Abstract:
A semiconductor device includes: a semiconductor element; a metallic plate having a heat radiation surface; a terminal connecting to the element; and a resin mold covering the element, the plate and the terminal. The metallic plate provides an electrode of the semiconductor element. The heat radiation surface is capable of radiating heat generated in the element. The heat radiation surface and a part of the terminal are exposed from the resin mold. The resin mold includes a concavity/convexity portion between the heat radiation surface and the part of the terminal in order to lengthen a creepage distance therebetween. The concavity/convexity portion is disposed on a surface of the resin mold.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is based on Japanese Patent Application No. 2005-259352 filed on Sep. 7, 2005, the disclosure of which is incorporated herein by reference. 
     FIELD OF THE INVENTION 
     The present invention relates to a resin mold type semiconductor device. 
     BACKGROUND OF THE INVENTION 
     Heretofore, as a semiconductor device of the specified type, there has been proposed one including a semiconductor element, a metal plate which is connected to the semiconductor element so as to function as the electrode and heat radiation member of the semiconductor element, and one surface of which is a heat radiation surface, terminals which are electrically connected to the semiconductor element, and a mold resin member in which the semiconductor element, the metal plate and the terminals are molded so as to be enveloped, wherein the heat radiation surface of the metal plate and parts of the terminals are exposed from the surface of the mold resin member (refer to, for example, JP-A-2005-123233). 
     In the semiconductor device of this type, however, the creepage distance between the heat radiation surface of the metal plate as is exposed from the surface of the mold resin member and the parts of the terminals becomes short on account of, for example, the reduction of a package size, and electrical dielectric breakdown, namely, creeping dielectric breakdown might occur between the exposed heat radiation surface and the parts of the terminals. 
     SUMMARY OF THE INVENTION 
     In view of the above-described problem, it is an object of the present disclosure to provide a resin mold type semiconductor device. 
     According to an aspect of the present disclosure, a semiconductor device includes: a semiconductor element; a metallic plate having a heat radiation surface; a terminal electrically connecting to the semiconductor element; and a resin mold covering the semiconductor element, the metallic plate and the terminal. The metallic plate connects to the semiconductor element so that the metallic plate provides an electrode of the semiconductor element. The heat radiation surface of the metallic plate is capable of radiating heat generated in the semiconductor element. The heat radiation surface of the metallic plate and a part of the terminal are exposed from the resin mold. The resin mold includes a concavity/convexity portion disposed between the heat radiation surface of the metallic plate and the part of the terminal in order to lengthen a creepage distance between the heat radiation surface and the part of the terminal. The concavity/convexity portion is disposed on a surface of the resin mold. 
     In the above device, since the creepage distance between the heat radiation surface and the part of the terminal is lengthened, a creepage dielectric breakdown in the device is prevented. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings: 
         FIG. 1A  is a cross sectional view showing a semiconductor device taken along line IA-IA in  FIG. 1B ,  FIG. 1B  is a top view showing the semiconductor device, and  FIG. 1C  is a bottom view showing the semiconductor device; 
         FIG. 2  is a top view showing parts in a resin mold in the device; 
         FIG. 3  is a circuit diagram showing an equivalent circuit of the semiconductor device; 
         FIG. 4  is a plan view showing another semiconductor device; 
         FIG. 5  is a cross sectional view showing further another semiconductor device; 
         FIGS. 6A to 6I  are cross sectional views showing various concavity/convexity portions; and 
         FIG. 7  is a cross sectional view showing a single-side heat radiation type semiconductor device. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIGS. 1A through 1C  are views showing the schematic configuration of a semiconductor device  100  according to a first example embodiment of the present disclosure. More specifically,  FIG. 1A  is a schematic sectional view of the semiconductor device,  FIG. 1B  is a schematic plan view of the semiconductor device in  FIG. 1A  as seen from above, and  FIG. 1C  is a schematic plan view of the semiconductor device in  FIG. 1A  as seen from below. Besides, the schematic sectional view of  FIG. 1A  is taken along line IA-IA indicated in  FIG. 1B , and along line IA-IA indicated in  FIG. 1C . 
