SEMICONDUCTOR DEVICE AND METHOD OF MANUFACTURING THE SEMICONDUCTOR DEVICE

A semiconductor device includes: a semiconductor element that includes an element main body having an element main surface and an element back surface facing opposite sides to each other in a thickness direction, and a first electrode arranged on the element main surface; an insulator that has an annular shape overlapping an outer peripheral edge of the first electrode when viewed in the thickness direction and is arranged over the first electrode and the element main surface; a first metal layer arranged over the first electrode and the insulator; and a second metal layer laminated on the first metal layer and overlapping both the first electrode and the insulator when viewed in the thickness direction.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2021-056817, filed on Mar. 30, 2021, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a semiconductor device and a method of manufacturing the semiconductor device.

BACKGROUND

There have been proposed various configurations for semiconductor devices equipped with semiconductor elements. Patent Document 1 discloses an example of a conventional semiconductor device. In the semiconductor device disclosed in this document, the peripheral portion of an electrode formed on the surface of a semiconductor element is covered with an insulating film (a passivation film5and a polyimide film11). A portion of the electrode on the semiconductor element, which is located inside the insulating film and is exposed from the insulating film, is referred to as an electrode pad portion. A plurality of metal layers such as titanium (Ti), copper (Cu), and nickel (Ni) are laminated on the electrode pad. These metal layers are formed over the electrode pad and the insulating film.

A stress or impact occurs in the plurality of metal layers on the insulating film depending on the specifications and the usage environments of the semiconductor device. There is a concern that the metal layers may crack or peel off due to the stress or the like.

PRIOR ART DOCUMENT

Patent Document

SUMMARY

Some embodiments of the present disclosure provide a semiconductor device suitable for suppressing peeling of a plurality of metal layers arranged over an electrode pad portion and an insulator.

According to one embodiment of the present disclosure, a semiconductor device includes: a semiconductor element that includes an element main body having an element main surface and an element back surface facing opposite sides to each other in a thickness direction, and a first electrode arranged on the element main surface; an insulator that has an annular shape overlapping an outer peripheral edge of the first electrode when viewed in the thickness direction and is arranged over the first electrode and the element main surface; a first metal layer arranged over the first electrode and the insulator; and a second metal layer laminated on the first metal layer and overlapping both the first electrode and the insulator when viewed in the thickness direction, wherein the first electrode includes a first electrode pad located inside an inner end edge of the insulator when viewed in the thickness direction, wherein a first end edge, which is an outer peripheral edge of the first metal layer, is located between an outer end edge and the inner end edge of the insulator when viewed in the thickness direction, and wherein a second end edge, which is an outer peripheral edge of the second metal layer, is located between the first end edge and the inner end edge when viewed in the thickness direction.

According to another embodiment of the present disclosure, a method of manufacturing a semiconductor device includes: arranging an insulator over a first electrode and an element main surface on a semiconductor element that includes an element main body having the element main surface facing one side of a thickness direction, and the first electrode arranged on the element main surface; forming a first metal layer material on the first electrode and the insulator; forming a second metal layer material on the first metal layer material; forming a third metal layer material on the second metal layer material; forming, on the third metal layer material, a resist having an opening that overlaps a portion of the insulator when viewed in the thickness direction; performing wet etching on the third metal layer material using the resist as a mask; performing wet etching on the second metal layer material using the resist as a mask; performing wet etching on the first metal layer material using the resist as a mask; performing wet etching on the second metal layer material using the resist as a mask; performing wet etching on the third metal layer material using the resist as a mask; and removing the resist.

Other features and advantages of the present disclosure will become more apparent with the detailed description given below with reference to the accompanying drawings.

DETAILED DESCRIPTION

Preferred embodiments of the present disclosure will be now described in detail with reference to the drawings.

In the present disclosure, the terms “first,” “second,” “third,” etc. are used merely as labels, and are not intended to mean an order of their objects.

In the present disclosure, the phases “a certain thing A is formed in another certain thing B” and “a certain thing A is formed on another certain thing B” include, unless otherwise specified, “a certain thing A is directly formed in another certain thing B” and “a certain thing A is formed in another certain thing B with another thing interposed between the certain thing A and the another certain thing B.” Similarly, the phases “a certain thing A is arranged in another certain thing B” and “a certain thing A is arranged on another certain thing B” include, unless otherwise specified, “a certain thing A is directly arranged in another certain thing B” and “a certain thing A is arranged in another certain thing B with another thing interposed between the certain thing A and the another certain thing B.” Similarly, the phase “a certain thing A is located on another certain thing B” includes, unless otherwise specified, “a certain thing A is located on another certain thing B in contact of the certain thing A with the another certain thing B” and “a certain thing A is located on another certain thing B with another thing interposed between the certain thing A and the another certain thing B.” In addition, the phase “a certain thing A overlaps with another certain thing B when viewed in a certain direction” includes, unless otherwise specified, “a certain thing A overlaps entirely with another certain thing B” and “a certain thing A overlaps partially with another certain thing B.”

First Embodiment

A semiconductor device A10according to a first embodiment of the present disclosure will be described with reference toFIGS. 1 to 10. The semiconductor device A10includes a first lead1A, a second lead1B, a third lead1C, a semiconductor element2, an insulator3, a metal laminated portion4, a conductive member5, a first conductive bonding material61, a second conductive bonding material62, a third conductive bonding material63, and a sealing resin7.

FIG. 1is a plan view showing the semiconductor device A10.FIG. 2is a bottom view showing the semiconductor device A10.FIG. 3is a plan view showing the semiconductor device A10.FIG. 4is a cross-sectional view taken along line IV-IV ofFIG. 3.FIG. 5is a cross-sectional view taken along line V-V ofFIG. 3.FIG. 6is a cross-sectional view taken along line VI-VI ofFIG. 3.FIG. 7is a plan view showing a semiconductor element.FIG. 8is an enlarged cross-sectional view taken along line VIII-VIII ofFIG. 7.FIG. 9is an enlarged view of a portion A ofFIG. 7.FIG. 10is an enlarged view of a portion B ofFIG. 7.FIG. 3is transparent to the sealing resin7for the sake of convenience of understanding.FIG. 7is transparent to the metal laminated portion4.

In the description of the semiconductor device A10, a thickness direction of the semiconductor element2is referred to as a “thickness direction z.” A direction orthogonal to the thickness direction z is referred to as a “first direction x.” A direction orthogonal to both the thickness direction z and the first direction x is referred to as a “second direction y.” As shown inFIGS. 1 and 2, the semiconductor device A10has substantially a rectangular shape when viewed in the thickness direction z. Further, in the description of the semiconductor device A10, for the sake of convenience, inFIG. 1, the right side in the figure is referred to as “one side of the first direction x,” and the left side in the figure is referred to as “the other side of the first direction x.” InFIG. 1, the upper side in the figure is referred to as “one side of the second direction y,” and the lower side in the figure is referred to as “the other side of the second direction y.” InFIG. 4, the upper side in the figure is referred to as “one side of the thickness direction z,” and the lower side in the figure is referred to as “the other side of the thickness direction z.” The size of the semiconductor device A10is not particularly limited. In the present embodiment, for example, the dimension of the first direction x is 2.6 mm to 3.6 mm, the dimension of the second direction y is 2.6 mm to 3.6 mm, and the dimension of the thickness direction z is 0.5 mm to 1.0 mm.

The first lead1A, the second lead1B, and the third lead1C are formed, for example, by subjecting a metal plate to a punching process or a bending process. Constituent materials of the first lead1A, the second lead1B, and the third lead1C are composed of, for example, either copper (Cu) or nickel (Ni), or an alloy thereof The thicknesses of the first lead1A, the second lead1B, and the third lead1C are, for example, 0.1 mm to 0.3 mm.

