Laser welding method
10442035 ยท 2019-10-15
Assignee
Inventors
Cpc classification
H01L2924/00012
ELECTRICITY
H01L2224/291
ELECTRICITY
B23K26/0006
PERFORMING OPERATIONS; TRANSPORTING
H01L2224/7555
ELECTRICITY
H01L24/00
ELECTRICITY
B23K26/32
PERFORMING OPERATIONS; TRANSPORTING
H01L2224/32225
ELECTRICITY
B23K2103/172
PERFORMING OPERATIONS; TRANSPORTING
H01L2224/37187
ELECTRICITY
H01L2224/40137
ELECTRICITY
H01L2224/29101
ELECTRICITY
H01L2224/32225
ELECTRICITY
H01L2924/00
ELECTRICITY
H01L2224/37663
ELECTRICITY
H01L2924/00
ELECTRICITY
B23K2103/50
PERFORMING OPERATIONS; TRANSPORTING
H01L2224/37138
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/834
ELECTRICITY
H01L2224/83895
ELECTRICITY
H01L24/75
ELECTRICITY
B23K26/037
PERFORMING OPERATIONS; TRANSPORTING
H01L2224/37638
ELECTRICITY
H01L2224/29101
ELECTRICITY
H01L2924/00014
ELECTRICITY
B23K2101/34
PERFORMING OPERATIONS; TRANSPORTING
H01L2924/00012
ELECTRICITY
B23K26/211
PERFORMING OPERATIONS; TRANSPORTING
B23K2103/08
PERFORMING OPERATIONS; TRANSPORTING
H01L2224/37638
ELECTRICITY
H01L2224/291
ELECTRICITY
H01L2224/37138
ELECTRICITY
H01L2224/37663
ELECTRICITY
H01L2224/37187
ELECTRICITY
H01L21/4846
ELECTRICITY
H01L2224/834
ELECTRICITY
H01L23/3735
ELECTRICITY
International classification
B23K26/211
PERFORMING OPERATIONS; TRANSPORTING
B23K26/32
PERFORMING OPERATIONS; TRANSPORTING
H01L21/48
ELECTRICITY
B23K26/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A laser welding method using a laser welding jig having a plurality of pressing parts, includes a step of placing a second member on a first member; a step of pressing the second member with the plurality of pressing parts in a direction toward the first member to thereby form a gap between the first member and the second member at most 300 m; and a first welding step of laser-welding the first member and the second member by irradiating on a surface of the second member at a location between the pressing parts with laser light while conducting the step of pressing.
Claims
1. A laser welding method using a laser welding jig having a plurality of pressing parts, comprising: a step of placing a second member on a first member; a step of pressing the second member with the plurality of pressing parts in a direction toward the first member to thereby form a gap between the first member and the second member at most 300 m, the plurality of pressing parts being a pair of claws with an interval therebetween; a first welding step of laser-welding the first member and the second member by irradiating on a surface of the second member through the interval between the pair of claws with laser light while conducting the step of pressing; and a second welding step of laser-welding the first member and the second member by irradiating on the surface of the second member with the laser light while the pair of claws does not press the second member toward the first member.
2. The laser welding method according to claim 1, further comprising: a step of preparing a semiconductor device that comprises a ceramic insulated substrate, a front surface conductor pattern fixed on a front surface of the ceramic insulated substrate, a semiconductor chip electrically connected to the front surface conductor pattern, the first member electrically connected to the semiconductor chip, and the second member laser-welded to the first member at at least one portion to electrically connect thereto, and a step of sealing the ceramic insulated substrate, the front surface conductor pattern, the semiconductor chip, and a part of the first member with a sealing material before the step of placing the second member on the first member.
