Heat-conducting multilayer substrate and power module substrate

Abstract

This power module substrate (1) is provided for satisfying both long life with respect to heat cycle and satisfactory thermal conductivity. The power module substrate is provided with an insulating substrate (2) a circuitry layer (3) laminated on one side of insulating substrate, a metal layer (4) laminated on the other side of insulating substrate, a semiconductor chip (5) loaded onto circuitry layer by means of solder (7), and a radiator (6) joined to metal layer. Circuit layer and metal layer are composed of copper of at least 99.999% purity. Temperature cycling life can be extended since there is no accumulation of internal stress even when subjected to repeated heat cycle. In addition, since circuitry layer and metal layer are composed of copper having satisfactory thermal conductivity, heat from semiconductor chip can be efficiently released by transferring to the side of radiator.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a power module substrate used in a semiconductor device that controls large voltage and large current, and more particularly, to a power module substrate equipped with a radiator that diffuses heat generated from a semiconductor chip.

[0003] 2. Description of Related Art

[0004] Known examples of this type of power module substrate of the prior art include a power module substrate 11 as shown in FIG. 2, in which a circuitry layer 13 composed of Al or Cu is laminated on one side of an insulating substrate 12 made of AlN, a metal layer 14 made of Al or Cu is laminated on the other side, a semiconductor chip 15 is loaded onto circuitry layer 13 by means of solder 17, and a radiator 16 is joined to a metal layer 14 by solder 18 or brazing and so forth, and a power module substrate as shown in FIG. 3, in which a circuitry layer 23 composed of 4N—Al (aluminum of at least 99.99% purity) is laminated onto one side of an insulating substrate 22 made of AlN, a metal layer 24 composed of 4N—Al is laminated onto the other side, a semiconductor chip 25 is loaded onto circuitry layer 23 by means of solder 27, and a radiator 26 is joined to metal layer 24 by solder 28, brazing and so forth. Various types of these power module substrates are provided (refer to, for example, Japanese Patent Application, First Publication No. 4-12554).

[0005] In the aforementioned power module substrates 11 and 21, radiators 16 and 26 are attached to, for example, a cooling sink section (not shown), and heat from semiconductor chips 15 and 25 that is transferred to radiators 16 and 26 is released to the outside through cooling water (or cooling air) inside the cooling sink.

[0006] However, in power module substrates 11 and 21 having a constitution like that described above, in the case of circuitry layers 13 and 23 and metal layers 14 and 24 being composed of Cu, when the substrate is subjected to repeated heat cycle of −40° C. to 125° C., cracks form in solder 17 and 27 interposed between circuitry layers 13 and 23 and semiconductor chips 15 and 25 after about several tens to 100 cycles, and after about 500 cycles, circuitry layers 13 and 23 end up separating from insulating substrates 12 and 22. However, in the case of composing circuitry layers 13 and 23 and metal layers 14 and 24 with Al, cracks do not form in solder 17 and 27 interposed between circuitry layers 13 and 23 and semiconductor chips 15 and 25 until about 3000 cycles. This is because, in the case of subjecting to repeated heat cycle, in contrast to internal stress not accumulating in the case of composing circuitry layers 13 and 23 and metal layers 14 and 24 with Al, in the case of composing with Cu, internal stress accumulates. Thus, a constitution should be employed for which there is no accumulation of internal stress in order to extend a life of the substrates toward heat cycle.

[0007] On the other hand, since Cu is better than Al when a comparison is made of the thermal conductivities of Al and Cu, it is better to compose circuitry layers 13 and 23 and metal layers 14 and 24 with Cu due to its satisfactory thermal conductivity in order to allow heat from semiconductor chips 15 and 25 to be efficiently released by transferring to the side of radiators 16 and 26. However, since there is the problem of accumulation of internal stress as previously described in the case of using Cu, it was difficult to satisfy requirements for both a long life toward heat cycle and satisfactory thermal conductivity, and one of the two had to be sacrificed.

[0008] In consideration of the aforementioned problems of the prior art, an object of the present invention is to provide a power module substrate which, together with being able to extend the life toward heat cycle, is also capable of obtaining a satisfactory heat transfer rate to allow heat from a semiconductor chip to be efficiently released by transferring to the side of a heat radiator.

