The present invention relates to a method of manufacturing a nitride ceramic substrate and a nitride ceramic base material.
As an electronic component, a nitride ceramic substrate may be used. The nitride ceramic substrate is excellent in various aspects, such as high thermal conductivity or high insulation properties. The nitride ceramic substrate can be used in various electronic devices, such as a power module.
Various ceramic substrates, including a nitride ceramic substrate, can be manufactured such that a ceramic base material is divided by laser scribing as described in, for example, Patent Documents 1 to 3. A scribe line is formed on the ceramic base material by laser scribing. The ceramic base material is divided into a plurality of ceramic substrates along the scribe line.
Patent Document 1 describes that a nitride ceramic base material is divided into a plurality of the nitride ceramic substrates by laser scribing. The scribe line formed by the laser scribing includes a plurality of recessed portions formed in a row on a surface of the nitride ceramic base material. An opening width of the recessed portion is 0.04 mm to 0.5 mm, a depth of the recessed portion is ¼ to ⅓ of a thickness of the nitride ceramic base material, and an inter-center distance of the plurality of recessed portions is 0.2 mm or smaller.
Patent Document 2 describes that an aluminum oxide base material is divided into a plurality of the aluminum oxide substrates by laser scribing. The scribe line formed by the laser scribing includes a plurality of recessed portions formed in a row on a surface of the nitride ceramic base material. The recessed portion has a conical shape.
Patent Document 3 describes that a silicon nitride base material is divided into a plurality of the silicon nitride substrates by laser scribing. The scribe line formed by the laser scribing has a groove that extends continuously in one direction.
RELATED DOCUMENT
[Patent Document 1] Japanese Unexamined Patent Publication No. 2007-324301
[Patent Document 2] Japanese Unexamined Patent Publication No. 2013-175667
[Patent Document 3] Japanese Unexamined Patent Publication No. 2014-42066
Regarding the nitride ceramic base material, favorable removal of a brazing material from the nitride ceramic base material, reduction of appearance of a scribe line in scanning acoustic tomography (SAT), and favorable breakage of the nitride ceramic base material may be required.
An example of an object of the present invention is to achieve favorable removal of a brazing material from the nitride ceramic base material, reduction of appearance of a scribe line in SAT, and favorable breakage of the nitride ceramic base material. Other objects of the present invention will be apparent from the description of the present application.
An aspect of the present invention is a method of manufacturing a nitride ceramic substrate, the method including:
forming a scribe line on a first surface of a nitride ceramic base material by a laser; and
dividing the nitride ceramic base material along the scribe line,
in which the scribe line includes a plurality of recessed portions formed in a row on the first surface of the nitride ceramic base material,
a depth of each of the plurality of recessed portions is equal to or greater than 0.70 times and equal to or smaller than 1.10 times an opening width of each of the plurality of recessed portions, and
the opening width of each of the plurality of recessed portions is equal to or greater than 1.00 times and equal to or smaller than 1.10 times an inter-center distance of the plurality of recessed portions.
Another aspect of the present invention is a nitride ceramic base material including
a first surface on which a scribe line is formed,
in which the scribe line includes a plurality of recessed portions formed in a row on the first surface,
a depth of each of the plurality of recessed portions is equal to or greater than 0.70 times and equal to or smaller than 1.10 times an opening width of each of the plurality of recessed portions, and
the opening width of each of the plurality of recessed portions is equal to or greater than 1.00 times and equal to or smaller than 1.10 times an inter-center distance of the plurality of recessed portions.
According to the aspect of the present invention, favorable removal of a brazing material from the nitride ceramic base material, reduction of appearance of a scribe line in SAT, and favorable breakage of the nitride ceramic base material can be realized.
Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In all the drawings, the same components are denoted by the same reference numerals, and the description thereof will not be repeated as appropriate.
An overview of a method of manufacturing a nitride ceramic substrate in the embodiment is illustrated using
According to the present embodiment, favorable removal of a brazing material from the nitride ceramic base material 100, reduction of appearance of the scribe line in scanning acoustic tomography (SAT), and favorable breakage of the nitride ceramic base material 100 can be realized. As described in detail later, the present inventors have been newly found that properties of each of removal of a brazing material from the nitride ceramic base material 100, appearance of the scribe line in SAT, and breakage of the nitride ceramic base material 100 depend on various parameters, especially the depth d of the recessed portion 112, the opening width w of the recessed portion 112, and the inter-center distance p of the plurality of recessed portions 112. Studies of the present inventors have revealed that in a case where the depth d of the recessed portion 112, the opening width w of the recessed portion 112, and the inter-center distance p of the plurality of recessed portions 112 have the above-mentioned relationships, favorable removal of a brazing material from the nitride ceramic base material 100, reduction of appearance of the scribe line in SAT, and favorable breakage of the nitride ceramic base material 100 are realized.
