Patent ID: 8431445
Filing Date: 2013-04-30
Classification: H01L

Abstract:
1. A method for forming a multi-component power structure, the method comprising: providing a semiconductor die, an insulating substrate having a first metal layer and a second metal layer, a thermal device having enclosed passages for liquid cooling, and a parent material system, wherein the parent material system comprises a low temperature material having a relatively low melting point and a high temperature material having a relatively high melting point, and the relatively low melting point is less than the relatively high melting point; bonding the semiconductor die and the first metal layer of the insulating substrate with a first transient liquid phase bond that is electrically and thermally conductive; coating the second metal layer of the insulating substrate with a first layer of the high temperature material of the parent material system; coating a surface of the thermal device with a second layer of the high temperature material of the parent material system; constraining the parent material system between the second metal layer of the insulating substrate and the thermal device; heating the parent material system to a melting temperature greater than the relatively low melting point and lower than the relatively high melting point to diffuse the low temperature material into the high temperature material; and solidifying the parent material system to form a second transient liquid phase bond that is electrically and thermally conductive.