Semiconductor device and semiconductor device manufacturing method

A semiconductor device includes: a circuit unit including a semiconductor chip; a plurality of pin terminals formed in a rod shape extending in a same direction from the circuit unit and electrically connected to the circuit unit; a sealing resin portion sealing the circuit unit and first portions of the plurality of pin terminals positioned on a side of the circuit unit; and a plurality of covering resin portions integrally extending from an outer surface of the sealing resin portion from which second portions of the plurality of pin terminals protrude, the plurality of covering resin portions being formed in a cylindrical shape respectively covering base end portions of the second portions of the plurality of pin terminals, which are positioned on a side of the sealing resin portion.

This application is the U.S. national phase of International Application No. PCT/JP2018/046875 filed Dec. 19, 2018 which designated the U.S., the entire contents of which are hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a semiconductor device and a semiconductor device manufacturing method.

BACKGROUND ART

Patent Document 1 discloses a semiconductor device in which a semiconductor chip (power semiconductor element) and one ends, in the longitudinal direction, of a plurality of pin terminals (external connection terminals) formed in a rod shape are joined to one surface of a substrate (power module substrate), and the substrate, the semiconductor device, and a portion on the one end side of each pin terminal are sealed with a sealing resin portion (sealing resin). In this semiconductor device, a portion on the other end side of each pin terminal protrudes from a flat outer surface of the sealing resin portion.

CITATION LIST

Patent Document

SUMMARY OF THE INVENTION

Problems to be Solved by the Invention

Miniaturization is required for this type of semiconductor device. However, in the semiconductor device of Patent Document 1, it is necessary to secure a creeping distance from a predetermined pin terminal to another pin terminal along the outer surface of the sealing resin portion. For this reason, there is a problem that the space between the adjacent pin terminals cannot be reduced, thereby inhibiting the miniaturization of the semiconductor device.

The present invention has been made in view of such problems, and it is an object of the present invention to provide a semiconductor device and a semiconductor device manufacturing method capable of achieving miniaturization while securing a creeping distance between terminal pins.

Means for Solving the Problems

A semiconductor device according to one aspect of the present invention includes: a circuit unit including a semiconductor chip; a plurality of pin terminals formed in a rod shape extending in a same direction from the circuit unit and electrically connected to the circuit unit; a sealing resin portion sealing the circuit unit and first portions of the plurality of pin terminals positioned on a side of the circuit unit; and a plurality of covering resin portions integrally extending from an outer surface of the sealing resin portion from which second portions of the plurality of pin terminals protrude, the plurality of covering resin portions being formed in a cylindrical shape respectively covering base end portions of the second portions of the plurality of pin terminals, which are positioned on a side of the sealing resin portion.

A semiconductor device manufacturing method according to one aspect of the present invention includes: a connection step of electrically connecting a plurality of pin terminals to a circuit unit such that the plurality of pin terminals formed in a rod shape extend in a same direction from the circuit unit including a semiconductor chip; after the connection step, an accommodation step of accommodating the circuit unit and first portions of the plurality of pin terminals positioned on a side of the circuit unit in a first cavity of a mold, and inserting second portions of the plurality of pin terminals respectively in a plurality of pin insertion holes of the mold extending from an inner surface of the first cavity; after the accommodation step, a molding step of pouring a resin into the first cavity to form a sealing resin portion sealing the circuit unit and the first portions of the plurality of pin terminals, wherein: in the accommodation step, after inserting the second portions of the plurality of pin terminals respectively into the plurality of pin insertion holes, a pair of slide portions of the mold are caused to protrude from an inner circumference of each pin insertion hole and to sandwich a tip end portion of the second portion of each pin terminal positioned away from the first cavity, thereby forming a plurality of second cavities connected to the first cavity, the plurality of second cavities being surrounded by an outer circumference of a base end portion of the second portion of each pin terminal positioned close to the first cavity, the inner circumference of each pin insertion hole, and the pair of slide portions; and in the molding step, the resin is flown into the second cavity to form a plurality of cylindrical covering resin portions respectively covering the base end portions of the second portions of the plurality of pin terminals.

Effects of the Invention

According to the present invention, the miniaturization of the semiconductor device can be achieved.

MODE FOR CARRYING OUT THE INVENTION

As shown inFIG. 1, a semiconductor device1according to the present embodiment includes a circuit unit2, a plurality of pin terminals3, a sealing resin portion4, and a plurality of covering resin portions5.

