The present disclosure relates to a semiconductor device.
Semiconductor devices incorporating power switching elements, such as metal oxide semiconductor field effect transistors (MOSFETs) and insulated gate bipolar transistors (IGBTs), have been conventionally known. Such semiconductor devices are mounted in various electronic devices, ranging from industrial devices to home appliances and information terminals, or even to vehicle-mount devices. JP-A-2021-190505 discloses a conventional semiconductor device (power module). The semiconductor device disclosed in JP-A-2021-190505 includes a semiconductor element, a main substrate, and a substrate. The main substrate has a metal layer. The semiconductor element is electrically bonded to the metal layer. A sub-substrate is supported by the main substrate. The semiconductor device disclosed in JP-A-2021-190505 also includes a support substrate (ceramic substrate). The support substrate supports the semiconductor element. The support substrate includes an insulating base member and conductive layers formed on the respective surfaces of the base member. The base member is made of a ceramic material, for example. The conductive layers are made of copper (Cu), for example, and the semiconductor element is bonded to one of the conductive layers. The semiconductor element and the conductive layer are electrically connected by, for example, a wire made of Al.
The following describes preferred embodiments of the present disclosure in detail with reference to the drawings. The reference numerals used in
The terms such as “first”, “second” and “third” in the present disclosure are used merely for identification, and are not intended to impose orders on the elements accompanied with these terms.
In the present disclosure, the phrases “an object A is formed in an object B” and “an object A is formed on an object B” include, unless otherwise specified, “an object A is formed directly in/on an object B” and “an object A is formed in/on an object B with another object interposed between the object A and the object B”. Similarly, the phrases “an object A is disposed in an object B” and “an object A is disposed on an object B” include, unless otherwise specified, “an object A is disposed directly in/on an object B” and “an object A is disposed in/on an object B with another object interposed between the object A and the object B”. Similarly, the phrase “an object A is located on an object B” includes, unless otherwise specified, “an object A is located on an object B in contact with the object B” and “an object A is located on an object B with another object interposed between the object A and the object B”. Further, the phrase “an object A overlaps with an object B as viewed in a certain direction” includes, unless otherwise specified, “an object A overlaps with the entirety of an object B” and “an object A overlaps with a portion of an object B”. Further, the phrase “a plane A faces (a first side or a second side) in a direction B” is not limited to the case where the angle of the plane A with respect to the direction B is 90°, but also includes the case where the plane A is inclined to the direction B.
First embodiment:
A thickness direction z in
First semiconductor elements 10A and second semiconductor elements 10B: Each of the first semiconductor elements 10A and the second semiconductor elements 10B is an electronic component that forms the functional core of the semiconductor device A1. The first semiconductor elements 10A and the second semiconductor elements 10B are made of a semiconductor material mainly containing silicon carbide (SiC), for example. The semiconductor material is not limited to silicon carbide (SiC), and may be silicon (Si), gallium nitride (GaN), or diamond (C). Each of the first semiconductor elements 10A and the second semiconductor elements 10B is a power semiconductor chip having a switching function such as a metal oxide semiconductor field effect transistor (MOSFET), for example. The first semiconductor elements 10A and the second semiconductor elements 10B are MOSFETs in the present embodiment, but may be other transistors such as insulated gate bipolar transistors (IGBTs) in other examples. The first semiconductor elements 10A and the second semiconductor elements 10B may have different configurations or the same configuration. In the following description, the first semiconductor elements 10A and the second semiconductor elements 10B are identical to each other. The first semiconductor elements 10A and the second semiconductor elements 10B are n-channel MOSFETs, but may be p-channel MOSFETs instead.
As shown in
The number of first semiconductor elements 10A and the number of second semiconductor elements 10B are changed appropriately according to the performance required such as the capacity of current handled by the semiconductor device A1. In the present embodiment, four first semiconductor elements 10A and four second semiconductor elements 10B are arranged as shown in
The semiconductor device A1 is configured as a half-bridge switching circuit, for example. In this case, the first semiconductor elements 10A form an upper arm circuit of the semiconductor device A1, and the second semiconductor elements 10B form a lower arm circuit. In the upper arm circuit, the first semiconductor elements 10A are connected in parallel. In the lower arm circuit, the second semiconductor elements 10B are also connected in parallel. Each first semiconductor element 10A is connected in series to a second semiconductor element 10B to form a bridge layer.
As shown in
As shown in
Each of the first semiconductor elements 10A and the second semiconductor elements 10B includes a first obverse-surface electrode 11, a second obverse-surface electrode 12, a third obverse-surface electrode 13, and a reverse-surface electrode 15. The description given below of the configurations of the first obverse-surface electrode 11, the second obverse-surface electrode 12, the third obverse-surface electrode 13, and the reverse-surface electrode 15 is common to all the first semiconductor elements 10A and the second semiconductor elements 10B. The first obverse-surface electrode 11, the second obverse-surface electrode 12, and the third obverse-surface electrode 13 are disposed on the element obverse surface 101. The first obverse-surface electrode 11, the second obverse-surface electrode 12, and the third obverse-surface electrode 13 are insulated by a non-illustrated insulating film. The reverse-surface electrode 15 is disposed on the element reverse surface 102.
The first obverse-surface electrode 11 is a gate electrode, for example, and receives a drive signal (e.g., gate voltage) inputted to drive the first semiconductor element 10A (the second semiconductor element 10B). The second obverse-surface electrode 12 of the first semiconductor element 10A (the second semiconductor element 10B) is a source electrode, for example, and conducts a source current. The third obverse-surface electrode 13 is a source sense electrode, for example, and conducts the source current. The reverse-surface electrode 15 is a drain electrode, for example, and conducts a drain current. The reverse-surface electrode 15 covers substantially the entirety of the element reverse surface 102. The reverse-surface electrode 15 is formed by silver (Ag) plating, for example.
Each first semiconductor element 10A (each second semiconductor element 10B) switches between a conducting state and a non-conducting state in response to a drive signal (gate voltage) inputted to the first obverse-surface electrode 11 (the gate electrode). In the conducting state, a current flows from the reverse-surface electrode 15 (the drain electrode) to the second obverse-surface electrode 12 (the source electrode). In the non-conducting state, the current does not flow. In short, each first semiconductor element 10A (each second semiconductor element 10B) performs a switching operation. With the switching functions of the first semiconductor elements 10A and the second semiconductor elements 10B, the semiconductor device A1 converts the DC voltage inputted between the fourth terminal 44 and each of the first terminal 41 and the second terminal 42 into AC voltage, for example, and outputs the AC voltage from the third terminals 43.
Main substrate 3: The main substrate 3 supports the first semiconductor elements 10A and the second semiconductor elements 10B. The specific configuration of the main substrate 3 is not particularly limited. For example, the main substrate 3 may be a direct bonded copper (DBC) substrate or an active metal brazing (AMB) substrate. The main substrate 3 includes a main insulating layer 31, a first main metal layer 32, and a second main metal layer 33. The first main metal layer 32 includes the first conductive portion 32A and the second conductive portion 32B. The dimension of the main substrate 3 in the thickness direction z is not particularly limited, and may be at least 0.4 mm and at most 3.0 mm, for example. In the illustrated example, the first main metal layer 32 is a single layer and does not include a plating layer or the like.
The constituent material of the main insulating layer 31 may contain ceramic having excellent thermal conductivity. Examples of such a ceramic material include silicon nitride (SiN). The constituent material of the main insulating layer 31 is not limited to ceramic, and may be an insulating resin sheet, for example. The main insulating layer 31 is rectangular in plan view, for example. The dimension of the main insulating layer 31 in the thickness direction z is not particularly limited, and may be at least 0.05 mm and at most 1.0 mm, for example.
As shown in
The first conductive portion 32A has a first obverse surface 301A. The first obverse surface 301A is a flat surface facing the z1 side in the thickness direction z. Each of the first semiconductor elements 10A is bonded to the first obverse surface 301A of the first conductive portion 32A via a first conductive bonding member 19A. The second conductive portion 32B has a second obverse surface 301B. The second obverse surface 301B is a flat surface facing the z1 side in the thickness direction z. Each of the second semiconductor elements 10B is bonded to the second obverse surface 301B of the second conductive portion 32B via a second conductive bonding member 19B. The constituent material of each of the first conductive bonding members 19A and the second conductive bonding members 19B is not particularly limited, and examples include solder, metal paste containing a metal such as silver (Ag), or a sintered metal containing a metal such as silver (Ag). The dimension of each of the first conductive portion 32A and the second conductive portion 32B in the thickness direction z is not particularly limited, and may be at least 0.1 mm and at most 1.5 mm, for example.
