣接部を経由して前記接合部まで覆っている、請求項１～５のいずれか１項に記載の半導体装置。
  7. 　前記第２樹脂部材は、ポリイミド系樹脂およびポリアミド系樹脂の少なくともいずれかを含む、請求項６に記載の半導体装置。
  8. 　前記第２樹脂部材のチクソトロピー・インデックスは、１．１以上である、請求項６または７に記載の半導体装置。
  9. 　前記少なくとも１つの導電ワイヤは、複数の導電ワイヤを含み、
    　前記複数の導電ワイヤの各々の前記凹部は、前記凸部に嵌合している、請求項１～８のいずれか１項に記載の半導体装置。
  10. 　前記少なくとも１つの導電ワイヤは、複数の導電ワイヤを含み、
    　前記第２樹脂部材は、前記複数の導電ワイヤにまたがっている、請求項６～８のいずれか１項に記載の半導体装置。
  11. 　請求項１～１０のいずれか１項に記載の前記半導体装置を有し、入力される電力を変換して出力する主変換回路と、
    　前記主変換回路を制御する制御信号を前記主変換回路に出力する制御回路と、
    　を備えた電力変換装置。
  12. 　本体部と、前記本体部に接合された第１面および前記第１面に対向する第２面を有する表面電極とを含む半導体素子が準備される工程と、
    　少なくとも１つの第１樹脂部材が前記表面電極の前記第２面に塗布されることによって、前記少なくとも１つの第１樹脂部材に前記表面電極に対して前記本体部の反対側に突出している凸部が形成される工程と、
    　少なくとも１つの導電ワイヤの接合部が前記少なくとも１つの第１樹脂部材に隣り合うように前記表面電極の前記第２面に接合されつつ、前記接合部に隣り合う前記凸部に沿って延びる凹部が形成され、かつ前記凹部が前記凸部に嵌合される工程とを備えた、半導体装置の製造方法。
  13. 　前記凸部が形成される工程において、前記少なくとも１つの第１樹脂部材の前記凸部が保持される状態に前記少なくとも１つの第１樹脂部材が仮硬化される、請求項１２に記載の半導体装置の製造方法。
  14. 　前記凹部が前記凸部に嵌合される工程の後に、前記半導体素子、前記少なくとも１つの第１樹脂部材および前記少なくとも１つの導電ワイヤが封止樹脂部材によって封止される工程をさらに備えた、請求項１２または１３に記載の半導体装置の製造方法。
  15. 　前記少なくとも１つの導電ワイヤは、前記接合部に隣り合う隣接部と、前記表面電極に対して前記本体部とは反対側に前記隣接部から立ち上がっている立ち上がり部とを含み、
    　前記少なくとも１つの導電ワイヤの前記立ち上がり部から前記隣接部を経由して前記接合部までが、前記少なくとも１つの導電ワイヤに対して前記表面電極とは反対側において、第２樹脂部材によって被覆される工程をさらに備えた、請求項１２または１３に記載の半導体装置の製造方法。
  16. 　前記第２樹脂部材によって被覆される工程の後に、前記半導体素子、前記少なくとも１つの第１樹脂部材、前記第２樹脂部材および前記少なくとも１つの導電ワイヤが封止樹脂部材によって封止される工程をさらに備えた、請求項１５に記載の半導体装置の製造方法。
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