Source: http://www.patentsencyclopedia.com/app/20110024883
Timestamp: 2018-01-21 05:30:35
Document Index: 456472452

Matched Legal Cases: ['art 24', 'art 24', 'art 18', 'art 24', 'art 24', 'art 24', 'art 18', 'art 24', 'art 18', 'art 18', 'art 18', 'art 24', 'art 18', 'art 24', 'art 24', 'art 28', 'art 28', 'art 28', 'art 28', 'art 28', 'art 28', 'art 24', 'art 24', 'art 18', 'art 18', 'art 18', 'art 24', 'art 24', 'art 18', 'art 28', 'art 28', 'art 28', 'art 28', 'art 28', 'art 28', 'art 24', 'art 24']

Inventors: Haruhiko Sakai (Ota-City, JP)
Patent application number: 20110024883
1. A method of manufacturing a semiconductor device, the method comprising:providing a lead frame comprising an island having a first main surface and a second main surface opposite from the first main surface and a lead elongated in a first direction in plan view of the lead frame and having one end located close to the islandmounting a semiconductor element on the first main surface of the island;electrically connecting an electrode of the semiconductor element to the lead;placing the island, the semiconductor element mounted on the island and part of the lead in a cavity of a mold for injection molding; andinjecting a liquefied or semi-solid sealing resin into the cavity of the mold through a gate provided having a lower end lower than the second main surface of the island so that the sealing resin flows under the island.
2. The method of claim 1, wherein a first side of the island has an inclined side surface between the first main surface and the second main surface in a cross-sectional view of the lead frame.
3. The method of claim 2, wherein the lead frame comprises units each including the island with the inclined side surface and the lead, and the units are arranged in a line so that the inclined side surfaces are aligned in the same direction, andduring the injection molding, the units are separately accommodated in a plurality of cavities communicating with each other, and the sealing resin is sequentially supplied to the cavities arranged in the line from a pod provided in the mold.
4. The method of claim 2, wherein the inclined side surface is inclined such that an edge of the second main surface is further away from the gate than an edge of the first main surface.
5. The method of claim 1, wherein a space between the second main surface of the island and the mold is smaller than a space between the first main surface of the island and the mold.
6. The method of claim 1, wherein a position of the island within the cavity is fixed.
7. A lead frame, comprising:an island having a first main surface configured to receive a semiconductor element and a second main surface opposite from the first main surface; anda lead elongated in a first direction in plan view of the lead frame and having one end located close to the island,wherein the island has a first side running in the first direction,the first side of the island has an inclined side surface between the first main surface and the second main surface in a cross-sectional view of the lead frame cut perpendicular to the first direction.
8. The lead frame of claim 7, further comprising a plurality of units each including the island with the inclined side surface and the lead, wherein the units are arranged in a second direction.
[0001]This application claims priority from Japanese Patent Application Number JP 2008-195784 filed on Jul. 30, 2008, and Japanese Patent Application Number JP 2008-195785 filed on Jul. 30, 2008, the contents of which are incorporated herein by reference in their entirety. This application is a divisional of U.S. Ser. No. 12/512,802, filed Jul. 30, 2009, now U.S. Pat. No. ______.
[0011]Moreover, the above-mentioned process is performed with the leads 110 and the island 102 being connected to each other by a frame-like lead frame. When the so-called power element in which switching is performed for large current is employed as the semiconductor element 104, a large amount of heat is discharged from the semiconductor element 104. In order to prevent the semiconductor device 100 from overheating due to this heat, a lower surface of the sealing resin 108 shown in FIG. 17B is brought into contact with a heat sink. In this case, a front surface of the sealing resin 108 is pressed downward by a pressing member such as a screw or the like, so that the lower surface of the sealing resin 108 is thermally coupled to the heat sink.
[0012]However, the above-mentioned semiconductor device 100 has a problem that the semiconductor element 104 could be destroyed by a pressing force of the screw that brings the semiconductor device 100 into contact with the heat sink.
