METAL MEMBER AND PRODUCTION METHOD THEREFOR
20210404066 · 2021-12-30
Assignee
Inventors
Cpc classification
C25D5/605
CHEMISTRY; METALLURGY
C23C18/1651
CHEMISTRY; METALLURGY
C25D7/00
CHEMISTRY; METALLURGY
H01L23/36
ELECTRICITY
H01L23/06
ELECTRICITY
C25D5/34
CHEMISTRY; METALLURGY
C23C18/32
CHEMISTRY; METALLURGY
H01L23/14
ELECTRICITY
C25D5/14
CHEMISTRY; METALLURGY
International classification
C23C18/16
CHEMISTRY; METALLURGY
C23C18/32
CHEMISTRY; METALLURGY
H01L21/48
ELECTRICITY
H01L23/14
ELECTRICITY
Abstract
A metal member includes a metal substrate, a first intermediate plating layer, a second intermediate plating layer, and a precious metal plating layer. The metal substrate includes a surface constituted of a plurality of crystal grains. The first intermediate plating layer is directly formed on the plurality of crystal grains of the metal substrate, contains a nickel element, and is non-oriented with respect to each crystal orientation of the plurality of crystal grains of the metal substrate. The second intermediate plating layer is directly formed on the first intermediate plating layer. The precious metal plating layer is formed on the second intermediate plating layer.
Claims
1. A metal member comprising: a metal substrate including a surface constituted of a plurality of crystal grains; a first intermediate plating layer being directly formed on the plurality of crystal grains of the metal substrate, containing a nickel element, and being non-oriented with respect to each crystal orientation of the plurality of crystal grains of the metal substrate; a second intermediate plating layer being directly formed on the first intermediate plating layer; and a precious metal plating layer being formed on the second intermediate plating layer.
2. The metal member according to claim 1, wherein the plurality of crystal grains of the metal substrate has a first average crystal grain diameter in an in-plane direction, and the first intermediate plating layer has a second crystal grain diameter smaller than the first average crystal grain diameter in the in-plane direction.
3. The metal member according to claim 1, wherein the surface of the metal substrate is a non-polished surface.
4. The metal member according to claim 1, wherein a Beilby layer is not formed in the surface of the metal substrate.
5. The metal member according to claim 1, wherein the second intermediate plating layer contains a nickel element.
6. The metal member according to claim 1, wherein the second intermediate plating layer has composition different from composition of the first intermediate plating layer.
7. The metal member according to claim 1, wherein the first intermediate plating layer is made of nickel, and the second intermediate plating layer is made of nickel alloy.
8. The metal member according to claim 7, wherein the nickel alloy contains a cobalt element.
9. The metal member according to claim 1, wherein the surface of the metal substrate contains a copper element.
10. The metal member according to claim 1, wherein the metal member includes a mounting surface on which an electronic component is to be mounted.
11. A manufacturing method for a metal member, comprising: preparing a metal substrate including a surface constituted of a plurality of crystal grains without polishing the surface; directly forming a first inter mediate plating layer on the plurality of crystal grains of the metal substrate using a first plating condition, the first intermediate plating layer containing a nickel element and being non-oriented with respect to each crystal orientation of the plurality of crystal grains of the metal substrate; directly forming a second intermediate plating layer containing a nickel element on the first intermediate plating layer using a second plating condition different from the first plating condition; and forming a precious metal plating layer on the second intermediate plating layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] An embodiment of the present invention will be described below with reference to the drawings.
[0020] <Configuration>
[0021]
[0022]
[0023] The heat sink plate 10 includes a surface SF (upper surface in
[0024]
[0025] The insulation frame 31 is made of ceramics. The metallization films 32 are respectively formed on the upper surface and the lower surface of the insulation frame 31. The plating films 33 are respectively formed on the metallization films 32. One metallization film 32 is joined to the heat sink plate 10 with the joining layer 40, and the other metallization film 32 is joined to the lead frame 50 with the joining layer 40. The joining layer 40 is, for example, a brazing material.
[0026] Note that a frame made of resin may be used instead of the frame 30 including the insulation frame 31, the metallization films 32, and the plating films 33. In this case, it is preferable that the joining layer 40 be an adhesive agent layer. The frame 30 made of resin and the lead frame 50 may be integrally molded, and in that case, the joining layer 40 between the frame 30 and the lead frame 50 is omitted.