       FIG. 2  is a view showing the planar arrangement configuration of individual portions within a mold resin member  7  in the semiconductor device  100  shown in  FIGS. 1A-1C . The semiconductor device  100  is applied as a device, which is mounted in a vehicle, for example, automobile and which serves to drive a vehicular electron device. 
     As shown in  FIGS. 1A-1C  and  FIG. 2 , the semiconductor device  100  includes two semiconductor elements  1  and  2 , which are arranged planarly. 
     In this example, the first semiconductor element  1  is an IGBT (insulated-gate bipolar transistor)  1 , while the second semiconductor element  2  is an FWD (flywheel diode)  2 . By the way, in  FIG. 1A , a section along the first semiconductor element  1  is shown, and a sectional shape along the second semiconductor element  2  is substantially the same. 
     Besides, both the surfaces of each of the semiconductor elements  1  and  2  are held between a pair of metal plates  3  and  4  which function as the electrodes and heat radiation members of the semiconductor elements  1  and  2 . The metal plates  3  and  4  are made of a metal of high thermal conductivity and high electric conductivity, such as copper alloy or aluminum alloy. 
     Here, the pair of metal plates  3  and  4  are opposingly arranged so as to hold the semiconductor elements  1  and  2  therebetween. Referring to  FIG. 1A , in the pair of metal plates  3  and  4 , the metal plate  3  which lies on the lower side shall be termed the “first metal plate  3 ”, and the metal plate  4  which lies on the upper side shall be termed the “second metal plate  4 ”. 
     In addition, one surface of each of the semiconductor elements  1  and  2  and the inner surface of the first metal plate  3  are electrically and thermally connected by an electrically-conductive bonding member  5  such as solder or electrically-conductive adhesive. Besides, a heatsink block  6  made of the same material as that of both the metal plates  3  and  4  is interposed between the other surface of each of the semiconductor elements  1  and  2  and the second metal plate  4 . 
     Further, each of the semiconductor elements  1  and  2  and the heatsink block  6 , and the heatsink block  6  and the inner surface of the second metal plate  4  are electrically and thermally connected by thermally-conductive bonding members  5 . 
     In addition, as shown in  FIGS. 1A-1C  and  FIG. 2 , in the semiconductor device  100  of this embodiment, the pair of metal plates  3  and  4  holding the semiconductor elements  1  and  2  therebetween are molded in the mold resin member  7 . The mold resin member  7  is made of an epoxy-based resin, and is formed by molding. 
     Besides, as shown in  FIGS. 1A-1C , those outer surfaces  3   a  and  4   a  of the respective metal plates  3  and  4  which are opposite to the inner surfaces thereof opposing to the semiconductor elements  1  and  2  are exposed from the mold resin member  7 . Thus, the semiconductor device  100  has the configuration of dual-side heat radiation type in which heat is radiated through the first metal plate  3  and the second metal plate  4  on both the surfaces of each of the first and second semiconductor elements  1  and  2 . 
     Although not shown, cooling members are respectively held in close touches with the heat radiation surfaces  3   a  and  4   a  exposed from the mold resin member  7 , whereby the heat radiations can be promoted. Members of aluminum, copper or the like, in which cooling water is circulatable, are usually used as such cooling members. 
     Besides, the pair of metal plates  3  and  4  is electrically connected to electrodes, not shown, on the respective surfaces of both the semiconductor elements  1  and  2 , through the electrically-conductive bonding members  5  and the heatsink block  6 . 
     Here, as shown in  FIGS. 1A-1C  and  FIG. 2 , the semiconductor device  100  is provided with a plurality of terminals  3   b ,  3   c ,  4   b,  and  8   a - 8   e  which are electrically connected with the semiconductor elements  1  and  2 . These terminals are molded in the mold resin member  7  so as to be partly exposed from this mold resin member  7 . 