The second main metal layer 33 is formed on the lower surface (the surface facing the z2 side in the thickness direction z) of the main insulating layer 31. The constituent material of the second main metal layer 33 is the same as that of the first main metal layer 32, for example. The second main metal layer 33 has a reverse surface 302. The reverse surface 302 is a flat surface facing the z2 side in the thickness direction z. In the example shown in
First terminal 41, second terminal 42, third terminals 43, and fourth terminal 44: The specific configuration of each of the first terminal 41, the second terminal 42, the third terminals 43, and the fourth terminal 44 is not particularly limited. In the present embodiment, each of these terminals may be made of a metal plate. The metal plate may contain copper (Cu) or an alloy of copper (Cu), for example. In the example shown in
The first terminal 41, the second terminal 42, and the fourth terminal 44 are input terminals for DC voltage that is to be converted. The fourth terminal 44 may be a positive electrode (P terminal), and the first terminal 41 and the second terminal 42 may be negative electrodes (N terminals). The third terminals 43 are output terminals for the AC voltage resulting from the power conversion by the first semiconductor elements 10A and the second semiconductor elements 10B. Each of the first terminal 41, the second terminal 42, the third terminals 43, and the fourth terminal 44 includes a portion covered with the sealing resin 8 and a portion exposed from the sealing resin 8.
As shown in
As shown in
As shown in
As can be seen from
First sub-substrate 48A and second sub-substrate 48B: The first sub-substrate 48A and the second sub-substrate 48B support the control terminals 45. The first sub-substrate 48A and the second sub-substrate 48B are located between the first and second obverse surfaces 301A and 301B and the control terminals 45 in the thickness direction z. The first sub-substrate 48A and the second sub-substrate 48B may have different configurations or the same configuration. The first sub-substrate 48A is disposed on the first conductive portion 32A. The second sub-substrate 48B is disposed on the second conductive portion 32B. In the present embodiment, the first sub-substrate 48A and the second sub-substrate 48B have the same configuration where one of them is rotated 180° with respect to the other as viewed in the thickness direction z.
The specific configuration of each of the first sub-substrate 48A and the second sub-substrate 48B is not particularly limited. Specific examples of the configuration of the first sub-substrate 48A and the second sub-substrate 48B include an insulated metal substrate (IMS substrate) and a glass epoxy resin substrate. In the present embodiment, the first sub-substrate 48A and the second sub-substrate 48B are IMS substrates. Each of the first sub-substrate 48A and the second sub-substrate 48B includes a stack of a sub-insulating layer 481, a first sub-metal layer 482, and a second sub-metal layer 483.
The sub-insulating layer 481 is made of a ceramic material, for example. The sub-insulating layer 481 is rectangular in plan view, for example. The thickness of the sub-insulating layer 481 is not particularly limited, and may be at least 0.05 mm and at most 1.0 mm, for example.
As shown in
As shown in
The region 482A includes a connecting portion 4821A and a terminal portion 4822A. In the first sub-substrate 48A, the connecting portion 4821A is located on the x2 side in the first direction x, and the terminal portion 4822A is located on the x1 side in the first direction x. In the second sub-substrate 48B, the connecting portion 4821A is located on the x1 side in the first direction x, and the terminal portion 4822A is located on the x2 side in the first direction x. The connecting portion 4821A is elongated in the second direction y. The terminal portion 4822A has a substantially circular shape.
A plurality of wires 71 are bonded to the connecting portion 4821A. In the present embodiment, the wires 71 are bonded to the surface metal layer 4829 of the connecting portion 4821A. The constituent material of the wires 71 is not particularly limited, and may contain aluminum (Al) or an alloy of aluminum (Al). The region 482A is electrically connected to the first obverse-surface electrodes 11 (gate electrodes) of the first semiconductor elements 10A (the second semiconductor elements 10B) via the wires 71.
The region 482B includes a connecting portion 4821B and a terminal portion 4822B. In the first sub-substrate 48A, the connecting portion 4821B is located on the x2 side in the first direction x, and the terminal portion 4822B is located on the x1 side in the first direction x. In the second sub-substrate 48B, the connecting portion 4821B is located on the x1 side in the first direction x, and the terminal portion 4822B is located on the x2 side in the first direction x. In the first sub-substrate 48A, the region 482B is located on the x1 side in the first direction x from the connecting portion 4821A. In the second sub-substrate 48B, the region 482B is located on the x2 side in the first direction x from the connecting portion 4821A. The connecting portion 4821B is elongated in the second direction y. The terminal portion 4822B has a substantially circular shape. In the first sub-substrate 48A, the terminal portion 4822B is located on the y2 side in the second direction y from the terminal portion 4822A. In the second sub-substrate 48B, the terminal portion 4822B is located on the y1 side in the second direction y from the terminal portion 4822A.
A plurality of wires 72 are bonded to the connecting portion 4821B. In the present embodiment, the wires 72 are bonded to the surface metal layer 4829 of the connecting portion 4821B. The constituent material of the wires 72 is not particularly limited, and may contain aluminum (Al) or an alloy of aluminum (Al). The region 482B is electrically connected to the third obverse-surface electrodes 13 (the source sense electrodes) of the first semiconductor elements 10A (the second semiconductor elements 10B) via the wires 72.
The region 482C includes a connecting portion 4821C and a terminal portion 4822C. In the first sub-substrate 48A, the connecting portion 4821C is located on the y2 side in the second direction y, and the terminal portion 4822C is located on the y1 side in the second direction y. In the second sub-substrate 48B, the connecting portion 4821C is located on the y1 side in the second direction y, and the terminal portion 4822C is located on the y2 side in the second direction y. The connecting portion 4821C has a bent shape extending in the second direction y. The terminal portion 4822C has a substantially circular shape. In the first sub-substrate 48A, the terminal portion 4822C is located on the x1 side in the first direction x from the connecting portion 4821A, and is located on the y2 in the second direction y from the terminal portion 4822B. In the second sub-substrate 48B, the terminal portion 4822C is located on the x2 side in the first direction x from the connecting portion 4821A, and is located on the y1 side in the second direction y from the terminal portion 4822B.
The region 482D includes a connecting portion 4821D and a terminal portion 4822D. In the first sub-substrate 48A, the connecting portion 4821D is located on the y2 side in the second direction y, and the terminal portion 4822D is located on the y1 side in the second direction y. The connecting portion 4821D has a rectangular shape, for example, and the terminal portion 4822D has a substantially circular shape, for example. In the first sub-substrate 48A, the connecting portion 4821D is located on the x1 side in the first direction x from the connecting portion 4821C. In the second sub-substrate 48B, the connecting portion 4821D is located on the x2 side in the first direction x from the connecting portion 4821C. In the first sub-substrate 48A, the terminal portion 4822D is located on the y2 side in the second direction y from the terminal portion 4822C. In the first sub-substrate 48A, the terminal portion 4822D is located on the y2 side in the second direction y from the terminal portion 4822C.
In the first sub-substrate 48A, the region 482E is located on the y2 side in the second direction y from the connecting portion 4821A, and on the x2 side in the first direction x from the connecting portion 4821C. In the second sub-substrate 48B, the region 482E is located on the y1 side in the second direction y from the connecting portion 4821A, and on the x1 side in the first direction x from the connecting portion 4821C. The region 482E is elongated in the second direction y.
The region 482E corresponds to the “first region” in the present disclosure. The region 482D corresponds to the “second region” in the present disclosure. The region 482C corresponds to the “third region” in the present disclosure. In other words, the region 482C is located between the region 482E and the region 482D in the first direction x.
The regions 482F are arranged alternately with the terminal portion 4822A, the terminal portion 4822B, the terminal portion 4822C, and the terminal portion 4822D in the second direction y. The shape of each region 482F is not particularly limited, and may be rectangular or circular, for example. In the illustrated example, each region 482F has a rectangular shape.