The circuit unit2constitutes a circuit of the semiconductor device1. The circuit unit2includes a semiconductor chip6and a wiring. The semiconductor chip6is formed in a plate shape, and has electrodes on both upper and lower surfaces. The semiconductor chip6of the present embodiment is a semiconductor element that generates heat by energization, such as a diode or a transistor. The wiring mainly connects the semiconductor chip6and the pin terminals3described later.

The circuit unit2of the present embodiment includes a plate-like lead frame7that constitutes the wiring of the circuit unit2. The lead frame7is manufactured by punching a plate material having conductivity, such as a copper plate. In the semiconductor device1, the lead frame7includes a plurality of leads11each formed in a band plate shape and spaced apart from each other. The lead frame7is formed with a plurality of insertion holes12penetrating in a plate thickness direction thereof. Specifically, the plurality of insertion holes12are formed respectively in the plurality of leads11. Although the number of leads11or insertion holes12inFIG. 1is two, it is not limited thereto.

One lead11of the lead frame7is joined by solder to the upper surface of the semiconductor chip6.

The plurality of pin terminals3are formed in a bar shape extending in the same direction from the circuit unit2. The plurality of pin terminals3are electrically connected to the wiring of the circuit unit2. Although the number of pin terminals3inFIG. 1is two, it is not limited thereto.

In the present embodiment, first portions21of the plurality of pin terminals3positioned on the lead frame7(circuit unit2) side in a longitudinal direction of the pin terminals3are inserted respectively into the plurality of insertion holes12of the lead frame7. Additionally, the first portion21of each pin terminal3is joined by solder to the lead frame7. Thus, the plurality of pin terminals3are electrically connected to the lead frame7. The plurality of pin terminals3are respectively connected to the plurality of different leads11.

In this state, each pin terminal3extends long in a direction away from a first main surface7aof the lead frame7. In other words, a second portion22in the longitudinal direction of each pin terminal3is positioned on the first main surface7aside of the lead frame7. Additionally, a part of the first portion21of each pin terminal3protrudes from a second main surface7bof the lead frame7opposing the first main surface7a.

The first portion21of each pin terminal3is formed with an overhanging portion23that overhangs from an outer circumference of the pin terminal3. The overhanging portion23is in surface contact with the first main surface7aof the lead frame7in a state where the first portion21of the pin terminal3is inserted into the insertion hole12of the lead frame7. Here, the overhanging portion23may, for example, be in surface contact with the second main surface7bof the lead frame7.

The overhanging portion23only needs to have a flat surface in surface contact with at least the first main surface7aor the second main surface7bof the lead frame7, and may be formed in an arbitrary shape. The overhanging portion23of the present embodiment is formed in an annular shape extending in a circumferential direction of the pin terminal3.

The semiconductor device1of the present embodiment further includes a wiring substrate8. The wiring substrate8has a wiring portion30which constitutes the wiring of the circuit unit2together with the lead frame7. The wiring substrate8is disposed to face the second main surface7bof the lead frame7. A portion of the first portion21of the pin terminal3protruding from the second main surface7bof the lead frame7(hereinafter referred to as a protruding portion24of the pin terminal3) is joined by solder to the wiring portion30of the wiring substrate8.

The wiring substrate8may be, for example, a printed wiring substrate. The wiring substrate8of the present embodiment is a ceramic substrate8having a ceramic plate31and metal plate portions32and33formed on both main surfaces31aand31bthereof. The ceramic substrate8is disposed such that the first main surface31aof the ceramic plate31faces the second main surface7bof the lead frame7. The first metal plate portion32formed on the first main surface31aof the ceramic plate31constitutes the wiring portion30of the wiring substrate8. The semiconductor chip6is joined to the first metal plate portion32. The second metal plate portion33formed on the second main surface31bof the ceramic plate31is formed in a region overlapping the first metal plate portion32in the thickness direction of the ceramic plate31. The second metal plate portion33is electrically insulated from the first metal plate portion32by the ceramic plate31.

Specifically, the plurality of first metal plate portions32are formed at an interval on the first main surface31aof the ceramic plate31. Although the number of first metal plate portions32inFIG. 1is two, it is not limited thereto. One first metal plate portion32of the plurality of first metal plate portions32is joined by solder to the lower surface of the semiconductor chip6. In other words, the semiconductor chip6is sandwiched between one first metal plate portion32(wiring substrate8) and one lead11(lead frame7). The protruding portions24of the plurality of pin terminals3are respectively joined by solder to the different first metal plate portions32(wiring portions30).

Only one second metal plate portion33is formed on the second main surface31bof the ceramic plate31. The second metal plate portion33is formed over the entire region of the second main surface31bof the ceramic plate31, which overlaps the plurality of first metal plate portions32.