[0013]Specifically, with reference to FIG. 17A, in order to achieve the semiconductor element 104 having low on resistance and high breakdown voltage, increasing the size of the semiconductor element 104 in a plane is effective. On the other hand, in order to implement miniaturization and weight reduction of the semiconductor device 100, a reduction in size the sealing resin 108 and the island 102 in planes is preferable. For that reason, the size of the semiconductor element 104 in the plane is a little smaller than those of the sealing resin 108 and the island 102. Namely, a portion used as an area for mounting the semiconductor element 104 accounts for a large percentage of the whole area of the semiconductor device 100.
[0014]Accordingly, when the front surface of the sealing resin 108 shown in FIG. 17B is pressed downward to bring the lower surface of the semiconductor device 100 into contact with a heat dissipating member such as a heat sink, the semiconductor element 104 is disposed under an area thus pressed. In other words, an area of the sealing resin 108 pressed by pressing member superimposes the area on which the semiconductor element 104 is placed. Therefore, this pressing force may apply large stress on the semiconductor element 104, resulting in breakage of the semiconductor element 104.
[0015]In addition, when a thickness of the sealing resin 108 that covers the semiconductor element 104 is made thinner in order to obtain a low profile semiconductor device, the above-mentioned problem is more likely to occur.
[0016]Furthermore, the above-mentioned method for manufacturing the semiconductor device has a problem that the lower surface of the island 102 is not sufficiently covered with the sealing resin 108.
[0017]Specifically, with reference to FIG. 17B, in order to efficiently discharge heat caused from the semiconductor element 104 to the outside while maintaining insulation of the island 102, it is important to make the sealing resin 108 to thinly cover the lower surface of the island 102.
[0018]However, as described above, the sealing resin 108 is formed by injection forming by use of a mold. Accordingly, if the sealing resin 108 for covering the lower surface of the island 102 is approximately 0.4 mm, for example, a space between the island 102 and an inner wall of the mold becomes very narrow, therefore making it very difficult to cause a liquefied sealing resin 108 to flow into this space. Accordingly, the space between the lower surface of the island 102 and the mold is not sufficiently filled with the sealing resin 108, leading to a problem that the island 102 is partially exposed to the outside from the sealing resin 108. Moreover, when a resin material filled with a particulate filler is employed as the sealing resin 108 in order to have improved heat dissipation properties, viscosity of the sealing resin 108 may increase, and the above-mentioned problem may frequently occur. Furthermore, when a large-sized discrete type transistor having low on resistance and high breakdown resistance is employed as the semiconductor element 104, an area of the island 102 also increases. Accordingly, there arises a problem that it is difficult to sufficiently cover the lower surface of the island 102 with the sealing resin 108.
[0019]The present invention has been made in consideration of the problems mentioned above. An object of the present invention is to provide a semiconductor device and a semiconductor module in which breakage of a semiconductor element due to a pressing force given from the outside is prevented. Other object of the present invention is to provide a method for manufacturing a semiconductor device and a lead frame that facilitate a sealing resin to flow into a lower surface of an island.
[0020]A semiconductor device according to one aspect of the present invention includes an island, a semiconductor element mounted on a main surface of the island, a sealing resin that seals the island and the semiconductor element in an integrated manner; a through-hole provided so as to penetrate the sealing resin in a thickness direction thereof; and a flat part obtained by flattening a main surface of the sealing resin at a periphery of the through-hole, in which the main surface of the sealing resin in a region overlapping the semiconductor element is depressed with respect to the flat part to form a depressed part.
[0021]One aspect of the present invention is a semiconductor module a semiconductor device and heat dissipating member that is in contact with the semiconductor device, in which the semiconductor device includes an island, a semiconductor element mounted on a main surface of the island, a sealing resin that seals the island and the semiconductor element in an integrated manner; a through-hole provided so as to penetrate the sealing resin in a thickness direction thereof; and a flat part obtained by flattening a main surface of the sealing resin at a periphery of the through-hole; the main surface of the sealing resin in a region overlapping the semiconductor element is depressed with respect to the flat part to form a depressed part; the semiconductor device is brought into contact with the heat dissipating member by pressing member that penetrates the through-hole of the semiconductor device and presses a main surface of the semiconductor device; and the pressing member is in contact with the flat part of the semiconductor device except the region overlapping the semiconductor element.
