JP2007012831A - パワー半導体装置 - Google Patents

パワー半導体装置 Download PDF

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Publication number
JP2007012831A
JP2007012831A JP2005190869A JP2005190869A JP2007012831A JP 2007012831 A JP2007012831 A JP 2007012831A JP 2005190869 A JP2005190869 A JP 2005190869A JP 2005190869 A JP2005190869 A JP 2005190869A JP 2007012831 A JP2007012831 A JP 2007012831A
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Japan
Prior art keywords
resin
power semiconductor
semiconductor device
semiconductor element
metal
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JP2005190869A
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English (en)
Inventor
Yoshihiko Koike
義彦 小池
Shinji Okubo
真司 大久保
Yasushi Toyoda
靖 豊田
Katsuaki Saito
克明 斉藤
Seiichi Hayakawa
誠一 早川
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Hitachi Ltd
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Hitachi Ltd
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Priority to JP2005190869A priority Critical patent/JP2007012831A/ja
Priority to EP06013397A priority patent/EP1739740A3/en
Publication of JP2007012831A publication Critical patent/JP2007012831A/ja
Pending legal-status Critical Current

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Abstract

【課題】
金属ワイヤと半導体素子間の接合長寿命化と絶縁基板の絶縁耐量を向上したパワー半導体装置を提供すること。
【解決手段】
本発明のパワー半導体装置では、絶縁基板で金属回路を接合していない沿面部分と半導体素子と金属ワイヤとの接合界面部分にモジュール全体の絶縁を確保するために充填した樹脂とに比べ(1)膨張係数が小さく、(2)ヤング率が大きく、(3)絶縁耐量が高い電気絶縁性樹脂をコーティングし、コーティングした樹脂の厚さを、ワイヤの断面方向でコーティング樹脂の変曲点が、ワイヤの断面高さに対して1/4以下になる形状にした。
【選択図】図1

Description

本発明はパワー半導体装置に係り、特に大容量で高い信頼性を達成した高耐圧用半導体装置のモジュール構造に関する。
従来から、IGBT、ダイオード、GTO等のパワー半導体素子を絶縁容器内に密封して構成したパワー半導体装置(パワー半導体モジュール)が知られている。これらの素子は、その耐圧や電流容量に応じて各種インバータ装置等に応用されている。中でもIGBT素子は、電圧制御型の素子であり、制御が容易であること。大電流の高周波動作が可能であること等の利点を有している。また、多くの場合はモジュール底面金属基板と電流通電部がモジュール内部で電気的に絶縁された構造となっていて、インバータ装置への実装が容易なこともあり急速に応用範囲拡がってきている。