SUMMARY OF THE INVENTION

[0009] The present invention employs the following means to solve the aforementioned problems.

[0010] Namely, the first invention of the present invention is a heat-conducting multilayer substrate comprising at least a Cu circuitry layer of at least 99.999% purity and a ceramic layer.

[0011] According to this heat-conducting multilayer substrate, since a Cu circuitry layer is composed of 99.999% or more pure copper, even when subjected to repeated heat cycle, recrystallization occurs in the Cu circuitry layer and internal stress generated within the Cu circuit dissipates, thereby making it difficult for cracks to form in the ceramic layer and Cu circuitry layer.

[0012] The second invention of the present invention is a heat-conducting multilayer substrate comprising a Cu circuitry layer having at least 99.999% purity, a ceramic layer provided on one side of the Cu circuitry layer, and a high-purity metal layer provided on the other side of the Cu circuitry layer.

[0013] According to this heat-conducting multilayer substrate, it is difficult for cracks to form in the Cu circuit substrate, ceramic layer and high-purity metal layer even when subjected to repeated heat cycle.

[0014] The third invention of the present invention is the heat-conducting multilayer substrate wherein, the high-purity metal layer is a Cu metal layer of at least 99.999% purity.

[0015] According to this heat-conducting multilayer substrate, since recrystallization occurs in the Cu circuitry layer and the metal layer, there is no accumulation of internal stress even if heat cycle is repeated, and life of the substrate toward heat cycle can be extended.

[0016] Moreover, since both the metal layer and Cu circuitry layer are composed of Cu of at least 99.999% purity, thermal conductivity is satisfactory.

[0017] The fourth invention of the present invention is a power module substrate comprising an insulating substrate, a circuitry layer laminated on one side of the insulating substrate, a metal layer laminated on the other side of the insulating substrate, a semiconductor chip loaded onto the circuitry layer by means of solder, and a radiator joined to the metal layer; wherein, the circuitry layer and the metal layer are composed of copper of at least 99.999% purity.

[0018] According to this power module substrate, since the circuitry layer and the metal layer are composed of copper of at least 99.999% purity, internal stress is dissipated by recrystallization in the case of subjecting to repeated heat cycle. Thus, since there is no accumulation of internal stress, life of the substrate toward heat cycle can be extended. In addition, since the circuitry layer and metal layer are composed of copper, the thermal conductivity can be improved. Thus, heat from a semiconductor chip can be efficiently released by transferring to the side of a heat radiator.

[0019] The fifth invention of the present invention is the power module substrate according to the above second invention wherein, the radiator is joined to the metal layer by at least one of solder, brazing, and a diffused bonding.

[0020] According to this power module substrate, since the circuitry layer and metal layer are composed of copper of at least 99.999% purity, internal stress is dissipated by recrystallization in the case of subjecting to repeated heat cycle. Thus, since there is no accumulation of internal stress, life of the substrate toward heat cycle can be extended. In addition, since the circuitry layer and metal layer are composed of copper, the thermal conductivity can be improved. Thus, heat from a semiconductor chip can be efficiently released by transferring to a circuitry layer composed of copper, insulating substrate and metal layer composed of copper.

[0021] The sixth invention of the present invention is the power module substrate according to the above fourth or fifth invention wherein, the insulating substrate is composed of AlN, Al2O3, Si3N4 or SiC.

[0022] According to this power module substrate according to this invention, since the circuitry layer and metal layer are composed of copper of at least 99.999% purity, internal stress is dissipated by recrystallization in the case of subjecting to repeated heat cycle. Thus, since there is no accumulation of internal stress, life of the substrate toward heat cycle can be extended. In addition, since the circuitry layer and metal layer are composed of copper, the thermal conductivity can be improved. Thus, heat from a semiconductor chip can be efficiently released by transferring to a circuitry layer composed of copper, an insulating substrate composed of AlN, Al2O3, Si3N4 or SiC and a metal layer composed of copper.

[0023] The seventh invention of the present invention is the power module substrate according to any of the above fourth, fifth, and sixth inventions wherein, the circuitry layer and the metal layer release stress within 24 hours at 100° C.