As shown inFIG. 3, the first lead1A is arranged apart from the second lead1B and the third lead1C in the second direction y. The second lead1B and the third lead1C are arranged in the first direction x. The first lead1A, the second lead1B, and the third lead1C are arranged apart from each other in the thickness direction z. The size of the first lead1A is the largest and the size of the third lead1C is the smallest when viewed in the thickness direction z.

As shown inFIGS. 3 to 6, the first lead1A includes an element bonding portion11and a plurality of (four in the present embodiment) terminal-shaped extending portions12. The element bonding portion11has a rectangular shape, for example, when viewed in the thickness direction z. The element bonding portion11has an element mounting surface111and a back surface mounting portion112. The element mounting surface111faces one side of the thickness direction z, and the back surface mounting portion112faces a side opposite to the element mounting surface111(the other side of the thickness direction z). The semiconductor element2is mounted on the element mounting surface111. As shown inFIGS. 2, 4, and the like, the back surface mounting portion112is exposed from the sealing resin7. The back surface mounting portion112is a portion to be bonded by a bonding material such as solder when the semiconductor device A10is mounted on a circuit board (not shown).

As shown inFIGS. 3 and 4, the second lead1B includes a bonding portion13, a plurality of (three in the present embodiment) terminal portions14, and a plurality of (three in the present embodiment) bent portions15. The bonding portion13is located on one side of the thickness direction z (the upper side ofFIG. 4) to the plurality of terminal portions14. Further, the bonding portion13is located inward in the second direction y to the plurality of terminal portions14. Each of the plurality of terminal portions14includes a back surface mounting portion141. The back surface mounting portion141faces the other side of the thickness direction z (a lower side ofFIG. 4). The back surface mounting portion141is exposed from the sealing resin7. The back surface mounting portion141is a portion to be bonded by a bonding material such as solder when the semiconductor device A10is mounted on a circuit board (not shown). The plurality of bent portions15separately connect the bonding portion13and the plurality of terminal portions14, respectively, and have a bent shape when viewed in the first direction x.

As shown inFIGS. 3 and 5, the third lead1C includes a wire bonding portion16, a terminal portion17, and a bent portion18. The wire bonding portion16is located on one side of the thickness direction z (an upper side ofFIG. 5) to the terminal portion17. Further, the wire bonding portion16is located inward in the second direction y to the terminal portion17. The terminal portion17includes a back surface mounting portion171. The back surface mounting portion171faces the other side of the thickness direction z (the lower side ofFIG. 5). The back surface mounting portion171is exposed from the sealing resin7. The back surface mounting portion171is a portion to be bonded by a bonding material such as solder when the semiconductor device A10is mounted on a circuit board (not shown). The bent portion18connects the wire bonding portion16and the terminal portion17, and has a bent shape when viewed in the first direction x.

The semiconductor element2is an element that exhibits an electrical function of the semiconductor device A10. The type of the semiconductor element2is not particularly limited. In the present embodiment, the semiconductor element2is configured as a transistor. As shown inFIGS. 3 to 5, the semiconductor element2includes an element main body20, a first electrode21, a second electrode22, and a third electrode23.

The element main body20has a rectangular shape when viewed in the thickness direction z. The element main body20has an element main surface201and an element back surface202. The element main surface201and the element back surface202face opposite to each other in the thickness direction z. The element main surface201faces the same side as the element mounting surface111of the element bonding portion11in the thickness direction z. Therefore, the element back surface202faces the element mounting surface111.

The first electrode21and the third electrode23are arranged on the element main surface201. The second electrode22is arranged on the element back surface202. The constituent materials of the first electrode21, the second electrode22, and the third electrode23are composed of, for example, either copper or aluminum (Al), or an alloy thereof. In the present embodiment, the first electrode21is a source electrode, the second electrode22is a drain electrode, and the third electrode23is a gate electrode.

In the present embodiment, the first electrode21covers most of the element main surface201. Specifically, the first electrode21is arranged in a region of the rectangular element main surface201excluding the peripheral edge portion and one corner portion (a lower right corner portion ofFIG. 3) of the element main surface201. The first electrode21includes a first electrode pad212. The first electrode pad212is located inside the insulator3when viewed in the thickness direction z. The third electrode23is arranged at one corner of the element main surface201(the lower right corner ofFIG. 3). The second electrode22covers substantially an entire surface of the element back surface202.

The second electrode22is electrically bonded to the element mounting surface111(the element bonding portion11) via the second conductive bonding material62. The second conductive bonding material62conductively bonds the element bonding portion11and the second electrode22. The second conductive bonding material62is, for example, solder.

The semiconductor device A10includes a wire65. The wire65is electrically bonded to the third electrode23and the wire bonding portion16of the third lead1C. The wire65conductively bonds the third electrode23and the third lead1C.

As shown inFIGS. 7 and 8, the insulator3is arranged over the first electrode21and the element main surface201. The insulator3has an annular shape that overlaps with the outer peripheral edge of the first electrode21when viewed in the thickness direction z. The outer end edge301of the insulator3is located near the outer peripheral edge of the element main surface201when viewed in the thickness direction z. In the first electrode21, a region located inside an inner end edge302of the insulator3when viewed in the thickness direction z is referred to as the first electrode pad212.

In the present embodiment, the insulator3is composed of a first insulating layer31and a second insulating layer33. The first insulating layer31is arranged over the peripheral edge portion211of the first electrode21and the element main surface201. InFIG. 7, a forming region of the first insulating layer31is shaded. The first insulating layer31is made of, for example, nitride such as SiN. The thickness of the first insulating layer31is, for example, 0.1 μm to 2 μm. Other insulating materials such as SiON and SiO2may be adopted as the constituent material of the first insulating layer31.

The first insulating layer31includes a first annular portion310. The first annular portion310has an annular shape corresponding to the outer peripheral edge of the first electrode21. In the present embodiment, the first annular portion310is composed of a plurality of strip-shaped portions each extending in the first direction x or the second direction y with substantially a constant width. In the present embodiment, the first annular portion310has outer end edges311,312,313,314,315, and316and inner end edges321,322,323,324,325, and326.

The outer end edge311is located on one side of the second direction y in the first annular portion310and extends in the first direction x. The outer end edge312is located on one side of the first direction x in the first annular portion310and extends in the second direction y. One side end of the outer end edge312in the second direction y is connected to one side end of the outer end edge311in the first direction x. The outer end edge313is located on the other side of the first direction x in the first annular portion310and extends in the second direction y. One side end of the outer end edge313in the second direction y is connected to the other side end of the outer end edge311in the first direction x. The outer end edge314is located on the other side of the second direction y in the first annular portion310and extends in the first direction x. The other side end of the outer end edge314in the first direction x is connected to the other side end of the outer end edge313in the second direction y. The outer end edge311and the outer end edge314correspond to a “first outer end edge” of the present disclosure. The outer end edge312and the outer end edge313correspond to a “second outer end edge” of the present disclosure.

The inner end edge321is located on one side of the second direction y in the first annular portion310and extends in the second direction y. The inner end edge321corresponds to the outer end edge311and is located inside the outer end edge311in the second direction y when viewed in the thickness direction z. The inner end edge322is located on one side of the first direction x in the first annular portion310and extends in the second direction y. One side end of the inner end edge322in the second direction y is connected to one side end of the inner end edge321in the first direction x. The inner end edge322corresponds to the outer end edge312and is located inside the outer end edge312in the first direction x when viewed in the thickness direction z. The inner end edge323is located on the other side of the first direction x in the first annular portion310and extends in the second direction y. One side end of the inner end edge323in the second direction y is connected to the other side end of the inner end edge321in the first direction x. The inner end edge323corresponds to the outer end edge313and is located inside the outer end edge313in the first direction x when viewed in the thickness direction z. The inner end edge324is located on the other side of the second direction y in the first annular portion310and extends in the first direction x. The other side end of the inner end edge324in the first direction x is connected to the other side end of the inner end edge323in the second direction y. The inner end edge324corresponds to the outer end edge314and is located inside the outer end edge314in the second direction y when viewed in the thickness direction z. The inner end edge321and the inner end edge324correspond to a “first inner end edge” of the present disclosure. The inner end edge322and the inner end edge323correspond to a “second inner end edge” of the present disclosure.