これらの半導体装置の基本構成はモジュール内部の絶縁基板に半導体素子を搭載し、電流容量に応じてモジュール内部で並列する半導体素子数を増やして対応させる。絶縁基板に搭載した素子は絶縁基板上の金属箔回路上にアルミワイヤにより接続される。モジュールの駆動時は半導体素子が発熱、冷却を繰り返す。この時、半導体素子上で接合したアルミワイヤとの界面が、温度変化による各部材の線膨張係数差 (Si:3ppm/℃、Al:
22ppm/℃)により応力が集中し、ワイヤ界面部分で亀裂が発生する。駆動期間が長くなると亀裂が進展し最終的には半導体素子とアルミワイヤの剥離が生じる。
これらの応力を低減させるために、特許文献1に示すように、アルミワイヤの接合位置を外周部、すなわち半導体素子内部で温度変化の小さい部分にすることで接合部の長寿命化を図ってきた。
一方、モジュール内部の絶縁は、絶縁基板の厚さと絶縁基板外周部の沿面距離とによって決まる。高い絶縁耐量が必要とされる用途で使用する場合には、絶縁基板の厚さを厚く、沿面距離を長くしていた。
特開平10−32218号公報(図1と、(0013)段落の記載。)
上記従来技術においては以下のような問題点がある。アルミワイヤの長寿命化のためにアルミワイヤ接合部を半導体チップ外周部に配置するが、半導体素子の電流容量が大きくなると、アルミワイヤ1本当たりの電流密度に上限があるためにワイヤ本数を増やす必要があり、IGBTチップ外周部だけの接合ではレイアウト上の限界が生じる。また還流ダイオードチップで同様に外周部だけにワイヤを配置させると、チップ上でのワイヤ接合部の間隔が大きくなり、異状動作時の最大許容電流(サージ電流)耐量が、半導体素子上の電極膜上で流れる電流がワイヤに達するまでに大きくなることで耐量が低下してしまう問題が生じる。
また、絶縁耐量の向上のために絶縁基板厚さを厚くすると、半導体素子の冷却効率が低下し、モジュールの熱抵抗を大きくし、駆動時の半導体素子温度が上昇し素子の寿命を低減させてしまう。また、絶縁耐量の向上のために沿面距離を広くすれば、モジュール内部で絶縁基板の占有する面積が増え、モジュール内部のレイアウトに制約が生じ、半導体素子を並列配置して大電流化する際の障害になる。
本発明の目的は、金属ワイヤと半導体素子間の接合長寿命化と絶縁基板の絶縁耐量を向上したパワー半導体装置を提供することである。
本発明のパワー半導体装置では前記問題を解決するため、絶縁基板で金属回路を接合していない沿面部分と半導体素子と金属ワイヤとの接合界面部分にモジュール全体の絶縁を確保するために充填した樹脂とに比べ(1)膨張係数が小さく、(2)ヤング率が大きく、(3)絶縁耐量が高い電気絶縁性樹脂をコーティングし、樹脂の厚さを、ワイヤの断面方向でコーティング樹脂の変曲点、すなわちコーティング樹脂の凹凸の向きが変化する点と半導体素子との間隔が、ワイヤの断面高さ(図4(c)のt)に対して1/4以下になる形状にした。
本発明のパワー半導体装置では、半導体素子とアルミワイヤ接合部に電気絶縁性の第一の樹脂をコーティングして半導体素子の寿命を向上させた。また、絶縁基板沿面部分に第一の樹脂をコーティングすることで高い電気絶縁性を安定して得ることができ、同じ絶縁耐量であるならば絶縁基板の厚さを約1/2にすることができるので、熱抵抗を低くすることができる。
本発明パワー半導体装置では、半導体素子とアルミワイヤの界面に電気絶縁性の第一の樹脂をコートし、金属ワイヤの接合寿命を向上させて、モジュールの寿命を向上させることができる。また、絶縁基板の金属回路箔終端に第一の樹脂をコートすることにより、モジュールの絶縁耐量も向上させることができる。以下本発明の詳細を、図面を用いながら説明する。
図1は本実施例のパワー半導体モジュールであるIGBTモジュールの一部の断面図を示す。図1で、符号101はIGBTチップやダイオードチップなどの半導体素子、102はチップ下半田、103は絶縁基板、104と105は金属回路箔、106は絶縁回路基板、107は金属ワイヤであるアルミワイヤ、108は絶縁回路基板下半田、109は金属などの導電性のベース、110は端子、111は端子ブロック樹脂、112は端子ブロック、113は端子下半田、114は樹脂ケース、115は接着剤、116は第二の樹脂、117はモジュール内部の空間部、118は応力緩和ベンド部を示す。