The sealing resin portion4seals the circuit unit2including the semiconductor chip6and the lead frame7, and the first portions21of the plurality of pin terminals3. The second portions22of the plurality of pin terminals3protrude from an outer surface of the sealing resin portion4. In the present embodiment, the outer surface of the sealing resin portion4from which the second portions22of the plurality of pin terminals3protrude is a flat upper surface4afacing upward.

The sealing resin portion4of the present embodiment further seals the ceramic substrate8(wiring substrate8). However, the second metal plate portion33of the ceramic substrate8is exposed to an outer surface of the sealing resin portion4. In the present embodiment, the outer surface of the sealing resin portion4from which the second metal plate portion33is exposed is a flat lower surface4bfacing downward.

The plurality of covering resin portions5integrally extend from the upper surface4aof the sealing resin portion4from which the second portions22of the plurality of pin terminals3protrude. In other words, the plurality of covering resin portions5are formed integrally with the sealing resin portion4. Each covering resin portion5is formed in a cylindrical shape that covers a base end portion22A of the second portion22of each pin terminal3, which is positioned on the sealing resin portion4side. For this reason, only a tip end portion22B of the second portion22of each pin terminal3protrudes from each covering resin portion5.

Additionally, in the semiconductor device1of the present embodiment, the tip end portion22B of the second portion22of each pin terminal3is formed with a pair of recessed portions25that are recessed from the outer circumference of the tip end portion22B. The pair of recessed portions25is formed in a region of the tip end portion22B of the second portion22of the pin terminal3, which is adjacent to the covering resin portion5(base end portion22A). The pair of recessed portions25formed in each pin terminal3are arranged in a radial direction of the pin terminal3. The recessed portion25is formed in the method of manufacturing the semiconductor device1described later.

In the semiconductor device1of the present embodiment illustrated inFIG. 1, a current path from one pin terminal3to the other pin terminal3is formed by the semiconductor chip6, the lead frame7, and the first metal plate portion32of the ceramic substrate8. Specifically, the semiconductor device1is formed the current path passing through one pin terminal3(and one lead11), one first metal plate portion32, the semiconductor chip6, the other lead11, and the other pin terminal3(and the other first metal plate portion32) in this order.

Next, a semiconductor device1manufacturing method of manufacturing the above-described semiconductor device1will be described. As shown inFIG. 2, the method of manufacturing the semiconductor device1includes a connection step S1, an accommodation step S2, and a molding step S3.

When manufacturing the semiconductor device1, first, the connection step S1is performed. In the connection step S1, as shown inFIG. 3, each pin terminal3is electrically connected to the circuit unit2so that the plurality of pin terminals3each formed in a bar shape protrude in the same direction from the circuit unit2including the semiconductor chip6. In the connection step S1of the present embodiment, the circuit unit2is formed by connecting the semiconductor chip6, the lead frame7, and the ceramic substrate8(wiring substrate8) at the same time as connecting the pin terminals3to the circuit unit2. Hereinafter, the connection process S1of the present embodiment will be specifically described.

In the connection step S1of the present embodiment, first, the semiconductor chip6is disposed on the first main surface31aside of the ceramic substrate8. Specifically, the semiconductor chip6is disposed so as to overlap the first metal plate portion32of the ceramic substrate8.

Next, the lead frame7is disposed on the first main surface31aside of the ceramic substrate8. The lead frame7used here includes the plurality of leads11forming the wiring of the circuit unit2, as well as a frame portion13that mutually connects the plurality of leads11. The frame portion13is positioned outside the sealing resin portion4in a state in which the plurality of leads11are sealed by the sealing resin portion4described later. Additionally, the leads11of the lead frame7are formed respectively with the plurality of insertion holes12penetrating in the thickness direction of the lead frame7. One lead11of the lead frame7is disposed so as to overlap the semiconductor chip6.

In the state where the lead frame7is disposed as described above, the second main surface7bof the lead frame7faces the first main surface31aof the ceramic substrate8. The first main surface7aof the lead frame7opposing the second main surface7bfaces in the same direction as the first main surface31aof the ceramic substrate8.

Thereafter, the first portions21in the longitudinal direction of the plurality of pin terminals3are respectively inserted into the plurality of insertion holes12of the lead frame7. In this state, the protruding portions24of the first portions21of the pin terminals3, which protrude from the second main surfaces7bof the lead frame7, respectively contact the different first metal plate portions32of the ceramic substrate8. Additionally, the overhanging portion23formed at the first portion21of each pin terminal3is in surface contact with the first main surface7aof the lead frame7.