As shown in
The second sub-metal layer 483 of the first sub-substrate 48A is electrically bonded to the first conductive portion 32A. The second sub-metal layer 483 of the second sub-substrate 48B is electrically bonded to the second conductive portion 32B. The method for electrically bonding a second sub-metal layer 483 to the first conductive portion 32A or the second conductive portion 32B is not particularly limited. The method for electrical bonding may be bonding with a conductive bonding member, laser bonding, ultrasonic bonding, or solid-phase bonding. In the present embodiment, the second sub-metal layer 483 of each of the first sub-substrate 48A and the second sub-substrate 48B is electrically bonded to the first conductive portion 32A or the second conductive portion 32B via a conductive bonding member 49, as shown in
As shown in
As shown in
As shown in
The wires 71, the wires 72, and the wire 73 are not connected to the first main metal layer 32. In other words, the first main metal layer 32 is spaced apart from the wires 71, 72, and 73.
Control terminals 45: The control terminals 45 are used to control the first semiconductor elements 10A and the second semiconductor elements 10B. The control terminals 45 include a plurality of control terminals 46A, 46B, and 46E, and a plurality of control terminals 47A to 47D. The control terminals 46A, 46B, and 46E are used to control the first semiconductor elements 10A, for example. The control terminals 47A to 47D are used to control the second semiconductor elements 10B, for example.
The control terminals 46A, 46B, and 46E are spaced apart from each other in the second direction y. As shown in
As shown in
The control terminal 46B is disposed on the terminal portion 4822B. The control terminal 46B is a terminal (a source sense terminal) for detecting the source signal of the first semiconductor elements 10A. The voltage (the voltage corresponding to the source current) applied to the second obverse-surface electrodes 12 (the source electrodes) of the first semiconductor elements 10A is detected at the control terminal 46B.
The control terminal 46E is disposed on the terminal portion 4822D. The control terminal 46E is a terminal (a drain sense terminal) for detecting the drain signal of the first semiconductor elements 10A. The voltage (the voltage corresponding to the drain current) applied to the reverse-surface electrodes 15 (the drain electrodes) of the first semiconductor elements 10A is detected at the control terminal 46E. The control terminal 46E corresponds to the “first control terminal” in the present disclosure.
The control terminals 47A to 47D are spaced apart from each other in the second direction y. As shown in
As shown in
The control terminal 47B is disposed on the terminal portion 4822B. The control terminal 47B is a terminal (a source sense terminal) for detecting the source signal of the second semiconductor elements 10B. The voltage (the voltage corresponding to the source current) applied to the second obverse-surface electrodes 12 (the source electrodes) of the second semiconductor elements 10B is detected at the control terminal 47B.
The control terminal 47C is disposed on the terminal portion 4822C. The control terminal 47D is disposed on the terminal portion 4822D. The control terminal 47C and the control terminal 47D are electrically connected to the thermistor 17.
As shown in
The holder 451 is made of a conductive material. As shown in
The metal pin 452 is a rod-like member extending in the thickness direction z. The metal pin 452 is pressed into the holder 451 and supported by the holder 451. The metal pin 452 is electrically connected to the first sub-metal layer 482 at least through the holder 451. As shown in
First conductive member 5 and second conductive member 6: The first conductive member 5 and the second conductive member 6, together with the first conductive portion 32A and the second conductive portion 32B, form the path of the main circuit current that is switched by the first semiconductor elements 10A and the second semiconductor elements 10B. The first conductive member 5 and the second conductive member 6 are spaced apart from the first obverse surface 301A and the second obverse surface 301B toward the z1 side in the thickness direction z. In plan view, the first conductive member 5 and the second conductive member 6 overlap with the first obverse surface 301A and the second obverse surface 301B. In the present embodiment, each of the first conductive member 5 and the second conductive member 6 is made of a metal plate. The metal may contain copper (Cu) or an alloy of copper (Cu), for example. Specifically, the first conductive member 5 and the second conductive member 6 are metal plates having been bent as needed.
The first conductive member 5 is connected to the second obverse-surface electrodes 12 (the source electrodes) of the first semiconductor elements 10A and the second conductive portion 32B, and electrically connects the second obverse-surface electrodes 12 of the first semiconductor elements 10A and the second conductive portion 32B. The first conductive member 5 forms the path of the main circuit current that is switched by the first semiconductor elements 10A. As shown in
The main portion 51 is located between the first semiconductor elements 10A and the second conductive portion 32B in the first direction x, and has the shape of a strip extending in the second direction y in plan view. The main portion 51 overlaps with both the first conductive portion 32A and the second conductive portion 32B in plan view, and is spaced apart from the first obverse surface 301A and the second obverse surface 301B to toward the z1 side in the thickness direction z. As shown in
In the present embodiment, the main portion 51 is parallel to the first obverse surface 301A and the second obverse surface 301B.
As shown in
As shown in
As shown in
The second conductive member 6 electrically connects the second obverse-surface electrodes 12 (the source electrodes) of the second semiconductor elements 10B to the first terminal 41 and the second terminal 42. The second conductive member 6 is integrally formed with the first terminal 41 and the second terminal 42. The second conductive member 6 forms the path of the main circuit current that is switched by the second semiconductor elements 10B. As shown in
The third bonding portions 61 are bonded to the respective second semiconductor elements 10B. Each of the third bonding portions 61 is bonded to the second obverse-surface electrode 12 of a second semiconductor element 10B via a conductive bonding member 69. The material of the conductive bonding members 69 is not particularly limited, and may be solder, metal paste, or sintered metal. In the present embodiment, each of the third bonding portions 61 includes two flat sections 611 and two first inclined sections 612.
The two flat sections 611 are aligned in the second direction y. The two flat sections 611 are spaced apart from each other in the second direction y. The shape of each flat section 611 is not particularly limited, and is rectangular in the illustrated example. The two flat sections are bonded to the second obverse-surface electrode 12 on the respective sides in the second direction y.
The two first inclined sections 612 are connected to the outer ends of the respective two flat sections 611 in the second direction y. In other words, the first inclined section 612 on the y1 side in the second direction y is connected to the y1-side end of the flat section 611 located on the y1 side in the second direction y. The first inclined section 612 on the y2 side in the second direction y is connected to the y2-side end of the flat section 611 located on the y2 side in the second direction y. Each of the first inclined sections 612 is inclined toward the z1 side in the thickness direction z with an increasing distance from the flat section 611 in the second direction y.
The first path portion 64 is located between the third bonding portions 61 and the first terminal 41. In the illustrated example, the first path portion 64 is connected to the first terminal 41 via a first ramp portion 602. The first path portion 64 overlaps with the first conductive portion 32A in plan view. The first path portion 64 generally extends in the first direction x.
The first path portion 64 includes a first band-shaped section 641 and a first extended section 643. The first band-shaped section 641 is located on the x2 side in the first direction x from the first terminal 41, and is substantially parallel to the first obverse surface 301A. The first band-shaped section 641 generally extends in the first direction x.
The first extended section 643 extends from the y1-side end of the first band-shaped section 641 in the second direction y toward the z2 side in the thickness direction z. The first extended section 643 is spaced apart from the first conductive portion 32A. In the illustrated example, the first extended section 643 is shaped along the thickness direction z, and has a rectangular shape elongated in the first direction x. Note that the first path portion 64 may be configured without the first extended section 643.
The second path portion 65 is located between the third bonding portions 61 and the second terminal 42. In the illustrated example, the second path portion 65 is connected to the second terminal 42 via a second ramp portion 603. The second path portion 65 overlaps with the first conductive portion 32A in plan view. The second path portion 65 generally extends in the first direction x.
The second path portion 65 includes a second band-shaped section 651 and a second extended section 653. The second band-shaped section 651 is located on the x2 side in the first direction x from the second terminal 42, and is substantially parallel to the first obverse surface 301A. The second band-shaped section 651 generally extends in the first direction x.
The second extended section 653 extends from the y2-side end of the second band-shaped section 651 in the second direction y toward the z2 side in the thickness direction z. The second extended section 653 is spaced apart from the first conductive portion 32A. In the illustrated example, the second extended section 653 is shaped along the thickness direction z, and has a rectangular shape elongated in the first direction x. Note that the second path portion 65 may be configured without the second extended section 653.
The third path portions 66 are individually connected to the third bonding portions 61. The third path portions 66 extend in the first direction x, and are spaced apart from each other in the second direction y. The number of third path portions 66 is not particularly limited. In the illustrated example, five third path portions 66 are provided. Each of the third path portions 66 is located either between two of the second semiconductor elements 10B in the second direction y or outside the second semiconductor elements 10B in the second direction y.
