Patent Description:
Conventionally, a semiconductor element is placed on a conductor layer of a substrate, and a front surface of the semiconductor element and a terminal are connected to each other with a wire or a connector via a conductive adhesive such as solder (refer to <CIT>). There is no small need for applying large-capacity current into the semiconductor device, and it is conceivable to use a plurality of wires in order to increase flowing current; however, a manufacturing step becomes complicated. For this reason, it is conceivable to adopt a connector having a large width, but since the connector having a large width has a heavy weight, the conductive adhesive such as solder provided on the front surface of the semiconductor element problematically becomes thin by its own weight. <CIT>, <CIT>, <CIT>, <CIT>, and <CIT> relate to semiconductor devices.

In view of the above, the present invention provides a highly-reliable electronic device in which the thickness of the conductive adhesive is secured while using an appropriate amount of conductive adhesive.

In this invention, the first terminal and the second terminal extending in the direction different from that of the first terminal are coupled to the head part, so that the first terminal and the second terminal can be utilized as jig receivers. Therefore, it is possible to prevent the thickness of the conductive adhesive such as solder provided on the front surface of the electronic element from becoming thin due to a weight of the connecting unit by adjusting the heights of the back surface of the first terminal and the back surface of the second terminal by using jig and the like and sealing the same with the sealing resin and the like.

As illustrated in <FIG>, a semiconductor device being an example of an electronic device of this embodiment may have a sealing part <NUM> (refer to <FIG>) made of a sealing resin and the like, a first main terminal <NUM> being a first terminal projecting outward from a first side surface of the sealing part <NUM>, a sensing terminal <NUM> being a second terminal projecting outward from a second side surface different from the first side surface of the sealing part <NUM>, a semiconductor element <NUM> provided inside the sealing part <NUM>, and a head part <NUM> coupled to the first main terminal <NUM> and the sensing terminal <NUM> and connected to a front surface of the semiconductor element <NUM> via a conductive adhesive <NUM>. In this embodiment, the first main terminal <NUM> through which main current flows is described as the first terminal, and the sensing terminal <NUM> on a front surface side used for sensing on a source side (hereinafter referred to as "front surface side sensing terminal <NUM>") is described as the second terminal, but there is no limitation. It is also possible to adopt an aspect in which the main current does not flow through the first terminal or to use an aspect in which the second terminal is not used for the sensing. Also, in this embodiment, "coupled" also includes an "integrated" aspect.

Although the semiconductor device is used as the electronic device, and the semiconductor element <NUM> is described as an electronic element in this embodiment, there is no limitation, and a "semiconductor" is not especially required.

The semiconductor device of this embodiment also has a second main terminal <NUM> projecting outward from the sealing part <NUM> through which the main current flows. The semiconductor element <NUM> illustrated in <FIG> is such that the front surface is electrically connected to the first main terminal <NUM> and a back surface is electrically connected to the second main terminal <NUM>. In this embodiment, the head part <NUM> and the first main terminal <NUM> may be integrally formed, or the head part <NUM> and the front surface side sensing terminal <NUM> may be integrally formed with a connecting unit <NUM>. Also, the first main terminal <NUM>, the head part <NUM>, the connecting unit <NUM>, and the front surface side sensing terminal <NUM> may be integrally formed in this order.

Also, it is not limited to such an aspect; for example, the connecting unit <NUM> and the head part <NUM> are integrally formed, but the connecting unit <NUM> and the front surface side sensing terminal <NUM> may be separately formed. As an example, as illustrated in <FIG>, a back surface of the connecting unit <NUM> may be coupled to a front surface of the front surface side sensing terminal <NUM> via a conductive adhesive and the like. Also, the first main terminal <NUM> and the head part <NUM> are originally separated from each other and may be coupled to each other by using the conductive adhesive <NUM> and the like.

As illustrated in <FIG>, the semiconductor device may have, for example, a substrate <NUM> made of an insulating material and a conductor layer <NUM> made of copper and the like provided on the substrate <NUM>. In an aspect illustrated in <FIG>, the second main terminal <NUM> is connected to the conductor layer <NUM>, and the second main terminal <NUM> is connected to the back surface of the semiconductor element <NUM> via the conductor layer <NUM>. A resist (not illustrated) may also be provided on a peripheral edge of a connecting portion of the second main terminal <NUM> to the conductor layer <NUM> in order to prevent the conductive adhesive such as solder from flowing. The back surface of the semiconductor element <NUM> and the conductor layer <NUM> may also be connected via the conductive adhesive such as solder. The head part <NUM> and the front surface of the semiconductor element <NUM> may also be connected to each other via the conductive adhesive <NUM> such as solder (refer to <FIG>). Also, a heat radiation plate <NUM> made of copper and the like may be provided on a back surface of the substrate <NUM>.