[0022]A method for manufacturing a semiconductor device according to one aspect of the present invention, the method comprising the steps of: preparing a lead frame that includes an island including a first main surface and a second main surface on the opposite side from the first main surface, and a lead having one end located close to the island, and an inclined surface located at a portion of a side surface of the island, the portion continuing to the second side surface; mounting a semiconductor element on the first main surface of the island, and electrically connecting an electrode of the semiconductor element to the lead; and sealing the island including the second main surface thereof, the semiconductor element, and the lead with a sealing resin by injection molding using a mold; in which in the sealing step, a liquefied or semi-solid sealing resin is injected into a cavity of the mold through a gate provided on a side of the island, and the sealing resin is caused to flow along the side surface of the island, the side surface being the inclined surface.
[0023]A lead frame according to one aspect of the present invention includes: an island including a first main surface on which a semiconductor element is mounted, and a second main surface on the opposite side from the first main surface; and a lead having one end located close to the island; in which a portion of a side surface of the island continuing to the second main surface is an inclined surface.
[0024]According to a semiconductor device and semiconductor module according to one aspect of the present invention, a main surface of a sealing resin has a part thereof pressed by pressing member depressed to form a depressed part. Moreover, this depressed part is formed in an area where the sealing resin superimposes a semiconductor element sealed with the sealing resin. This prevents pressing member such as a screw from pressing the main surface of the sealing resin that superimposes an area where the semiconductor element is disposed. As a result, a pressing force caused by the pressing member acting on the semiconductor element is suppressed, and breakage of the semiconductor element due to the pressing force is prevented.
[0025]According to one aspect of the present invention, by providing the sealing resin on the side surface of the island having an inclined surface from the gate provided in the mold, the sealing resin can be caused to flow along the inclined surface of the island to cover a lower surface of the island thinly. Accordingly, generation of a void in which the lower surface of the island is not partially covered by the sealing resin is prevented.
[0026]FIGS. 1A and 1B are drawings each showing a semiconductor device according to a preferred embodiment of the present invention, FIG. 1A is a plan view thereof, and FIG. 1B is a sectional view thereof;
[0027]FIGS. 2A and 2B are drawings each showing a semiconductor module according to a preferred embodiment of the present invention, FIG. 2A is a plan view thereof, and FIG. 2B is a sectional view thereof;
[0028]FIG. 3 is a plan view showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention;
[0029]FIG. 4 is a plan view showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention;
[0030]FIGS. 5A and 5B are plan views each showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, FIG. 5A is a sectional view thereof, and FIG. 5B is a plan view thereof;
[0031]FIG. 6 is a plan view showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention;
[0032]FIG. 7 is a diagram showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, and is a plan view showing a lead frame according to another embodiment;
[0033]FIGS. 8A and 8B are drawings each showing a lead frame used for a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, FIG. 8A is a plan view thereof, and FIG. 8B is an enlarged plan view thereof;
[0034]FIGS. 9A to 9C are drawings each showing a lead frame used for a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, FIG. 9A is a plan view, FIG. 9B is a side view thereof, and FIG. 9C is a sectional view thereof;
[0035]FIG. 10 is a plan view showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention;
[0036]FIGS. 11A and 11B are diagrams each showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, FIG. 11A is a plan view thereof, and FIG. 11B is a sectional view thereof;
[0037]FIGS. 12A and 12B are diagrams each showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, FIG. 12A is a sectional view thereof, and FIG. 12B is an enlarged sectional view thereof;
[0038]FIG. 13 is a plan view showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention;
[0039]FIG. 14 is a plan view showing a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention;
[0040]FIGS. 15A and 15B are drawings each showing a semiconductor device manufactured by a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, FIG. 15A is a plan view thereof, and FIG. 15B is a sectional view thereof;
[0041]FIGS. 16A and 16B are drawings each showing a semiconductor module including a semiconductor device manufactured by a method for manufacturing a semiconductor device according to a preferred embodiment of the present invention, FIG. 16A is a plan view thereof, and FIG. 16B is a sectional view thereof; and
[0042]FIGS. 17A and 17B are drawings each showing a semiconductor device in the prior art,
[0043]FIG. 17A is a plan view thereof, and FIG. 17B is a sectional view thereof.