The inner end edge325is located near one side of the first direction x and near the other side of the second direction y in the first annular portion310, and extends in the first direction x. One side end of the inner end edge325in the first direction x is connected to the other side end of the inner end edge322in the second direction y. The inner end edge325is located inside the inner end edge322in the first direction x when viewed in the thickness direction z. The inner end edge326is located near one side of the first direction x and near the other side of the second direction y in the first annular portion310, and extends in the second direction y. The other side end of the inner end edge326in the second direction y is connected to the other side end of the inner end edge325in the first direction x. The inner end edge326is located on the side opposite to the inner end edge321to the inner end edge325in the second direction y when viewed in the thickness direction z. Further, in the present embodiment, the inner end edge326is also connected to the inner end edge324. The inner end edge325corresponds to a “fifth inner end edge” of the present disclosure. The inner end edge326corresponds to a “sixth inner end edge” of the present disclosure.

The outer end edge315is located near one side of the first direction x and near the other side of the second direction y in the first annular portion310, and extends in the first direction x. One side end of the outer end edge315in the first direction x is connected to the other side end of the outer end edge312in the second direction y. The outer end edge315corresponds to the inner end edge325and is located outside the inner end edge325in the second direction y when viewed in the thickness direction z. The outer end edge316is located near one side of the first direction x and near the other side of the second direction y in the first annular portion310, and extends in the second direction y. The other side end of the outer end edge316in the second direction y is connected to the other side end of the outer end edge315in the first direction x. The outer end edge316corresponds to the inner end edge326and is located outside the inner end edge326in the first direction x in the thickness direction z. Further, in the present embodiment, the outer end edge316is also connected to the outer end edge314. The outer end edge315corresponds to a “fifth outer end edge” of the present disclosure. The outer end edge316corresponds to a “sixth outer end edge” of the present disclosure.

As shown inFIGS. 7 and 8, the second insulating layer33is laminated on the first insulating layer31. In the present embodiment, the second insulating layer33covers the entire first insulating layer31and a portion of each of the first electrode21and the element main surface201. In the present embodiment, the second insulating layer33shown inFIG. 8includes the outer end edge301and the inner end edge302in the insulator3.

The constituent material of the second insulating layer33is not particularly limited. In the present embodiment, the second insulating layer33is made of, for example, a resin material such as a polyimide resin. The thickness of the second insulating layer33is larger than the thickness of the first insulating layer31. Preferably, the thickness of the second insulating layer33is 5 to 50 times the thickness of the first insulating layer31. The thickness of the second insulating layer33is, for example, 5 μm to 10 μm.

As shown inFIG. 7, the second insulating layer33includes a second annular portion330. The second annular portion330has an annular shape corresponding to the first annular portion310, and covers the entire first annular portion310. In the present embodiment, the second annular portion330is composed of a plurality of strip-shaped portions each extending in the first direction x or the second direction y. In the present embodiment, the second annular portion330has outer end edges331,332,333,334,335, and336and inner end edges341,342,343,344,345, and346.

The outer end edge331is located on one side of the second direction y in the second annular portion330and extends in the first direction x. The outer end edge331is located outside the outer end edge311in the second direction y when viewed in the thickness direction z.

The outer end edge332is located on one side of the first direction x in the second annular portion330and extends in the second direction y. One side end of the outer end edge332in the second direction y is connected to one side end of the outer end edge331in the first direction x. The outer end edge332is located outside the outer end edge312in the first direction x when viewed in the thickness direction z.

As shown inFIG. 9, in the present embodiment, the outer end edge331includes an outer end edge first portion331A and an outer end edge overhanging portion331E. The outer end edge first portion331A extends linearly along the first direction x and occupies most of the outer end edge331except for the end portion thereof. The outer end edge overhanging portion331E is connected to the outer end edge first portion331A and is located at the end portion near the outer end edge332. The outer end edge overhanging portion331E is located outside the outer end edge first portion331A in the second direction y. Therefore, in the outer end edge331, the end portion (the outer end edge overhanging portion331E) near the outer end edge332protrudes outward in the second direction y as compared with the center of the first direction x (the outer end edge first portion331A).

The outer end edge332includes an outer end edge first portion332A and an outer end edge overhanging portion332E. The outer end edge first portion332A extends linearly along the second direction y and occupies most of the outer end edge332except for the end portion thereof. The outer end edge overhanging portion332E is connected to the outer end edge first portion332A and is located at the end portion near the outer end edge331. The outer end edge overhanging portion332E is located outside the outer end edge first portion332A in the first direction x. Therefore, in the outer end edge332, the end portion (the outer end edge overhanging portion332E) near the outer end edge331protrudes outward in the first direction x as compared with the center of the second direction y (the outer end edge first portion332A). Further, the outer end edge overhanging portion332E is also connected to the outer end edge overhanging portion331E. InFIG. 9, a two-dot chain line inclined at an angle of 45° to the first direction x and the second direction y indicates a boundary between the outer end edge overhanging portion331E and the outer end edge overhanging portion332E. As a result, the corner portion (the outer end edge overhanging portion331E and the outer end edge overhanging portion332E) of the outer end edge331and the outer end edge332has a shape protruding outward in both the first direction x and the second direction y.

As shown inFIG. 7, the outer end edge333is located on the other side of the first direction x in the second annular portion330and extends in the second direction y. One side end of the outer end edge313in the second direction y is connected to the other side end of the outer end edge311in the first direction x. The outer end edge333is located outside the outer end edge313in the first direction x when viewed in the thickness direction z.

Although detailed illustration and description are omitted, in the outer end edge333, the end portion near the outer end edge331protrudes outward in the first direction x as compared with the center of the second direction y. As a result, the corner portion of the outer end edge331and the outer end edge333(the upper left corner portion inFIG. 7) has a shape that protrudes outward in both the first direction x and the second direction y, similarly to the corner portion of the outer end edge331and the outer end edge332.

The outer end edge334is located on the other side of the second direction y in the second annular portion330and extends in the first direction x. The other side end of the outer end edge334in the first direction x is connected to the other side end of the outer end edge333in the second direction y. The outer end edge334is located outside the outer end edge314in the second direction y when viewed in the thickness direction z.

Although detailed illustration and description are omitted, in the outer end edge334, the end portion near the outer end edge333protrudes outward in the second direction y as compared with the center of the first direction x. Further, in the outer end edge333, the end portion near the outer end edge334protrudes outward in the first direction x as compared with the center of the second direction y. The end portion of the outer end edge334near the outer end edge333is connected to the end portion of the outer end edge333near the outer end edge334. As a result, the corner portion of the outer end edge333and the outer end edge334(the lower left corner inFIG. 7) has a shape that protrudes outward in both the first direction x and the second direction y, similarly to the corner portion of the outer end edge331and the outer end edge332. The outer end edge331and the outer end edge334correspond to a “third outer end edge” of the present disclosure. The outer end edge332and the outer end edge333correspond to a “fourth outer end edge” of the present disclosure.