図1に示すように、モジュール内部での絶縁性を確保するために、半導体素子101は、例えばAlNやアルミナ、SiNなどのセラミックスからなる絶縁基板103の上下に金属回路箔104、105を接合した絶縁回路基板106に、チップ下半田102で接合した。IGBTモジュールの電流容量を大きくするためには、この半導体素子101を同一の絶縁回路基板106に複数個搭載して、同一モジュール内部の並列動作素子数を増やす。
本実施例のIGBTモジュールでは、半導体素子101を絶縁回路基板106に接合した後、例えば第一の樹脂120であるポリアミドイミド系樹脂を、絶縁回路基板106の外周沿面部や、金属回路箔104の間に塗布し、硬化する。このポリアミドイミド系樹脂は電気絶縁性(以下絶縁性と略す。)樹脂であるので、このように絶縁回路基板106の外周沿面部や、金属回路箔104の間に配置しても絶縁耐量の劣化がない。
図2は絶縁回路基板106の沿面部分にポリアミドイミド系樹脂120−1を塗布した部分の平面図であり、図3はベース109などを含む断面図である。絶縁回路基板106上で絶縁耐量が必要な領域は、モジュールの外部端子110(図3では記載を省略)とモジュール裏面のベース109の間に試験電源301で電圧をかけた時に絶縁耐量が必要な、絶縁回路基板106の外周沿面部分(E)と、モジュールの駆動時に電圧差が生じるゲート回路104−1とエミッタ回路104−2間、エミッタ回路104−2とコレクタ回路104−3間(F)になる。金属回路箔間の絶縁耐量はモジュールの定格電圧によって決まる。しかし、絶縁基板103が薄い場合は、端子110とベース109間の絶縁特性検査時にも、半導体素子101搭載側の金属回路箔104と裏面側の金属回路箔105間にも絶縁基板103を介して発生する電界(G)によって、半導体素子搭載側の金属回路箔104に、例えばエッチングむらによる突起など電界が集中する部分が存在すると、絶縁基板103をコーティングする図3には示さない第二の樹脂116の劣化が発生して部分放電が発生する。部分放電の発生が直ちに絶縁破壊に至ることは無いが、破壊の前駆症状で、樹脂の劣化が進行すると絶縁破壊に至るため放電を防止する必要がある。このため金属回路箔104の間にも第一の樹脂であるポリアミドイミド系樹脂120−2をコーティングすることが有効になる。
ポリアミドイミド系樹脂120−1、120−2の塗布後に、例えばφ400μmのアルミワイヤ107を複数本数用いて半導体素子101と金属回路箔104との間を配線する。アルミワイヤ107で配線後、ポリアミドイミド系樹脂120−3を半導体素子101とアルミワイヤ107との接合部分に塗布、硬化する。図4にこの塗布部分の詳細を示す。ポリアミドイミド系樹脂120−3の塗布に必要な領域は接合部分の線膨張係数の差が大きい半導体素子101とアルミワイヤ107との接合部分になる。塗布した樹脂の厚さは20〜200μm程度で、Siである半導体素子101とアルミワイヤ107との線膨張係数差による応力を抑える充分な効果がある。ここで、塗布した樹脂の厚さとは、図4(c)の断面図に示すように、半導体素子101とアルミワイヤ107との接合している角部Hから測った第一の樹脂であるポリアミドイミド系樹脂120−3表面の最も近い点(I)までの距離Lである。
なお、ポリアミドイミド系樹脂120−3を半導体素子101の表面に塗布しても素子特性に影響を与えることはないので、半導体素子101の全面、あるいは半導体素子101を搭載している絶縁回路基板106上の金属回路箔104の上に塗布されても問題ない。
本実施例のIGBTモジュールでは、半導体素子101とアルミワイヤ107の界面と、絶縁基板103の沿面部分に塗布する樹脂の材質を共通のポリアミドイミド系樹脂にしているので、例えば、アルミワイヤ107を半導体素子101に接合した後で、溶剤などを加えてポリアミドイミド系樹脂の粘度を下げて、半導体素子101とアルミワイヤ107界面及び絶縁基板103全面に塗布し、アルミワイヤ107下の金属回路箔104間の沿面部分に濡れ広げさせるといった、1回の塗布、硬化によっても構わない。