The semiconductor element <NUM> may have a withstand voltage structure such as a guard ring. In a case where the semiconductor element <NUM> has such withstand voltage structure, avoiding parts <NUM> and <NUM> formed integrally with the head part <NUM> for avoiding contact with the withstand voltage structure may be provided as illustrated in <FIG>. Such avoiding parts <NUM> and <NUM> are provided corresponding to the withstand voltage structure of the semiconductor element <NUM> and designed in advance on the basis of an arrangement position of the withstand voltage structure such as the guard ring, a thickness in a planar direction thereof and the like.

The avoiding parts <NUM> and <NUM> may have a first avoiding part <NUM> provided between the first main terminal <NUM> and the head part <NUM> and a second avoiding part <NUM> provided between the front surface side sensing terminal <NUM> and the head part <NUM>. The first avoiding part <NUM> may be a first concave part 31a concaved so as to be separated from the semiconductor element <NUM> and the second avoiding part <NUM> may be a second concave part 32a concaved so as to be separated from the semiconductor element <NUM>.

The first main terminal <NUM> and the second main terminal <NUM> may be power terminals through which large-capacity current flows.

The conductor layer <NUM> may not be provided below the first main terminal <NUM>, the first avoiding part <NUM> may be exposed outside from the side surface of the sealing part <NUM> in the middle of the first avoiding part <NUM>, and the first main terminal <NUM> may be exposed outside from the side surface of the sealing part <NUM> just after the first avoiding part <NUM>.

In a case where the first main terminal <NUM> and the head part <NUM> are integrally formed and the front surface side sensing terminal <NUM>, the connecting unit <NUM>, and the head part <NUM> are integrally formed, a back surface side height of the first main terminal <NUM> may correspond to a back surface side height of the front surface side sensing terminal <NUM> as illustrated in <FIG>. Herein, when the heights correspond to each other, this means that they coincide with each other with difference within a range of <NUM>% of a thickness of a thicker terminal out of the first main terminal <NUM> and the front surface side sensing terminal <NUM>. In a case where a thickness T<NUM> of the first main terminal <NUM> and that of the front surface side sensing terminal <NUM> are the same, difference between the back surface side height of the first main terminal <NUM> and the back surface side height of the second main terminal <NUM> is not larger than <NUM>% of the thickness T<NUM>, which means that this is not larger than <NUM> T<NUM>. In a case where the thicknesses of the first main terminal <NUM> and the front surface side sensing terminal <NUM> are different from each other, the difference therebetween is not larger than <NUM>% of a thickness T<NUM> of the thicker one, which means that this is not larger than <NUM> T<NUM>. The back surface side height of the first main terminal <NUM> and the back surface side height of the front surface side sensing terminal <NUM> may coincide with each other. In a case of coincidence, this means that the difference between the back surface side height of the first main terminal <NUM> and the back surface side height of the front surface side sensing terminal <NUM> is within a manufacturing error range.

Also, in a case where the first main terminal <NUM> and the head part <NUM> are integrally formed and the connecting unit <NUM> and the head part <NUM> are integrally formed as illustrated in <FIG>, the back surface side height of the first main terminal <NUM> and the back surface side height of the front surface side sensing terminal <NUM> coupled to the connecting unit <NUM> may correspond to each other. Herein, when the heights correspond to each other, this means that they coincide with each other with difference within a range of <NUM>% of the thickness of the thicker terminal out of the first main terminal <NUM> and the front surface side sensing terminal <NUM> as in the above-described aspect. The back surface side height of the first main terminal <NUM> and the back surface side height of the front surface side sensing terminal <NUM> may coincide with each other. In a case of coincidence, this means that the difference between the back surface side height of the first main terminal <NUM> and the back surface side height of the front surface side sensing terminal <NUM> is within a manufacturing error range.

