JP2014220329A - 半導体装置の製造方法 - Google Patents

半導体装置の製造方法 Download PDF

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Publication number
JP2014220329A
JP2014220329A JP2013097728A JP2013097728A JP2014220329A JP 2014220329 A JP2014220329 A JP 2014220329A JP 2013097728 A JP2013097728 A JP 2013097728A JP 2013097728 A JP2013097728 A JP 2013097728A JP 2014220329 A JP2014220329 A JP 2014220329A
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adherend
semiconductor device
wiring
electrode terminal
bonding surface
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JP2013097728A
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Inventor
貴弘 杉村
Takahiro Sugimura
貴弘 杉村
浩史 野津
Hiroshi Nozu
浩史 野津
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Sumitomo Electric Industries Ltd
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Sumitomo Electric Industries Ltd
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Priority to JP2013097728A priority Critical patent/JP2014220329A/ja
Priority to PCT/JP2014/060528 priority patent/WO2014181638A1/ja
Publication of JP2014220329A publication Critical patent/JP2014220329A/ja
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Abstract

【課題】設計自由度の高い半導体装置の製造方法を提供する。
【解決手段】半導体装置の製造方法は、第1被着体としての電極端子12Aと第2被着体としての半導体チップ14Aの間を配線16Aにより接続する接続工程と、接続工程の後、電極端子12A及び半導体チップ14Aの少なくとも1つを移動することによって、電極端子12Aを半導体チップ14Aに対して相対的に移動する移動工程と、半導体チップ14Aに対する電極端子12Aの相対的な位置を固定する固定工程と、を含む。
【選択図】図2

Description

本発明は、半導体装置の製造方法に関する。
半導体装置の例として、ケース型の半導体装置が知られている(非特許文献1参照)。このような半導体装置は、ワイヤボンディングにより、ケース内に収容された半導体チップと、ケースに取り付けられた電極端子とをワイヤにより接続することによって製造される。
「Cuワイヤを中心としたワイヤボンディングの不良原因と信頼性向上・評価技術」株式会社技術情報協会出版、2011年7月29日、p.163
ワイヤボンディングでは、ワイヤを半導体チップ上に載せて圧力及び超音波を印加することによって、ワイヤを半導体チップに接続する。同様に、ワイヤを電極端子上に載せて圧力及び超音波を印加することによって、ワイヤを電極端子に接続する。半導体チップに対する電極端子の相対的な位置は固定されており、ワイヤボンディング後に変えることができない。よって、半導体装置の設計自由度は高くない。
本発明は、設計自由度の高い半導体装置の製造方法を提供することを目的とする。
本発明の一側面に係る半導体装置の製造方法は、第1被着体と第2被着体との間を配線により接続する接続工程と、前記接続工程の後、前記第1被着体及び前記第2被着体の少なくとも1つを移動することによって、前記第1被着体を前記第2被着体に対して相対的に移動する移動工程と、前記第2被着体に対する前記第1被着体の相対的な位置を固定する固定工程と、を含む。