The inner end edge341is located on one side of the second direction y in the second annular portion330and extends in the second direction y. The inner end edge341is located inside the inner end edge321in the second direction y when viewed in the thickness direction z. The inner end edge342is located on one side of the first direction x in the second annular portion330and extends in the second direction y. One side end of the inner end edge342in the second direction y is connected to one side end of the inner end edge341in the first direction x. The inner end edge342is located inside the inner end edge322in the first direction x when viewed in the thickness direction z. The inner end edge343is located on the other side of the first direction x in the second annular portion330and extends in the second direction y. One side end of the inner end edge343in the second direction y is connected to the other side end of the inner end edge341in the first direction x. The inner end edge343is located inside the inner end edge323in the first direction x when viewed in the thickness direction z. The inner end edge344is located on the other side of the second direction y in the second annular portion330and extends in the first direction x. The other side end of the inner end edge344in the first direction x is connected to the other side end of the inner end edge343in the second direction y. The inner end edge344is located inside the inner end edge324in the second direction y when viewed in the thickness direction z. The inner end edge341and the inner end edge344correspond to a “third inner end edge” of the present disclosure. The inner end edge342and the inner end edge343correspond to a “fourth inner end edge” of the present disclosure.

The inner end edge345is located near one side of the first direction x and near the other side of the second direction y in the second annular portion330, and extends in the first direction x. One side end of the inner end edge345in the first direction x is connected to the other side end of the inner end edge342in the second direction y. The inner end edge345is located inside the inner end edge325in the second direction y when viewed in the thickness direction z. The inner end edge346is located near one side of the first direction x and near the other side of the second direction y in the second annular portion330, and extends in the second direction y. The other side end of the inner end edge346in the second direction y is connected to the other side end of the inner end edge345in the first direction x. The inner end edge346is located inside the inner end edge326in the first direction x when viewed in the thickness direction z. Further, in the present embodiment, the inner end edge346is also connected to the inner end edge344.

As shown inFIG. 10, in the present embodiment, the inner end edge345includes an inner end edge first portion345A and an inner end edge overhanging portion345E. The inner end edge first portion345A extends linearly along the first direction x and occupies most of the inner end edge345except for the end portion thereof. The inner end edge overhanging portion345E is connected to the inner end edge first portion345A and is located at the end portion near the inner end edge346. The inner end edge overhanging portion345E is located inside the inner end edge overhanging portion345E in the second direction y. Therefore, in the inner end edge345, the end portion (the inner end edge overhanging portion345E) near the inner end edge346protrudes inward in the second direction y as compared with the center of the first direction x (the inner end edge first portion345A).

The inner end edge346includes an inner end edge first portion346A and an inner end edge overhanging portion346E. The inner end edge first portion346A extends linearly along the second direction y and occupies most of the inner end edge346except for the end portion thereof. The inner end edge overhanging portion346E is connected to the inner end edge first portion346A and is located at the end portion near the inner end edge345. The inner end edge overhanging portion346E is located inside the inner end edge first portion346A in the first direction x. Therefore, in the inner end edge346, the end portion (the inner end edge overhanging portion346E) near the inner end edge345protrudes inward in the first direction x as compared with the center of the second direction y (the inner end edge first portion346A). Further, the inner end edge overhanging portion346E is also connected to the inner end edge overhanging portion345E. InFIG. 10, a two-dot chain line inclined at an angle of 45° to the first direction x and the second direction y indicates a boundary between the inner end edge overhanging portion345E and the inner end edge overhanging portion346E. As a result, the corner portion (the inner end edge overhanging portion345E and the inner end edge overhanging portion346E) of the inner end edge345and the inner end edge346has a shape that protrudes inward in both the first direction x and the second direction y. The inner end edge345corresponds to a “seventh inner end edge” of the present disclosure. The inner end edge346corresponds to an “eighth inner end edge” of the present disclosure.

As shown inFIG. 7, the outer end edge335is located near one side of the first direction x and near the other side of the second direction y in the second annular portion330, and extends in the first direction x. One side end of the outer end edge335in the first direction x is connected to the other side end of the outer end edge332in the second direction y. The outer end edge335is located outside the outer end edge315in the second direction y when viewed in the thickness direction z. The outer end edge336is located near one side of the first direction x and near the other side of the second direction y in the second annular portion330, and extends in the second direction y. The other side end of the outer end edge336in the second direction y is connected to the other side end of the outer end edge335in the first direction x. The outer end edge336is located outside the outer end edge316in the first direction x when viewed in the thickness direction z. Further, in the present embodiment, the outer end edge336is also connected to the outer end edge334. The outer end edge335corresponds to a “seventh outer end edge” of the present disclosure. The outer end edge336corresponds to an “eighth outer end edge” of the present disclosure.

As shown inFIGS. 7 and 8, the metal laminated portion4is arranged over the first electrode21and the insulator3, and has a structure in which a plurality of metal layers are laminated. In the present embodiment, the metal laminated portion4includes a first metal layer41, a second metal layer42, and a third metal layer43.

The first metal layer41is arranged over the first electrode21and the insulator3(the second insulating layer33). Specifically, the first metal layer41covers the first electrode pad212of the first electrode21, which is located inside the inner end edge302of the insulator3(the second insulating layer33) when viewed in the thickness direction z, and a portion of the second insulating layer33(the second annular portion330). The first metal layer41includes a first extending portion411located on the outer peripheral portion when viewed in the thickness direction z. A first end edge412, which is the outer peripheral edge of the first metal layer41, is located between the outer end edge301and the inner end edge302of the insulator3(the second insulating layer33) when viewed in the thickness direction z. The constituent material of the first metal layer41includes titanium (Ti). The thickness of the first metal layer41is, for example, 0.1 μm to 0.5 μm.

The second metal layer42is laminated on the first metal layer41. The second metal layer42overlaps both the first electrode21and the insulator3when viewed in the thickness direction z. The second metal layer42covers a region located inside the first extending portion411except for the outer peripheral portion (the first extending portion411) of the first metal layer41when viewed in the thickness direction z. As a result, the first extending portion411of the first metal layer41is not covered with the second metal layer42, but is exposed from the second metal layer42. The second metal layer42includes a second extending portion421located on the outer peripheral portion when viewed in the thickness direction z. A second edge422, which is the outer peripheral edge of the second metal layer42, is located between the first end edge412of the first metal layer41and the inner end edge302of the insulator3(the second insulating layer33) when viewed in the thickness direction z. The constituent material of the second metal layer42includes nickel. The thickness of the second metal layer42is, for example, 0.1 μm to 0.5 μm.

The third metal layer43is laminated on the second metal layer42. The third metal layer43overlaps both the first electrode21and the insulator3when viewed in the thickness direction z. The third metal layer43covers a region located inside the second extending portion421except for the outer peripheral portion (the second extending portion421) of the second metal layer42when viewed in the thickness direction z. As a result, the second extending portion421of the second metal layer42is not covered with the third metal layer43, but is exposed from the third metal layer43. A third end edge431, which is the outer peripheral edge of the third metal layer43, is located between the second end edge422of the second metal layer42and the inner end edge302of the insulator3(the second insulating layer33) when viewed in the thickness direction z. The constituent material of the second metal layer42includes silver (Ag). The thickness of the third metal layer43is larger than either the thickness of the first metal layer41or the thickness of the second metal layer42. The thickness of the third metal layer43is, for example, 0.5 μm to 1.5 μm.

As can be seen fromFIG. 8and the above description, the second end edge422of the second metal layer42is located closer to the inner end edge302of the insulator3(the second insulating layer33) than the first end edge412of the first metal layer41. The third end edge431of the third metal layer43is located closer to the inner end edge302than the second end edge422of the second metal layer42. As a result, the first metal layer41, the second metal layer42, and the third metal layer43are laminated in a stepped manner. In the configuration shown inFIG. 8, when viewed in the thickness direction z, the first dimension L1, which is a distance between the first end edge412and the second end edge422, is, for example, 10 to 50 times the thickness of the first metal layer41. When viewed in the thickness direction z, the second dimension L2, which is a distance between the second end edge422and the third end edge431, is, for example, 10 to 50 times the thickness of the second metal layer42. When viewed in the thickness direction z, the third dimension L3, which is a distance between the third end edge431and the inner end edge302, is, for example, 1 to 5 times the thickness of the third metal layer43.