The front surface side sensing terminal <NUM> and the connecting unit <NUM>, and the first main terminal <NUM> may be provided so as to extend in opposite directions from the head part <NUM>. It is sufficient that the front surface side sensing terminal <NUM> and the connecting unit <NUM>, and the first main terminal <NUM> extend in the different directions as seen from the head part <NUM>, and there is no limitation. For example, the front surface side sensing terminal <NUM> and the connecting unit <NUM>, and the first main terminal <NUM> may extend so as to form an angle (obtuse angle) of <NUM> degrees or larger.

As illustrated in <FIG>, <FIG>, and <FIG>, the head part <NUM> may have a second convex part <NUM> projecting toward the semiconductor element <NUM> and a first convex part <NUM> projecting from the second convex part <NUM> toward the semiconductor element <NUM>. As illustrated in <FIG>, the second convex part <NUM> may not be provided and only the first convex part <NUM> may be provided.

In the aspect illustrated in <FIG>, as an example, widths of the first avoiding part <NUM>, the head part <NUM>, and the second avoiding part <NUM> are larger than widths of the front surface side sensing terminal <NUM> and the connecting unit <NUM>, and widths of the first main terminal <NUM> and the second main terminal <NUM> are larger than the widths of the first avoiding part <NUM>, the head part <NUM>, and the second avoiding part <NUM>.

Regarding a sensing current path, it is not necessary to apply large-capacity current, so that the widths of the second avoiding part <NUM>, the connecting unit <NUM>, and the front surface side sensing terminal <NUM> may be narrow. As an example, the width of each of the second avoiding part <NUM>, the connecting unit <NUM>, and the front surface side sensing terminal <NUM> is narrowed; this may be one-third or less, or one-fifth or less of the width of the head part <NUM>. Meanwhile, in the aspect illustrated in <FIG>, the width of the second avoiding part <NUM> on a side of the head part <NUM> is large, but such aspect is not needed. However, it is possible to surely secure the width of the planar-shaped head part <NUM> of the second avoiding part <NUM> by making the width of the second avoiding part <NUM> on the head part <NUM> side large and allowing the width of the head part <NUM> side to correspond to the width of the head part <NUM> as illustrated in <FIG>. That is, when forming the head part <NUM>, the second avoiding part <NUM> and the like, it is conceivable to punch out a conductive member such as a copper plate, but from a viewpoint of surely securing the width of the head part <NUM>, it is preferable that the width of the second avoiding part <NUM> adjacent to the head part <NUM> is made approximately the same as the width of the head part <NUM>. On the other hand, in a case of sacrificing the width of the head part <NUM> to some extent, it is conceivable to make the width of an entire second avoiding part <NUM> narrow.

In an aspect illustrated in <FIG>, the second main terminal <NUM>, the front surface side sensing terminal <NUM>, a back surface side sensing terminal <NUM>, and a control terminal <NUM> project from outside from the side surface on one side of the sealing part <NUM>, and the first main terminal <NUM> projects outward from the side surface on the other side of the sealing part <NUM>. The first main terminal <NUM>, the second main terminal <NUM>, the front surface side sensing terminal <NUM>, the back surface side sensing terminal <NUM>, and the control terminal <NUM> are bent toward the front surface side to be connected to the control substrate <NUM> provided on the front surface side. The control substrate <NUM> is used for controlling the semiconductor element <NUM>.

An inner structure of the sealing part <NUM> of the semiconductor device may be line-symmetric. As an example, each of the first main terminal <NUM>, the second main terminal <NUM>, the front surface side sensing terminal <NUM>, the back surface side sensing terminal <NUM>, the control terminal <NUM>, and the conductor layer <NUM> may be arranged so as to be symmetric with respect to an arbitrary straight line. Meanwhile, a wire <NUM> is also illustrated in <FIG>.

Operations and effects according to this embodiment having the above-described configuration are next described.

In this embodiment, as illustrated in <FIG> and the like, the first main terminal <NUM> being the first terminal and the front surface side sensing terminal <NUM> being the second terminal extending in the direction different from that of the first terminal are coupled to the head part <NUM>, so that the first main terminal <NUM> and the front surface side sensing terminal <NUM> can be utilized as jig receivers. Therefore, it is possible to prevent the thickness of the conductive adhesive <NUM> such as solder provided on the front surface of the semiconductor element <NUM> from becoming thin due to a weight of the connecting unit <NUM> by adjusting the heights of the back surface of the first main terminal <NUM> and the back surface of the front surface side sensing terminal <NUM> by using jigs <NUM> and the like and sealing the same with the sealing resin and the like as illustrated in <FIG>.