3. A laser welding method using a laser welding jig having a plurality of pressing parts, comprising a step of placing a second member on a first member; a step of inserting a spacer between the first and second members so that a gap between the first and second members is more than 0 m and at most 300 m, a step of pressing the second member with the plurality of pressing parts in a direction toward the first member to thereby form the gap between the first member and the second member at most 300 m, the plurality of pressing parts being a pair of claws with an interval therebetween; and a first welding step of laser-welding the first member and the second member by irradiating on a surface of the second member through the interval between the pair of claws with laser light while conducting the step of pressing, wherein in the first welding step, the laser is irradiated on the surface of the second member above the gap where the spacer is not inserted, to melt the first and second members and form a welded part, and a melted part of the first and second members enters into the gap to expand the welded part in a direction perpendicular to the direction toward the first member for increasing a shear strength of the welded part.
4. The laser welding method according to claim 3, further comprising a second welding step of laser-welding the first member and the second member at a region with a gap between the first member and the second member of at most 300 m after the first welding step.
5. The laser welding method according to claim 4, wherein a distance between centers of welding portions at the first and second welding steps is at most 4 mm.
6. The laser welding method according to claim 4, further comprising a step of forming engaging parts on the first member and the second member, for positioning the first member and the second member, wherein a portion of laser welding is different from the engaging parts.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(16) Some preferred embodiments of the present invention will be described in detail in the following with reference to the accompanying drawings.
First Embodiment
(17)
(18) Referring to
(19) Then as shown in
(20) Then as shown in
(21) If there are two or more welding places, as shown in
(22) According to the welding procedure, the step of pressing by the pair of claws 39 can be eliminated in laser welding of second and thereafter. Thus, a dead time can be shortened. When the places of laser welding of second and thereafter are set at a vicinity of within 2 mm from the first laser welding place, the distance between welded places 5 is sufficiently small, enhancing joint strength.
(23) Laser welding can of course be conducted by pressing with the pair of claws 39 after moving the pair of claws 39 and the laser light 35 together.
(24) Laser welding can be favorably carried out when the thickness of the first member 1 to be welded, which corresponds to the lower emitter terminal 30 in
(25) The distance between centers of laser welded parts is desirably not larger than 4 mm. If the distance is larger than 4 mm, the joining strength between the first member and the second member tends to decrease.
Second Embodiment
(26)
(27) The laser welding jig comprises a support column 40 and two claws 39 facing each other and connected to the support column 40. The pair of claws 39 pushes the both ends of an area of a welding part. The edges of the pair of claws are linear like a knife edge, but blunt. The pair of claws 39 depicted in
(28) As shown in
(29) If the interval T between the two claws 39 is too wide, the first member 1 to be welded and the second member 2 to be welded are insufficiently close contacting each other and the gap 10 between the two members is wider than 300 m, lowering the joining strength of the welded part 5. Use of the laser welding jig 100 allows to press the vicinity of the welding part 5 and to narrow the gap 10 between the members 1 and 2 to be welded within 300 m achieving a stable joint condition.
Third Embodiment
(30)
(31) Referring to
(32) Then, as shown in
(33) The resin sealing material 32 seals the upper surface of the heat radiating base 21, the DCB substrate, the semiconductor chip 27, and the front surface conductor pattern 25. The surface 32a of the resin sealing material 32 is disposed not to contact the rear surface 30a of the lower emitter terminal 30. If the surface 32a of the resin sealing material 32 is contacting the rear surface 30a of the lower emitter terminal 30, the heat dissipation from the rear surface 30a of the lower emitter terminal 30 in the laser welding process is restricted, which expands the melted region and the melted region may unfavorably penetrate through the lower emitter terminal 30.
(34) The step of resin sealing can be omitted in the case of rare sputtering particles in the laser welding process.
(35) Then as shown in
(36) Then as shown in
(37) The distance between the outer peripheries of laser welded places is preferably at most 2 mm. If the distance is larger than 2 mm, the gap between the first member and the second member is liable to increase, which decreases the joining strength of the first and second members.
(38)
(39) In order to reduce the gap 10 between the emitter terminals 30 and 33, the surface of the upper emitter terminal 33 is pressed with the pair of claws 39 of the laser welding jig 100, and laser light irradiates the upper emitter terminal 33 in the configuration with the gap 10 between the upper emitter terminal 33 and the lower emitter terminal 30 disposed under the upper emitter terminal 33 being at most 300 m. Thus, a good welded part 34 is obtained.