As shown inFIGS. 3 and 4, the conductive member5is bonded to the first electrode21of the semiconductor element2, and the second lead1B. The conductive member5is made of a metal plate material. The metal is copper or a copper alloy. The conductive member5is a metal plate material that has been punched or bent. In the present embodiment, the conductive member5includes an element side bonding portion51, a lead side bonding portion52, and an intermediate portion53. As shown inFIG. 4, the element side bonding portion51, the lead side bonding portion52, and the intermediate portion53are appropriately bent and connected when viewed in the first direction x.

The element side bonding portion51is bonded to the first electrode pad212of the first electrode21via the first conductive bonding material61. The first conductive bonding material61conductively bonds the element side bonding portion51(the conductive member5) and the first electrode pad212. The first conductive bonding material61is, for example, solder.

As shown inFIGS. 4 to 6, a protruding portion511and a concave portion512are formed in the element side bonding portion51. The protruding portion511protrudes downward (the other side of the thickness direction z) from the lower surface of the element side bonding portion51(a surface facing the element main surface201). In the illustrated example, two protruding portions511are provided at an interval in the second direction y, and each protruding portion511extends in the first direction x with a constant width. The concave portion512is a portion that is partially recessed upward (one side of the thickness direction z) from the lower surface of the element side bonding portion51. In the illustrated example, two concave portions512are provided at an interval in the first direction x, and each concave portion512extends in the second direction y with a constant width.

At the time of bonding the first electrode pad212and the element side bonding portion51, while the protruding portion511is pressed against the first electrode pad212side, a sufficient amount of first conductive bonding material61is present around the protruding portion511. As a result, the conduction between the element side bonding portion51and the first electrode pad212is appropriately maintained. Further, the concave portion512is provided on the lower surface of the element side bonding portion51. As a result, even if voids (vacancy) are present in the first conductive bonding material61, the voids can be accommodated in the concave portion512. Therefore, the voids in the first conductive bonding material61can be suppressed. Instead of the illustrated concave portion512, a through-hole may be formed through the element side bonding portion51in the thickness direction z in order to suppress the voids.

The lead side bonding portion52is bonded to the bonding portion13of the second lead1B via the third conductive bonding material63. The third conductive bonding material63conductively bonds the lead side bonding portion52(the conductive member5) and the bonding portion13(the second lead1B). The third conductive bonding material63is, for example, solder. As shown inFIG. 4, the lead side bonding portion52includes a convex portion located on the other side (the lower side of the figure) of the thickness direction z from the periphery. At the time of bonding the bonding portion13and the lead side bonding portion52, while the convex portion is pressed against the bonding portion13, a sufficient amount of third conductive bonding material63is present around the convex portion. As a result, the conduction between the lead side bonding portion52and the bonding portion13is appropriately maintained.

The intermediate portion53is located between the element side bonding portion51and the lead side bonding portion52in the second direction y. The intermediate portion53is connected to both the element side bonding portion51and the lead side bonding portion52.

The sealing resin7covers a portion of each of the first lead1A, the second lead1B, and the third lead1C, the semiconductor element2, the insulator3, the metal laminated portion4, the conductive member5, and the wire65. The sealing resin7is made of, for example, a black epoxy resin.

As shown inFIGS. 1, 2, 4, and 6, the sealing resin7has a sealing resin main surface71, a sealing resin back surface72, and a sealing resin side surface73. The sealing resin main surface71and the sealing resin back surface72face opposite sides in the thickness direction z. The sealing resin main surface71faces the same side as the element main surface201and the element mounting surface111. The sealing resin back surface72faces the same side as the element back surface202and the back surface mounting portion112. The sealing resin side surface73is connected to the sealing resin main surface71and the sealing resin back surface72, and is slightly inclined to the thickness direction z.

Next, an example of a method of manufacturing the semiconductor device A10will be described below with reference toFIGS. 11 to 29.FIGS. 12, 14, 16, and 20 to 29each of which is a cross-sectional view showing one step of the method of manufacturing the semiconductor device A10and is the same cross-sectional view as the partially enlarged cross-sectional view shown inFIG. 8.

First, as shown inFIG. 11, a substrate2′ is prepared. The substrate2′ includes a base material20′, a first electrode21, and a third electrode23. The base material20′ is a member that becomes the element main body20of the semiconductor element2. In the present embodiment, the base material20′ has a size that can be divided into a plurality of element main bodies20(the semiconductor element2), for example, by cutting the base material20′ (the substrate2′) in a subsequent step. In the plan views afterFIG. 11, a region corresponding to one element main body20(the semiconductor element2) to be divided is shown. The base material20′ has a main surface201′. The main surface201′ faces one side of the thickness direction z. The first electrode21and the third electrode23are arranged on the main surface201′. Although not shown, a plurality of first electrodes21and a plurality of third electrodes23are arranged on the main surface201′ with a distance in each of the first direction x and the second direction y. In the plan views afterFIG. 11, a region corresponding to the element main surface201of one element main body20(the semiconductor element2) to be divided is represented as the main surface201′. This step corresponds to a “step of preparing a substrate” of the present disclosure. In addition, unlike the example shown inFIG. 11, when the semiconductor element2including a single element main body20corresponding to the base material20′ is prepared as the substrate2′, it also corresponds to the “step of preparing a substrate” of the present disclosure.

Next, as shown inFIG. 13, the first insulating layer31is formed on the main surface201′ side of the substrate2′. The first insulating layer31can be formed by, for example, a thin film forming technique such as CVD (chemical vapor deposition). In the formation of the first insulating layer31, for example, a mask having an opening corresponding to the first annular portion310is arranged on the substrate2′ to form a thin film made of SiN, and then the mask is removed. As a result, the first insulating layer31including the first annular portion310is formed. Here, the first annular portion310is arranged over the peripheral edge portion211of the first electrode21, and the main surface201′. The first annular portion310has outer end edges311,312,313,314,315, and316and inner end edges321,322,323,324,325, and326, similar to the configuration described with reference toFIG. 7.

Next, as shown inFIG. 15, the second insulating layer33is formed on the main surface201′ side of the substrate2′. The formation of the second insulating layer33can be performed, for example by arranging a polyamic acid (resin material) by coating, and heating it. In the formation of the second insulating layer33, for example, a mask having an opening corresponding to the second annular portion330is first arranged on the substrate2′, the polyamic acid (resin material) is coated on the mask, and then the mask is removed. As a result, the second annular portion330made of a resin material is arranged. The second annular portion330overlaps with the first annular portion310when viewed in the thickness direction z. Here, the second annular portion330has outer end edges331,332,333,334,335, and336and inner end edges341,342,343,344,345, and346. The second annular portion330is similar to the configuration described with reference toFIG. 7. On the other hand, the second annular portion330shown inFIG. 15is different from the configuration shown inFIG. 7in the shape of the corner portion of the outer end edge331and the outer end edge332(the upper right corner portion ofFIG. 15), the shape of the corner portion of the outer end edge331and the outer end edge333(the upper left corner ofFIG. 15), the shape of the corner portion of the outer end edge333and the outer end edge334(the lower left corner ofFIG. 15), and the shape of the corner portion of the inner end edge345and the inner end edge346.