Here, the step of inserting the first portions21of the pin terminals3into the insertion holes12of the lead frame7may be performed, for example, before disposing the lead frame7on the first main surface31aside of the ceramic substrate8. In this case, the lead frame7is disposed on the first main surface31aside of the ceramic substrate8so that the protruding portion24of the first portion21of each pin terminal3contacts the corresponding one first metal plate portion32of the ceramic substrate8.

Finally, the semiconductor chip6, the lead frame7, and the ceramic substrate8(wiring substrate8) are electrically connected to one another by appropriately joining the semiconductor chip6, the lead frame7, the ceramic substrate8, and the pin terminals3. In other words, the circuit unit2is formed. Additionally, the pin terminals3are electrically connected to the circuit unit2. The joining of the semiconductor chip6, the lead frame7, the ceramic substrate8, and the pin terminals3can be performed by, for example, solder reflow. Solder paste for performing the solder reflow only need be applied to each joining portion before disposing the semiconductor chip6, the lead frame7, and the pin terminals3on the ceramic substrate8and before attaching the pin terminals3to the lead frame7.

Thus, the connection step S1of the present embodiment is completed.

As shown inFIG. 2, the accommodation step S2is performed after the connection step S1. In the accommodation step S2, as shown inFIG. 5, a connection unit10which connected the circuit unit2and the plurality of pin terminals3is accommodated inside a mold100.

The mold100has: a first cavity C1accommodating the circuit unit2and the first portions21of the plurality of pin terminals3positioned on the circuit unit2side; and a plurality of pin insertion holes101for individually inserting the second portions22of the plurality of pin terminals3positioned away from the circuit unit2. Each pin insertion hole101extends from an inner surface of the first cavity C1.

As shown inFIG. 5, a plurality of slide portions102are provided inside the mold100. The slide portions102in a pair protrude from the inner circumference of each pin insertion hole101. The pair of slide portions102are slidable in directions approaching or separating from each other in the radial direction of the corresponding pin insertion hole101(left and right directions inFIG. 5). The pair of slide portions102is disposed at a position away from the first cavity C1in an extending direction (upward direction inFIG. 5) of the pin insertion hole101with respect to the pin insertion hole101. The pair of slide portions102sandwiches the second portion22of the pin terminal3inserted into each pin insertion hole101. The pair of slide portions102may be slidable, for example, to a position not protruding from the inner circumference of each pin insertion hole101.

In the present embodiment, each slide portion102is formed in a plate shape whose thickness direction is the extending direction of the pin insertion hole101. The plate thickness of each slide portion102is smaller than the dimension in the extending direction of the pin insertion hole101. Each slide portion102is disposed at a position apart from the tip end (upper end inFIG. 5) of the pin insertion hole101in the extending direction of the pin insertion hole101. That is, each slide portion102is positioned between the base end (the end on the first cavity C1side) and the tip end of the pin insertion hole101in the extending direction of the pin insertion hole101.

As shown inFIG. 8, the tip end portion102A in the projecting direction of the slide portion102with respect to the pin insertion hole101is formed in a tapered shape. Specifically, the tip end portion102A of the slide portion102is formed such that the thickness of the slide portion102becomes smaller as it approaches the tip end of the slide portion102in the projecting direction. A first surface102bof the tip end portion102A of the slide portion102, which faces the first cavity C1side in the thickness direction of the slide portion102, extends in the protruding direction of the slide portion102(direction orthogonal to the extending direction of the pin insertion hole101). On the other hand, a second surface102cof the tip end portion102A of the slide portion102, which faces the tip end side of the pin insertion hole101, tilts so as to be closer to the first surface102bas it approaches the tip end of the slide portion102in the projecting direction.

Here, the thickness of the tip end portion102A of the slide portion102may be, for example, the same as the thickness of another portion of the slide portion102. That is, the thickness of the slide portion102may be constant.

Further, as shown inFIG. 6, in plan view seen from the extending direction of the pin insertion hole101, the tip end of each slide portion102in contact with the circumferential surface of the pin terminal3is formed in an arc shape corresponding to the shape of the circumferential surface of the pin terminal3.

The pin terminal3of the present embodiment is formed in a circular shape when viewed from the longitudinal direction. For this reason, the tip end of the slide portion102is formed in an arc shape (semicircle shape). Thus, in a state in which the second portion22of the pin terminal3is sandwiched by the pair of slide portions102, the pair of slide portions102is pressed against the entire circumferential direction of the pin terminal3.