In the present embodiment, each of the third bonding portions 61 is located between two third path portions 66 adjacent in the second direction y. Each of the third bonding portions 61 has two first inclined sections 612, one on the y1 side in the second direction y and the other on the y2 side in the second direction y. The first inclined section 612 on the y1 side is connected to one of the two adjacent third path portions 66 that is located on the y1 side in the second direction y. The first inclined section 612 on the y2 side is connected to one of the two adjacent third path portions 66 that is located on the y2 side in the second direction y.
The fourth path portion 67 is connected to the ends of the respective third path portions 66 on the x1 side in the first direction x. The fourth path portion 67 extends in the second direction y. The fourth path portion 67 is connected to the x2-side end of the first band-shaped section 641 of the first path portion 64 in the first direction x, and to the x2-side end of the second band-shaped section 651 of the second path portion 65 in the first direction x. In the illustrated example, the fourth path portion 67 is connected to the first path portion 64 at the end on the y1 side in the second direction y and to the second path portion 65 at the end on the y2 side in the second direction y.
Scaling resin 8: The sealing resin 8 covers the first semiconductor elements 10A, the second semiconductor elements 10B, the main substrate 3 (except for the reverse surface 302), a part of each of the first terminal 41, the second terminal 42, the third terminals 43, and the fourth terminal 44, a part of each of the control terminals 45, the first sub-substrate 48A and the second sub-substrate 48B, the first conductive member 5, the second conductive member 6, and the wires 71 to 73. The sealing resin 8 may be made of a black epoxy resin, for example. The scaling resin 8 may be formed by molding, for example. The size of the sealing resin 8 is not particularly limited. For example, the sealing resin 8 may have a dimension of about 35 mm to 60 mm in the first direction x, a dimension of about 35 mm to 50 mm in the second direction y, and a dimension of about 4 mm to 15 mm in the thickness direction z. These dimensions are measured at the largest portions in the respective directions. The sealing resin 8 has a resin obverse surface 81, a resin reverse surface 82, and resin side surfaces 831 to 834.
As shown in
The resin side surfaces 831 to 834 are connected to both the resin obverse surface 81 and the resin reverse surface 82, and are located between the resin obverse surface 81 and the resin reverse surface 82 in the thickness direction z. As shown in
As shown in
Next, a vehicle B1 provided with the semiconductor device A1 will be described with reference to
As shown in
The drive system 93 drives the vehicle B1. The drive system 93 includes an inverter 931 and a drive source 932. The semiconductor device A1 constitutes a part of the inverter 931. The power stored in the storage battery 92 is supplied to the inverter 931. The power supplied from the storage battery 92 to the inverter 931 is DC power. In an example different from
The drive source 932 include an AC motor and a transmission. The AC power converted by the inverter 931 is supplied to the drive source 932 to rotate the AC motor. The rotation of the AC motor is transmitted to the transmission. The transmission appropriately reduces the rotational speed transmitted from the AC motor and rotates the drive shaft of the vehicle B1. This drives the vehicle B1. Driving the vehicle B1 requires freely regulating the rotational speed of the AC motor based on the amount of accelerator pedal operation and other information. The semiconductor device A1 in the inverter 931 is necessary for outputting the AC power at a frequency appropriately adjusted to correspond to the required rotational speed of the AC motor. The following describes advantages of the semiconductor device A1.
As shown in
The first sub-metal layer 482 has the surface metal layer 4829. The wires 71, 72, and 73 are connected to the surface metal layer 4829. This makes it possible to avoid the Kirkendall void phenomenon occurring at the portion where the wires 71, 72, and 73 are connected to the base layer 4820. When the wires 71, 72, and 73 contain aluminum (Al) and the base layer 4820 contains copper (Cu), the Kirkendall void phenomenon can be more reliably prevented by providing a surface metal layer 4829 containing nickel (Ni).
In addition, there is no need to connect a wire or the like to the first conductive portion 32A for the purpose of detecting a potential in the first conductive portion 32A with use of the control terminal 46E. This eliminates the need of providing the first conductive portion 32A with a metal layer or the like to prevent the Kirkendall void phenomenon. This is desirable for reducing the cost of the semiconductor device A1.
As shown in
First variation of the first embodiment:
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. In addition, the removal process for forming the connecting conductive portion 485 includes forming a through-hole that completely penetrates the sub-insulating layer 481. This allows the connecting conductive portion 485 to be electrically connected to the second sub-metal layer 483 more reliably.
Second variation of the first embodiment:
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. As can be understood from the present variation, the connecting conductive portion 485 may be configured to penetrate through the first sub-metal layer 482, or to penetrate through the second sub-metal layer 483.
Third variation of the first embodiment:
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. As can be understood from the present variation, the connecting conductive portion 485 may be configured to penetrate through the entirety of the first sub-substrate 48A or the second sub-substrate 48B in the thickness direction z.
Fourth variation of the first embodiment:
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. As can be understood from the present variation, the number of connecting conductive portions 485 is not particularly limited. The regions 482F do not have the wires 71 to 73 or the control terminals 45 connected thereto. Thus, the semiconductor device A14 still achieves its electrical function even when the regions 482F are electrically connected to the second sub-metal layer 483 by the connecting conductive portions 485.
Second embodiment:
The sub-insulating layer 481 has an opening 4811. The opening 4811 penetrates through the sub-insulating layer 481 in the thickness direction z, and allows the second sub-metal layer 483 to be exposed to the z1 side in the thickness direction z. The second sub-metal layer 483 has a bonding portion 4839 formed therein.
The bonding portion 4839 may be formed by placing the first sub-substrate 48A on the first conductive portion 32A, and in that state, irradiating a part of the second sub-metal layer 483 exposed from the opening 4811 with laser light. The irradiation of laser light causes a part of the second sub-metal layer 483 and a part of the first conductive portion 32A to melt together to form the bonding portion 4839 as shown in the figures.
In the illustrated example, the sub-insulating layer 481 has three openings 4811. A control terminal support 48 (the second sub-metal layer 483) has three bonding portions 4839. The three openings 4811 and the three bonding portions 4839 are spaced apart from each other in the second direction y. Two openings 4811 and two bonding portions 4839 are formed on the respective ends of the first sub-substrate 48A in the second direction y. One opening 4811 and one bonding portion 4839 are formed between the terminal portion 4822B and the terminal portion 4822C in the second direction y, substantially at the center of the first sub-substrate 48A in the second direction y.
The present embodiment also makes it possible to set a greater variety of conductive paths to the main substrate 3. In addition, the laser bonding can reduce the amount of heat applied to the first sub-substrate 48A and the first conductive portion 32A when the first sub-substrate 48A is bonded to the first conductive portion 32A. This is suitable for suppressing unintended thermal deformation of the first sub-substrate 48A, etc.
First variation of the second embodiment:
For example, the recess 4831 is formed by penetrating the sub-insulating layer 481 in a removal process for forming an opening 4811 and then removing a part of the second sub-metal layer 483. The bottom of the recess 4831 is irradiated with laser light to form a bonding portion 4839.
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. In addition, the recess 4831 formed in the present variation makes it possible to more reliably form an opening 4811 that penetrates through the sub-insulating layer 481. This can avoid insufficient formation of a bonding portion 4839 as a result of a part of the sub-insulating layer 481 unintentionally remaining in the laser bonding process for forming the bonding portion 4839.
Second variation of the second embodiment:
The opening 4825 penetrates through the first sub-metal layer 482 in the thickness direction z. The opening 4825 substantially coincides with an opening 4811 as viewed in the thickness direction z.
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. As can be understood from the present variation, in the laser bonding for forming a bonding portion 4839, the first sub-metal layer 482 can be irradiated with laser light through the opening 4825 and the opening 4811.
Third variation of the second embodiment:
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. Since the recess 4831 is formed, the part of the second sub-metal layer 483 that is irradiated with laser light in the laser bonding for forming a bonding portion 4839 is farther away from the first sub-metal layer 482 to the z2 side in the thickness direction z. This can prevent the heat generated in the laser bonding from reaching the first sub-metal layer 482.
Fourth variation of the second embodiment:
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. As can be understood from the present variation, the shape and arrangement of each opening 4811 are not particularly limited. According to the present variation, the first sub-substrate 48A can be downsized in the second direction y as compared to that in the semiconductor device A2.