As shown inFIG. 17, the outer end edge331includes an outer end edge first portion331A and an outer end edge second portion331B. The outer end edge second portion331B is connected to the outer end edge first portion331A and is located at the end portion near the outer end edge332. The outer end edge second portion331B is located outside the outer end edge first portion331A in the second direction y. In the illustrated example, the outer end edge second portion331B has an outer end edge straight line portion331cand an outer end edge connecting portion331d. The outer end edge straight line portion331cextends linearly along the first direction x. The outer end edge connecting portion331dis connected to both the outer end edge first portion331A and the outer end edge straight line portion331c. Therefore, with respect to the outer end edge311of the first annular portion310and the outer end edge331of the second annular portion330, a distance (first distance D1) between the outer end edge311and the outer end edge331in the second direction y is set to be larger at the end portion near the outer end edge332than the center of the first direction x. The first distance D1is not particularly limited. In the present embodiment, for example, the first distance D1at the center of the first direction x (a distance between the outer end edge311and the outer end edge first portion331A in the second direction y) is about 10 μm to 20 μm, and the first distance D1at the end portion near the outer end edge332(a distance between the outer end edge311and the outer end edge straight line portion331cin the second direction y) is about 15 μm to 35 μm.

The outer end edge332includes an outer end edge first portion332A and an outer end edge second portion332B. The outer end edge second portion332B is connected to both the outer end edge first portion332A and the outer end edge straight line portion331c(the outer end edge second portion331B) and is located at the end portion near the outer end edge331. The outer end edge second portion332B is located outside the outer end edge first portion332A in the first direction x. In the illustrated example, the outer end edge second portion332B includes an outer end edge straight line portion332cand an outer end edge connecting portion332d. The outer end edge straight line portion332cextends linearly along the second direction y. The outer end edge connecting portion332dis connected to both the outer end edge first portion332A and the outer end edge straight line portion332c. Therefore, with respect to the outer end edge312of the first annular portion310and the outer end edge332of the second annular portion330, a distance (second distance D2) between the outer end edge312and the outer end edge332in the first direction x is set to be larger at the end portion near the outer end edge331than the center of the second direction y. The second distance D2is not particularly limited. In the present embodiment, for example, the second distance D2at the center of the second direction y (a distance between the outer end edge312and the outer end edge first portion332A in the first direction x) is about 10 μm to 20 μm, and the second distance D2at the end portion near the outer end edge331(a distance between the outer end edge312and the outer end edge straight line portion332cin the first direction x) is about 15 μm to 35 μm.

Further, the outer end edge second portion332B is also connected to the outer end edge second portion331B. As a result, the corner portion (the outer end edge second portion331B and the outer end edge second portion332B) of the outer end edge331and the outer end edge332has a shape that protrudes outward in both the first direction x and the second direction y. The corner portion (the outer end edge second portion331B and the outer end edge second portion332B) of the outer end edge331and the outer end edge332shown inFIG. 17protrudes outward from the corner portion (the outer end edge overhanging portion331E and the outer end edge overhanging portion332E) of the outer end edge331and the outer end edge332shown inFIG. 9.

Although detailed illustration and description are omitted, the end portion of the outer end edge331near the outer end edge333is located on the outside in the second direction y, similarly to the end portion (the outer end edge second portion331B) of the outer end edge331near the outer end edge332. Further, the end portion of the outer end edge333near the outer end edge331is located on the outside in the first direction x, similarly to the end portion (the outer end edge second portion332B) of the outer end edge332near the outer end edge331. As a result, the corner portion of the outer end edge331and the outer end edge333(the upper left corner ofFIG. 15) has a shape that protrudes outward in both the first direction x and the second direction y, similarly to the corner portion of the outer end edge331and the outer end edge332.

Although detailed illustration and description are omitted, the end portion of the outer end edge334near the outer end edge333is located on the outside in the second direction y, similarly to the end portion (the outer end edge second portion331B) of the outer end edge331near the outer end edge332. Further, the end portion of the outer end edge333near the outer end edge334is located on the outside in the first direction x, similarly to the end portion (the outer end edge second portion332B) of the outer end edge332near the outer end edge331. As a result, the corner portion of the outer end edge333and the outer end edge334(the lower left corner ofFIG. 15) has a shape that protrudes outward in both the first direction x and the second direction y, similarly to the corner portion of the outer end edge331and the outer end edge332.

As shown inFIG. 18, the inner end edge345includes an inner end edge first portion345A and an inner end edge second portion345B. The inner end edge second portion345B is connected to the inner end edge first portion345A and is located at the end portion near the inner end edge346. The inner end edge second portion345B is located inside the inner end edge first portion345A in the second direction y. In the illustrated example, the inner end edge second portion345B has an inner end edge straight line portion345cand an inner end edge connecting portion345d. The inner end edge straight line portion345cextends linearly along the first direction x. The inner end edge connecting portion345dis connected to both the inner end edge first portion345A and the inner end edge straight line portion345c. Therefore, with respect to the inner end edge325of the first annular portion310and the inner end edge345of the second annular portion330, a distance (third distance D3) between the inner end edge325and the inner end edge345in the second direction y is set to be larger at the end portion near the inner end edge346than the center of the first direction x. The third distance D3is not particularly limited. In the present embodiment, for example, the third distance D3at the center of the first direction x (a distance between the inner end edge325and the inner end edge first portion345A in the second direction y) is about 20 μm to 30 μm, and the third distance D3at the end portion near the inner end edge346(a distance between the inner end edge325and the inner end edge straight line portion345cin the second direction y) is about 30 μm to 50 μm.

The inner end edge346includes an inner end edge first portion346A and an inner end edge second portion346B. The inner end edge second portion346B is connected to both the inner end edge first portion346A and the inner end edge straight line portion345c(the inner end edge second portion345B) and is located at the end portion near the inner end edge345. The inner end edge second portion346B is located inside the inner end edge first portion346A in the first direction x. In the shown example, the inner end edge second portion346B has an inner end edge straight line portion346cand an inner end edge connecting portion346d. The inner end edge straight line portion346cextends linearly along the second direction y. The inner end edge connecting portion346dis connected to both the inner end edge first portion346A and the inner end edge straight line portion346c. Therefore, with respect to the inner end edge326of the first annular portion310and the inner end edge346of the second annular portion330, a distance (fourth distance D4) between the inner end edge326and the inner end edge346in the first direction x is set to be larger at the end portion near the inner end edge345than the center of the second direction y. The fourth distance D4is not particularly limited. In the present embodiment, for example, the fourth distance D4at the center of the second direction y (a distance between the inner end edge326and the inner end edge first portion346A in the first direction x) is about 20 μm to 30 μm, and the fourth distance D4at the end portion near the inner end edge345(a distance between the inner end edge326and the inner end edge straight line portion346cin the first direction x) is about 30 μm to 50 μm.

Further, the inner end edge second portion346B is also connected to the inner end edge second portion345B. As a result, the corner portion (the inner end edge second portion345B and the inner end edge second portion346B) of the inner end edge345and the inner end edge346has a shape that protrudes inward in both the first direction x and the second direction y. The corner portion (the inner end edge second portion345B and the inner end edge second portion346B) of the inner end edge345and the inner end edge346shown inFIG. 18protrudes inward from the corner portion (the inner end edge overhanging portion345E and the inner end edge overhanging portion346E) of the inner end edge345and the inner end edge346shown inFIG. 10.

FIG. 19shows the second annular portion330after being heat-treated. Here, the second annular portion330(the second insulating layer33) made of a polyimide resin is formed. The heat-treated second annular portion330shrinks as compared with the non-heat-treated second annular portion330shown inFIG. 15. The shrinkage of the resin material portion is remarkable at the corner portion of the outer end edge331and the outer end edge332, the corner portion of the inner end edge345and the inner end edge346, and the like. As shown inFIG. 19, the outer end edge overhanging portion331E and the outer end edge overhanging portion332E are formed at the corner portion of the outer end edge331and the outer end edge332, and the inner end edge overhanging portion345E and the inner end edge overhanging portion346E are formed at the corner portion of the inner end edge345and the inner end edge346. In this way, the insulator3including the first insulating layer31and the second insulating layer33is formed.