[0027]
[0028]
[0029] The heat sink plate 10 includes the surface SF that is constituted of a plurality of crystal grains including crystal grains C1 to C5 illustrated in the figure. Note that, in the following description, a large number of crystal grains constituting the surface SF may be referred to as the crystal grains C1 to C5 as an example. The surface SF of the heat sink plate 10 may be a non-polished surface. In other words, the surface SF may be a surface of the heat sink plate 10 immediately after being formed (i.e. an as-grown surface), such as a cast surface or a sintered surface. With the surface SF of the heat sink plate 10 not being polished, a Beilby layer is not formed on the surface SF. The crystal grains C1 to C5 have a first average crystal grain diameter in the in-plane direction (in the figure, the horizontal direction).
[0030] The first intermediate plating layer 21 is directly formed on the crystal grains C1 to C5 of the heat sink plate 10. The first intermediate plating layer 21 is substantially non-oriented with respect to the crystal grains C1 to C5 of the heat sink plate 10. Specifically, the first intermediate plating layer 21 is substantially non-oriented with respect to each crystal orientation of the crystal grains C1 to C5 of the heat sink plate 10. The crystal grains of the first intermediate plating layer 21 have a second crystal grain diameter smaller than the first average crystal grain diameter in the in-plane direction. In other words, the average crystal grain diameter of the first intermediate plating layer 21 is smaller than the average crystal grain diameter of the heat sink plate 10 at positions to face the surface SF.
[0031] Note that the average crystal grain diameter may be calculated with the method of sections. Specifically, the average crystal grain diameter may be calculated as follows: a line segment of a known length completely crossing 10 to 50 crystal grains is drawn on an image or a photograph of a microscope, and the known length is divided by the number of these crystal grains.
[0032] It is preferable that surface roughness of the surface (in the figure, the upper surface) of the first intermediate plating layer 21 be coarse to a certain degree. The surface roughness has, for example, a maximum height Ry of 0.3 μm or more. With this configuration, the crystal grain diameter of the second intermediate plating layer 22 can be easily reduced. Further, as a result of selecting a plating condition that the first intermediate plating layer 21 becomes non-oriented, the surface roughness of the first intermediate plating layer 21 may be liable to be increased. Provided that the precious metal plating layer 23 is formed directly on the coarse surface as described above, to obtain a uniform precious metal plating layer 23, a large thickness is required. Precious metal, in particular Au, is expensive, which thus leads to increase of material costs. Thus, in the present embodiment, the precious metal plating layer 23 is formed on the first intermediate plating layer 21, with the second intermediate plating layer 22 being interposed therebetween. It is preferable that the surface roughness of the second intermediate plating layer 22 be smaller than the surface roughness of the first intermediate plating layer 21. Note that, the maximum height Ry refers to a height obtained by extracting only a reference length from a roughness curve in a direction of an average line, and measuring an interval between a top line and a bottom line in the extracted part in a direction of longitudinal magnification of the roughness curve. The reference length may approximately be the view (for example) illustrated in
[0033] As described above, the first intermediate plating layer 21 is substantially non-oriented with respect to the crystal grains C1 to C5 of the heat sink plate 10. Specifically, the first intermediate plating layer 21 is substantially non-oriented with respect to each crystal orientation of the crystal grains C1 to C5 of the heat sink plate 10. This means that information of the crystal orientations of the surface of the heat sink plate 10 is substantially lost in the surface (in the figure, the upper surface) of the first intermediate plating layer 21. As a result, the second intermediate plating layer 22 grows without substantially receiving the difference of the crystal orientations among the plurality of crystal grains of the heat sink plate 10.
[0034] The thickness of the first intermediate plating layer 21 is preferably 0.3 μm or more, more preferably 1.0 μm or more, and 2 μm or less is usually sufficient. The interface between the first intermediate plating layer 21 and the second intermediate plating layer 22 can be identified in many cases through crystal orientation observation and composition observation.
[0035] <Manufacturing Method>
[0036]
[0037]
[0038] Next, the second intermediate plating layer 22 containing a Ni element is directly formed on the first intermediate plating layer 21, using a second plating condition different from the first plating condition. The second plating condition can be selected without the restriction being imposed on the first plating condition. In order to implement a plating process of the precious metal plating layer 23 to be described later uniformly with a smaller thickness, it is preferable that the second plating condition be a condition that the surface roughness becomes smaller than the first plating condition. Next, the precious metal plating layer 23 is formed on the second intermediate plating layer 22. With this, the package 100 is obtained.