Third embodiment:
In the present embodiment, each of the first sub-substrate 48A and the second sub-substrate 48B is composed of a glass epoxy resin substrate. The sub-insulating layer 481 is made of glass epoxy resin. The first sub-metal layer 482 and the second sub-metal layer 483 may be metal plating layers formed on the respective sides of the sub-insulating layer 481, and may contain copper (Cu). The shape of the first sub-metal layer 482 as viewed in the thickness direction z may be the same as that of the first sub-metal layer 482 of the semiconductor device A1, for example. The second sub-metal layer 483 is electrically bonded to the first conductive portion 32A or the second conductive portion 32B with a conductive bonding member 49, for example.
The connecting conductive portion 485 of the present embodiment may have a configuration called “through-hole conductive portion”. A through-hole is formed through the sub-insulating layer 481, the first sub-metal layer 482, and the second sub-metal layer 483, and the connecting conductive portion 485 is composed of a metal plating layer formed on the inner surface of the through-hole.
The present embodiment also makes it possible to set a greater variety of conductive paths to the main substrate 3. As can be understood from the present embodiment, the specific configuration of each of the first sub-substrate 48A and the second sub-substrate 48B is not particularly limited. The first sub-substrate 48A and the second sub-substrate 48B, which are composed of glass epoxy resin substrates, are suitable for forming the first sub-metal layer 482 to have a fine shape.
First variation of the third embodiment:
In the present variation, a recessed groove that extends in the thickness direction z is formed at the end of the sub-insulating layer 481 on the y2 side in the second direction y. The connecting conductive portion 485 is formed to cover the groove, and electrically connects the first sub-metal layer 482 and the second sub-metal layer 483.
The present variation also makes it possible to set a greater variety of conductive paths to the main substrate 3. As can be understood from the present variation, the specific configuration of the connecting conductive portion 485 is not particularly limited. According to the present variation, the conductive bonding member 49 is expected to adhere along the connecting conductive portion 485, as shown in
The semiconductor device and the vehicle according to the present disclosure are not limited to the embodiments described above. Various design changes can be made to the specific configurations of the elements of the semiconductor device and the vehicle according to the present disclosure.
A semiconductor device comprising:
The semiconductor device according to clause 1A, wherein the first semiconductor element is electrically bonded to the first main metal layer.
The semiconductor device according to clause 1A or 2A, further comprising a first control terminal that is electrically connected to the first region and protrudes from the sealing resin.
The semiconductor device according to clause 3A, wherein the first sub-metal layer further includes a second region spaced apart from the first region.
The semiconductor device according to clause 4A, wherein the first control terminal is supported by the second region.
The semiconductor device according to clause 5A, further comprising a first wire connected to the first region and the second region.
The semiconductor device according to clause 6A, wherein the first sub-metal layer further includes a third region that is spaced apart from the first region and the second region and located between the first region and the second region.
The semiconductor device according to clause 6A or 7A, wherein the first sub-metal layer includes a base layer and a surface metal layer.
The semiconductor device according to clause 8A, wherein the base layer includes Cu.
The semiconductor device according to clause 9A, wherein the surface metal layer contains Ni.
The semiconductor device according to clause 10A, wherein the first sub-metal layer contains Cu.
The semiconductor device according to clause 11A, wherein the first wire contains Al.
The semiconductor device according to any of clauses 1A to 12A, wherein the second sub-metal layer is electrically bonded to the first main metal layer by a conductive bonding member.
The semiconductor device according to any of clauses 1A to 12A, wherein the second sub-metal layer is electrically bonded to the first main metal layer by laser bonding.
The semiconductor device according to clause 14A, wherein the second sub-metal layer has a bonding portion formed by laser bonding, and
The semiconductor device according to any of clauses 1A to 15A, wherein the sub-insulating layer contains ceramic.
The semiconductor device according to any of clauses 1A to 15A, wherein the sub-insulating layer contains glass epoxy resin.
A vehicle comprising:
The following describes fourth to sixth embodiments according to the present disclosure, with reference to
In
Each of the first semiconductor elements 10A and the second semiconductor elements 10B is an electronic component that forms the functional core of the semiconductor device A1. The first semiconductor elements 10A and the second semiconductor elements 10B are made of a semiconductor material mainly containing silicon carbide (SiC), for example. The semiconductor material is not limited to SiC, and may be silicon (Si), gallium nitride (GaN), or diamond (C). Each of the first semiconductor elements 10A and the second semiconductor elements 10B is a power semiconductor chip having a switching function such as a metal oxide semiconductor field effect transistor (MOSFET), for example. The first semiconductor elements 10A and the second semiconductor elements 10B are MOSFETs in the present embodiment, but may be other transistors such as insulated gate bipolar transistors (IGBTs) in other examples. The first semiconductor elements 10A and the second semiconductor elements 10B are identical to each other. The first semiconductor elements 10A and the second semiconductor elements 10B are n-channel MOSFETs, but may be p-channel MOSFETs instead.
As shown in
In the present embodiment, the semiconductor device A1 includes four first semiconductor elements 10A and four second semiconductor elements 10B. However, the number of first semiconductor elements 10A and the number of second semiconductor elements 10B are not limited to the present example, and can be changed appropriately according to the performance required for the semiconductor device A1. In the example shown in
The semiconductor device A1 is configured as a half-bridge switching circuit, for example. In this case, the first semiconductor elements 10A form an upper arm circuit of the semiconductor device A1, and the second semiconductor elements 10B form a lower arm circuit. In the upper arm circuit, the first semiconductor elements 10A are connected in parallel. In the lower arm circuit, the second semiconductor elements 10B are also connected in parallel. Each first semiconductor element 10A is connected in series to a second semiconductor element 10B to form a bridge layer.
As shown in
As shown in
Each of the first semiconductor elements 10A and the second semiconductor elements 10B includes a first obverse-surface electrode 11, a second obverse-surface electrode 12, a third obverse-surface electrode 13, and a reverse-surface electrode 15. The description given below of the configurations of the first obverse-surface electrode 11, the second obverse-surface electrode 12, the third obverse-surface electrode 13, and the reverse-surface electrode 15 is common to all the first semiconductor elements 10A and the second semiconductor elements 10B. The first obverse-surface electrode 11, the second obverse-surface electrode 12, and the third obverse-surface electrode 13 are disposed on the element obverse surface 101. The first obverse-surface electrode 11, the second obverse-surface electrode 12, and the third obverse-surface electrode 13 are insulated by a non-illustrated insulating film. The reverse-surface electrode 15 is disposed on the element reverse surface 102. The first obverse-surface electrode 11 is a gate electrode, for example, and receives a drive signal (e.g., gate voltage) inputted to drive the first semiconductor element 10A (the second semiconductor element 10B). The second obverse-surface electrode 12 of the first semiconductor element 10A (the second semiconductor element 10B) is a source electrode, for example, and conducts a source current. The second obverse-surface electrode 12 of the present embodiment includes a gate finger 121. The gate finger 121 is a linear insulator that extends in the first direction x, for example, and divides the second obverse-surface electrode 12 into two regions in the second direction y. The third obverse-surface electrode 13 is a source sense electrode, for example, and conducts the source current. The reverse-surface electrode 15 is a drain electrode, for example, and conducts a drain current. The reverse-surface electrode 15 covers substantially the entirety of the element reverse surface 102. The reverse-surface electrode 15 is formed by silver (Ag) plating, for example.
Each first semiconductor element 10A (each second semiconductor element 10B) switches between a conducting state and a non-conducting state in response to a drive signal (gate voltage) inputted to the first obverse-surface electrode 11 (the gate electrode). In the conducting state, a current flows from the reverse-surface electrode 15 (the drain electrode) to the second obverse-surface electrode 12 (the source electrode). In the non-conducting state, the current does not flow. In short, each first semiconductor element 10A (each second semiconductor element 10B) performs a switching operation. With the switching functions of the first semiconductor elements 10A and the second semiconductor elements 10B, the semiconductor device A1 converts the DC voltage inputted between the fourth terminal 44 and each of the first terminal 41 and the second terminal 42 into AC voltage, for example, and outputs the AC voltage from the third terminals 43.
The thermistor 17 is used as a temperature detection sensor. Note that the semiconductor device A1 may include a temperature-sensing diode, for example, in addition to the thermistor 17, or may not include a thermistor 17.
The support substrate 3 supports the first semiconductor elements 10A and the second semiconductor elements 10B. The specific configuration of the support substrate 3 is not particularly limited. For example, the support substrate 3 may be a direct bonded copper (DBC) substrate or an active metal brazing (AMB) substrate. The support substrate 3 includes an insulating layer 31, a surface metal layer 32, and a reverse-surface metal layer 33. The surface metal layer 32 includes the first conductive portion 32A and the second conductive portion 32B. The first conductive portion 32A corresponds to the first conductive component in the present disclosure. The dimension of the support substrate 3 in the thickness direction z is at least 0.4 mm and at most 3.0 mm, for example.