[0024] According to this power module substrate, the metal layer and the circuitry layer are resistant to work hardening, the formation of cracks in the solder is prevented, and the circuitry layer is prevented from separating from the insulating substrate.

[0025] The eighth invention of the present invention is the power module substrate according to any of the above fourth, fifth, and sixth inventions wherein, elongation during rupture of the circuitry layer and the metal layer is from 20% to 30% within the range of −40° C. to 150° C.

[0026] According to this power module substrate, the metal layer and the circuitry layer are resistant to work hardening, the formation of cracks in the solder is prevented, and the circuitry layer is prevented from separating from the insulating substrate.

[0027] In other words, in the case elongation over a range of −40° C. to 150° C. is less than 20%, work hardening occurs easily in the circuitry layer and the metal layer, and there is the risk of cracks forming in the solder between the circuitry layer and the semiconductor chip. In addition, in the case elongation over a range of −40° C. to 150° C. is greater than 30%, excessive thermal stress occurs between the circuitry layer and the solder, cracks form in the solder between the circuitry layer and the semiconductor, and there is the risk of the circuitry layer separating from the insulating substrate.

[0028] The ninth invention of the present invention is the power module substrate according to any of the above fourth, fifth, and sixth inventions wherein, the thickness of the circuitry layer and the metal layer is from 0.04 mm to 1.0 mm.

[0029] According to this power module substrate, the metal layer and the circuitry layer are resistant to work hardening, the formation of cracks in the solder is prevented, and the circuitry layer is prevented from separating from the insulating substrate.

[0030] Furthermore, in the case the thickness of the metal layer and the circuitry layer is less than 0.04 mm, the circuitry layer is unable to alleviate stress generated between the semiconductor chip and insulating substrate, and there is the risk of cracks forming in the solder. In addition, in the case the thickness if greater than 1.0 mm, the strength of the circuitry layer becomes excessively large, resulting in the risk of the insulating substrate being cracked by repeated heat cycle.

[0031] The tenth invention of the present invention is the power module substrate described in any of the above fourth, fifth, and sixth inventions wherein, the conductivity of the circuitry layer and the metal layer is at least 99% IACS. IACS refers to the International Annealed Copper Standard.

[0032] According to this power module substrate, the circuitry layer is prevented from being separated from the insulating substrate.

[0033] The eleventh invention of the present invention is the power module substrate according to any of the above fourth, fifth, and sixth inventions wherein, the average particle diameter of crystalline particles of the circuitry layer and the metal layer is from 1.0 mm to 30 mm.

[0034] According to this power module substrate, there is no occurrence of warping or other problems in the circuitry layer and the metal layer, and work hardening is prevented in the circuitry layer and the metal layer.

[0035] Furthermore, the average particle diameter described in this invention refers the average of the average crystalline particle diameter following production of the power module.

[0036] On the other hand, in the case the average particle diameter is less than 1.0 mm, work hardening occurs easily during heat cycle in the metal layer and the circuitry layer, and there is the risk of cracks forming in the solder between the circuitry layer and the semiconductor chip. In addition, if the average particle diameter exceeds 30 mm, anisotropy of mechanical strength occurs in the metal layer and the circuitry layer, resulting in the occurrence of warping and other problems.

[0037] Moreover, according to the power module substrate of the present invention, since a circuitry layer and a metal layer are composed of copper of at least 99.999% purity, internal stress is dissipated by recrystallization even when subjected to repeated heat cycle. Thus, since there is no accumulation of internal stress, life of the substrate toward heat cycle can be extended considerably. In addition, since the circuitry layer and metal layer are composed of copper having satisfactory thermal conductivity, heat from a semiconductor chip can be efficiently released by transferring to the side of a radiator. Thus, a power module substrate can be provided that satisfies both long life toward heat cycle and satisfactory thermal conductivity.

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG. 1 is a schematic cross-sectional view showing one embodiment of a power module substrate according to the present invention.

[0039] FIG. 2 is a schematic cross-sectional view showing an example of a power module substrate of the prior art.

[0040] FIG. 3 is a schematic cross-sectional view showing another example of a power module substrate of the prior art.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] The following provides an explanation of an embodiment of the present invention with reference to the drawings.