In a case where the aspect in which the front surface side sensing terminal <NUM>, the connecting unit <NUM>, and the head part <NUM> are integrally formed is adopted as illustrated in <FIG> and the like, it is possible to prevent height positions thereof from changing due to the coupling aspect of the front surface side sensing terminal <NUM> and the connecting unit <NUM> and to more accurately adjust the height by the jig <NUM> and the like. Therefore, an appropriate amount of the conductive adhesive <NUM> can be positioned between the front surface of the semiconductor element <NUM> and the head part <NUM>, so that it is possible to more surely prevent cracking and the like due to a thinned thickness of the conductive adhesive <NUM>. In a case of adopting an aspect in which the first main terminal <NUM> and the head part <NUM> are integrally formed also, it is possible to prevent the height positions thereof from changing due to the coupling aspect of the first main terminal <NUM> and the head part <NUM> and the height adjustment by the jig <NUM> and the like can be performed more accurately.

Also in a case where the head part <NUM> and the connecting unit <NUM> are integrally formed, and the connecting unit <NUM> and the front surface side sensing terminal <NUM> are separately formed as illustrated in <FIG>, it is possible to prevent the height positions thereof from changing due to the coupling aspect of the head part <NUM> and the connecting unit <NUM> and to more accurately adjust the height by the jig <NUM> and the like.

As illustrated in <FIG>, the connection body <NUM> is in contact with the semiconductor element <NUM> only with the head part <NUM>, and is provided apart from the substrate <NUM> in other portions, so that it is conceivable that the conductor layer <NUM> is not provided on the back surface side of the first main terminal <NUM>. When such an aspect is adopted, a manufacturing cost can be reduced. Also, in a case where the first main terminal <NUM> and the head part <NUM> are integrally formed, it is possible to expose the terminal outward from the side surface of the sealing part <NUM> without intervention of the conductor layer <NUM>, so that it is expected that a size in an in-plane direction is reduced because of absence of the conductor layer <NUM>. It is also conceivable to adopt an aspect in which the substrate <NUM> itself is not provided on the back surface side of the first main terminal <NUM>. When such aspect is adopted, it is possible to expect further reduction in manufacturing cost, and it is also possible to expect reduction in size in a planar direction of the semiconductor device.

In a case where the aspect in which the front surface side sensing terminal <NUM> and the connecting unit <NUM>, and the first main terminal <NUM> are provided so as to extend in the opposite directions from the head part <NUM> as illustrated in <FIG> and the like is adopted, it is possible to perform positioning by the jigs <NUM> in a stable state. Therefore, it is possible to improve operation efficiency and to reduce the possibility that the head part <NUM> is erroneously inclined with respect to the front surface of the semiconductor element <NUM>.

When an aspect in which the back surface side height of the first main terminal <NUM> corresponds to the back surface side height of the front surface side sensing terminal <NUM> is adopted as illustrated in <FIG>, operation of finely adjusting the jig <NUM> can be reduced, and it is possible to efficiently perform the positioning. It is also possible to reduce the possibility that the head part <NUM> is erroneously inclined with respect to the front surface of the semiconductor element <NUM>. From the viewpoint of these effects, it is preferable that the difference between the back surface side height of the first main terminal <NUM> and the back surface side height of the front surface side sensing terminal <NUM> is not larger than <NUM>% of the thickness T<NUM> or T<NUM>, it is more preferable that this is not larger than <NUM>% of the thickness T<NUM>, and it is still more preferable that this is not larger than <NUM>% of the thickness T<NUM> or T<NUM>.

If the semiconductor element <NUM> has the withstand voltage structure, in a case where the avoiding parts <NUM> and <NUM> for avoiding contact with the withstand voltage structure are provided as illustrated in <FIG> and the like, it is possible to prevent electric contact of the withstand voltage structure of the semiconductor element <NUM> and the connection body <NUM>. Also, in this aspect, in a case of adopting an aspect in which the head part <NUM> is integrally formed with the first main terminal <NUM>, the connecting unit <NUM>, and the front surface side sensing terminal <NUM> (which may include the avoiding parts <NUM> and <NUM>), it is possible to prevent the height positions thereof from changing due to the coupling aspect thereof and to more accurately adjust the height by the jig <NUM> and the like.