この方法では、接続工程後に第2被着体に対する第1被着体の相対的な位置を任意に変えることができる。よって、半導体装置の設計自由度が高くなる。
前記移動工程では、前記第1被着体と前記配線との接合面を含む第1平面が、前記第2被着体と前記配線との接合面を含む第2平面に対向配置されるように、前記第1被着体及び前記第2被着体の少なくとも1つを移動してもよい。
この場合、第2被着体と配線との接合面の法線方向から見て、半導体装置を小型化することができる。
前記移動工程では、前記第1被着体と前記配線との接合面を含む第1平面が、前記第2被着体と前記配線との接合面を含む第2平面と略直交するように、前記第1被着体及び前記第2被着体の少なくとも1つを移動してもよい。
この場合、第2被着体と配線との接合面の法線方向から見て、半導体装置を小型化することができる。
前記固定工程では、前記第1被着体を熱硬化性樹脂部に固定してもよい。
この場合、ゲル等に比べて半導体装置の耐熱性を向上させることができる。
前記固定工程では、前記第1被着体をケースに固定してもよい。
前記固定工程では、前記第1被着体を、ケースに取り付けられた支持部材に固定してもよい。
前記配線が、ワイヤ又はボンディングリボンであってもよい。
本発明によれば、設計自由度の高い半導体装置の製造方法が提供され得る。
第1実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す斜視図である。 図1のII−II線に沿った半導体装置の断面図である。 第1実施形態に係る半導体装置の製造方法の一工程を模式的に示す断面図である。 第1実施形態に係る半導体装置の製造方法の一工程を模式的に示す断面図である。 第2実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す断面図である。 第2実施形態に係る半導体装置の製造方法の一工程を模式的に示す断面図である。 第2実施形態に係る半導体装置の製造方法の一工程を模式的に示す断面図である。 第3実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す斜視図である。 第4実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す斜視図である。
以下、添付図面を参照しながら本発明の実施形態が詳細に説明される。図面の説明において、同一又は同等の要素には同一符号が用いられ、重複する説明は省略される。
(第1実施形態)
図1は、第1実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す斜視図である。図2は、図1のII−II線に沿った半導体装置の断面図である。図1及び図2に示される半導体装置10は、例えば電源等に使用される電力用半導体装置である。
半導体装置10は、電極端子12A、半導体チップ14A、及び配線16Aを備える。配線16Aは、電極端子12Aと半導体チップ14Aとの間を接続する。電極端子12Aと配線16Aとの間には接合面11Aが形成される。半導体チップ14Aと配線16Aとの間には接合面13Aが形成される。これにより、電極端子12Aが半導体チップ14Aの表面電極に電気的に接続される。本実施形態では、接合面11Aを含む第1平面PA1が接合面13Aを含む第2平面PA2に対向配置される。
半導体装置10は、電極端子12B、配線基板20、及び配線16Bを備え得る。配線16Bは、電極端子12Bと配線基板20との間を接続する。電極端子12Bと配線16Bとの間には接合面11Bが形成される。配線基板20と配線16Bとの間には接合面13Bが形成される。本実施形態では、接合面11Bを含む第1平面PB1が接合面13Bを含む第2平面PB2に対向配置される。
配線基板20上には、半導体チップ14A,14Bが配置され得る。半導体チップ14A,14Bは、同じ構造を有してもよい。半導体チップ14A,14Bは、鉛入り金属半田、鉛を含まない金属半田又は導電性樹脂等を含む材料から構成される接着層42をそれぞれ介して配線基板20に実装され得る。配線基板20は、絶縁性基板22と、絶縁性基板22の表面に設けられた配線パターン層24と、絶縁性基板22の裏面に設けられた放熱層26とを備える。放熱層26は放熱層26の裏面全体に設けられ得る。半導体チップ14A,14Bは、接着層42をそれぞれ介して配線パターン層24に接続される。これにより、電極端子12Bが半導体チップ14Aの裏面電極に電気的に接続される。