[0042] FIG. 1 shows one embodiment of a power module substrate according to the present invention. This power module substrate 1 is provided with a insulating substrate (ceramic layer) 2, a circuitry layer 3 laminated on one side of insulating substrate 2, a metal layer 4 laminated on the other side of insulating substrate 2, a semiconductor chip 5 loaded on circuitry layer 3, and a radiator 6 joined to metal layer 4.

[0043] Insulating substrate 2 is formed to a desired size from, for example, AlN, Al2O3, Si3N4 or SiC, and circuitry layer 3 and metal layer 4 are laminated and adhered to its upper and lower surfaces, respectively.

[0044] Examples of methods for laminating and adhering circuitry layer 3 and metal layer 4 to insulating substrate 2 include the so-called Direct Bonding Copper (DBC) method in which a load of 0.5-2 kgf/cm2 (4.9×104 to 19.6×104 Pa) is applied thereto followed by heating to 1065° C. in an N2 atmosphere, and an active metal method in which a load of 0.5-2 kgf/cm2 (4.9×104 to 19.6×104 Pa) is applied thereto followed by heating to 800-900° C. in a vacuum. These methods should be suitably selected and used according to the specific application.

[0045] Circuit layer 3 and metal layer 4 are composed of Cu (5N—Cu) of at least 99.999% purity. 5N—Cu has a recrystallization temperature from room temperature (RT) to 150° C. Thus, work hardening that occurs at high temperatures during heat cycle can be inhibited without the accumulation of internal stress even when subjected to repeated heat cycle of −40 to 125° C.

[0046] Circuit layer 3 and metal layer 4 may also be composed of Cu (6N—Cu) of at least 99.9999% purity. 6N—Cu has a recrystallization temperature from room temperature (RT) to 100° C. Thus, similar to 5N—Cu, work hardening that occurs at high temperatures during heat cycle can be inhibited without the accumulation of internal stress even when subjected to repeated heat cycle of −40 to 125° C., and the substrate which can stand toward more than 3000 cycles can be obtained similar to the case of composing the circuitry layer and metal layer with Al.

[0047] A circuit pattern for loading semiconductor chip 5 is formed in circuitry layer 3, and semiconductor chip 5 is loaded by means of solder 7 in the upper section of this circuitry layer 3. Radiator 6 is integrally joined to the lower surface of metal layer 4 by solder 8, brazing or a diffused bonding.

[0048] Radiator 6 couples a plurality of radiator bodies composed of a heat-conducting material such as Al or Cu (material having satisfactory thermal conductivity) and a low thermal expansion material like high carbon steel (Fe—C) to form a multilayer structure. It is used by attaching to a cooling sink 9 located below it, and heat from semiconductor chip 5 that is transferred to radiator 6 is discharged to the outside by means of cooling water (or cooling air) within cooling sink 9.

[0049] In this power module substrate 1 according to this embodiment composed in the manner described above, since circuitry layer 3 and metal layer 4 are composed of Cu (5N—Cu) of at least 99.999% purity, there is no accumulation of internal stress even when used under conditions of being repeatedly subjected to heat cycle of −40 to 125° C., and work hardening at high temperatures during heat cycle can be inhibited. Thus, this power module substrate can be used in devices that operate at high temperatures in the manner of SiC or GaN.

[0050] In addition, also in the case of composing circuitry layer 3 and metal layer 4 with Cu (6N—Cu) of at least 99.9999% purity, there is no accumulation of internal stress even when used under conditions of being repeatedly subjected to heat cycle of −40 to 125° C., and work hardening at high temperatures during heat cycle can be inhibited. Thus, this power module substrate can be used even in devices that operate at temperatures of 125° C. and above (such as Si semiconductors).

[0051] Table 1 shows the results of comparing the lives toward heat cycle of power module substrates of the prior art and power module substrates of the present invention. Here, ceramics is used for the insulating substrate, the metal circuit indicates a circuitry layer and a metal layer, and OFC indicates oxygen-free copper (Cu: 99.9-99.99%). It can be understood from Table 1 that the power module substrates according to the present invention have a longer life than the power module substrates of the prior art.