ポリアミドイミド系樹脂を塗布した絶縁回路基板106は絶縁回路基板下半田108により、例えば無酸素銅や銅合金、Al−SiCやCu−Moからなる複合材のベース109上に接合される。モジュール内部の回路に接続した外部取出しの端子110と、フタを構成する端子ブロック樹脂111とが一体で形成された端子ブロック112をセットし、端子110と絶縁回路基板106とを端子下半田113で接合する。これらの構造の端子110には電気抵抗が小さく、熱伝導率が大きいNiメッキされた無酸素銅、銅合金などを使用する。
次に、IGBTモジュールの外周を構成する樹脂ケース114を接着剤115によってベース109と接合し、モジュール内部の半導体素子101、アルミワイヤ107、端子110の絶縁を確保するために第二の樹脂116であるシリコーンゲルを注入する。この時、第二の樹脂116であるシリコーンゲルの樹脂ケース114内での熱膨張を吸収するためモジュール内部上面に空間部117を設ける。最後にモジュール内部の気密性を確保するために端子ブロック樹脂111と樹脂ケース114との間を接着剤119で密封させ半導体装置を完成させる。
表1に本実施例で使用した第一の樹脂と第二の樹脂の物性値を示す。
Figure 2007012831
第一の樹脂は、半導体素子101とアルミワイヤ107との線膨張係数差による歪を押さえ込むために、1500MPa〜5000MPaのヤング率を必要とする。また、第一の樹脂の線膨張係数は40ppm/℃〜60ppm/℃の範囲が好ましい。第一の樹脂の線膨張係数がこの値より小さくても大きくても半導体素子101とアルミワイヤ107との歪が大きくなるので好ましくない。さらに、第一の樹脂は、電界が集中するエッチングむらによる突起などを直接被覆する場合もあるので絶縁耐量が100KVrms/mm以上であることが好ましい。また、本実施例では第二の樹脂のヤング率は第一の樹脂より小さな1MPa以下がよく、線膨張係数は200ppm/℃〜500ppm/℃の範囲が好ましい。第二の樹脂の線膨張係数がこの値より小さくても大きくても第一の樹脂との界面に歪が生じ、亀裂などが生じる場合があるので好ましくない。さらに、第二の樹脂は、電界が集中するエッチングむらによる突起などを直接被覆する場合が少なく第一の樹脂の上に配置するので絶縁耐量が10〜30KVrms/mmの範囲であることが好ましく、第二の樹脂の絶縁耐量を第一の樹脂より上げてもモジュール全体の絶縁耐量の向上に寄与しない。
このように、本実施例に用いた第一の樹脂は絶縁耐量が高い樹脂であるので、絶縁基板沿面部分に塗布した時に高い絶縁耐量が得られる。上記の説明では第一の樹脂としてポリアミドイミド系樹脂を例にして説明したが、物性値が表1に示す範囲であれば、ポリアミド系樹脂や、エポキシ系樹脂等を使用しても同様な効果が得られる。
図5に半導体素子駆動時に半導体素子101とアルミワイヤ107との接合部をヤング率が異なる樹脂で覆った場合に、生じる歪を計算した結果を示す。アルミワイヤ107外周をヤング率の大きい(硬い)樹脂で覆った場合接合部の歪が低下し、接合部の長寿命化が達成できることが図5から分かる。
図6に樹脂コートを実施した本実施例のIGBTモジュールで駆動条件を模擬したパワーサイクル試験を実施した結果を示す。本実施例のIGBTモジュールでは、樹脂コートなしの従来技術のIGBTモジュールに比べ約5倍に破壊耐量が向上することが確認できた。
図7は本実施例のIGBTモジュールで第一の樹脂120−3の厚さを厚くした場合の断面図を示す。アルミワイヤ107に第一の樹脂を厚くコートすると第一の樹脂コート部と第二の樹脂コート部の界面701に応力が集中し、この部分で断線する可能性がある。このため、第一の樹脂120−3のコーティングは必要以上に厚くぬらないようにする必要がある。逆に第一の樹脂でアルミワイヤ全体をコートすることが出来ればワイヤ変形全体を抑えることができるので半導体素子の寿命を向上させることができる。但し、図1のように大容量であるために、主端子の応力を緩和するための応力緩和ベンド部118が必要な構造ではモジュール全体を線膨張係数が大きく、ヤング率が大きな樹脂で充填することはモジュール全体の反りが大きくなる。このため、絶縁基板の割れ、モジュール実装時のグリース厚さの増大による接触熱抵抗の増加などが生じる。これらの理由から、金属ワイヤの接合界面をコーティングする部分の樹脂の厚さがワイヤの断面方向でコーティング樹脂の変曲点、すなわちコーティング樹脂の凹凸の向きが変化する点と半導体素子との間隔が、ワイヤの断面高さ(図4(c)のt)に対して1/4以下であることが望ましい。この変曲点の位置が1/4以上の高さにあると、図4(c)に示す第一の樹脂が薄くなり、半導体素子とアルミワイヤ接合部との信頼性を高くできない。変曲点と半導体素子との間隔は、第一の樹脂のコーティング時の表面張力にも依存するが、ワイヤの断面高さ(図4(c)のt)に対して1/4〜1/10の範囲にあれば良く、好ましくは1/5〜1/10の範囲にあれば十分である。