Although the number of slide portions102in the mold100may be, for example, twice the number of pin insertion holes101(pin terminals3), it may be, for example, less than the twice the number of pin insertion holes101, as shown inFIG. 6. In the configuration illustrated inFIG. 6, some of the slide portions102is provided for the two pin insertion holes101.

More specifically, as shown inFIGS. 4 and 5, the mold100of the present embodiment has a lower mold110and an upper mold120which are movable in the vertical direction.

The lower mold110is formed with a first concave portion111which is recessed from an upper surface110afacing the upper mold120. On the other hand, the upper mold120is formed with a second concave portion121which is recessed from a lower surface120bfacing the lower mold110. The first concave portion111of the lower mold110and the second concave portion121of the upper mold120constitute the first cavity C1when the lower mold110and the upper mold120are stacked.

The upper mold120is formed with a plurality of pin insertion holes101. Each pin insertion hole101extends upward from a bottom surface of the second concave portion121. Additionally, the plurality of slide portions102are provided inside the upper mold120.

Furthermore, the mold100of the present embodiment has a driving member130for causing the pair of slide portions102corresponding to each pin insertion hole101to slide in the direction in which they approach each other. The driving member130has a main body portion131and a plurality of pressing portions132.

The main body portion131is disposed on the upper surface120aof the upper mold120(surface opposing the lower surface120b). The plurality of pressing portions132are each formed in a bar shape so as to protrude from the main body portion131into the inside of the upper mold120. The tip end of each pressing portion132contacts the base end portion of the slide portion102in the protruding direction. As the pressing portion132is pressed against the base end portion of the slide portion102, the slide portion102slides in its protruding direction (seeFIG. 7). On the other hand, as the pressing portion132moves in the direction away from the base end portion of the slide portion102(upward inFIGS. 5 and 7), the slide portion102slides in the direction opposite to its protruding direction (seeFIG. 5). At this time, the slide portion102may slide in the direction opposite to the protruding direction by, for example, an elastic force of a spring or the like.

The plurality of pressing portions132are provided integrally with the main body portion131. For this reason, as shown inFIG. 7, as the main body portion131moves toward the upper surface120aof the upper mold120, the plurality of slide portions102simultaneously slide in the protruding direction. That is, the pair of slide portions102corresponding to the same pin insertion hole101can slide in the direction in which they approach each other. On the other hand, as shown inFIG. 5, as the main body portion131moves in the direction away from the upper surface120aof the upper mold120, the plurality of slide portions102simultaneously slide in the direction opposite to the protruding direction.

Although the number of pressing portions132in the driving member130may be, for example, twice the number of pin insertion holes101, it may be, for example, less than twice the number of pin insertion holes101, as shown inFIG. 6. In the configuration illustrated inFIG. 6, some of the pressing portions132is provided for the plurality of (four inFIG. 6) slide portions102each corresponding to different pin insertion holes101.

Here, the configuration for causing the slide portion102to slide in the direction opposite to the protruding direction is not limited to a spring or the like and may be arbitrary. The configuration for causing the slide portion102to slide in the direction opposite to the protruding direction may be, for example, another driving member having a main body portion and a pressing portion, similarly to the driving member130described above. The other driving member pushes the pressing portion toward the slide portion102, thereby causing the slide portion102to slide in the direction opposite to the protruding direction, that is, causing the pair of slide portions102corresponding to each pin insertion hole101to slide in the direction in which they separate from each other.

In the accommodation step S2of the present embodiment, first, as shown inFIG. 4, the connection unit10is placed on the lower mold110of the mold100. In this state, the second metal plate portion33of the ceramic substrate8in the connection unit10is in surface contact with the bottom surface of the first concave portion111of the lower mold110. Further, the frame portion13of the lead frame7is placed on the upper surface110aof the lower mold110. In the first concave portion111, portions of the connection unit10on the second main surface7bside of the lead frame7(the ceramic substrate8, the semiconductor chip6, and the protruding portions24of the plurality of pin terminals3) are accommodated.

Next, as shown inFIG. 5, the upper mold120is stacked on the lower mold110. In this state, the first cavity C1including the first concave portion111of the lower mold110and the second concave portion121of the upper mold120is formed. The first cavity C1accommodates the circuit unit2and the first portions21of the plurality of pin terminals3(positioned on the circuit unit2side) of the connection unit10. Further, the second portions22of the plurality of pin terminals3are inserted into the plurality of pin insertion holes101of the upper mold120. Further, the frame portion13of the lead frame7is sandwiched between the lower mold110and the upper mold120.

