Patent ID: 8158458
Filing Date: 2012-04-17
Classification: H01L

Abstract:
1. The method of manufacturing a power semiconductor module for mounting on a control circuit board of a main apparatus, the method comprising the steps of: (a) providing at least one semiconductor chip; (b) providing an insulating circuit board comprising an insulator layer, electrode layers constituting electrodes on one major surface of the insulator layer, and a radiator layer constituting a radiator plane on the other major surface of the insulator layer; (c) forming first solder layers on the respective electrodes; (d) mounting the at least one semiconductor chip on the first solder layers; (e) forming second solder layers on the at least one semiconductor chip; (f) stamping a predetermined metal plate to form a lead frame having leads connected to each other via tie-bars, the leads having inner lead portions and outer lead portions; (g) forming a terminal casing by injection molding a resin using a predetermined molding die for housing part of the leads therein; (h) mounting the insulating circuit board on the terminal casing by bringing the inner lead portions into contact with the respective second solder layers; (i) reflowing the first and second solder layers to solder the insulating circuit board and the at least one semiconductor chip to each other and to solder the at least one semiconductor chip and the inner lead portions to each other; (j) filling the terminal casing with a hardening thermosetting resin for insulating sealing which is rigid when cured; and (k) separating the outer lead portions by cutting off the tie-bars.