Next, as shown inFIG. 20, a first metal layer material41′ is formed. The first metal layer material41′ is formed on at least the insulator3and the first electrode21. The first metal layer material41′ is a metal layer formed by a thin film forming technique such as sputtering. The first metal layer material41′ is, for example, a Ti layer.

Next, as shown inFIG. 21, a second metal layer material42′ is formed. The second metal layer material42′ is formed on the first metal layer material41′. The second metal layer material42′ is a metal layer formed by a thin film forming technique such as sputtering. The second metal layer material42′ is formed of a metal material different from the first metal layer material41′, and is, for example, a Ni layer.

Next, as shown inFIG. 22, a third metal layer material43′ is formed. The third metal layer material43′ is formed on the second metal layer material42′. The third metal layer material43′ is a metal layer formed by a thin film forming technique such as sputtering. The third metal layer material43′ is formed of a metal material different from any of the first metal layer material41′ and the second metal layer material42′, and is, for example, an Ag layer.

Next, as shown inFIG. 23, a resist8is formed. The resist8can be formed, for example, by exposure/development by a photolithography technique. In the formation of the resist8, a photosensitive material is coated on the third metal layer material43′, and is subjected to an exposing/developing process of a predetermined pattern. As a result, the resist8having an opening81is formed. The opening81overlaps with a portion of the insulator3(a portion on the outer end edge301side) when viewed in the thickness direction z. Here, since the thickness of the second insulating layer33is relatively large, the thickness of the resist8formed over the first electrode pad212and the second insulating layer33is increased so that a large step does not occur in the resist8. Further, in order to appropriately form the opening81in the resist8having a large thickness, it is preferable that the amount of exposure to the photosensitive material is twice or more the usual amount and the development of the photosensitive material is performed a plurality of times.

Next, as shown inFIG. 24, a portion of the third metal layer material43′ is removed. Specifically, wet etching is performed on the third metal layer material43′ using the resist8as a mask (first etching step). The wet etching process of the third metal layer material43′ is performed using a chemical solution that dissolves the third metal layer material43′. As a result, as shown inFIG. 24, in the third metal layer material43′, a part exposed from the resist8and a portion of a part covered with the resist8are removed to form an end edge431′.

Next, as shown inFIG. 25, a portion of the second metal layer material42′ is removed. Specifically, wet etching is performed on the second metal layer material42′ using the resist8as a mask (second etching step). The wet etching process of the second metal layer material42′ is performed using a chemical solution that dissolves the second metal layer material42′. As a result, as shown inFIG. 25, in the second metal layer material42′, a part exposed from the third metal layer material43′ and a portion of a part covered with the third metal layer material43′ are removed to form an end edge421′.

Next, as shown inFIG. 26, a portion of the first metal layer material41′ is removed. Specifically, wet etching is performed on the first metal layer material41′ using the resist8as a mask (third etching step). The wet etching process of the first metal layer material41′ is performed using a chemical solution that dissolves the first metal layer material41′. As a result, as shown inFIG. 26, in the first metal layer material41′, a part exposed from the second metal layer material42′ and a portion of a part covered with the second metal layer material42′ are removed to form the first metal layer41having the first end edge412.

Next, as shown inFIG. 27, a portion of the second metal layer material42′ is removed. Specifically, wet etching is performed on the second metal layer material42′ using the resist8as a mask (fourth etching step). The wet etching process of the second metal layer material42′ is performed using a chemical solution that dissolves the second metal layer material42′. As a result, as shown inFIG. 27, in the second metal layer material42′, a part exposed from the first metal layer41and a portion of a part covered with the first metal layer41are removed to form the second metal layer42having the second end edge422.

Next, as shown inFIG. 28, a portion of the third metal layer material43′ is removed. Specifically, wet etching is performed on the third metal layer material43′ using the resist8as a mask (fifth etching step). The wet etching process of the third metal layer material43′ is performed using a chemical solution that dissolves the third metal layer material43′. As a result, as shown inFIG. 28, in the third metal layer material43′, a part exposed from the second metal layer42and a portion of a part covered with the second metal layer42are removed to form the third metal layer43having the third end edge431. In this way, the first metal layer41, the second metal layer42, and the third metal layer43, which are laminated in a stepped manner, are formed. The positions of the first end edge412, the second end edge422, and the third end edge431(inFIG. 28, the position of each of the first edge412, the second edge422, and the third end edge431in the first direction x) can be adjusted by changing the etching conditions in each etching process. Next, as shown inFIG. 29, the resist8is removed.

After that, the base material20′ (the substrate board2′) is cut along a plane perpendicular to the first direction x and a plane perpendicular to the second direction y to be divided into a plurality of semiconductor elements2. Next, a lead frame having a shape including the first lead1A, the second lead1B, and the third lead1C is prepared, and bonding of the semiconductor element2, boding of the conductive member5, and wire bonding of the wire65to the lead frame are performed. Next, the sealing resin7is formed by molding. Next, the lead frame is appropriately cut to separate the first lead1A, the second lead1B, and the third lead1C from one another. Through the above steps, the semiconductor device A10shown inFIGS. 1 to 10is manufactured.

Next, the operation and effects of the present embodiment will be described.

The semiconductor device A10includes the semiconductor element2, the insulator3, the first metal layer41, and the second metal layer42. The insulator3is arranged over the first electrode21and the element main surface201of the semiconductor element2. The first metal layer41is arranged on the first electrode21(the first electrode pad212) and the insulator3, and the second metal layer42is laminated on the first metal layer41. The outer peripheral edge (the first end edge412) of the first metal layer41is located between the outer end edge301and the inner end edge302of the insulator3when viewed in the thickness direction z, and the outer peripheral edge (the second end edge422) of the second metal layer42is located between the first end edge412and the inner end edge302when viewed in the thickness direction z. With such a configuration, since the first metal layer41and the second metal layer42are laminated in a stepped manner on the first electrode pad212and the insulator3, it is possible to suppress peeling of the first metal layer41and the second metal layer42.

The semiconductor device A10includes the third metal layer43. The third metal layer43is laminated on the second metal layer42. The outer peripheral edge (the third end edge431) of the third metal layer43is located between the second end edge422and the inner end edge302when viewed in the thickness direction z. With such a configuration, since the first metal layer41, the second metal layer42, and the third metal layer43are laminated in a stepped manner on the first electrode pad212and the insulator3, it is possible to suppress peeling of the first metal layer41, the second metal layer42, and the third metal layer43.

The insulator3includes the first insulating layer31and the second insulating layer33. The first insulating layer31is arranged over the first electrode21and the element main surface201. The second insulating layer33is laminated on the first insulating layer31. With such a configuration, the insulator3(the first insulating layer31and the second insulating layer33) can have different characteristics according to the properties of each insulating layer.

The thickness of the second insulating layer33is larger than the thickness of the first insulating layer31. With such a configuration, the mechanical properties of the insulator3including the second insulating layer33are enhanced. As a preferred example, the thickness of the second insulating layer33is 5 to 50 times the thickness of the first insulating layer31. The second insulating layer33is made of a polyimide resin. With such a configuration, the mechanical properties of the insulator3are further enhanced. As a result, the semiconductor device A10is suitable for being mounted on, for example, a device in which relatively large vibration can occur (for example, a device for automobile).

The second insulating layer33covers the entire first insulating layer31and a portion of each of the first electrode21and the element main surface201. With such a configuration, the mechanical properties of the insulator3can be enhanced, and the first insulating layer31can be appropriately protected by the second insulating layer33.