[0048]The leads 14 are electrically connected with a built-in semiconductor element 20. Each lead 14 is partially exposed to the outside, and functions as an external connection terminal. Moreover, at least one of the multiple leads 14 is bent. In other words, an intermediate part of the lead 14B in a center is bent, and leads 14A and 14C located on both sides of the lead 14B are flat without being bent. Here, portions of the leads 14A, 14B, and 14C projecting to the outside are located on the same plane. When the semiconductor device 10 is to be mounted on a mounting board or the like, end portions of the leads 14 are inserted into a hole provided in the mounting board so that the semiconductor device 10 is fitted and mounted. The semiconductor element 20 is a semiconductor element including a main electrode on a lower surface thereof, and specifically, a metal-oxide semiconductor field effect transistor (MOSFET), a bipolar transistor, or an insulated gate bipolar translator (IGBT) is employed. Further, a semiconductor element that configures a power circuit is employed as the semiconductor element 20 in the present embodiment, for example, a power semiconductor element (power element) that performs switching for large current not less than 1 A is employed. As an example, when a MOSFET is employed as the semiconductor element 20, a drain electrode on a lower surface of the MOSFET is connected to the front surface of the island 12 through a conductive fixing material, a gate electrode on a front surface of the MOSFET is connected to the lead 14A through thin metal wires 34, and a source electrode on the front surface of the MOSFET is connected to the lead 14C through the thin metal wire 34. Then, on the basis of a control signal supplied from the lead 14A, the semiconductor element 20 performs switching operation for large current that flows in the lead 14B and the lead 14C. Here, a thickness of the semiconductor element 20 is, for example, approximately 20 μm to 400 μm.
[0049]Further, in order to implement low on resistance and high breakdown voltage, a larger plane size of the semiconductor element 20 is suitable. With reference to FIG. 1A, the semiconductor element 20 has a plane size of, for example, a height and a width of approximately 6 mm and 8 mm, and is a little smaller than the island 12 on which the semiconductor element 20 is placed.
[0050]The sealing resin 16 covers a part of each lead 14, the island 12, the semiconductor element 20, and the thin metal wire 34 in an integrated manner, and has a function to mechanically support these components as a whole. As a material of the sealing resin 16, thermosetting resins such as epoxy resins and thermoplastic resins such as acrylic resins may be employed. In order to have improved heat dissipation properties, the sealing resin 16 is made of a resin material to which a filler such as granular silica and alumina is added. Furthermore, a through-hole 22 is provided so as to penetrate the sealing resin 16 in a thickness direction thereof. This through-hole 22 is used as a hole for screwing a screw when the semiconductor device 10 is attached to a heat sink or the like. Additionally, in order to bring the lower surface of the sealing resin 16 into contact with a heat dissipating device such as the heat sink, the lower surface of the sealing resin 16 is entirely flat.
[0051]With reference to FIG. 1B, the through-hole 22 is provided so as to partially penetrate the sealing resin 16, and a periphery of a front surface of this through-hole 22 is a flat part 24. Then, a portion of the front surface of the sealing resin 16 continuing to the flat part 24 is depressed to form a depressed part 18.
[0052]The flat part 24 is a portion obtained by forming the front surface of the sealing resin 16 at a periphery of the through-hole 22 to be flat, and is a part with which pressing member such as a screw, a washer, etc. comes in contact. Since the semiconductor element 20 does not lay under this flat part 24, even when a pressing force caused by the pressing member acts on the flat part 24 from above, the pressing force does not act on the semiconductor element 20 so much.