     Here in this example, the first metal plate  3  and the second metal plate  4  in the pair of metal plates  3  and  4  function as the electrode on the collector side of the IGBT  1  being the first semiconductor element  1  and the electrode on the cathode side of the FWD  2  being the second semiconductor element  2 , and as the electrode on the emitter side of the IGBT  1  and the electrode on the anode side of the FWD  2 , respectively. 
     In addition, among the terminals, a collector lead  3   b  and collector sense  3   c  are formed integrally with the first metal plate  3 , and they are protrusively exposed outside the mold resin member  7  from the end faces of the first metal plate  3 . The collector lead  3   b  is a terminal for connecting the collector side of the IGBT  1  and the exterior, while the collector sense  3   c  is an inspecting terminal for the collector of the IGBT  1 . 
     Besides, an emitter lead  4   b  is formed integrally with the second metal plate  4 , and it is protrusively exposed outside the mold resin member  7  from the end face of the second metal plate  4 . This emitter lead  4   b  is a terminal for connecting the emitter side of the IGBT  1  and the exterior. 
     Further, as shown in  FIGS. 1A-1C  and  FIG. 2 , among the terminals, the terminals  8   a - 8   e  which are formed by a lead frame  8  being a conductor member separate from the metal plates  3  and  4  are control terminals  8   a - 8   e  which are disposed around the IGBT  1  within the mold resin member  7 . The lead frame  8  is made of an ordinary lead-frame material such as copper or  42  alloy. 
     The control terminals  8   a - 8   e  are such that their distal end parts protruding from the mold resin member  7  are connected to a circuit board not shown. Besides, as shown in  FIG. 2 , the IGBT  1  is electrically connected with the control terminals  8   a - 8   e  through bonding wire pieces  9  on its surface nearer to the heatsink block  6 . 
     Concretely, in this example, the control terminals  8   a - 8   e  consist of a temperature sense cathode  8   a , a temperature sense anode  8   b , a gate  8   c , a current sense  8   d  and a Kelvin emitter  8   e.    
     The temperature sense cathode  8   a  and temperature sense anode  8   b  function as the cathode and anode of a temperature sense diode, not shown, disposed on the chip of the IGBT  1 , respectively, and they serve to detect the temperature of the IGBT  1 . 
     Besides, the gate  8   c  is connected with the gate electrode of the IGBT  1 . Further, the current sense  8   d  functions to detect the abnormality of a current flowing through the IGBT  1 , and the Kelvin emitter  8   e  is an inspecting terminal for the emitter side of the IGBT  1 . 
     In this manner, the terminals of this embodiment include the control terminals  8   a - 8   e  which are formed by the lead frame  8  separate from the metal plates  3  and  4 , and the terminals  3   b ,  3   c  and  4   b  which are integral with the metal plates  3  and  4 . Incidentally, although the functions of the individual terminals  3   b ,  3   c ,  4   b , and  8   a - 8   e  are general ones, an equivalent circuit diagram based on the IGBT  1  and the FWD  2  in the semiconductor device  100  is shown in  FIG. 3 . 
     Besides, the heatsink block  6  ensures the distance between the wire bonding surface of the IGBT  1  and the second metal plate  4  in order to keep the height of the wire pieces  9  in performing the wire bonding of the IGBT  1  and the control terminals  8   a - 8   e.    
     In such a semiconductor device  100 , in this embodiment, as shown in  FIGS. 1A-1C , rugged portions  10  and  11  are provided at those positions of the surfaces of the mold resin member  7  which lie between the heat radiation surfaces  3   a  and  4   a  and parts of the individual terminals as are electrically independent of these heat radiation surfaces  3   a  and  4   a.    