COMPARATIVE EXAMPLES
[0039]
[0040]
[0041] The package 100B is manufactured by forming a Beilby layer 19 instead of the first intermediate plating layer 21 (
[0042] <Effects>
[0043]
[0044] Projections or foreign substances on the mounting surface RM may give negative influence to connection reliability of the electronic component 501 (
[0045] The crystal grains C1 to C5 (
[0046] The surface SF of the heat sink plate 10 may be a non-polished surface. This eliminates the need of a surface polishing process of the heat sink plate 10. The polishing process is a process that requires much labor, and thus by omitting the polishing process, the manufacturing method of the heat sink plate 10 can be simplified. Note that, when the surface SF of the heat sink plate 10 is a non-polished surface, the Beilby layer 19 (
[0047] It is preferable that the second intermediate plating layer 22 contain a Ni element. With this configuration, the second intermediate plating layer 22 can be formed inexpensively as compared to the precious metal plating layer.
[0048] The first intermediate plating layer 21 is required to be non-oriented with respect to the crystal grains C1 to C5 of the heat sink plate 10, and thus it is preferable that composition appropriate therefor be selected. Specifically, the first intermediate plating layer 21 is required to be non-oriented with respect to each crystal orientation of the crystal grains C1 to C5 of the heat sink plate 10, and thus it is preferable that composition appropriate therefor be selected. In contrast, the second intermediate plating layer 22 is not subjected to such a restriction, and thus composition different from the composition of the first intermediate plating layer 21 can be more freely selected. For example, the first intermediate plating layer 21 is made of Ni, and the second intermediate plating layer 22 is made of Ni alloy. The Ni alloy may contain a Co element.
[0049] It is preferable that the surface SF of the heat sink plate 10 contain a Cu element. With this, thermal conductivity of the surface SF of the heat sink plate 10 can be enhanced.
[0050] <Experiment>
[0051] The following shows manufacturing conditions of packages Nos. 1 to 5, and results of an automatic visual inspection carried out on the mounting surface RM of the packages.
TABLE-US-00001 TABLE 1 STACKED PLATING ROUGHENED Ni PLATING NiCo LAYER PLATING Au PLATING LAYER SURFACE SURFACE LAYER DEGREE AUTOMATIC OF THICKNESS ROUGHNESS THICKNESS THICKNESS OF VISUAL No. HEAT SINK (μm) Ry (μm) (μm) (μm) LUSTER INSPECTION WORKING 1 WITHOUT 1.0 0.35 6 0.8 0.45 NORMAL EXAMPLE 2 POLISHING 1.5 0.40 0.40 NORMAL 3 2.0 0.45 0.35 NORMAL COMPARATIVE 4 — — 1.0 OR FALSE EXAMPLE MORE RECOGNITION 5 WITH — — LESS NORMAL POLISHING THAN 1.0
[0052] Note that each of No. 1 to No. 3 corresponds to the package 100 (
[0053] In any of No. 1 to No. 5, a Cu/Cu—Mo/Cu joined metal plate was used as the heat sink plate. In No. 1 to No. 4, this was used without being polished. In No. 5, a Cu surface on the mounting surface side was polished, and the Beilby layer 19 (
[0054] In No. 1 to No. 3, a roughened Ni plating layer being an Ni plating layer having a roughened surface was formed as the first intermediate plating layer 21 (
[0055] The degree of luster of the mounting surface including the Au plating layer was measured, and the results shown in the table were obtained. Note that, as a measurement device for the degree of luster, VSR-300A manufactured by NIPPON DENSHOKU INDUSTRIES Co., Ltd. was used. As a measurement method, the Black mode of the device was used.
[0056] The automatic visual inspection of the mounting surface was performed. As a result, in No. 1 to No. 3 and No. 5, the inspection was performed normally; however, false recognition occurred in No. 4. Specifically, in No. 4, a locally dark part was falsely recognized as foreign substances. It is considered that such false recognition was liable to be caused because No. 4 had a high degree of luster of 1.0 or more and the contrast of the image acquired by a camera was high.
[0057] Note that the above describes a case in which the metal substrate is the heat sink plate of the package. However, the metal substrate is not limited to this. The metal substrate may be, for example, a metal frame for a package. The metal frame constitutes a side surface of the cavity of the package, and a support part that supports the frame constitutes a bottom surface of the cavity. In this case, in the visual inspection of the surface of the metal frame performed before a process of attaching the cover to the metal frame, false recognition can be prevented. When the support part is made of ceramics, it is desirable that the thermal expansion coefficient of the metal frame be close to the thermal expansion coefficient of the ceramics. In view of this, as a material of the metal frame, for example, for example, iron (Fe)—Ni-based alloy or Fe—Ni—Co-based alloy is used.
[0058] While the invention has been shown and described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is therefore understood that numerous unillustrated modifications can be devised without departing from the scope of the present invention.