In a case where the avoiding parts <NUM> and <NUM> have the first avoiding part <NUM> provided between the first main terminal <NUM> and the head part <NUM> and the second avoiding part <NUM> provided between the front surface side sensing terminal <NUM> and the head part <NUM>, it is useful in that electrical contact with the withstand voltage structure provided over a full circle such as the guard ring can be more surely prevented.

In a case of adopting an aspect in which the first avoiding part <NUM> is the first concave part 31a and the second avoiding part <NUM> is the second concave part 32a, it is useful in that the back surface side height of the first main terminal <NUM> and the back surface side height of the front surface side sensing terminal <NUM> can more easily correspond to each other and the operation efficiency can be improved.

In a case of adopting the aspect in which the head part <NUM> has the first convex part <NUM> projecting toward the semiconductor element <NUM> as illustrated in <FIG> and the like, in a portion where the first convex part <NUM> is not provided, the thickness of the conductive adhesive <NUM> such as solder can be more surely made equal to or larger than a predetermined thickness. Meanwhile, the first convex part <NUM> may be in contact with the front surface of the semiconductor element <NUM> or not.

In a case where an aspect in which the head part <NUM> has the first convex part <NUM> and the second convex part <NUM> projecting toward the semiconductor element <NUM>, a usage amount of the conductive adhesive <NUM> can be reduced, and further the second convex part <NUM> can also be used to secure the width of the current path.

A manufacturing method for the semiconductor device having the above-described configuration is next described. Although detailed description is omitted because this will be repetitive description, in the manufacturing method for the semiconductor device, any aspect described in <Configuration> and <Action/Effect> described above can be adopted.

The connection body <NUM> having the sealing part <NUM>, the first main terminal <NUM> being the first terminal for projecting outward from the first side surface of the sealing part <NUM>, the front surface side sensing terminal <NUM> being the second terminal for projecting outward from the second side surface different from the first side surface of the sealing part <NUM>, and the head part <NUM> coupled to the first main terminal <NUM> and the front surface side sensing terminal <NUM> and for being connected to the front surface of the semiconductor element <NUM> via the conductive adhesive <NUM> is prepared (preparing step).

Next, the conductive adhesive <NUM> is placed on the semiconductor element <NUM> placed on the conductor layer <NUM> on the substrate <NUM> (conductive adhesive placing step).

Next, the first main terminal <NUM> and the front surface side sensing terminal <NUM> are placed on the jigs <NUM> so that the head part <NUM> is connected to the front surface of the semiconductor element <NUM> via the conductive adhesive <NUM> (positioning step, refer to <FIG>). Thereafter, the conductive adhesive <NUM> is cured, and the connection body <NUM> is positioned on the semiconductor element <NUM> (conductive adhesive curing step).

Next, the semiconductor element <NUM>, the conductor layer <NUM> and the like are covered with a metal mold, and the sealing resin is poured into the metal mold. After that, the sealing resin is cured (sealing resin curing step).

Next, various terminals such as the first main terminal <NUM>, the second main terminal <NUM>, the front surface side sensing terminal <NUM>, the back surface side sensing terminal <NUM>, and the control terminal <NUM> are cut at predetermined positions, and thereafter bent toward the front surface side (cutting/bending step, refer to <FIG>).

In this manner, the semiconductor device as illustrated in <FIG> is manufactured.

Claim 1:
An electronic device comprising:
an insulating substrate (<NUM>);
a conductor layer (<NUM>) provided on the insulating substrate (<NUM>);
an electronic element (<NUM>) provided on the conductor layer (<NUM>);
a connection body (<NUM>) connected to a front surface of the electronic element (<NUM>) via a conductive adhesive (<NUM>); and
a sealing part (<NUM>) sealing the conductor layer (<NUM>) and the electronic element (<NUM>) inside;
wherein the connection body (<NUM>) has a head part (<NUM>) connected to the front surface of the electronic element (<NUM>), a first terminal (<NUM>) extending from the head part (<NUM>) and projecting outward from the sealing part (<NUM>), and a second terminal (<NUM>) extending from the head part (<NUM>) in an opposite direction of the first terminal (<NUM>) and projecting outward from the sealing part (<NUM>).