電極端子12Aは、接合面11Aに沿って延びる第1部分18Aと、接合面11Aに直交する第2部分19Aとを備え得る。電極端子12Bは、接合面11Bに沿って延びる第1部分18Bと、接合面11Bに直交する第2部分19Bとを備え得る。電極端子12A,12Bは、例えば折り曲げられた金属板である。
半導体チップ14A,14Bの例は、バイポーラトランジスタ、MOS−FET、絶縁ゲートバイポーラトランジスタ(IGBT)等のトランジスタ、ダイオードを含む。半導体チップ14A,14Bの材料の例は、ワイドバンドギャップ半導体、シリコンその他の半導体を含む。ワイドバンドギャップ半導体は、シリコンのバンドギャップよりも大きいバンドギャップを有する。ワイドバンドギャップ半導体の例は、シリコンカーバイド(SiC)、窒化ガリウム(GaN)、ダイヤモンドを含む。
配線16A,16Bは、例えば可撓性を有する。配線16A,16Bは、ワイヤ又はボンディングリボンであってもよい。配線16A,16Bの断面形状は例えば円形である。配線16A,16Bの径は、例えば100〜500μmである。配線16A,16Bの材料の例は、アルミニウム、金、銅等の金属を含む。
配線パターン層24の材料の例は、銅及び銅合金等の金属を含む。絶縁性基板22の材料の例は、アルミナ等のセラミックを含む。放熱層26の材料の例は、銅及び銅合金等の金属を含む。放熱層26は、例えば半田等からなる接着層44を介してヒートシンク32に接着される。ヒートシンク32の材料の例は、金属を含む。
半導体チップ14A,14B及び配線基板20は、ケース30内に収容され得る。ケース30は、例えば、半導体チップ14A,14Bを収容する箱状の電気絶縁性のケースである。ケース30は、例えば筒状である。ケース30の一方の開口はヒートシンク32によって封止され得る。ケース30の他方の開口は蓋によって封止され得る。ケース30の材料の例は、ポリブチレンテレフタレート(PBT)又はポリフェニレンサルファイド(PPS)樹脂といったエンジニヤリングプラスチック等の樹脂を含む。蓋の材料の例は熱可塑性樹脂を含む。ケース30内には熱硬化性樹脂部50が充填され得る。
熱硬化性樹脂部50は、電極端子12A,12B及び配線16A,16Bを固定する。電極端子12A,12Bの第2部分19A,19Bは、熱硬化性樹脂部50から外側に突出する。
図3及び図4は、本実施形態に係る半導体装置の製造方法の一工程を模式的に示す断面図である。半導体装置10は、例えば以下のように製造される。
(接続工程)
まず、図3(a)に示されるように、第1被着体としての電極端子12Aと第2被着体としての半導体チップ14Aとの間を配線16Aにより接続する。これにより、電極端子12Aと配線16Aとの間に接合面11Aが形成される。半導体チップ14Aと配線16Aとの間に接合面13Aが形成される。接続工程において、接合面11Aは接合面13Aと略平行である。略平行とは、接合面11Aと接合面13Aとのなす角度が±5度以下であることを意味する。通常、ワイヤボンディングでは、2つの接合面11A,13Aが互いに平行になる。
配線16Aは、例えばワイヤボンディングにより、電極端子12A及び半導体チップ14Aに接続される。ワイヤボンディングを行う際に、電極端子12A及び半導体チップ14Aは、治具60によって保持される。電極端子12Aの第2部分19Aは、治具60に形成された孔62A内に挿入される。配線16Aを電極端子12A上に載せて圧力及び超音波を印加することによって、配線16Aが電極端子12Aに接合される。同様に、配線16Aを半導体チップ14A上に載せて圧力及び超音波を印加することによって、配線16Aが半導体チップ14Aに接合される。
また、図3(b)に示されるように、第1被着体としての電極端子12Bと第2被着体としての配線基板20との間を配線16Bにより接続する。これにより、電極端子12Bと配線16Bとの間に接合面11Bが形成される。配線基板20と配線16Bとの間に接合面13Bが形成される。接続工程において、接合面11Bは接合面13Bと略平行である。略平行とは、接合面11Bと接合面13Bとのなす角度が±5度以下であることを意味する。通常、ワイヤボンディングでは、2つの接合面11B,13Bが互いに平行になる。
配線16Bは、例えばワイヤボンディングにより電極端子12B及び配線基板20に接続される。ワイヤボンディングを行う際に、電極端子12B及び配線基板20は、治具60によって保持される。電極端子12Bの第2部分19Bは、治具60に形成された孔62B内に挿入される。配線16Bを電極端子12B上に載せて圧力及び超音波を印加することによって、配線16Bが電極端子12Bに接合される。同様に、配線16Bを配線基板20上に載せて圧力及び超音波を印加することによって、配線16Bが配線基板20に接合される。