The thickness of the third metal layer43is larger than either the thickness of the first metal layer41or the thickness of the second metal layer42. With such a configuration, the mechanical properties of the third metal layer43can be enhanced. Further, when the conductive member5is bonded onto the first electrode pad212, an impact at the time of bonding can be alleviated. The constituent material of the third metal layer43includes silver. With such a configuration, the third metal layer43is excellent in thermal conductivity. As a result, heat generated by the semiconductor element2can be efficiently released to the conductive member5side via the third metal layer43.

<First Modification of the First Embodiment>

FIG. 30shows a semiconductor device according to a first modification of the first embodiment.FIG. 30is a cross-sectional view similar toFIG. 8shown in the above embodiment. Throughout the drawings afterFIG. 30, the same or similar elements as those in the semiconductor device A10of the above embodiment are denoted by the same reference numerals as those of the above embodiment, and explanation thereof will be omitted as appropriate.

A semiconductor device A11of this modification is different from the semiconductor device A10of the above embodiment in the configuration of the insulator3. In this modification, the second insulating layer33does not cover all of the first insulating layer31. Both ends of the strip-shaped portion constituting the first insulating layer31in the width direction (the left-right direction inFIG. 30) are exposed from the second insulating layer33. Also in the semiconductor device A11of this modification, since the first metal layer41, the second metal layer42, and the third metal layer43are laminated in a stepped manner on the first electrode pad212and the insulator3, it is possible to suppress peeling of the first metal layer41, the second metal layer42, and the third metal layer43. In addition, the same operation and effects as those of the above embodiment are obtained within the range of the same configuration as the semiconductor device A10of the above embodiment.

<Second Modification of the First Embodiment>

FIG. 31shows a semiconductor device according to a second modification of the first embodiment.FIG. 31is a cross-sectional view similar toFIG. 8shown in the above embodiment. A semiconductor device A12of this modification is different from the semiconductor device A10of the above embodiment in the configuration of the insulator3. In this modification, the insulator3does not include the second insulating layer33, but includes the first insulating layer31. Also in the semiconductor device A12of this modification, since the first metal layer41, the second metal layer42, and the third metal layer43are laminated in a stepped manner on the first electrode pad212and the insulator3, it is possible to suppress peeling of the first metal layer41, the second metal layer42, and the third metal layer43. In addition, the same operation and effects as those of the above embodiment are obtained within the range of the same configuration as the semiconductor device A10of the above embodiment.

The semiconductor device according to the present disclosure is not limited to the above-described embodiment. The specific configurations of various parts of the semiconductor device according to the present disclosure can be freely changed in design.

The present disclosure includes the configurations related to the following Supplementary Notes.

A semiconductor device including:

a semiconductor element that includes an element main body having an element main surface and an element back surface facing opposite sides to each other in a thickness direction, and a first electrode arranged on the element main surface;

an insulator that has an annular shape overlapping an outer peripheral edge of the first electrode when viewed in the thickness direction and is arranged over the first electrode and the element main surface;

a first metal layer arranged over the first electrode and the insulator; and

a second metal layer laminated on the first metal layer and overlapping both the first electrode and the insulator when viewed in the thickness direction,

wherein the first electrode includes a first electrode pad located inside an inner end edge of the insulator when viewed in the thickness direction,

wherein a first end edge, which is an outer peripheral edge of the first metal layer, is located between an outer end edge and the inner end edge of the insulator when viewed in the thickness direction, and

wherein a second end edge, which is an outer peripheral edge of the second metal layer, is located between the first end edge and the inner end edge when viewed in the thickness direction.

The semiconductor device of Supplementary Note 1, further including: a third metal layer laminated on the second metal layer and overlapping both the first electrode and the insulator when viewed in the thickness direction,

wherein a third end edge, which is an outer peripheral edge of the third metal layer, is located between the second end edge and the inner end edge when viewed in the thickness direction.

The semiconductor device of Supplementary Note 2, wherein the insulator includes a first insulating layer arranged over the first electrode and the element main surface, and a second insulating layer laminated on the first insulating layer.

The semiconductor device of Supplementary Note 3, wherein a thickness of the second insulating layer is larger than a thickness of the first insulating layer.

The semiconductor device of Supplementary Note 4, wherein the thickness of the second insulating layer is 5 to 50 times the thickness of the first insulating layer.

The semiconductor device of any one of Supplementary Notes 3 to 5, wherein the second insulating layer is made of a polyimide resin.

The semiconductor device of any one of Supplementary Notes 3 to 6, wherein the second insulating layer covers the entire first insulating layer and a portion of each of the first electrode and the element main surface.

The semiconductor device of any one of Supplementary Notes 2 to 7, wherein a thickness of the third metal layer is larger than either a thickness of the first metal layer or the thickness of the second metal layer.

The semiconductor device of any one of Supplementary Notes 2 to 8, wherein a constituent material of the third metal layer includes silver.

The semiconductor device of any one of Supplementary Notes 2 to 9, wherein a first dimension, which is a distance between the first end edge and the second end edge when viewed in the thickness direction, is 10 to 50 times a thickness of the first metal layer.

The semiconductor device of any one of Supplementary Notes 2 to 10, wherein a second dimension, which is a distance between the second end edge and the third end edge when viewed in the thickness direction, is 10 to 50 times a thickness of the second metal layer.

The semiconductor device of Supplementary Note 7, wherein a third dimension, which is a distance between the third end edge and the inner end edge when viewed in the thickness direction, is 1 to 5 times a thickness of the third metal layer.

The semiconductor device of any one of Supplementary Notes 1 to 12, further including:

a conductive member made of a metal plate; and

a first conductive bonding material that conductively bonds the first electrode pad and the conductive member.

The semiconductor device of Supplementary Note 13, wherein the semiconductor element includes a second electrode arranged on the element back surface, and

wherein the semiconductor device further includes:a first lead formed of a metal plate and including an element bonding portion on which the semiconductor element is mounted; anda second conductive bonding material that conductively bonds the element bonding portion and the second electrode.

The semiconductor device of Supplementary Note 14, further including:

a second lead arranged apart from the first lead when viewed in the thickness direction and formed of a metal plate; and

a third conductive bonding material that conductively bonds the second lead and the conductive member.

The semiconductor device of Supplementary Note 15, wherein the semiconductor element includes a third electrode arranged on the element main surface, and

wherein the semiconductor device further includes:a third lead arranged apart from the first lead and the second lead when viewed in the thickness direction and formed of a metal plate; anda wire that conductively bonds the third electrode and the third lead.

The semiconductor device of Supplementary Note 16, wherein the first electrode is a source electrode, the second electrode is a drain electrode, and the third electrode is a gate electrode.

A method of manufacturing a semiconductor device, including:

a step of arranging an insulator over a first electrode and an element main surface on a semiconductor element that includes an element main body having an element main surface facing one side of a thickness direction, and the first electrode arranged on the element main surface;

a step of forming a first metal layer material on the first electrode and the insulator;

a step of forming a second metal layer material on the first metal layer material;

a step of forming a third metal layer material on the second metal layer material;

a step of forming, on the third metal layer material, a resist having an opening that overlaps a portion of the insulator when viewed in the thickness direction;

a first etching step of performing wet etching on the third metal layer material using the resist as a mask;

a second etching step of performing wet etching on the second metal layer material using the resist as a mask;

a third etching step of performing wet etching on the first metal layer material using the resist as a mask;

a fourth etching step of performing wet etching on the second metal layer material using the resist as a mask;

a fifth etching step of performing wet etching on the third metal layer material using the resist as a mask; and

a step of removing the resist.

According to a semiconductor device of the present disclosure, it is possible to suppress peeling of a metal layer arranged over an electrode pad portion and an insulator.