[0053]A depth of the depressed part 18 depressed from the flat part 24 is, for example, approximately 0.2 mm. Referring to of FIG. 1A, this depressed part 18 is formed continuously from a left side of the semiconductor device 10 to a right side thereof. In addition, the depressed part 18 is provided so as to overlap an area on which the semiconductor element 20 is placed. The front surface of the sealing resin 16 that overlaps the semiconductor element 20 is partially depressed in this way to form the depressed part 18, and thus, stress given to the semiconductor element 20 by the pressing member such as a screw can be reduced. Details of this matter will be explained in full detail with reference to FIGS. 2A and 2B.
[0054]Further, the portions in which the flat part 24 and the depressed part 18 are provided are thinner than other portions. Thereby, this pressing member can be prevented from projecting upward even when the pressing member such as a screw presses the flat part 24, and a thickness of the whole device can be reduced. On the other hand, since the thin metal wire 34 formed in a loop shape needs to be covered with the sealing resin 16, a portion in which the thin metal wire 34 is formed is formed thicker than the portion in which the flat part 24 is formed.
[0055]With reference to FIGS. 2A and 2B, next, description will be given on a configuration of a semiconductor module 10A into which the semiconductor device 10 having the above-mentioned configuration is incorporated. FIG. 2A is a plan view showing the semiconductor module 10A, and FIG. 2B is a sectional view taken along the line B-B' in FIG. 2A.
[0056]With reference to FIGS. 2A and 2B, the semiconductor module 10A has a configuration including the semiconductor device 10, a heat sink 26, a screw 28 (pressing member) that thermally couples the semiconductor device 10 to the heat sink 26 by pressing a circuit device.
[0057]With reference to FIG. 2B, the heat sink 26 is in planar contact with the lower surface of the semiconductor device 10, which is a flat surface of the sealing resin 16. The heat sink 26 is made of a metal such as copper or aluminum. The front surface of the heat sink 26 is flat in order to come into planar contact with the semiconductor device 10, and the lower surface of the heat sink 26 has an odd shape in order to have improved heat dissipation properties. Instead of the heat sink 26, it is also possible to employ a set of housing made of a metal as heat dissipating member.
[0058]A pore 32 is formed from the front surface of the heat sink 26, and a screw 28 penetrates this pore 32 and the through-hole 22 of the semiconductor device 10. The screw 28 includes a pillar-shaped pillar part 28B having a screw thread formed in a circumference of the pillar part 28B, and a head part 28A continuing to the pillar part 28B. Further, a circularly formed washer 30 made of a metal such as aluminum is interposed between the head part 28A of the screw 28 and the semiconductor device 10. In other words, while having the pillar part 28B threading the washer 30, the screw 28 penetrates the through-hole 22, and is screwed to the pore 32. Then, a front surface of the washer 30 comes into contact with the head 28A of the screw 28, and a lower surface of the washer 30 comes into contact with the flat part 24 of the semiconductor device 10. Accordingly, when the screw 28 is fixed to the heat sink 26, a pressing force given to the flat part 24 by the washer 30 brings the lower surface of the semiconductor device 10 into contact with the front surface of the heat sink 26.
[0059]With reference to FIG. 2A, an area in which the washer 30 is placed overlaps the semiconductor element 20. With such a disposition that the washer 30 overlaps the semiconductor element 20, the plane size of the semiconductor device 10 can be reduced. However, if the front surface of the sealing resin 16 is a simple flat surface and a pressing force is applied to the flat surface by the washer 30, the stress given to the semiconductor element 20 by this pressing force increases, and as a result, failures such cracks of the semiconductor element 20 may occur. In order to eliminate this, in the present embodiment, the front surface of the sealing resin 16 corresponding to an area in which the semiconductor element 20 is mounted and the washer 30 is disposed is partially depressed to form the depressed part 18.
[0060]This configuration prevents the pressing force by the washer 30 from acting on the depressed part 18, and thus the stress acting on the semiconductor element 20 located under the depressed part 18 is also reduced.