(移動工程)
次に、図4に示されるように、電極端子12A及び半導体チップ14Aの少なくとも1つを移動することによって、電極端子12Aを半導体チップ14Aに対して相対的に移動する。例えば、電極端子12Aを第1位置から第2位置まで移動する。本実施形態では、電極端子12Aと配線16Aとの接合面11Aを含む第1平面PA1が、半導体チップ14Aと配線16Aとの接合面13Aを含む第2平面PA2に対向配置されるように、電極端子12A及び半導体チップ14Aの少なくとも1つを移動する。
また、電極端子12B及び配線基板20の少なくとも1つを移動することによって、電極端子12Bを配線基板20に対して相対的に移動する。例えば、電極端子12Bを第1位置から第2位置まで移動する。本実施形態では、電極端子12Bと配線16Bとの接合面11Bを含む第1平面PB1が、配線基板20と配線16Bとの接合面13Bを含む第2平面PB2に対向配置されるように、電極端子12B及び配線基板20の少なくとも1つを移動する。
(固定工程)
次に、図2に示されるように、半導体チップ14Aに対する電極端子12Aの相対的な位置を固定する。配線基板20に対する電極端子12Bの相対的な位置を固定する。本実施形態では、電極端子12A,12Bを熱硬化性樹脂部50に固定する。配線16A,16Bも熱硬化性樹脂部50に固定され得る。未硬化の熱硬化性樹脂材料をケース30内に流し込んで加熱することによって、熱硬化性樹脂部50を形成することができる。
固定工程の前に、必要に応じて、接着層44を介して配線基板20をヒートシンク32に接着する。
本実施形態では、接続工程後に半導体チップ14Aに対する電極端子12Aの相対的な位置を任意に変えることができる。接続工程後に配線基板20に対する電極端子12Bの相対的な位置を任意に変えることができる。そのため、半導体装置10の設計自由度が高くなる。
接合面11Aを含む第1平面PA1が接合面13Aを含む第2平面PA2に対向配置されるように、電極端子12A及び半導体チップ14Aの少なくとも1つを移動すると、接合面11A,13Aの法線方向から見て、半導体装置10を小型化することができる。接合面11Bを含む第1平面PB1が接合面13Bを含む第2平面PB2に対向配置されるように、電極端子12B及び配線基板20の少なくとも1つを移動すると、接合面11B,13Bの法線方向から見て、半導体装置10を小型化することができる。
熱硬化性樹脂部50が電極端子12A,12Bを固定すると、ゲル等に比べて半導体装置10の耐熱性を向上させることができる。半導体チップ14A,14Bの材料がワイドバンドギャップ半導体を含む場合、半導体装置10に大電流が流れるので、半導体装置10が高温になる傾向がある。そのような場合であっても、半導体装置10の信頼性を向上させることができる。
(第2実施形態)
図5は、第2実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す断面図である。図5に示される半導体装置110は、電極端子12A,12Bに代えて電極端子112A,112Bをそれぞれ備えること以外は、半導体装置10と同じ構成を備える。電極端子112A,112Bは、例えば折り曲げられていない金属板である。
電極端子112Aは、電極端子112Aと配線16Aとの接合面11Aを含む第1平面PA1が、半導体チップ14Aと配線16Aとの接合面13Aを含む第2平面PA2と略直交するように、配置される。略直交とは、第1平面PA1と第2平面PA2とのなす角度が90±5度以下であることを意味する。
電極端子112Bは、電極端子112Bと配線16Bとの接合面11Bを含む第1平面PB1が、配線基板20と配線16Bとの接合面13Bを含む第2平面PB2と略直交するように、配置される。略直交とは、第1平面PB1と第2平面PB2とのなす角度が90±5度以下であることを意味する。
図6及び図7は、第2実施形態に係る半導体装置の製造方法の一工程を模式的に示す断面図である。半導体装置110は、例えば以下のように製造される。
(接続工程)
まず、図6(a)に示されるように、第1被着体としての電極端子112Aと第2被着体としての半導体チップ14Aとの間を配線16Aにより接続する。図6(b)に示されるように、第1被着体としての電極端子112Bと第2被着体としての配線基板20との間を配線16Bにより接続する。本実施形態の接続工程は、電極端子12A,12Bに代えて電極端子112A,112Bをそれぞれ用いたこと以外は、第1実施形態の接続工程と同様に実施される。電極端子112A,112Bは、例えば折り曲げられていない金属板である。そのため、治具60には、孔62A,62Bを形成する必要がない。