The insulating layer 31 is made of a ceramic material with excellent thermal conductivity, for example. Examples of such a ceramic material include silicon nitride (SiN). The material of the insulating layer 31 is not limited to ceramic, and may be an insulating resin sheet, for example. The insulating layer 31 is rectangular in plan view, for example. The dimension of the insulating layer 31 in the thickness direction z is at least 0.05 mm and at most 1.0 mm, for example.
The first conductive portion 32A supports the first semiconductor elements 10A, and the second conductive portion 32B supports the second semiconductor elements 10B. The first conductive portion 32A and the second conductive portion 32B are formed on the upper surface (the surface facing the z1 side in the thickness direction z) of the insulating layer 31. The constituent material of each of the first conductive portion 32A and the second conductive portion 32B contains copper (Cu), for example. The constituent material may contain aluminum (Al) instead of copper (Cu), for example. The first conductive portion 32A and the second conductive portion 32B are spaced apart from each other in the first direction x. The first conductive portion 32A is located on the x1 side in the first direction x from the second conductive portion 32B. Each of the first conductive portion 32A and the second conductive portion 32B is rectangular in plan view, for example. The first conductive portion 32A and the second conductive portion 32B, together with the first conductive member 5 and the second conductive member 6, form the path of a main circuit current that is switched by the first semiconductor elements 10A and the second semiconductor elements 10B.
The first conductive portion 32A has a first obverse surface 301A. The first obverse surface 301A is a flat surface facing the z1 side in the thickness direction z. Each of the first semiconductor elements 10A is bonded to the first obverse surface 301A of the first conductive portion 32A via a first conductive bonding member 19A. The second conductive portion 32B has a second obverse surface 301B. The second obverse surface 301B is a flat surface facing the z1 side in the thickness direction z. Each of the second semiconductor elements 10B is bonded to the second obverse surface 301B of the second conductive portion 32B via a second conductive bonding member 19B. The constituent material of each of the first conductive bonding members 19A and the second conductive bonding members 19B is not particularly limited, and examples include solder, metal paste containing a metal such as silver (Ag), or a sintered metal containing a metal such as silver (Ag). The dimension of each of the first conductive portion 32A and the second conductive portion 32B in the thickness direction z may be at least 0.1 mm and at most 1.5 mm, for example.
The reverse-surface metal layer 33 is formed on the lower surface (the surface facing the z2 side in the thickness direction 2) of the insulating layer 31. The constituent material of the reverse-surface metal layer 33 is the same as that of the surface metal layer 32. The reverse-surface metal layer 33 has a reverse surface 302. The reverse surface 302 is a flat surface facing the z2 side in the thickness direction z. In the example shown in
The first terminal 41, the second terminal 42, the third terminals 43, and the fourth terminal 44 are made with metal plates. The metal plates may contain copper (Cu) or an alloy of copper (Cu), for example. In the example shown in
The first terminal 41, the second terminal 42, and the fourth terminal 44 are input terminals for DC voltage that is to be converted. The fourth terminal 44 is a positive electrode (P terminal), and the first terminal 41 and the second terminal 42 are negative electrodes (N terminals). The third terminals 43 are output terminals for the AC voltage resulting from the power conversion by the first semiconductor elements 10A and the second semiconductor elements 10B. Each of the first terminal 41, the second terminal 42, the third terminals 43, and the fourth terminal 44 includes a portion covered with the sealing resin 8 and a portion exposed from the scaling resin 8.
As shown in
The first terminal 41 and the second terminal 42 are electrically connected to the second conductive member 6. In the present embodiment, the first terminal 41 and the second conductive member 6 are integrally formed. The first terminal 41 and the second conductive member 6 that are integrally formed have no bonding material or joint, and they may be formed by cutting and bending a single metal plate, for example. In the present embodiment, the second terminal 42 and the second conductive member 6 are also integrally formed. As long as the first terminal 41 and the second terminal 42 are electrically connected to the second conductive member 6, they may be separate components unlike the present embodiment, and may include bonding portions bonded to the second conductive member 6. As shown in
As shown in
As can be seen from
The control terminals 45 are pin-like terminals for controlling the first semiconductor elements 10A and the second semiconductor elements 10B. The control terminals 45 include a plurality of first control terminals 46A to 46E and a plurality of second control terminals 47A to 47D. The first control terminals 46A to 46E are used to control the first semiconductor elements 10A, for example. The second control terminals 47A to 47D are used to control the second semiconductor elements 10B, for example.
The first control terminals 46A to 46E are spaced apart from each other in the second direction y. As shown in
The first control terminal 46A is a terminal (a gate terminal) for receiving input of a drive signal for the first semiconductor elements 10A. The first control terminal 46A receives a drive signal (e.g., gate voltage) for driving the first semiconductor elements 10A.
The first control terminal 46B is a terminal (a source sense terminal) for detecting the source signal of the first semiconductor elements 10A. The voltage (the voltage corresponding to the source current) applied to the second obverse-surface electrodes 12 (the source electrodes) of the first semiconductor elements 10A is detected at the first control terminal 46B.
The first control terminals 46C and 46D are electrically connected to the thermistor 17.
The first control terminal 46E is a terminal (a drain sense terminal) for detecting the drain signal of the first semiconductor elements 10A. The voltage (the voltage corresponding to the drain current) applied to the reverse-surface electrodes 15 (the drain electrodes) of the first semiconductor elements 10A is detected at the first control terminal 46E.
The second control terminals 47A to 47D are spaced apart from each other in the second direction y. As shown in
The second control terminal 47A is a terminal (a gate terminal) for receiving input of a drive signal for the second semiconductor elements 10B. The second control terminal 47A receives a drive signal (e.g., gate voltage) for driving the second semiconductor elements 10B. The second control terminal 47B is a terminal (a source sense terminal) for detecting the source signal of the second semiconductor elements 10B. The voltage (the voltage corresponding to the source current) applied to the second obverse-surface electrodes 12 (the source electrodes) of the second semiconductor elements 10B is detected at the second control terminal 47B. The second control terminals 47C and 47D are electrically connected to the thermistor 17.
Each of the control terminals 45 (the first control terminals 46A to 46E and the second control terminals 47A to 47D) includes a holder 451 and a metal pin 452.
The holder 451 is made of a conductive material. As shown in
The metal pin 452 is a rod-like member extending in the thickness direction z. The metal pin 452 is pressed into the holder 451 and supported by the holder 451. The metal pin 452 is electrically connected to the control terminal support 48 (the first metal layer 482 described below) at least through the holder 451. When the lower end (the end on the z2 side in the thickness direction z) of the metal pin 452 is in contact with the conductive bonding member 459 within the insertion hole of the holder 451 as in the example shown in
The control terminal support 48 supports the control terminals 45. In the thickness direction z, the control terminal support 48 is located between the first and second obverse surfaces 301A and 301B and the plurality of control terminals 45.
The control terminal support 48 includes a first support portion 48A and a second support portion 48B. The first support portion 48A is disposed on the first conductive portion 32A and supports the first control terminals 46A to 46E out of the plurality of control terminals 45. As shown in
The control terminal support 48 (each of the first support portion 48A and the second support portion 48B) may be composed of a direct bonded copper (DBC) substrate, for example. The control terminal support 48 includes a stack of an insulating layer 481, a first metal layer 482, and a second metal layer 483.
The insulating layer 481 is made of a ceramic material, for example. The insulating layer 481 is rectangular in plan view, for example.
As shown in
A plurality of wires 71 are bonded to the first region 482A. The wires 71 electrically connect the first region 482A to the first obverse-surface electrodes 11 (the gate electrodes) of the first semiconductor elements 10A (the second semiconductor elements 10B). A plurality of wires 73 are bonded to the first region 482A and the sixth region 482F. Thus, the sixth region 482F is electrically connected to the first obverse-surface electrodes 11 (the gate electrodes) of the first semiconductor elements 10A (the second semiconductor elements 10B) via the wires 73 and 71. As shown in
A plurality of wires 72 are bonded to the second region 482B. The wires 72 electrically connect the second region 482B to the third obverse-surface electrodes 13 (the source sense electrodes) of the first semiconductor elements 10A (the second semiconductor elements 10). As shown in
The thermistor 17 is bonded to the third region 482C and the fourth region 482D. As shown in
The fifth region 482E is electrically connected to the first conductive portion 32A via a wire 74. As shown in
As shown in
The wire 74 electrically bonds the first conductive portion 32A and the fifth region 482E. The wire 74 corresponds to the second conductive component in the present disclosure. The wire 74 contains a second metal. In the present embodiment, the wire 74 contains the second metal as a primary component. The second metal is aluminum (Al), for example.