	TABLE 1
	Ceramics	Metal Circuit
	Dim.	Thick.			Thick.		Temperature
	(mm)	(mm)	Material	Dim. (mm)	(mm)	Material	cycling life
Prior	30 × 30	0.635	AlN	28 × 28	0.3	OFC	520
Art	40 × 50	0.635	AlN	38 × 48	0.4	Al	5200
	30 × 15	0.635	AlN	28 × 13	0.6	Al	3100
	50 × 50	0.635	Al2O3	48 × 48	0.3	OFC	1320
	70 × 35	0.32	Al2O3	68 × 33	0.3	OFC	510
	60 × 35	0.32	Al2O3	58 × 33	0.4	Al	2900
	30 × 30	0.635	Si3N4	28 × 28	0.3	OFC	2800
	30 × 20	0.32	Si3N4	28 × 18	0.6	Al	3500
	50 × 40	0.32	Si3N4	48 × 38	0.4	Al	3800
Present	30 × 30	0.635	AlN	28 × 28	0.3	6N—Cu	5200
Invention	40 × 50	0.635	AlN	38 × 48	0.4	6N—Cu	5210
	30 × 15	0.635	AlN	28 × 13	0.6	6N—Cu	6200
	50 × 50	0.635	Al2O3	48 × 48	0.3	6N—Cu	5800
	70 × 35	0.32	Al2O3	68 × 33	0.3	6N—Cu	4800
	60 × 35	0.32	Al2O3	58 × 33	0.4	6N—Cu	3520
	30 × 30	0.635	Si3N4	28 × 28	0.3	6N—Cu	8250
	30 × 20	0.32	Si3N4	28 × 18	0.6	6N—Cu	5630
	50 × 40	0.32	Si3N4	48 × 38	0.4	6N—Cu	7520

[0052] The following provides an explanation of a second embodiment of the present invention. Since the constitution of the present embodiment is the same as the constitution shown in FIG. 1, an explanation is provided using different reference symbols.

[0053] Circuit layer 3a and metal layer 4a in the present embodiment are composed of Cu (5N—Cu) that releases stress at 100° C. or lower. Here, the release of stress refers to the dissipation of point defects, the rearrangement of dislocation and so forth that occur within crystals prior to the occurrence of recrystallization.

[0054] Consequently, circuitry layer 3a and metal layer 4a are resistant to the accumulation of internal stress due to the ease of occurrence of the dissipation of defects, rearrangement of dislocation and so forth.

[0055] In other words, even if subjected to repeated heat cycle of −40 to 125° C., since dissipation of defects, rearrangement of dislocation and so forth occur at 100° C. or lower, circuitry layer 3a and metal layer 4a return to a stress-free state and demonstrate little change in hardness as a result of being resistant to work hardening.

[0056] Thus, circuitry layer 3a is able to alleviate stress generated between semiconductor chip 5 and insulating substrate 2. In addition, it is also able to prevent the formation of cracks in solder 7.

[0057] Table 2 shows the relationship between changes in hardness following heat cycle (−40 to 125° C.×15 minutes, 3000 cycles) and the defect rate of insulating circuit substrates (defect: cracking of ceramic substrate or separation between Cu circuit and ceramic substrate). Samples were produced having different changes in hardness by changing the purity of the Cu (2N, 3N, 4N, 5N and 6N).

[0058] It can be understood from Table 2 that defects such as cracking of the ceramic substrate or separation between the Cu circuit and ceramic substrate occur in the case of a change in hardness of 30% or more.

	TABLE 2
	Cu purity	Defect rate	Change in hardness
	2N	100%	42%
	3N	83%	39%
	4N	26%	30%
	5N	0%	24%
	6N	0%	22%

[0059] In addition, in the following Table 3, it can be seen that in the case dissipation of dislocation occurs due to release of stress, defects such as cracking of insulating substrate 2 or separation between circuitry layer 3a and insulating substrate 2 do not occur.

[0060] The following provides an explanation of a third embodiment of the present invention. Since the constitution of this embodiment is the same as the constitution shown in FIG. 1, an explanation is provided using different reference symbols.