図8は本発明の樹脂コーティングを半導体パワーモジュールの金属ワイヤ以外に適用した実施例を示す。本実施例のIGBTモジュールでは、実施例1のアルミワイヤ107に代えて金属リボン801を備えた点が異なり、それ以外は実施例1と同様である。パワー半導体モジュールでは、金属ワイヤ以外にも例えばAl材からなる金属リボン801を超音波で接合した場合にも、実施例1でアルミワイヤ107で接合した場合と同じメカニズムでAl/Siの接合界面が熱応力歪で劣化することがあるので、第一の樹脂120を図8(a)に示すようにコーティングすることで実施例1と同様にモジュールを長寿命化できる。
また、図8(b)に示すように、超音波接合以外に金属電極802を半田803、805、応力緩衝板804を介して接合する場合でも、半導体素子101を駆動する時の温度変化が大きいことと、半導体素子101との応力差が大きいことで電極の半田803部分が最も早く劣化する。この時も半田803の接合部分を第一の樹脂120でコーティングすることで、半田803の劣化を抑えてモジュールを長寿命化することができる。
図9は実施例1と同じポリアミドイミド系樹脂を第一の樹脂として絶縁基板103の沿面部に塗布した試料で絶縁試験を実施した結果を示す。第一の樹脂120でコートすることで同じ絶縁耐量を約1/2の絶縁基板103の厚さで得られる。これにより、半導体パワーモジュールの熱抵抗を低減できる。
実施例1のパワー半導体モジュールの断面図である。 実施例1のパワー半導体モジュールの絶縁基板上へのコーティングを説明する平面図。 実施例1のパワー半導体モジュールの絶縁基板上へのコーティングを説明する断面図。 実施例1のパワー半導体モジュールのアルミワイヤへのコーティングの説明図。 実施例1のパワー半導体モジュールのコーティング樹脂のヤング率と歪との関係の計算結果の説明図。 実施例1のパワー半導体モジュールの寿命試験の説明図。 実施例1のパワー半導体モジュールでアルミワイヤへのコーティングが厚い場合の説明図。 実施例2のパワー半導体モジュールの説明図。 実施例2の別のパワー半導体モジュールの説明図。
符号の説明
101…半導体素子、102…チップ下半田、103…絶縁基板、104、105…金属回路箔、104−1…ゲート回路、104−2…エミッタ回路、104−3…コレクタ回路、106…絶縁回路基板、107…アルミワイヤ、108…絶縁回路基板下半田、109…ベース、110…端子、111…端子ブロック樹脂、112…端子ブロック、113…端子下半田、114…樹脂ケース、115、119…接着剤、116…第二の樹脂、117…空間部、118…応力緩和ベンド部、120…第一の樹脂、120−1〜120−3…ポリアミドイミド系樹脂、301…試験電源、701…第一の樹脂コード部と第二の樹脂コード部の界面、801…金属リボン、802…金属電極、803、805…半田、804…応力緩衝板。

Claims (8)

  1. 底面に配置した金属基板と、側面部と上面部とを覆う有機樹脂部材と、前記金属基板に第一の金属回路箔を介して一方の面を接合した絶縁基板と、該絶縁基板の他方の面に第二の金属回路箔を介して接合した半導体素子とを備えたパワー半導体装置において、
    該パワー半導体装置が、前記絶縁基板の他方の面に第三の金属回路箔を配置してあり、
    該第三の金属回路箔と前記半導体素子とが金属ワイヤで接続されており、
    該半導体素子と金属ワイヤとの接続部が絶縁性の第一の樹脂で被覆され、
    該接続部を被覆する第一の樹脂の表面の変曲点が、前記接続部の金属ワイヤの断面高さの1/4より半導体素子に近い位置にあることを特徴とするパワー半導体装置。
  2. 請求項1に記載のパワー半導体装置において、前記第一の樹脂が第二の樹脂で被覆されていることを特徴とするパワー半導体装置。