As shown in
The specific configuration of the third conductive component 38 is not particularly limited. In the illustrated example, the third conductive component 38 has a core 381 and a first layer 382, as shown in
The first conductive member 5 and the second conductive member 6, together with the first conductive portion 32A and the second conductive portion 32B, form the path of the main circuit current that is switched by the first semiconductor elements 10A and the second semiconductor elements 10B. The first conductive member 5 and the second conductive member 6 are spaced apart from the first obverse surface 301A and the second obverse surface 301B toward the z1 side in the thickness direction z. In plan view, the first conductive member 5 and the second conductive member 6 overlap with the first obverse surface 301A and the second obverse surface 301B. In the present embodiment, each of the first conductive member 5 and the second conductive member 6 is made of a metal plate. The metal may contain copper (Cu) or an alloy of copper (Cu), for example. Specifically, the first conductive member 5 and the second conductive member 6 are metal plates having been bent as needed.
The first conductive member 5 is connected to the second obverse-surface electrodes 12 (the source electrodes) of the first semiconductor elements 10A and the second conductive portion 32B, and electrically connects the second obverse-surface electrodes 12 of the first semiconductor elements 10A and the second conductive portion 32B. The first conductive member 5 forms the path of the main circuit current that is switched by the first semiconductor elements 10A. As shown in
The main portion 51 is located between the first semiconductor elements 10A and the second conductive portion 32B in the first direction x, and has the shape of a strip extending in the second direction y in plan view. The main portion 51 overlaps with both the first conductive portion 32A and the second conductive portion 32B in plan view, and is spaced apart from the first obverse surface 301A and the second obverse surface 301B to toward the z1 side in the thickness direction z. As shown in
In the present embodiment, the main portion 51 is parallel to the first obverse surface 301A and the second obverse surface 301B.
As shown in
As shown in
As shown in
The second conductive member 6 electrically connects the second obverse-surface electrodes 12 (the source electrodes) of the second semiconductor elements 10B to the first terminal 41 and the second terminal 42. The second conductive member 6 is integrally formed with the first terminal 41 and the second terminal 42. The second conductive member 6 forms the path of the main circuit current that is switched by the second semiconductor elements 10B. As shown in
The third bonding portions 61 are bonded to the respective second semiconductor elements 10B. Each of the third bonding portions 61 is bonded to the second obverse-surface electrode 12 of a second semiconductor element 10B via a conductive bonding member 69. The material of the conductive bonding members 69 is not particularly limited, and may be solder, metal paste, or sintered metal. In the present embodiment, each of the third bonding portions 61 includes two flat sections 611 and two first inclined sections 612.
The two flat sections 611 are aligned in the second direction y. The two flat sections 611 are spaced apart from each other in the second direction y. The shape of each flat section 611 is not particularly limited, and is rectangular in the illustrated example. The two flat sections 611 are bonded to the second obverse-surface electrode 12 of a corresponding second semiconductor element 10B on the respective sides of the gate finger 121 of the second obverse-surface electrode 12 in the second direction y.
The two first inclined sections 612 are connected to the outer ends of the respective two flat sections 611 in the second direction y. In other words, the first inclined section 612 on the y1 side in the second direction y is connected to the y1-side end of the flat section 611 located on the y1 side in the second direction y. The first inclined section 612 located on the y2 side in the second direction y is connected to the y2-side end of the flat section 611 located on the y2 side in the second direction y. Each of the first inclined sections 612 is inclined toward the z1 side in the thickness direction z with an increasing distance from the flat section 611 in the second direction y.
The first path portion 64 is located between the third bonding portions 61 and the first terminal 41. In the illustrated example, the first path portion 64 is connected to the first terminal 41 via the first ramp portion 602. The first path portion 64 overlaps with the first conductive portion 32A in plan view. The first path portion 64 generally extends in the first direction x.
The first path portion 64 includes a first band-shaped section 641 and a first extended section 643. The first band-shaped section 641 is located on the x2 side in the first direction x from the first terminal 41 and is substantially parallel to the first obverse surface 301A. The first band-shaped section 641 generally extends in the first direction x. In the illustrated example, the first band-shaped section 641 has a recess 649. The recess 649 is a portion of the first band-shaped section 641 that is recessed toward the y1 side in the second direction y.
The first extended section 643 extends from the y1-side end of the first band-shaped section 641 in the second direction y toward the z2 side in the thickness direction z. The first extended section 643 is spaced apart from the first conductive portion 32A. In the illustrated example, the first extended section 643 extends in the thickness direction z and has a rectangular shape elongated in the first direction x. Note that the first path portion 64 may be configured without the first extended section 643.
The second path portion 65 is located between the third bonding portions 61 and the second terminal 42. In the illustrated example, the second path portion 65 is connected to the second terminal 42 via the second ramp portion 603. The second path portion 65 overlaps with the first conductive portion 32A in plan view. The second path portion 65 generally extends in the first direction x.
The second path portion 65 includes a second band-shaped section 651 and a second extended section 653. The second band-shaped section 651 is located on the x2 side in the first direction x from the second terminal 42 and is substantially parallel to the first obverse surface 301A. The second band-shaped section 651 generally extends in the first direction x. In the illustrated example, the second band-shaped section 651 has a recess 659. The recess 659 is a portion of the second band-shaped section 651 that is recessed toward the y2 side in the second direction y.
The second extended section 653 extends from the y2-side end of the second band-shaped section 651 in the second direction y toward the z2 side in the thickness direction z. The second extended section 653 is spaced apart from the first conductive portion 32A. In the illustrated example, the second extended section 653 extends in the thickness direction z and has a rectangular shape that is elongated in the first direction x. Note that the second path portion 65 may be configured without the second extended section 653.
In the description given below, other configurations of the first path portion 64 are presented according to variations and other embodiments. Such configurations may also apply to the second path portion 65 because the first path portion 64 and the second path portion 65 are symmetrical with respect to, for example, the centerline extending in the first direction x.
The third path portions 66 are individually connected to the third bonding portions 61. The third path portions 66 extend in the first direction x, and are spaced apart from each other in the second direction y. The number of third path portions 66 is not particularly limited. In the illustrated example, five third path portions 66 are provided. Each of the third path portions 66 is located either between two of the second semiconductor elements 10B in the second direction y or outside the second semiconductor elements 10B in the second direction y.
The two outermost third path portions 66 in the second direction y are formed with recesses 669. Each of the recesses 669 is recessed from the inner side toward the outer side in the second direction y. In the illustrated example, each of the two outermost third path portions 66 has one recess 669. In
In the present embodiment, each of the third bonding portions 61 is located between two third path portions 66 adjacent in the second direction y. Each of the third bonding portions 61 has two first inclined sections 612, one on the y1 side in the second direction y and the other on the y2 side in the second direction y. The first inclined section 612 on the y1 side is connected to one of the two adjacent third path portions 66 that is located on the y1 side in the second direction y. The first inclined section 612 on the y2 side is connected to one of the two adjacent third path portions 66 that is located on the y2 side in the second direction y.
The fourth path portion 67 is connected to the ends of the respective third path portions 66 on the x1 side in the first direction x. The fourth path portion 67 extends in the second direction y. The fourth path portion 67 is connected to the x2-side end of the first band-shaped section 641 of the first path portion 64 in the first direction x, and to the x2-side end of the second band-shaped section 651 of the second path portion 65 in the first direction x. In the illustrated example, the fourth path portion 67 is connected to the first path portion 64 at the end on the y1 side in the second direction y and to the second path portion 65 at the end on the y2 side in the second direction y.
The sealing resin 8 covers the first semiconductor elements 10A, the second semiconductor elements 10B, the support substrate 3 (except for the reverse surface 302), a part of each of the first terminal 41, the second terminal 42, the third terminals 43, and the fourth terminal 44, a part of each of the control terminals 45, the control terminal support 48, the first conductive member 5, the second conductive member 6, and the wires 71 to 74. The sealing resin 8 may be made of a black epoxy resin, for example. The sealing resin 8 may be formed by molding, for example. The size of the sealing resin 8 may have a dimension of about 35 mm to 60 mm in the first direction x, a dimension of about 35 mm to 50 mm in the second direction y, and a dimension of about 4 mm to 15 mm in the thickness direction z. These dimensions are measured at the largest portions in the respective directions. The sealing resin 8 has a resin obverse surface 81, a resin reverse surface 82, and resin side surfaces 831 to 834.