[0061] In the present embodiment, circuitry layer 3b and metal layer 4b are formed from Cu of at least 99.999% purity in which the range of elongation when ruptured over a range of −40° C. to 150° C. is from 20% to 30%. Here, since circuitry layer 3b and metal layer 4b are formed by the aforementioned copper, circuitry layer 3b and metal layer 4b are resistant to work hardening even when repeatedly subjected to heat cycle of −40 to 125° C.

[0062] Consequently, in the present embodiment as well similar to the first embodiment, work hardening at high temperatures of heat cycle can be inhibited, enabling the power module substrate to be used in devices that operate at high temperatures in the manner of SiC and GaN.

[0063] Furthermore, it can be understood from the results of a tensile test at −40 to 150° C. in Table 3 that, in the case of an elongation percentage of 20% to 30%, defects such as cracking of insulating substrate 2 or separation between circuitry layer 3a and insulating substrate 2 do not occur.

[0064] The following provides an explanation of a fourth embodiment of the present invention. Since the constitution of the present embodiment is the same as the constitution shown in FIG. 1, an explanation is provided using different reference symbols.

[0065] In the present embodiment, circuitry layer 3c and metal layer 4c are formed from pure copper of at least 99.999% purity, and the thickness of circuitry layer 3c and metal layer 4c is formed to be from 0.04 mm to 1.0 mm.

[0066] Since the thickness of circuitry layer 3c and metal layer 4c is formed to be from 0.04 mm to 1.0 mm, there is no accumulation of internal stress even when subjected to repeated heat cycle of −40 to 125° C., work hardening at high temperatures of heat cycle can be inhibited, and a life of 3000 cycles or more can be obtained. A particularly long life toward heat cycle can be obtained in the case insulating substrate 2 is formed from AlN or Al2O3.

[0067] The following provides an explanation of a fourth embodiment of the present invention. Since the constitution of the present embodiment is the same as the constitution shown in FIG. 1, an explanation is provided using different reference symbols. In the present embodiment, circuitry layer 3d and metal layer 4d are formed from pure copper of at least 99.999% purity and having a conductivity of at least 99% IACS.

[0068] It can be understood from Table 3 that in the case of N=5 or N=6 pure copper having conductivity of at least 99% IACS, defects such as cracking of the ceramic substrate or separation between the Cu circuit and ceramic substrate do not occur.

[0069] The following provides an explanation of a fifth embodiment of the present invention. Since the constitution of the present embodiment is the same as the constitution shown in FIG. 1, an explanation is provided using different reference symbols. In the present embodiment, circuitry layer 3e and metal layer 4e are formed from pure copper of at least 99.999% purity and having an average crystal particle diameter of 1.0 mm to 30 mm.

[0070] In the case of a crystal particle diameter of 1.0 mm to 30 mm, since circuitry layer 3e and metal layer 4e are both resistant to work hardening and resistant to the effects of solder 7 and 8, they are resistant to the occurrence of defects such as cracking of the ceramic substrate or separation between circuitry layer 3e and metal layer 4e.

[0071] Consequently, life of the substrate toward heat cycle of 3000 cycles of more can be obtained even when subjected to repeated heat cycle of −40 to 125° C.

[0072] Table 3 shows the results of measuring the defect rate, decrease in the number of dislocations, conductivity, average particle diameter and elongation percentage for the Cu circuit section cut out from each insulating substrate (residual ceramics were removed by etching with 20% NaOH).

[0073] Elongation percentage was determined using a thickness of the Cu circuit of 0.3 mm and a pulling speed of 0.5 mm/min. The number of dislocations was measured for the presence or absence of a decrease in the number of dislocations following heat treatment at 100° C. Measurement was performed by TEM observation of portions of the Cu material of an insulating circuit substrate, measuring the number of dislocations for N=3, determining the average number of dislocations, and then determining whether the measured average number of dislocations decreased following heat treatment of the insulating circuit substrate for 3 hours at 100° C. with respect to that before heat treatment. Conductivity was expressed as a ratio with the electrical conductivity of the International Annealed Copper Standard (IACS). Average crystal particle diameter was obtained by averaging the crystal particle diameter following heat treatment at 100° C.

[0074] Defect rate was determined by judging whether or not defects such as cracking of the ceramic substrate or separation between the Cu circuit and ceramic substrate occur for each of the test parameters.