Furthermore, in the accommodation step S2, after inserting the second portion22of each pin terminal3into each pin insertion hole101, as shown inFIGS. 7 and 8, the pair of slide portions102is caused to protrude from the inner circumference of each pin insertion hole101, so that the tip end portion22B of the second portion22of each pin terminal3is sandwiched by the pair of slide portions102. The tip end portion22B of the second portion22of the pin terminal3is a portion of the second portion22of the pin terminal3inserted into the pin insertion hole101, which is positioned apart from the first cavity C1.

When sandwiching the tip end portion22B of the second portion22of the pin terminal3, the main body131of the driving member130is moved toward the upper surface120aof the upper mold120. As a result, the pair of slide portions102corresponding to the same pin insertion hole101slides in the direction in which they approach each other, thereby sandwiching the tip end portion22B of the second portion22of the pin terminal3. Further, the tip end portions22B of the second portions22of the plurality of pin terminals3inserted into the plurality of pin insertion holes101are each sandwiched simultaneously by the pair of slide portions102.

In the accommodation step S2of the present embodiment, the pair of slide portions102sandwich a part of the tip end portion22B of the second portion22of the pin terminal3, which is adjacent to the base end portion22A of the second portion22of the pin terminal3. That is, the pair of slide portions102does not sandwich a part of the tip end portion22B of the second portion22of the pin terminal3, which is apart from the base end portion22A of the second portion22of the pin terminal3. The base end portion22A of the second portion22of the pin terminal3is a portion of the second portion22of the pin terminal3inserted into the pin insertion hole101, which is positioned close to the first cavity C1.

Here, the pair of slide portions102may sandwich, for example, the entire tip end portion22B of the second portion22of the pin terminal3.

Furthermore, in the accommodation step S2of the present embodiment, when the tip end portion22B of the second portion22of each pin terminal3is sandwiched by the pair of slide portions102, the tip end portions102A of the pair of slide portions102each bite into the outer circumference of the tip end portion22B of the second portion22of each pin terminal3. In the present embodiment, since the tip end portion102A of the slide portion102is formed in the tapered shape, the tip end portion102A of the slide portion102can reliably bite into the outer circumference of the pin terminal3.

Furthermore, in the state in which the tip end portion22B of the second portion22of each pin terminal3is sandwiched by the pair of slide portions102, a plurality of second cavities C2are formed. Each second cavity C2is a space surrounded by the outer circumference of the base end portion22A of the second portion22of each pin terminal3, the inner circumference of each pin insertion hole101facing thereto, and the pair of slide portions102, and is connected to one cavity C1. The second cavity C2is formed for each pin insertion hole101.

Each second cavity C2is a space on the base end side (first cavity C1side) of each pin insertion hole101, and is divided from the space on the tip end side of each pin insertion hole101by the pair of slide portions102and the pin terminal3. As shown inFIG. 9, the tip ends of the pair of slide portions102are pressed against, and thus in close contact with, the circumference of the pin terminal3, and the tip ends of the pair of slide portions102are in close contact with each other, thereby dividing the space at the base end side of the pin insertion hole101and the space at the tip end side of the pin insertion hole101from each other.

Thus, the accommodation step S2of the present embodiment is completed.

As shown inFIG. 2, the molding step S3is performed after the accommodation step S2, thus completing the method of manufacturing the semiconductor device1.

In the molding step S3, as shown inFIG. 10, a resin is poured into the first cavity C1to form the sealing resin portion4that seals the circuit unit2and the first portions21of the plurality of pin terminals3. Further, in the molding step S3, the resin poured into the first cavity C1is flown into the second cavity C2to form the cylindrical covering resin portion5that covers the base end portion22A of the second portion22of each pin terminal3. In the molding step S3, a plurality of covering resin portions5corresponding respectively to the plurality of pin terminals3are formed.

In the molding step S3, the semiconductor device1is taken out of the mold100after the resin forming the sealing resin portion4and the covering resin portion5is cured. When taking the semiconductor device1out of the mold100, first, the driving member130is moved upward with respect to the upper mold120, so that the pair of slide portions102corresponding to each pin insertion holes101slides in the direction in which they separate from each other. Thereafter, the upper mold120and the lower mold110are moved away from each other, so that the semiconductor device1can be taken out of the mold100.

Further, in the manufacturing method of the present embodiment, after the semiconductor device1is taken out of the mold100, the frame portion13of the lead frame7protruding from the sealing resin portion4is cut off. Thereby, the semiconductor device1shown inFIG. 1is completed.