The details of the nitride ceramic base material 100 will be described with reference to
The nitride ceramic base material 100 may be, for example, a silicon nitride base material or an aluminum nitride base material, and more specifically, may be a silicon nitride sintered body base material or an aluminum nitride sintered body base material.
The nitride ceramic base material 100 has a first surface 102 and a second surface 104. In the example shown in
The scribe line 110 includes a plurality of recessed portions 112. As shown in
The depth d of each recessed portion 112 may be, for example, equal to or greater than 9/64 times and equal to or smaller than 2/9 times the thickness t of the nitride ceramic base material 100, or may be equal to or greater than 45 μm and equal to or smaller than 90 μm. In a case where the depth d of each recessed portion 112 is too shallow, the nitride ceramic base material 100 cannot be favorably divided along the scribe line 110. On the other hand, in a case where the depth d of each recessed portion 112 is too deep, it may be difficult to remove a brazing material that has entered each recessed portion 112. On the other hand, in a case where the depth d of each recessed portion 112 is within the above-mentioned range, these obstacles can be reduced.
The details of the nitride ceramic base material 100 will be described with reference to
Each of the recessed portions 112 has a conical shape with a rounded tip, and has a rounded bottom surface in the cross-section shown in
The nitride ceramic base material 100 may have a ridge 114. The ridge 114 is located around the recessed portion 112. The ridge 114 is formed such that a part of the nitride ceramic base material 100 is raised due to the influence of heating by the laser.
The ridge 114 may be removed. The ridge 114 can be removed by, for example, wet blasting.
The scribe line 110 of the nitride ceramic base material 100 includes a plurality of first scribe lines 110a and a plurality of second scribe lines 110b. The first scribe line 110a extends in a first direction (X direction in
A plurality of sectioned regions RG are defined by the plurality of first scribe lines 110a and the plurality of second scribe lines 110b. The plurality of sectioned regions RG are arranged in a matrix. Each sectioned region RG has a substantially rectangular shape. The scribe line 110 is divided along the scribe line 110 to cut the plurality of sectioned regions RG (a plurality of nitride ceramic substrates) out from the nitride ceramic base material 100.
The first scribe line 110a includes a plurality of recessed portions 112 (a first group of recessed portions 112). The second scribe line 110b includes a plurality of recessed portions 112 (a second group of recessed portions 112). The recessed portion 112 located closest to the first scribe line 110a among the second group of recessed portions 112 is not overlapped with any of the first group of recessed portions 112. In a case where the first group of recessed portions 112 included in the first scribe line 110a and the second group of recessed portions 112 included in the second scribe line 110b overlap each other, there is a possibility that the nitride ceramic base material 100 may be chipped at a section where the recessed portions 112 are overlapped each other after the nitride ceramic base material 100 is divided. On the other hand, according to the present embodiment, it is possible to reduce chippings of the nitride ceramic base material 100 after the nitride ceramic base material 100.
A center of the recessed portion 112 closest to the first scribe line 110a among the second group of recessed portions 112 included in the second scribe line 110b is spaced apart from a center line C1 of the first scribe line 110a in the second direction (Y direction) by a distance g2. The distance g2 is, for example, equal to or smaller than 1.50 times, preferably equal to or smaller than 1.10 times an inter-center distance p2 of the second group of recessed portions 112. In this way, the recessed portion 112 closest to the first scribe line 110a among the second group of recessed portions 112 included in the second scribe line 110b can be disposed close to the first scribe line 110a. Therefore, favorable breakage of the nitride ceramic base material 100 at the intersection of the first scribe line 110a and the second scribe line 110b can be realized.
At the corner of the scribe line 110 (
First, as shown in
Next, as shown in
The brazing material 120 may be an active metal brazing material . The active metal brazing material contains, for example, at least one of Ag, Cu, or Sn as a metal, and contains at least one of Ti or Zr as an active metal. The brazing material 120 can be formed by coating. In this case, a part of the brazing material 120 may enter the scribe line 110 (recessed portions 112).
The metal layer 130 is bonded to the nitride ceramic base material 100 through the brazing material 120.
Next, the bond between the nitride ceramic base material 100 and the metal layer 130 is inspected by ultrasonic flaw detection inspection. The present inventors have found that under certain conditions, the scribe line 110 appears in a flaw detection image obtained by the ultrasonic flaw detection inspection. The appearance of the scribe line 110 in the flaw detection image is determined to be bonding voids between the nitride ceramic base material 100 and the metal layer 130, and it is desirable to reduce the appearance of the scribe line 110 from the viewpoint that the bonding voids between the nitride ceramic base material 100 and the metal layer 130 cannot be distinguished from bonding voids caused by the brazing material 120, or are difficult to be distinguished. As described in detail later, the present inventors have been newly found that the appearance of the scribe line 110 in SAT depends on various parameters, especially the depth d of the recessed portion 112, the opening width w of the recessed portion 112, and the inter-center distance p of the plurality of recessed portions 112.