[0075] As a result, defects such as cracking of the ceramic substrate or separation between the Cu circuit and ceramic substrate were determined not to occur in the case of an elongation percentage of 20% to 30% for N=5 or N=6 pure copper.

[0076] In addition, defects such as cracking of the ceramic substrate or separation between the Cu circuit and ceramic substrate were determined not to occur in the case of an average crystal particle diameter of 1.0 mm or more for N=5 or N=6 pure copper.

[0077] Moreover, defects such as cracking of the ceramic substrate or separation between the Cu circuit and ceramic substrate were determined not to occur in the case of conductivity being 99% IACS for N=5 or N=6 pure copper.

[0078] Moreover, defects such as cracking of the ceramic substrate or separation between the Cu circuit and ceramic substrate were determined not to occur in N=5 or N=6 pure copper in which a decrease in the number of dislocations occurs following heat treatment for 3 hours at 100° C.

TABLE 3
				Average
		Decrease	crystal
Cu	Defect	in no. of	Conductivity	particle	Elongation percentage
purity	rate	dislocations	(20° C.)	diameter	−40° C.	RT	80° C.	150° C.
2N	100%		95	0.1 mm	13%	12%	11%	12%
3N	83%		96	0.2 mm	16%	15%	15%	13%
4N	26%		98	0.5 mm	17%	15%	13%	12%
5N	0%	Present	99	1.9 mm	22%	21%	23%	22%
6N	0%	Present	99	3.8 mm	28%	22%	22%	23%

[0079] Table 4 describes the results of performing tensile tests on a pure copper A (N=5, vacuum-annealed material, thickness: 0.3 mm), pure copper B (N=3, vacuum-annealed material, thickness: 0.3 mm) and aluminum (vacuum-annealed material, thickness: 0.4 mm).

[0080] As a result, the elongation of pure copper A at −40 to 150° C. was determined to be from 20% to 30%.

TABLE 4
Samples:
(1) Pure copper A: Vacuum-annealed, thickness: 0.3
(2) Pure copper B: Vacuum-annealed, thickness: 0.3
(3) Aluminum: Vacuum-annealed, thickness: 0.4
	Cross-				Elongation
	sectional	Yield strength	Actual	Tensile	GL = 50		Test
		area	Load	Stress	load	load	Actual		Cutting	temp.
	Mark	(mm2)	(N)	(N/mm2)	(N)	(N/mm2)	(mm)	(%)	location	(° C.)
A	A-1	3.85	180	47	529	137	13.7	27	B	−40
	A-2	3.85	164	43	583	151	14.8	30	B	−40
	A-3	3.85	149	39	458	119	10.7	21	A	RT
	A-4	3.85	167	43	457	119	11.0	22	B	RT
	A-5	3.85	134	35	480	125	12.0	24	B	80
	A-6	3.85	185	48	427	111	9.1	18	C	80
	A-7	3.85	155	40	409	106	9.0	18	C	150
	A-8	3.85	159	41	375	97	10.8	22	C	150
B	B-1	3.93	184	47	698	178	8.8	18	C	−40
	B-2	3.93	199	51	671	171	8.2	16	C	−40
	B-3	3.93	169	43	584	149	7.4	15	C	RT
	B-4	3.93	179	46	579	147	7.2	14	C	RT
	B-5	3.93	161	41	519	132	6.7	13	C	80
	B-6	3.93	177	45	517	132	6.4	13	C	80
	B-7	3.93	167	42	454	116	5.9	12	C	150
	B-8	3.93	160	41	454	116	5.8	12	C	150
C	C-1	5.08	123	24	199	39	16.0	32	B	−40
	C-2	5.08	118	23	188	37	12.2	24	C	−40
	C-3	5.08	120	24	158	31	10.4	21	C	RT
	C-4	5.08	89	18	174	34	7.8	16	C	RT
	C-5	5.08	103	20	117	23	13.4	27	B	80
	C-6	5.08	83	16	130	26	14.1	28	B	80
	C-7	5.08	72	14	88	17	12.5	25	A	150
	C-8	5.08	73	14	108	21	17.0	34	C	150
Test piece: 12.5 (W) × 50 GL
Strain gauge: KFH-5-120-C1-16 BIM3 for Cu, affixed to both sides
KFH-5-120-C1-23 BIM3 for Al, affixed to both Sides
Adhesive: EP-34B
Cross head speed: 0.5 mm/min until yield strength, 5 mm/min after yield strength