     Here, the rugged portions  10  and  11  are respectively provided on that surface part of the mold resin member  7  which lies between the heat radiation surface  3   a  of the first metal plate  3  and the control terminals  8   a - 8   b , and on that surface part of the mold resin member  7  which lies between the heat radiation surface  4   a  of the second metal plate  4  and the collector sense  3   c . Hereinbelow, the rugged portion  10  on the side of the control terminals  8   a - 8   e  shall be termed the “control-terminal-side rugged portion  10 ”, while the rugged portion  11  on the side of the collector sense  3   c  shall be termed the “collector-sense-side rugged portion  11 ”. 
     The rugged portions  10  and  11  serve to lengthen the creepage distances of the mold resin member  7  at those positions between the heat radiation surfaces  3   a  and  4   a  and the parts of the terminal  3   c  and terminals  8   a - 8   e  at which the rugged portions  10  and  11  intervene, by bringing the surfaces of the mold resin member  7  into rugged shapes. 
     That is, the control-terminal-side rugged portion  10  enlarges the creepage distance of the mold resin member  7  between the heat radiation surface  3   a  of the first metal plate  3  and the control terminals  8   a - 8   e , and the collector-sense-side rugged portion  11  enlarges the creepage distance of the mold resin member  7  between the heat radiation surface  4   a  of the second metal plate  4  and the collector sense  3   c.    
     In this example, the rugged portions  10  and  11  are respectively configured of combined structures each of which consists of two convex parts and a concave part formed between them, and which extend so as to interrupt the interspaces between the heat radiation surfaces  3   a  and  4   a  and the parts of the terminal  3   c  and terminals  8   a - 8   e . By way of example, the depth d of the concave part is on the order of several hundred μm in  FIG. 1A . 
     Besides, both the rugged portions  10  and  11  are respectively located at planes parallel to those planes of the surfaces of the mold resin member  7  to which the heat radiation surfaces  3   a  and  4   a  are exposed. In addition, both the rugged portions  10  and  11  are recessed with respect to the heat radiation surfaces  3   a  and  4   a.    
     Concretely, in this example, as shown in  FIG. 1A , the distal end parts of the convex parts of both the rugged portions  10  and  11  are recessed with respect to the heat radiation surfaces  3   a  and  4   a . By way of example, the dimension  t  of the recess is on the order of several hundred μm in  FIG. 1A . 
     Such a semiconductor device  100  is manufactured in the way that, as in the prior art, the semiconductor elements  1  and  2  are held between the metal plate  3  and the heatsink block  6  as well as the metal plate  4 , while the IGBT  1  and the control terminals  8   a - 8   e  are connected, followed by resin molding. 
     Here, the rugged portions  10  and  11  are fabricated in the way that the shapes corresponding to these rugged portions  10  and  11  are provided in a forming metal mold. Besides, in the semiconductor device  100 , after the resin molding, each of the heat radiation surfaces  3   a  and  4   a  is cut along the surface by employing a cutting tool, in order to afford the flatness of each of these heat radiation surfaces  3   a  and  4   a.    
     Meanwhile, according to this embodiment, the rugged portions  10  and  11  for lengthening the creepage distances between the heat radiation surfaces  3   a  and  4   a  at the surfaces of the mold resin member  7  and the parts of the terminal  3   c  and terminals  8   a - 8   e  are provided at those positions of the surfaces of the mold resin member  7  which lie between the heat radiation surfaces  3   a  and  4   a  exposed from the mold resin member  7  and the parts of the terminal  3   c  and terminals  8   a - 8   e.    
     With this measure, the rugged portions  10  and  11  for lengthening the creepage distances between the heat radiation surfaces  3   a  and  4   a  in the surfaces of the mold resin member  7  and the parts of the terminal  3   c  and terminals  8   a - 8   e  are provided in these surfaces, so that the creepage distances between the heat radiation surfaces  3   a  and  4   a  and the parts of the terminal  3   c  and terminals  8   a - 8   e  can be gained to suppress creeping dielectric breakdown. 