  3. 請求項2に記載のパワー半導体装置において、前記第一の樹脂のヤング率が前記第二の樹脂のヤング率より大きいことを特徴とするパワー半導体装置。
  4. 請求項2に記載のパワー半導体装置において、前記第一の樹脂のヤング率が1500〜5000MPaであることを特徴とするパワー半導体装置。
  5. 請求項2に記載のパワー半導体装置において、前記第一の樹脂がポリアミド系樹脂あるいはポリアミドイミド系樹脂であることを特徴とするパワー半導体装置。
  6. 請求項2に記載のパワー半導体装置において、前記第二の樹脂がシリコーンゲルであることを特徴とするパワー半導体装置。
  7. 請求項1に記載のパワー半導体装置において、前記縁基板の他方の面の周縁部が前記第一の樹脂で被覆されていることを特徴とするパワー半導体装置。
  8. 請求項1に記載のパワー半導体装置において、前記縁基板の他方の面に配置した前記第二の金属回路箔と前記第三に金属回路箔との間の絶縁基板面が前記第一の樹脂で被覆されていることを特徴とするパワー半導体装置。
JP2005190869A 2005-06-30 2005-06-30 パワー半導体装置 Pending JP2007012831A (ja)

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JP2012015222A (ja) * 2010-06-30 2012-01-19 Hitachi Ltd 半導体装置
WO2013054408A1 (ja) 2011-10-12 2013-04-18 日本碍子株式会社 大容量モジュールの周辺回路用の回路基板、及び当該回路基板を用いる周辺回路を含む大容量モジュール
WO2013084334A1 (ja) 2011-12-08 2013-06-13 日本碍子株式会社 大容量モジュール用基板、及び当該基板の製造方法
DE112014006759B4 (de) 2014-07-30 2019-02-21 Hitachi, Ltd. Halbleitervorrichtung, Verfahren zum Herstellen einer Halbleitervorrichtung und Leistungsumsetzungsvorrichtung
JPWO2021111563A1 (ja) * 2019-12-04 2021-06-10
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JP2012015222A (ja) * 2010-06-30 2012-01-19 Hitachi Ltd 半導体装置
WO2013054408A1 (ja) 2011-10-12 2013-04-18 日本碍子株式会社 大容量モジュールの周辺回路用の回路基板、及び当該回路基板を用いる周辺回路を含む大容量モジュール
US9064758B2 (en) 2011-10-12 2015-06-23 Ngk Insulators, Ltd. High-capacity module including the peripheral circuit using the circuit board and the circuit board concerned for peripheral circuits of a high-capacity module
WO2013084334A1 (ja) 2011-12-08 2013-06-13 日本碍子株式会社 大容量モジュール用基板、及び当該基板の製造方法
US9012786B2 (en) 2011-12-08 2015-04-21 Ngk Insulators, Ltd. Circuit board for high-capacity modules, and a production method of the circuit board
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JPWO2021111563A1 (ja) * 2019-12-04 2021-06-10
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