[0081] According to the power module substrate of the present invention, since a circuitry layer and a metal layer are composed of copper of at least 99.999% purity, internal stress is dissipated by recrystallization even when subjected to repeated heat cycle. Thus, since there is no accumulation of internal stress, life of the substrate toward heat cycle can be significantly extended. In addition, since the circuitry layer and metal layer are composed of copper having satisfactory thermal conductivity, heat from a semiconductor chip can be efficiently released by transferring to the side of a heat radiator. Thus, the potential for industrial utilization is recognized since a power module substrate can be provided that satisfies both long life with respect to heat cycle and satisfactory thermal conductivity.

Claims

1. A heat-conducting multilayer substrate comprising: at least a Cu circuitry layer of at least 99.999% purity and a ceramic layer.

2. A heat-conducting multilayer substrate comprising: a ceramic layer, a Cu circuitry layer having at least 99.999% purity provided on one side of said ceramic layer, and a high-purity metal layer provided on the other side of the ceramic layer.

3. A heat-conducting multilayer substrate according to claim 2, wherein the high-purity metal layer is a Cu metal layer of at least 99.999% purity.

4. A power module substrate comprising: an insulating substrate, a circuitry layer laminated on one side of said insulating substrate, a metal layer laminated on the other side of said insulating substrate, a semiconductor chip loaded onto the circuitry layer by means of solder, and a radiator joined to the metal layer; wherein, the circuitry layer and the metal layer are composed of copper of at least 99.999% purity.

5. A power module substrate according to claim 4, wherein the radiator is joined to the metal layer by solder, brazing or a diffused bonding.

6. A power module substrate according to claim 4, wherein the insulating substrate is composed of AlN, Al2O3, Si3N4 or SiC.

7. A power module substrate according to claim 5, wherein the insulating substrate is composed of AlN, Al2O3, Si3N4 or SiC.

8. A power module substrate according to claim 4, wherein the circuitry layer and the metal layer release stress within 24 hours at 100° C.

9. A power module substrate according to claim 5, wherein the circuitry layer and the metal layer release stress within 24 hours at 100° C.

10. A power module substrate according to claim 6, wherein the circuitry layer and the metal layer release stress within 24 hours at 100° C.

11. A power module substrate according to claim 4, wherein elongation during rupture of the circuitry layer and the metal layer is from 20% to 30% within the range of −40° C. to 150° C.

12. A power module substrate according to claim 5, wherein elongation during rupture of the circuitry layer and the metal layer is from 20% to 30% within the range of −40° C. to 150° C.

13. A power module substrate according to claim 6, wherein elongation during rupture of the circuitry layer and the metal layer is from 20% to 30% within the range of −40° C. to 150° C.

14. A power module substrate according to claim 4, wherein the thickness of the circuitry layer and the metal layer is from 0.04 mm to 1.0 mm.

15. A power module substrate according to claim 5, wherein the thickness of the circuitry layer and the metal layer is from 0.04 mm to 1.0 mm.

16. A power module substrate according to claim 6, wherein the thickness of the circuitry layer and the metal layer is from 0.04 mm to 1.0 mm.

17. A power module substrate according to claim 4, wherein the conductivity of the circuitry layer and the metal layer is at least 99% IACS.

18. A power module substrate according to claim 5, wherein the conductivity of the circuitry layer and the metal layer is at least 99% IACS.

19. A power module substrate according to claim 6, wherein the conductivity of the circuitry layer and the metal layer is at least 99% IACS.

20. A power module substrate according to claim 4, wherein the average particle diameter of crystalline particles of the circuitry layer and the metal layer is from 1.0 mm to 30 mm.

21. A power module substrate according to claim 5, wherein the average particle diameter of crystalline particles of the circuitry layer and the metal layer is from 1.0 mm to 30 mm.

22. A power module substrate according to claim 6, wherein the average particle diameter of crystalline particles of the circuitry layer and the metal layer is from 1.0 mm to 30 mm.