(移動工程)
次に、図7に示されるように、電極端子112A及び半導体チップ14Aの少なくとも1つを移動することによって、電極端子112Aを半導体チップ14Aに対して相対的に移動する。本実施形態では、電極端子112Aと配線16Aとの接合面11Aを含む第1平面PA1が、半導体チップ14Aと配線16Aとの接合面13Aを含む第2平面PA2と略直交するように、電極端子112A及び半導体チップ14Aの少なくとも1つを移動する。略直交とは、第1平面PA1と第2平面PA2とのなす角度が90±5度以下であることを意味する。
また、電極端子112B及び配線基板20の少なくとも1つを移動することによって、電極端子112Bを配線基板20に対して相対的に移動する。本実施形態では、電極端子112Bと配線16Bとの接合面11Bを含む第1平面PB1が、配線基板20と配線16Bとの接合面13Bを含む第2平面PB2と略直交するように、電極端子112B及び配線基板20の少なくとも1つを移動する。略直交とは、第1平面PB1と第2平面PB2とのなす角度が90±5度以下であることを意味する。
(固定工程)
次に、図5に示されるように、半導体チップ14Aに対する電極端子112Aの相対的な位置を固定する。配線基板20に対する電極端子112Bの相対的な位置を固定する。本実施形態では、熱硬化性樹脂部50が電極端子112A,112Bを固定する。
本実施形態では、第1実施形態と同様の作用効果が得られる。さらに、折り曲げられていない金属板を電極端子112A,112Bとして用いても、電極端子112A,112Bを接合面11A,11Bに沿う方向に突出させることができる。
(第3実施形態)
図8は、第3実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す斜視図である。図8に示される半導体装置210は、電極端子12A,12Bに代えて電極端子212A,212B(第1被着体)をそれぞれ備え、熱硬化性樹脂部50に代えて絶縁材250を備えること以外は、半導体装置10と同じ構成を備える。絶縁材250は、例えばシリコーンゲル等のゲルである。電極端子212A,212Bは、ケース30に固定される。
電極端子212Aは、ケース30に固定される第1部分219Aと、第1部分219Aに接続され、ケース30から外側に突出する第2部分218Aとを備え得る。第1部分219Aには配線16Aが接続される。第1部分219Aは、例えば、ケース30の一方の開口を横切る金属板である。第2部分218Aは、例えば、第1部分219Aの縁に接続され、第1部分219Aに直交する金属板である。
電極端子212Bは、ケース30に固定される第1部分219Bと、第1部分219Bに接続され、ケース30から外側に突出する第2部分218Bとを備え得る。第1部分219Bには配線16Bが接続される。第1部分219Bは、例えば、ケース30の一方の開口を横切る金属板である。第2部分218Bは、例えば、第1部分219Bの縁に接続され、第1部分219Bに直交する金属板である。
半導体装置210は、接続工程(図3参照)、移動工程(図4参照)及び固定工程を経ることによって製造され得る。接続工程及び移動工程は、第1実施形態と同様に実施される。固定工程では、図8に示されるように、電極端子212A,212Bを、ケース30に固定する。電極端子212Aの第1部分219Aの両端がケース30に固定され得る。電極端子212Bの第1部分219Bの両端がケース30に固定され得る。その後、必要に応じて絶縁材250がケース30内に充填される。
本実施形態では、第1実施形態と同様の作用効果が得られる。さらに、高い位置精度で電極端子212A,212Bをケース30に固定することができる。
(第4実施形態)
図9は、第4実施形態に係る半導体装置の製造方法により製造される半導体装置を模式的に示す斜視図である。図9に示される半導体装置310は、熱硬化性樹脂部50に代えて絶縁材250を備え、支持部材319A,319Bを更に備えること以外は、半導体装置10と同じ構成を備える。
電極端子12A,12Bは、ケース30に取り付けられた支持部材319A,319Bに固定される。電極端子12A,12Bはケース30に固定されてもよい。支持部材319A,319Bは、例えば、ケース30の一方の開口を横切る絶縁板である。支持部材319Aには、電極端子12Aを嵌め込むための開口318Aが形成されている。支持部材319Bには、電極端子12Bを嵌め込むための開口318Bが形成されている。