[0101]The semiconductor element 20 is a semiconductor element including a main electrode on a lower surface thereof, and specifically, a metal-oxide semiconductor field effect transistor (MOSFET), a bipolar transistor, or an insulated gate bipolar translator (IGBT) is employed. Further, a semiconductor element that configures a power circuit is employed as the semiconductor element 20 in the present embodiment, for example, a power semiconductor element (power element) that performs switching for large current not less than 1 A is employed.
[0102]As an example, when a MOSFET is employed as the semiconductor element 20, a drain electrode on a lower surface of the MOSFET is connected to the front surface of the island 12 through a conductive fixing material, a gate electrode on a front surface of the MOSFET is connected to the lead 14A through thin metal wires 34, and a source electrode on the front surface of the MOSFET is connected to the lead 14C through the thin metal wires 34. Then, on the basis of a control signal supplied from the lead 14A, the semiconductor element 20 performs switching operation for large current that flows in the lead 14B and the lead 14C. Here, a thickness of the semiconductor element 20 is, for example, approximately 20 μm to 400 μm.
[0103]The sealing resin 16 covers a part of each lead 14, the island 12, the semiconductor element 20, and the thin metal wires 34 in an integrated manner, and has a function to mechanically support these components as a whole. As a material of the sealing resin 16, thermosetting resins such as epoxy resins and thermoplastic resins such as acrylic resins may be employed. In order to have improved heat dissipation properties, the sealing resin 16 is made of a resin material to which a filler such as granular silica and alumina is added. Furthermore, a through-hole 22 is provided so as to penetrate the sealing resin 16 in a thickness direction thereof. This through-hole 22 is used as a hole for screwing a screw when the semiconductor device 10 is attached to a heat sink or the like. Additionally, in order to bring the lower surface of the sealing resin 16 into contact with a heat dissipating device such as the heat sink, the lower surface of the sealing resin 16 is entirely flat.
[0104]With reference to FIG. 15B, the through-hole 22 is provided so as to partially penetrate the sealing resin 16, and a periphery of a front surface of this through-hole 22 is a flat part 24. Then, a portion of the front surface of the sealing resin 16 continuing to the flat part 24 is depressed to form a depressed part 18.
[0105]With reference to FIGS. 16A and 16B, next, description will be given on a configuration of a semiconductor module 10A into which the semiconductor device 10 having the above-mentioned configuration is incorporated. FIG. 16A is a plan view showing the semiconductor module 10A, and FIG. 16B is a sectional view taken along the line B-B' in FIG. 16A.
[0106]With reference to FIGS. 16A and 16B, the semiconductor module 10A has a configuration including the semiconductor device 10, a heat sink 26, a screw 28 (pressing ωmember) that thermally couples the semiconductor device 10 to the heat sink 26 by pressing a circuit device.
[0107]With reference to FIG. 16B, the heat sink 26 is in planar contact with the lower surface of the semiconductor device 10, which is a flat surface of the sealing resin 16. The heat sink 26 is made of a metal such as copper or aluminum. The front surface of the heat sink 26 is flat in order to come into planar contact with the semiconductor device 10, and the lower surface of the heat sink 26 has an odd shape in order to have improved heat dissipation properties. Instead of the heat sink 26, it is also possible to employ a set of housing made of a metal as the heat dissipating member.
[0108]A pore 32 is formed from the front surface of the heat sink 26, and a screw 28 penetrates this pore 32 and the through-hole 22 of the semiconductor device 10. The screw 28 includes a pillar-shaped pillar part 28B having a screw thread formed in a circumference of the pillar part 28B, and a head part 28A continuing to the pillar part 28B. Further, a circularly formed washer 30 made of a metal such as aluminum is interposed between the head part 28A of the screw 28 and the semiconductor device 10. In other words, while having the pillar part 28B threading the washer 30, the screw 28 penetrates the through-hole 22, and is screwed to the pore 32. Then, a front surface of the washer 30 comes into contact with the head 28A of the screw 28, and a lower surface of the washer 30 comes into contact with the flat part 24 of the semiconductor device 10. Accordingly, when the screw 28 is fixed to the heat sink 26, a pressing force given to the flat part 24 by the washer 30 brings the lower surface of the semiconductor device 10 into contact with the front surface of the heat sink 26.
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