Next, as shown in
Next, as shown in
As shown in
Next, the nitride ceramic base material 100 is divided along the scribe line 110 to form a plurality of nitride ceramic substrates (base plates). As described in detail later, the present inventors have been newly found that the property of the breakage of the nitride ceramic base material 100 depends on various parameters, especially the depth d of the recessed portion 112, the opening width w of the recessed portion 112, and the inter-center distance p of the plurality of recessed portions 112.
The nitride ceramic base material (base plate) can be used as an electronic component. For example, a semiconductor element may be mounted on the circuit layer 132 of the nitride ceramic base material (base plate) via solder.
In Example 1, the nitride ceramic base material 100 was manufactured as follows.
The nitride ceramic base material 100 was a silicon nitride sintered body base material having a thickness of 0.32 mm.
The scribe line 110 (the plurality of recessed portions 112) was formed by a carbon dioxide laser. The depth d of the recessed portion 112 (for example,
In each of Examples 2 to 7 and Comparative Examples 1 to 5, the depth d of the recessed portion 112 (for example,
(Removal of Brazing Material from Nitride Ceramic Base Material)
As described with reference to
A residue of the brazing material 120 in each of Examples 1 to 7 and Comparative Examples 1 to 4 is as shown in Table 1. In the column of “Removal of brazing material” in Table 1, “o” indicates that no residue of the brazing material 120 was confirmed in the scribe line 110 (recessed portions 112), and “x” indicates that a residue of the brazing material 120 was confirmed in the scribe line 110 (recessed portions 112)
(Appearance of Scribe Line in SAT)
After the brazing material 120 was formed on the nitride ceramic base material 100, the nitride ceramic base material 100 and the metal layer 130 were bonded to each other by the brazing material 120. Thereafter, the bonding between the nitride ceramic base material 100 and the metal layer 130 was inspected by ultrasonic flaw detection inspection.
The appearance of the scribe line 110 in SAT in each of Examples 1 to 7 and Comparative Examples 1 to 4 was as shown in Table 1. In the column of “SAT” in Table 1, “O” indicates that no appearance of the scribe line 110 was confirmed in SAT of the ultrasonic flaw detection inspection, and “x” indicates that the appearance of the scribe line 110 was confirmed in SAT of the ultrasonic flaw detection inspection.
(Breakage of Nitride Ceramic Base Material)
After the brazing material 120 remaining in the nitride ceramic base material 100 was removed, the nitride ceramic base material 100 was divided along the scribe line 110 by a four-point bending test.
The maximum bending stress when the nitride ceramic base material 100 in each of Examples 1 to 7 and Comparative Examples 1 to 4 was broken was as shown in Table 1.
A division failure rate of the nitride ceramic base material 100 in each of Examples 1 to 7 and Comparative Examples 1 to 4 was as shown in Table 1.
From Comparative Example 1, in a case where a ratio w/p is equal to or smaller than 0.60, favorable breakage of the nitride ceramic base material 100 would be difficult to be achieved.
From Comparative Example 2, in a case where a ratio d/w is equal to or smaller than 0.45, favorable breakage of the nitride ceramic base material 100 would be difficult to be achieved.
From Comparative Example 3, in a case where a ratio d/w is equal to or greater than 1.20, favorable removal of the brazing material 120 from the nitride ceramic base material 100 would be difficult to be achieved.
From Comparative Example 4, in a case where a ratio w/p is equal to or greater than 1.16, reduction of the appearance of the scribe line 110 in SAT would be difficult to be achieved.
From these examinations, the ratio d/w may be, for example, equal to or greater than 0.70 and 1.10, and preferably equal to or greater than 0.75 and equal to or smaller than 1.08, and the ratio w/p may be, for example, equal to or greater than 1.00 and equal to or smaller than 1.10, and preferably, equal to or greater than 1.00 and equal to or smaller than 1.07.
Although the embodiment of the present invention has been described with reference to the drawings, these are an example of the present invention, and various configurations other than the above can be adopted.
This application claims priority based on Japanese Patent Application No. 2019-048079 filed on March 15, 2019, the disclosure of which is incorporated herein its entirety.
100: nitride ceramic base material
102: first surface
104: second surface
110: scribe line
110
a: first scribe line
110
b: second scribe line
112: recessed portion
114: ridge
120: brazing material
130: metal layer
132: circuit layer
134: heat dissipation layer
140: resist
Number | Date | Country | Kind |
---|---|---|---|
2019-048079 | Mar 2019 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2020/010913 | 3/12/2020 | WO | 00 |