In the manufactured semiconductor device1, the pair of recessed portions25of each pin terminal3is formed by the tip end portions102A of the pair of slide portions102biting into the outer circumference of the tip end portion22B of the second portion22of each pin terminal3in the accommodation step S2.

As described above, according to the semiconductor device1of the present embodiment, the base end portions22A of the second portions22of the plurality of pin terminals3protruding from the upper surface4a(outer surface) of the sealing resin portion4are each covered with the cylindrical covering resin portion5extending from the upper surface4aof the sealing resin portion4. Therefore, the creeping distance R1from the predetermined pin terminal3to the other pin terminal3is the distance which is a sum of the length of the outer surface of the sealing resin portion4and the lengths of the outer surfaces of the two covering resin portions5which respectively cover the two pin terminals3(seeFIG. 1). That is, the creeping distance R1from a predetermined pin terminal3to another pin terminal3can be extended. As a result, even if the distance between two adjacent pin terminals3is reduced, it is possible to secure the creeping distance R1. As a result, the semiconductor device1can be miniaturized.

According to the method of manufacturing the semiconductor device1of the present embodiment, the semiconductor device1of the present embodiment can be manufactured.

Further, according to the method of manufacturing the semiconductor device1of the present embodiment, in the accommodation step S2, the tip end portion22B of the second portion22of each pin terminal3is sandwiched by the pair of slide portions102. Thereby, the resin flowing into the second cavity C2in the molding step S3can be prevented from reaching the outer circumference of the tip end portion22B of the second portion22of each pin terminal3. That is, it is possible to suppress the resin from adhering to the tip end portion22B of the second portion22of the pin terminal3functioning as an external connection terminal.

According to the semiconductor device1of the present embodiment, the first portions21of the plurality of pin terminals3are respectively inserted into the plurality of insertion holes12of the lead frame7. Further, according to the method of manufacturing the semiconductor device1of the present embodiment, in the connection step S1, the first portions21of the plurality of pin terminals3are respectively inserted into the plurality of insertion holes12of the lead frame7.

The plurality of insertion holes12of the lead frame7can be formed by punching with high accuracy. Therefore, the relative positions of the plurality of pin terminals3can be accurately positioned in the connection step S1. Thus, the plurality of pin terminals3can be accurately positioned with respect to the plurality of pin insertion holes101of the mold100in the accommodation step S2.

Accordingly, it is possible to suppress or prevent the base end portion22A of the second portion22of the pin terminal3from, for example, coming into contact with the inner circumference of the pin insertion hole101, thereby causing the base end portion22A of the second portion22of the pin terminal3to be exposed from the covering resin portion5. That is, the base end portions22A of the second portions22of the plurality of pin terminals3can be reliably covered with the covering resin portions5. Further, the thickness of the covering resin portion5in the circumferential direction of the pin terminal3can be made uniform.

Further, since positional deviation of the pin terminal3with respect to the pin insertion hole101can be suppressed, when the pin terminal3is sandwiched by the pair of slide portions102, the pair of slide portions102can be pressed against the outer circumference of the pin terminal3with equal force. Thereby, when sandwiching the pin terminal3by the pair of slide portions102, it is possible to suppress the pin terminal3from deforming (for example, the pin terminal3from bending).

In the semiconductor device1and the method of manufacturing the semiconductor device1according to the present embodiment, the overhanging portion23formed in the first portion21of each pin terminal3is in surface contact with the first main surface7a(main surface) of the lead frame7. Thereby, each pin terminal3can stably be attached to the lead frame7. For example, in a state in which the first portion21of each pin terminal3is inserted into the insertion hole12of the lead frame7, it is possible to prevent deviation of the direction of the axis of the pin terminal3with respect to the first main surface7aof the lead frame7. Therefore, the plurality of pin terminals3can be positioned with respect to the lead frame7with higher accuracy.

In the semiconductor device1of the present embodiment, the lead frame7and the wiring substrate8which constitute the wiring of the circuit unit2are arranged in the thickness direction thereof. That is, the wiring of the circuit unit2is divided into two layers. Therefore, the size of the semiconductor device1in the direction orthogonal to the thickness direction of the lead frame7or the wiring substrate8can be reduced as compared to the case where the wiring of the circuit unit2is formed in one layer. Therefore, the semiconductor device1can be further miniaturized.

In the semiconductor device1of the present embodiment, since the wiring of the circuit unit2is configured by the lead frame7and the wiring unit30of the wiring substrate8which are arranged in the plate thickness direction, the length of the wiring in the circuit unit2can be shortened. Therefore, the resistance and the inductance of the wiring of the circuit unit2can be reduced.