半導体装置310は、接続工程(図3参照)、移動工程(図4参照)及び固定工程を経ることによって製造され得る。接続工程及び移動工程は、第1実施形態と同様に実施される。固定工程では、図9に示されるように、電極端子12A,12Bを、ケース30に取り付けられた支持部材319A,319Bに固定する。その後、必要に応じて絶縁材250がケース30内に充填される。
本実施形態では、第1実施形態と同様の作用効果が得られる。さらに、高い位置精度で電極端子12A,12Bを支持部材319A,319Bに固定することができる。また、絶縁性の支持部材319A,319Bを用いることにより、電極端子12A,12Bをケース30から電気的に絶縁することができる。
以上、本発明の好適な実施形態について詳細に説明されたが、本発明は上記実施形態に限定されない。各実施形態の構成は任意に組み合わせ得る。例えば、半導体装置210,310は、絶縁材250に代えて熱硬化性樹脂部50を備えてもよい。半導体装置210は、電極端子212A,212Bに代えて電極端子112A,112Bを備えてもよい。この場合、電極端子112A,112Bは、ケース30に固定される部分を有する。半導体装置310は、電極端子12A,12Bに代えて電極端子112A,112Bを備えてもよい。この場合、電極端子112A,112Bは、支持部材319A,319Bに固定される。
第1被着体及び第2被着体のそれぞれは、電極端子、半導体チップ、又は配線基板等であってもよい。
10,110,210,310…半導体装置、11A,13A,11B,13B…接合面、12A,12B,112A,112B,212A,212B…電極端子(第1被着体)、14A…半導体チップ(第2被着体)、16A,16B…配線、20…配線基板(第2被着体)、50…熱硬化性樹脂部、30…ケース、319A,319B…支持部材、PA1,PB1…第1平面、PA2,PB2…第2平面。

Claims (7)

  1. 第1被着体と第2被着体との間を配線により接続する接続工程と、
    前記接続工程の後、前記第1被着体及び前記第2被着体の少なくとも1つを移動することによって、前記第1被着体を前記第2被着体に対して相対的に移動する移動工程と、
    前記第2被着体に対する前記第1被着体の相対的な位置を固定する固定工程と、
    を含む、半導体装置の製造方法。
  2. 前記移動工程では、前記第1被着体と前記配線との接合面を含む第1平面が、前記第2被着体と前記配線との接合面を含む第2平面に対向配置されるように、前記第1被着体及び前記第2被着体の少なくとも1つを移動する、請求項1に記載の半導体装置の製造方法。
  3. 前記移動工程では、前記第1被着体と前記配線との接合面を含む第1平面が、前記第2被着体と前記配線との接合面を含む第2平面と略直交するように、前記第1被着体及び前記第2被着体の少なくとも1つを移動する、請求項1に記載の半導体装置の製造方法。
  4. 前記固定工程では、前記第1被着体を熱硬化性樹脂部に固定する、請求項1〜3のいずれか一項に記載の半導体装置の製造方法。
  5. 前記固定工程では、前記第1被着体をケースに固定する、請求項1〜4のいずれか一項に記載の半導体装置の製造方法。
  6. 前記固定工程では、前記第1被着体を、ケースに取り付けられた支持部材に固定する、請求項1〜5のいずれか一項に記載の半導体装置の製造方法。
  7. 前記配線が、ワイヤ又はボンディングリボンである、請求項1〜6のいずれか一項に記載の半導体装置の製造方法。
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JPH0855881A (ja) * 1994-07-07 1996-02-27 Tessera Inc マイクロエレクトロニクス素子の実装構造及びその製造方法
JP2003224243A (ja) * 2002-01-30 2003-08-08 Toyota Industries Corp 半導体装置

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0855881A (ja) * 1994-07-07 1996-02-27 Tessera Inc マイクロエレクトロニクス素子の実装構造及びその製造方法
JP2003224243A (ja) * 2002-01-30 2003-08-08 Toyota Industries Corp 半導体装置

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