     By the way, in the case where the rugged portions  10  and  11  are located in the planes parallel to those planes of the surfaces of the mold resin member  7  to which the heat radiation surfaces  3   a  and  4   a  are exposed, they may well be protruded with respect to the heat radiation surfaces  3   a  and  4   a , but they are recessed in this example. 
     As the reasons therefore, in the cutting works of the heat radiation surfaces  3   a  and  4   a  as stated above, the interferences between the cutting tool and the rugged portions  10  and  11  are avoided to suppress the abrasion of this cutting tool, and the interferences between the cooling members and the rugged portions  10  and  11  are prevented to ensure the close touches between the cooling members and the heat radiation surfaces  3   a  and  4   a  and to appropriately realize the enhancement of a heat radiation property. 
     Incidentally, although the two rugged portions  10  and  11  of the control-terminal-side rugged portion  10  and the collector-sense-side rugged portion  11  are provided in this embodiment, only either of the two rugged portions  10  and  11  may well be provided. 
     By way of example, when that surface part of the mold resin member  7  which lies between the heat radiation surface  3   a  of the first metal plate  3  and the control terminals  8   a - 8   e  is compared with that surface part of the mold resin member  7  which lies between the heat radiation surface  4   a  of the second metal plate  4  and the collector sense  3   c , the creepage distance is comparatively smaller on the side of the control terminals  8   a - 8   e  in the semiconductor device  100  shown in  FIGS. 1A-1C , in the absence of the rugged portions. In consideration of this point, therefore, the rugged portion  10  may well be provided on only the side of the control terminals  8   a - 8   e.    
       FIG. 4  is a schematic plan view of a semiconductor device according to the second example embodiment. In the foregoing embodiment, the rugged portions  10  and  11  have been provided at the positions between the heat radiation surfaces  3   a  and  4   a  and the terminal  3   c  and terminals  8   a - 8   e  at the outer peripheries of the heat radiation surfaces  3   a  and  4   a , but a rugged portion  10  may well be provided so as to surround the whole periphery of the heat radiation surface  3   a  as in the second embodiment here. 
     In this case, the rugged portion  10  intervenes between the heat radiation surface  3   a  and all the terminals  4   b  and  8   a - 8   e  which lie around the heat radiation surface  3   a  and which are electrically independent of this heat radiation surface  3   a , and creeping dielectric breakdown through the rugged portion  10  can be prevented. 
     By the way, in this example, the control-terminal-side rugged portion  10  has been shown as the configuration of the rugged portion surrounding the whole periphery of the heat radiation surface, but the configuration of the rugged portion in this embodiment may well be adopted for the collector-sense-side rugged portion  11 . 
       FIG. 5  is a schematic sectional view of a semiconductor device according to the third example embodiment. In each of the preceding embodiments, the rugged portions  10  and  11  have been located at the planes parallel to those planes of the surfaces of the mold resin member  7  to which the heat radiation surfaces  3   a  and  4   a  are exposed. 
     Here, as shown in  FIG. 5 , rugged portions  12  may well be further provided at planes orthogonal to those planes of the surfaces of the mold resin member  7  to which the heat radiation surfaces  3   a  and  4   a  are exposed, in other words, on the side surfaces of the mold resin member  7 . 
     That is, in this embodiment, in the semiconductor device of dual-side heat radiation type, parts of the control terminals  8   a - 8   e  are exposed between the respective heat radiation surfaces  3   a  and  4   a  of the pair of metal plates  3  and  4  in the surfaces of the mold resin member  7 , and the rugged portions  10  and  12  are provided on both the side of one heat radiation surface  3   a  and the side of the other heat radiation surface  4   a , for those parts of the control terminals  8   a - 8   e  which are exposed from the mold resin member  7 . 
     In this case, the control terminals  8   a - 8   e  can have their creepage distance lengthened, not only for the heat radiation surface  3   a  of the first metal plate  3  as is comparatively near to these control terminals  8   a - 8   e , but also for the heat radiation surface  4   a  of the second metal plate  4  as is comparatively remote from them. 