For example, when the wiring of the circuit unit2is constituted of only the lead frame7or only the wiring portion30of the wiring substrate8, the electrode of the semiconductor chip6and the lead frame7or the wiring portion30of the wiring substrate8need be electrically connected by bonding wires or connection plates. When a bonding wire or a connection plate is used for wiring of the circuit unit2, the wiring of the circuit unit2becomes long.

On the other hand, when the wiring of the circuit section2is constituted of the lead frame7and the wiring unit30of the wiring substrate8which are arranged in the thickness direction, the above-mentioned bonding wires and connection plates (clips) become unnecessary. For this reason, the length of the wiring of the circuit unit2can be shortened. Therefore, the resistance and the inductance of the wiring of the circuit unit2can be reduced.

According to the semiconductor device1of the present embodiment, the semiconductor chip6is joined to the first metal plate portion32formed on the first main surface31aof the ceramic plate31. In addition, the second metal plate portion33formed on the second main surface31bof the ceramic plate31is formed in the region overlapping the first metal plate portion32in the thickness direction of the ceramic plate31, and is exposed to the lower surface4b(outer surface) of the sealing resin portion4. Therefore, the heat generated in the semiconductor chip6can be efficiently dissipated to the outside of the semiconductor device1through the ceramic substrate8(the first metal plate portion32, the ceramic plate31, the second metal plate portion33). In particular, by placing the semiconductor device1on a heat dissipation member so that the second metal plate portion33contacts the heat dissipation member made of aluminum or the like, the heat of the semiconductor chip6can be efficiently dissipated to the heat dissipation member.

According to the method of manufacturing the semiconductor device1of the present embodiment, the pair of slide portions102of the mold100is formed in a plate shape whose thickness direction is the extending direction of the pin insertion hole101. Further, in the accommodation step S2, the pair of slide portions102sandwiches a part of the tip end portion22B of the second portion22of the pin terminal3, which is adjacent to the base end portion22A of the second portion22of the pin terminal3, and does not sandwich a part of the tip end portion22B of the second portion22of the pin terminal3, which is apart from the base end portion22A of the second portion22of the pin terminal3. Therefore, in a state where the second portion22of the pin terminal3is sandwiched by the pair of slide portions102in the accommodation step S2, it is possible to suppress or prevent a gap from being generated between each slide portion102and the outer circumference of the pin terminal3. Moreover, protection of the pin terminal3can also be achieved. Hereinafter, this point will be described.

For example, when the longitudinal direction of the second portion22of the pin terminal3inserted into the pin insertion hole101is inclined with respect to the extending direction of the pin insertion hole101, if the pair of slide portions102sandwiches the entire tip end portion22B of the second portions22of the pin terminal3, a gap may be generated between each slide portion102and the outer circumference of the pin terminal3. Further, it is not preferable that the pair of slide portions102sandwich the entire tip end portion22B of the second portion22of the pin terminal3because a stress to bend the second portion22of the pin terminal3acts on the second portion22.

On the other hand, when the pair of slide portions102sandwiches the part of the tip end portion22B of the second part22of the pin terminal3, which is adjacent to the base end portion22A of the second part22of the pin terminal3, even if the longitudinal direction of the second portions22of the pin terminal3is inclined, it is possible to suppress or prevent a gap from being generated between each slide portion102and the outer circumference of the pin terminal3. Moreover, it is also possible to suppress the stress to bend the second portion22of the pin terminal3from acting on the second portion22.

From the above, it is possible to effectively suppress the resin flowing into the second cavity C2from reaching the outer circumference of the tip end portion22B of the second portion22of each pin terminal3in the molding step S3. Moreover, protection of the pin terminal3can also be achieved.

According to the method of manufacturing the semiconductor device1of the present embodiment, when the tip end portion22B of the second portion22of each pin terminal3is sandwiched by the pair of slide portions102in the accommodation step S2, the tip end portions of the pair of slide portions102each bite into the outer circumference of the tip end portion22B of the second portion22of the pin terminal3. In particular, in the present embodiment, since the tip end portion102A of each slide portion102is formed in the tapered shape, the tip end portion102A of each slide portion102can reliably bite into the outer circumference of the tip end portion22B of the second portion22of the pin terminal3. Thus, it is possible to reliably prevent the resin flowing into the second cavity C2from reaching the outer circumference of the tip end portion22B of the second portion22of each pin terminal3in the molding step S3.

As described above, although the details of the present invention have been described, the present invention is not limited to the embodiment described above, and various changes can be added without deviating from the gist of the present invention.

DESCRIPTION OF REFERENCE NUMERALS