As shown in
As shown in
As shown in
The first protrusions 851 protrude from the resin obverse surface 81 in the thickness direction z. The first protrusions 851 are located near the four corners of the sealing resin 8 in plan view. Each of the first protrusions 851 has a first protrusion end surface 851a at its end (the end on the z1 side in the thickness direction z). The first protrusion end surface 851a of each first protrusion 851 is substantially parallel to the resin obverse surface 81 and located in the same plane (x-y plane). Each of the first protrusions 851 has the shape of a hollow truncated cone with a bottom, for example. The first protrusions 851 serve as spacers when the semiconductor device A1 is mounted on, for example, a control circuit board of a device that operates with the power generated by the semiconductor device A1. Each of the first protrusions 851 has a recess 851b and an inner wall surface 851c of the recess 851b. Each of the first protrusions 851 is columnar, which is preferably a cylindrical column. The recess 851b has a cylindrical shape, preferably with the inner wall surface 851c defining a perfect circle in plan view.
The semiconductor device A1 may be mechanically fastened to the control circuit board or the like by screwing, for example. In such a case, each first protrusion 851 may be formed with an internal thread on the inner wall surface 851c of the recess 851b. For example, an insert nut may be inserted into the recess 851b of each first protrusion 851.
As shown in
The following describes advantages of the present embodiment.
When the surface metal layer 32 mainly contains a first metal and the wire 74 mainly contains a second metal, direct bonding between the wire 74 and the surface metal layer 32 may cause an unintentional phenomenon. In the present embodiment, the third conductive component 38 is disposed between the surface metal layer 32 and the wire 74. The third conductive component 38 contains a third metal different from the first metal and the second metal. This prevents direct contact between an element made of the first metal and an element made of the second metal, and the occurrence of an intentional phenomenon can be avoided as a result.
Suppose that the first metal is copper (Cu) and the second metal is aluminum (Al). In this case, the Kirkendall phenomenon may occur when these metals are left under a high temperature. Thus, nickel (Ni) is selected for the third metal to avoid the Kirkendall phenomenon.
The third conductive component 38 may be divided into a core and a first layer 382. The first layer 382 may contain the third metal as a main component, and may be provided to be in contact with the wire 74. This is because in order to avoid the Kirkendall phenomenon, only the surface in contact with the wire 74 may be made of a material mainly containing the third metal. This reduces the cost of forming the third conductive component 38.
The third conductive component 38 is bonded to the surface metal layer 32 via the conductive bonding member 39. The third conductive component 38 includes the second layer that is in contact with the conductive bonding member 39 and mainly contains the third metal. This makes it possible to prevent the Kirkendall phenomenon between the third conductive component 38 and the conductive bonding member 39.
The control terminal support 48 includes the insulating layer 481, and further includes the first metal layer 482 and the second metal layer 483 on the respective sides of the insulating layer 481. The control terminal support 48 is located on the support substrate 3. In this example, the thickness T1 of the third conductive component 38 may be smaller than the thickness T2 of the control terminal support 48. This makes it possible to prevent other components from being caught on the third conductive component 38 during assembly.
The first terminal 41 and the second conductive member 6 are integrally formed. Unlike the configuration in which the first terminal 41 and the second conductive member 6 are bonded to each other, the semiconductor device A1 with this configuration can be manufactured without a bonding process. In addition, the semiconductor device A1 with this configuration can avoid a risk of cracking or delamination at a bonding portion during operation. Thus, the semiconductor device A1 can be manufactured with simplified processes and enhance operational reliability.
The second terminal 42 and the second conductive member 6 are integrally formed. Unlike the configuration in which the second terminal 42 and the second conductive member 6 are bonded to each other, the semiconductor device A1 with this configuration can be manufactured without a bonding process. In addition, the semiconductor device A1 with this configuration can avoid a risk of cracking or delamination at a bonding portion during operation. Thus, the semiconductor device A1 can be manufactured with simplified processes and enhance operational reliability.
The second conductive member 6 includes the first ramp portion 602 connected to the first terminal 41. This configuration increases the rigidity of the connection between the second conductive member 6 and the first terminal 41.
The second conductive member 6 includes the second ramp portion 603 connected to the second terminal 42. This configuration increases the rigidity of the connection between the second conductive member 6 and the second terminal 42.
Each of the third bonding portions 61 includes two flat sections 611 and two first inclined sections 612. The two first inclined sections 612 are connected to the outer ends of the two flat sections 611 in the second direction y. This means that the current flowing through each second obverse-surface electrode 12 flows to both sides in the second direction y through the flat sections 611 and the first inclined sections 612. This prevents concentration of electric current flowing through the second obverse-surface electrode 12 at one location.
The two flat sections 611 are spaced apart from each other in the second direction y. This ensures that the electric current flows through both of the two flat sections 611 and both of the two first inclined sections 612, which is effective for preventing current concentration.
The two flat sections 611 are spaced apart from each other. This allows the gate finger 121 of a second obverse-surface electrode 12 to be placed between the two flat sections 611.
Each of the third bonding portions 61 is provided between two third path portions 66 adjacent to each other in the second direction y. This enables the electric current flowing through the second obverse-surface electrode 12 of a second semiconductor element 10B to disperse into two third path portions 66.
The following describes a first variation of the fourth embodiment. The present variation relates to the third conductive component 38. As shown in
The following describes a second variation of the fourth embodiment. As shown in
The following describes a third variation of the fourth embodiment. As shown in
In the fifth embodiment, the control terminal support 48 corresponds to the first conductive component in the present disclosure, and each of the wires 71 to 74 corresponds to the second conductive component in the present disclosure. The wires 71 to 74 are bonded to a plurality of third conductive components 38. The third conductive components 38 are bonded to a plurality of control terminal supports 48 via conductive bonding members 39.
As shown in
As shown in
According to the present embodiment, it is also possible to prevent the Kirkendall phenomenon that may occur between the control terminal supports 48 and the wires 71 to 74.
As shown in
As shown in
According to the present embodiment, it is also possible to prevent the Kirkendall phenomenon that may occur between the second conductive portion 32B and the wire 75 and between the second conductive member 6 and the wire 76.
The semiconductor device according to the present disclosure is not limited to the embodiments described above. Various design changes can be made to the specific configurations of the elements of the semiconductor device according to the present disclosure.
A semiconductor device comprising:
The semiconductor device according to clause 1B, wherein the third conductive component includes a core and a first layer,
The semiconductor device according to clause 2B, wherein the third conductive component further includes a second layer,
The semiconductor device according to any of clauses 1B to 3B, wherein the first metal is Cu.
The semiconductor device according to any of clauses 1B to 4B, wherein a main component of the first conductive component is the first metal.
The semiconductor device according to any of clauses 1B to 5B, wherein the second metal is Al.
The semiconductor device according to any of clauses 1B to 6B, wherein a main component of the second conductive component is the second metal.
The semiconductor device according to any of clauses 1B to 7B, wherein the third metal is Ni.
The semiconductor device according to any of clauses 1B to 8B, wherein a main component of the third conductive component is the third metal.
The semiconductor device according to any of clauses 1B to 9B, wherein the first conductive component has a plate shape.
The semiconductor device according to any of clauses 1B to 10B, wherein the second conductive component is a wire.
The semiconductor device according to any of clauses 1B to 11B, wherein a conductive bonding member is provided between the first conductive component and the third conductive component.
The semiconductor device according to any of clauses 1B to 12B, further comprising a support substrate including an insulating layer and conductive layers on respective surfaces of the insulating layer,
The semiconductor device according to clause 13B, further comprising a control terminal support including an insulating layer and a first metal layer and a second metal layer on respective surfaces of the insulating layer,
The semiconductor device according to clause 13B or 14B, wherein the control terminal support is directly bonded to the second conductive component.
Number | Date | Country | Kind |
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2022-145138 | Sep 2022 | JP | national |
2023-014398 | Feb 2023 | JP | national |
Number | Date | Country | |
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Parent | PCT/JP2023/030456 | Aug 2023 | WO |
Child | 19074964 | US |