     Besides, although no illustration is made in  FIG. 5 , it is possible to expect such advantages as the prevention of the creeping dielectric breakdown between the collector lead  3   b  or emitter lead  4   b  and the heat radiation surface  3   a  or  4   a , and the prevention of the creeping dielectric breakdown between both the heat radiation surfaces  3   a  and  4   a.    
     Incidentally, apart from the combinations of the concave part(s) and convex part(s) as in the illustrated examples, the “rugged portion” may well consist only of a concave part, or it may well consist only of a convex part. Further, it may well consist of a plurality of concave parts or convex parts. Examples of the sectional shapes of such various rugged portions are shown in  FIGS. 6A through 6I . 
     By way of example, the rugged portion  10  shown in each of  FIGS. 6A-6C  consists only of the concave part, and the rugged portion  10  shown in each of  FIGS. 6D-6F  consists only of the convex part. Various shapes such as tetragonal, triangular and semicircular shapes can be adopted as the sectional shapes of the concave and convex parts. Besides, the rugged portions  10  which consist of the combination of the concave and convex parts, the plurality of convex parts, and the plurality of concave parts are respectively shown in  FIGS. 6G-6I . 
     Besides, apart from the examples shown in the figures, the rugged portions may well be provided between those parts of the plurality of terminals  3   b ,  3   c ,  4   b , and  8   a - 8   e  which are exposed from the mold resin member  7  and the heat radiation surfaces  3   a  and  4   a . Also, regarding the heat radiation surfaces  3   a  and  4   a  or the positions of the individual terminals as are exposed from the mold resin member  7 , the illustrated examples are not restrictive. 
     Besides, each of the embodiments has exemplified the semiconductor device of dual-side heat radiation type, in which the metal plates  3  and  4  are the pair of ones which are opposingly arranged so as to hold the semiconductor elements  1  and  2  therebetween, and those surfaces of the respective metal plates  3  and  4  which are on the sides opposite to the sides of the semiconductor elements  1  and  2  are exposed from the surfaces of the mold resin member  7  as the heat radiation surfaces  3   a  and  4   a.    
     Here, in such a semiconductor device of dual-side heat radiation type, the semiconductor elements which are held between the pair of metal plates  3  and  4  need not be the IGBT  1  and the FWD  2  stated before, as long as the pair of metal plates  3  and  4  arranged on both the sides of the semiconductor device are employable as the electrodes. Besides, the semiconductor device may well include only one semiconductor element, or three or more semiconductor elements. 
     Besides, as stated before, the heatsink block  6  intervenes between the IGBT  1  and the second metal plate  4 , and it functions to ensure the height between both these members  1  and  4 . If possible, however, the heatsink block  6  may well be nonexistent in each of the embodiments. 
     Further, the invention may well be applied to a single-side heat radiation type as long as a semiconductor device is concerned in which a semiconductor element/semiconductor elements and a metal plate and terminals are connected and are molded in a mold resin member so as to be enveloped, and in which the heat radiation surface of the metal plate and parts of the terminals are exposed from the surface of the mold resin member. 
       FIG. 7  is a schematic sectional view showing an example of the semiconductor device of single-side heat radiation type. The metal plate  3  is electrically and thermally connected to one surface of the semiconductor element  1 , the terminals  8  formed by a lead frame or the like are connected to the semiconductor element  1  by bonding wire pieces  9 , and the semiconductor element  1 , the metal plate  3 , the bonding wire pieces  9 , and parts of the terminals  8  are molded in the mold resin member  7 . 
     In this case, the rugged portion  10  is formed on the surface of the mold resin member  7  between that heat radiation surface  3   a  of the metal plate  3  which is exposed from the mold resin member  7  and those parts of the terminals  8  which are similarly exposed from the mold resin member  7 . 
     While the invention has been described with reference to preferred embodiments thereof, it is to be understood that the invention is not limited to the preferred embodiments and constructions. The invention is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, which are preferred, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention.