Patent Application
20220177376
The present disclosure relates to a silicon nitride sintered body, a method for producing the same, a multilayer body, and a power module.
Power modules that control a large current are used in fields related to automobiles, electric railways, industrial equipment, power generation, and the like. Ceramic substrates are used as insulating substrates mounted on power modules. In such applications, ceramic substrates are required to have favorable heat dissipation characteristics in addition to insulation property. For example, in Patent Literature 1, ceramic substrates made of a material containing aluminum nitride, alumina, silicon nitride, or silicon carbide as a main component have been proposed.
In addition, in Patent Literature 2, technology in which rare earth elements and Mg are added as components of a sintering aid to perform heat treatment under predetermined conditions and a silicon nitride sintered body having a thermal conductivity of greater than or equal to 100 W/(m·K) at normal temperature is produced has been proposed.
Since power modules are important parts that control various devices, it is required for the power modules to stably function. In order to improve the stability, not only is it necessary for each member constituting a power module to be reliable, but it is also necessary to reduce the amount of heat generation due to large currents. In order to satisfy such requirements, it is thought that it would be useful to use ceramic substrates which allow excellent heat dissipation and do not easily break even with a large number of heat cycles. However, in ceramic substrates in the related art, both excellent heat dissipation and high reliability are unlikely to be achieved.
In the present disclosure, a silicon nitride sintered body having both excellent heat dissipation and high reliability, and a method for producing the same are provided. In addition, in the present disclosure, a multilayer body including such a silicon nitride sintered body is provided. In addition, in the present disclosure, a multilayer body including the above-described multilayer body is provided.
A method for producing a silicon nitride sintered body according to an aspect of the present disclosure includes a step of molding and firing a raw material powder containing silicon nitride, in which an α-conversion rate of the silicon nitride contained in the raw material powder is less than or equal to 30 mass %. In this production method, a raw material powder in which an α-conversion rate of the silicon nitride is less than or equal to 30 mass % is used. If the α-conversion rate of the silicon nitride of the raw material powder is high, the grain growth rate in the firing step tends to be high. In this case, it is thought that, although sintering is promoted, the number of defects remaining in an obtained sintered body increases.
Whereas, if the α-conversion rate of the silicon nitride of the raw material powder is low, a β-conversion rate of the raw material powder tends to be high and the grain growth rate in the firing step tends to be low. In this case, it is thought that, although it takes time for sintering, the number of defects included in an obtained sintered body decreases, whereby thermal conductivity and fracture toughness improve. Regarding the silicon nitride sintered body obtained through the above-described production method, the silicon nitride sintered body having both excellent heat dissipation and high reliability due to such an action can be produced.
The silicon nitride sintered body obtained through the above-described production method may have a thermal conductivity (at 20° C.) of greater than 100 W/m·K and a fracture toughness (KIC) of greater than or equal to 7.4 MPa·m1/2. In addition, a transverse strength of the silicon nitride sintered body obtained through the above-described production method may exceed 600 MPa. Due to such characteristics, the heat dissipation and the reliability of the silicon nitride sintered body are further improved, and the silicon nitride sintered body can be more suitably used, for example, for a substrate of a power module.
A silicon nitride sintered body according to an aspect of the present disclosure has a thermal conductivity (at 20° C.) exceeding 100 W/m·K and a fracture toughness (KIC) of greater than or equal to 7.4 MPa·m1/2. Since this silicon nitride sintered body has excellent thermal conductivity and fracture toughness, it allows excellent heat dissipation and has high reliability. For this reason, the silicon nitride sintered body can be suitably used, for example, for a substrate of a power module.
In the above-described silicon nitride sintered body, a transverse strength may exceed 600 MPa. Due to such characteristics, the reliability of the silicon nitride sintered body is further improved, and the silicon nitride sintered body can be more suitably used, for example, for a substrate of a power module.
The thermal conductivity of the above-described silicon nitride sintered body at 150° C. to 200° C. may exceed 60 W/m·K. Accordingly, the silicon nitride sintered body can be more suitably used for a substrate of a power module to be used under particularly severe conditions.
A multilayer body according to an aspect of the present disclosure includes: a metal layer made of a first metal; a heat dissipation portion made of a second metal having a thermal conductivity higher than that of the first metal; and a substrate which is provided between the metal layer and the heat dissipation portion and made of any of the above-described silicon nitride sintered bodies. The substrate of this multilayer body is made of a silicon nitride sintered body having both excellent heat dissipation and high reliability. This substrate is provided between the metal layer and the heat dissipation portion. For this reason, heat generated on the metal layer side can be efficiently radiated from the heat dissipation portion side. Accordingly, the substrate can be suitably used, for example, in a multilayer body for a power module.
A power module according to an aspect of the present disclosure includes: the above-described multilayer body; and a semiconductor element electrically connected to the metal layer. Since such a power module includes the above-described substrate, it has excellent heat dissipation and reliability.
According to the present disclosure, a silicon nitride sintered body having both excellent heat dissipation and high reliability, and a method for producing the same can be provided. In addition, according to the present disclosure, a multilayer body including such a silicon nitride sintered body can be provided. In addition, according to the present disclosure, a multilayer body including the above-described multilayer body can be provided.
Hereinafter, one embodiment of the present invention will be described with reference to the drawings according to circumstances. However, the following embodiments are merely examples for describing the present invention and are not intended to limit the present invention to the following contents. In the description, the same reference numerals are given to the same elements or elements having the same function, and description thereof will not be repeated according to circumstances. The dimensional ratios of elements are not limited to the ratios shown in the drawings.
A silicon nitride sintered body according to one embodiment has a thermal conductivity exceeding 100 W/m·K at 20° C. The thermal conductivity (at 20° C.) of the present disclosure can be measured according to JIS R 1611:2010. This thermal conductivity (at 20° C.) is calculated by a calculation equation of A×B×C from values of a thermal diffusivity A [m2/second], a density B [kg/m3], and a specific heat C [J/(kg·K)]. The thermal diffusivity A is obtained through a laser flash method using a sample having a size of length×width×thickness=10 mm×10 mm×2 mm. Specifically, the thermal diffusivity is obtained by an equation of A=0.1388×(thickness [mm])2/t1/2. t1/2 is the time [seconds] required for increasing the temperature to half of ΔT when the total temperature rise width is set to ΔT. The density B is obtained through an Archimedes method. The specific heat C is obtained through differential thermal analysis.
The thermal conductivity (at 20° C.) of the silicon nitride sintered body may be, for example, greater than 110 W/m·K, greater than 120 W/m·K, or greater than 140 W/m·K from the viewpoint of further improving the heat dissipation. The upper limit of the thermal conductivity (at 20° C.) may be, for example, 200 W/m·K from the viewpoint of easiness of the production.
For example, the thermal conductivity of the silicon nitride sintered body at 150° C. to 200° C. may be greater than 60 W/m·K or greater than 65 W/m·K from the viewpoint of sufficiently increasing the heat dissipation when the silicon nitride sintered body is used in a power module or the like. The upper limit of the thermal conductivity at 150° C. to 200° C. may be, for example, 150 W/m·K from the viewpoint of easiness of the production. The thermal conductivity in such a temperature range can also be obtained by the calculation equation of A×B×C as described above. At this time, the thermal diffusivity A may be a measurement value obtained by performing the above-described measurement at the temperature, and the specific heat C may be a literature value. A value at 20° C. can be used as the density B as it is.
The silicon nitride sintered body has a fracture toughness (KIC) of greater than or equal to 7.4 MPa·m1/2. The fracture toughness (KIC) is a value measured through an SEPB method and is measured according to JIS R 1607:2015. The fracture toughness (KIC) of the silicon nitride sintered body may exceed 7.5 MPa·m1/2 or exceed 8 MPa·m1/2 from the viewpoint of further improving reliability. The upper limit of the fracture toughness (KIC) may be, for example, 15 MPa·m1/2 from the viewpoint of easiness of the production.
The silicon nitride sintered body may have a transverse strength of greater than 600 MPa from the viewpoint of further improving reliability. The transverse strength is a three-point bending transverse strength and can be measured with a commercially available transverse strength meter according to JIS R 1601:2008. The transverse strength of the silicon nitride sintered body may exceed 620 MPa or exceed 650 MPa from the viewpoint of further improving reliability. The upper limit of the transverse strength may be, for example, 800 MPa from the viewpoint of easiness of the production.
The silicon nitride sintered body may substantially consist of only silicon nitride, or may contain components derived from a sintering aid and unavoidable components derived from raw materials, production processes, and the like. The content of silicon nitride in the silicon nitride sintered body may be, for example, greater than or equal to 90 mol %, greater than or equal to 95 mol %, or greater than or equal to 98 mol % from the viewpoint of achieving both high thermal conductivity and excellent insulation properties at a high level.
Since the amount of sintering aid to be used can be reduced to produce the silicon nitride sintered body, the total content of rare earth elements in the silicon nitride sintered body can be sufficiently reduced. The total content of rare earth elements in the silicon nitride sintered body may be less than or equal to 6.0 mass % or less than or equal to 3.0 mass %. 17 elements in total including the 2 elements of scandium (Sc) and yttrium (Y) and the 15 lanthanoid elements from lanthanum (La) to lutetium (Lu) correspond to the rare earth elements.
The silicon nitride sintered body may have a dielectric fracture strength of greater than or equal to 10 [kV/0.32 mm]. The dielectric fracture strength can be measured according to JIS C-2110:2016. The dielectric fracture strength may be, for example, greater than or equal to 11 [kV/0.32 mm]. The upper limit of the dielectric fracture strength may be, for example, 15 [kV/0.32 mm] from the viewpoint of easiness of the production.
The substrate 10 is made of the silicon nitride sintered body. Accordingly, the metal layer 11 and the metal layer 12 are electrically insulated from each other. The metal layer 12 may or may not form an electrical circuit. The materials of the metal layer 11 and the metal layer 12 may be the same as or different from each other. The metal layer 11 and the metal layer 12 may be made of copper corresponding to a first metal. However, the materials thereof are not limited to copper.
The metal layer 12 is joined to the base plate 20 via the solder layer 32. The shape of the base plate 20 may be, for example, a substantially rectangular plate shape with length×width×thickness=90 to 140 mm×120 to 200 mm×3 to 6 mm. A screw 23 for fixing the cooling fin 22 forming a heat dissipation member to the base plated 20 is provided at an end portion of the base plate. The base plate 20 may be made of aluminum corresponding to a second metal. The base plate 20 is joined to the cooling fin 22 via grease 24 on a side opposite to the metal layer 12 side.
The base plate 20 and the cooling fin 22 function as heat dissipation portions since these are made of the second metal having a thermal conductivity higher than that of the metal layer 11. Since the substrate 10 has a high thermal conductivity, the semiconductor element 60, the metal layer 11, and the metal layer 12 are efficiently cooled by the heat dissipation portions.
A resin case 36 is attached to one surface side (a side on which the semiconductor element 60 is installed) of the base plate 20 so as to accommodate the above-described members (the semiconductor element 60, the metal layers 11 and 12, and the substrate 10). The above-described members are accommodated in the space formed by the one surface of the base plate 20 and the case 36, and the space is filled with a filler 30 such as silicone gel so as to fill the gap. In order to electrically connect the exterior of the case 36 and the metal layer 11, a predetermined portion of the metal layer 11 is connected to an electrode 33 provided through the case 36 via a solder layer 35.
The power module 100 includes a multilayer body 50 consisting of the metal layer 11, the substrate 10, the metal layer 12, the base plate 20, and the cooling fin 22. The substrate 10 is made of the silicon nitride sintered body having both the high thermal conductivity and a high fracture toughness. Since the substrate 10 has a high thermal conductivity, heat can be smoothly radiated from the semiconductor element 60 and the metal layer 11 to the substrate 10 and the cooling fin 22. In addition, the silicon nitride sintered body is not easily broken even if it receives an impact. For this reason, the power module 100 can stably exhibit its performance and has excellent reliability. In this manner, the silicon nitride sintered body is suitably used for the substrate of the power module 100. However, use of the silicon nitride sintered body 10 is not limited to a power module.
The material of the base plate 20 is not limited to aluminum. For example, the base plate 20 may be made of the first metal (for example, copper), and only the cooling fin may be made of the second metal (such as aluminum). In this case, only the cooling fin 22 functions as a heat dissipation portion. In addition, in another embodiment, there may be no cooling fin 22 and only the base plate 20 may function as a heat dissipation portion. Furthermore, in still another embodiment, there may be no metal layer 12 and the base plate 20 and the substrate 10 may be joined to each other.
The method for producing a silicon nitride sintered body will be described below. The method for producing the silicon nitride sintered body according to one embodiment includes a step of molding and firing a raw material powder containing silicon nitride. An α-conversion rate of silicon nitride contained in a raw material powder to be used is less than or equal to 30 mass %. Accordingly, the grain growth rate of silicon nitride in the firing step can be slowed down. Accordingly, although it takes time for sintering, the number of defects remaining in the silicon nitride sintered body to be obtained can be decreased.
The α-conversion rate of silicon nitride contained in the raw material powder may be less than or equal to 20 mass % or may be less than or equal to 15 mass % from the viewpoint of further increasing the thermal conductivity. The α-conversion rate of silicon nitride contained in the raw material powder may be greater than or equal to 5 mass % from the viewpoint of increasing the transverse strength of the silicon nitride sintered body.
The raw material powder may contain a sintering aid in addition to silicon nitride. An oxide-based sintering aid can be used as the sintering aid. Examples of the oxide-based sintering aid include Y2O3, MgO, and Al2O3. The content of the oxide-based sintering aid in the raw material powder may be, for example, 4.0 to 8.0 mass % or may be 4.0 to 5.0 mass % from the viewpoint of obtaining a silicon carbide sintered body capable of achieving both the high thermal conductivity and excellent insulation properties at a high level.
The above-described raw material powder is pressurized at, for example, a molding pressure of 3.0 to 10.0 MPa to obtain a molded body. The molded body may be produced through uniaxial pressurization or may be produced through CIP. In addition, the firing may be performed while performing molding through hot pressing. The firing of a molded body may be performed in an inert gas atmosphere of nitrogen gas, argon gas, or the like. The pressure during firing may be 0.7 to 0.9 MPa. The firing temperature may be 1,860° C. to 2,100° C. or may be 1,880° C. to 2,000° C. The firing time at the firing temperature may be 6 to 20 hours or may be 8 to 16 hours. The temperature increase rate to the firing temperature may be, for example, 1.0° C./hour to 10.0° C./hour.
Pores, lattice defects such as dislocations, and the like can be considered as the defects contained in the silicon nitride sintered body. The porosity of the silicon nitride sintered body of the present embodiment may be, for example, less than or equal to 1.0 volume % or less than or equal to 0.5 volume %.
Since the silicon nitride sintered body of the present embodiment has a high thermal conductivity, it has an excellent heat dissipation. In addition, since the silicon nitride sintered body has a high fracture toughness, it can be stably used for a long period of time without a fracture even in a use environment subjected to a so-called heat cycle in which a high temperature and a low temperature are repeated. For this reason, the silicon nitride sintered body has excellent reliability. In this manner, since the silicon nitride sintered body has both excellent heat dissipation and excellent reliability, it can be suitably used as a substrate of a power module.
Some embodiments have been described above, but the present disclosure is not limited to any of the above-described embodiments.
The contents of the present disclosure will be described in more detail with reference to examples and comparative examples, but the present disclosure is not limited to the following examples.
A silicon nitride powder (manufactured by Starck) having an α-conversion rate of 15 mass % was prepared. This silicon nitride powder and MgO and Y2O3 which were sintering aids were formulated at a ratio of Si3N4:MgO:Y2O3=95.2:1.5:3.3 (mass ratio) to obtain a raw material powder. This raw material powder was uniaxially pressed and molded at a pressure of 6.0 MPa to produce a columnar molded body.
This molded body was placed in an electric furnace equipped with a carbon heater, and the temperature was raised to 1,900° C. at a rate of temperature increase of 2.1° C./hour in a nitrogen gas atmosphere (pressure: 0.88 MPa). After firing was performed at a firing temperature of 1,900° C. for 12 hours, the molded body was cooled at a temperature lowering rate of about 5.0° C./hour to obtain a silicon nitride sintered body. The content of silicon nitride in the silicon nitride sintered body was 92 mol %.
The thermal conductivity (at 20° C.) of the silicon nitride sintered body was measured according to JIS R 1611:2010. A thermal diffisivity A [m2/second] was obtained through a laser flash method using a sample having a size of length×width×thickness=10 mm×10 mm×2 mm. A measurement device (device name: LFA447) manufactured by Netzch was used. A density B was measured through an Archimedes method, and a specific heat C was obtained through differential thermal analysis. The thermal conductivity was calculated by a calculation equation of A×B×C. The results are as shown in Table 1.
The thermal conductivity at 50° C. to 200° C. was measured in the same manner as the thermal conductivity at 20° C. except that the thermal diffusivity A was measured at each temperature and a literature value was used as the specific heat C. These results are plotted in
A fracture toughness (KIC) was a value measured through an SEPB method and was measured with a commercially available measurement device (manufactured by Instron, device name: Universal Testing Systems Type 5582) according to JIS R 1607:2015. The results are as shown in Table 1.
A transverse strength was a three-point bending transverse strength and was measured with a commercially available transverse strength meter (manufactured by Shimadzu Corporation, device name: AG-2000) according to JIS R 1601:2008. The results are as shown in Table 1.
A dielectric fracture strength was measured using a commercially available measurement device (manufactured by Keisoku Giken Co., Ltd., device name: 7474 type) according to JIS C-2110:2016. The results are as shown in Table 1.
A fracture surface of the silicon nitride sintered body was observed with a scanning electron microscope (SEM).
A silicon nitride sintered body was obtained in the same manner as in Example 1 except that a silicon nitride powder having an α-conversion rate of 93 mass % was used and fired at a firing temperature of 1,850° C. for 4 hours. The obtained silicon nitride sintered body was evaluated in the same manner as in Example 1. The evaluation results are as shown in Table 1 and
A fracture surface of the silicon nitride sintered body was observed with a scanning electron microscope (SEM).
Silicon nitride sintered bodies were obtained as shown in Table 2 in the same manner as in Example 1 except that silicon nitride powders having an α-conversion rate of 10 to 25 mass % were used. The obtained silicon nitride sintered bodies were evaluated in the same manner as in Example 1. The evaluation results are as shown in Table 2.
Silicon nitride sintered bodies were obtained as shown in Table 3 in the same manner as in Example 1 except that silicon nitride powders having an α-conversion rate of 46 to 90 mass % were used. The obtained silicon nitride sintered bodies were evaluated in the same manners as in the examples. The evaluation results are as shown in Table 3.
As shown in Tables 1 to 3, it was confirmed that the thermal conductivity can be increased by lowering the α-conversion rate of a silicon nitride powder used in a raw material powder.
According to the present disclosure, a silicon nitride sintered body having both excellent heat dissipation and high reliability, and a method for producing the same can be provided. In addition, according to the present disclosure, a multilayer body including such a silicon nitride sintered body can be provided. In addition, according to the present disclosure, a multilayer body including the above-described multilayer body can be provided.
10: Substrate (Silicon nitride sintered body), 11, 12: Metal layer, 30: Filler, 33: Electrode, 20: Base plate, 22: Cooling fin, 23: Screw, 24: Grease, 31, 32, 35: Solder layer, 34: Metal wire, 36: Case, 50: Multilayer body, 60: Semiconductor element, 100: Power module.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-066154 | Mar 2019 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2020/013787 | 3/26/2020 | WO | 00 |