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(42) A gap larger than 300 m causes adverse effect of increased heat resistance at the welded part 34 as well as decrease in the shear strength. Therefore, the gap between the terminals 30 and 33 is necessarily at most 300 m.
(43)
(44) Referring to
(45) Referring to
(46) Referring to
(47)
(48) Stable joining strength is ensured by pressing the upper emitter terminal 33 using the laser welding jig 100 of the invention to make the gap between the upper emitter terminal 33 and the lower emitter terminal 30 be at most 300 m, and joining the lower emitter terminal 30 and the upper emitter terminal 33 according to the laser welding method of the invention.
(49) The lower emitter terminal 30 and the upper emitter terminal 33 are made of a high thermal conductivity material exhibiting a thermal conductivity of at least 100 W/(m.Math.K). Preferable materials include: copper (Cu), a copper-molybdenum (CuMo) alloy, a copper-tungsten (CuW) alloy, molybdenum (Mo), tungsten (W), an aluminum-silicon carbide (AlSiC) alloy, and a silicon-silicon carbide (SiSIC) alloy, for example.
(50) The thickness of the lower emitter terminal 30 is preferably at least 0.5 mm, and the thickness of the upper emitter terminal 33 is at most 1 mm. If the thickness of the lower emitter terminal 30 less than 0.5 mm causes the laser welded part penetrates through the lower emitter terminal 30. The thickness of the lower emitter terminal 30 is more preferably, not smaller than 0.8 mm.
(51) The thickness of the upper emitter terminal 33 thicker than 1 mm increases the proportion of the energy of laser welding consumed in the upper emitter terminal 33 and decreases the proportion of the energy consumed in the lower emitter terminal 30. As a consequence, the area of melted part of the lower emitter terminal decreases resulting in lowered shear strength.
(52) Both of the lower emitter terminal 30 and the upper emitter terminal 33, or only the upper emitter terminal 33, which is irradiated by laser light is preferably plated with a material that absorbs much energy of laser light. Preferable plating includes electroless nickel-phosphorus (NiP) plating, electroless nickel-boron (NiB) plating, and electrolytic nickel (Ni) plating, for example. The plating is favorable because it improves absorption coefficient of laser light.
Fourth Embodiment
(53)
(54) The semiconductor device 200 comprises a heat radiating base 21, a DCB substrate 24 having a rear surface conductor pattern 23 that is fixed through a joining material 22 such as solder to the heat radiating base 21, and a semiconductor chip 27 fixed to a front surface conductor pattern 25 through a joining material 26 such as solder. The DCB substrate 24 is composed of a ceramic insulated substrate 24a, a rear surface conductor pattern 23 fixed on the rear surface of the ceramic insulated substrate 24a, and a front surface conductor pattern 25 fixed on the front surface of the ceramic insulated substrate 24a. The semiconductor device 200 further comprises a lower emitter terminal 30 fixed to the surface electrode of the semiconductor chip 27 through a joining material 28 such as solder, an upper emitter terminal 33 fixed to the lower emitter terminal by means of laser welding, and a collector terminal 31 fixed to the front surface conductor pattern 25 through a joining material 29 such as solder. The semiconductor device 200 also comprises a resin sealing material 32 that seals the whole device excepting the side face and rear face of the heat radiating base 21, the front surface of the lower emitter terminal 30, a tip portion of the collector terminal 31, and the upper emitter terminal 33, which are exposed to the air.
(55) A high shear strength is obtained by ensuring the gap 10 between lower emitter terminal 30 and the upper emitter terminal 33 to be within 300 m. Positional shift of the upper emitter terminal 33 in assembling process of the semiconductor device 200 is avoided by forming a recessed part 37 on the lower emitter terminal 30 and a protruding part 36 on the upper emitter terminal 33 and positioning a welding place of the terminals 30 and 33 with the aid of the protruding part and the recessed part. Alternatively, positional shift of the upper emitter terminal 33 in assembling process of the semiconductor device 200 is likewise avoided by forming a protruding part on the lower emitter terminal 30 and a recessed part on the upper emitter terminal 33 and positioning a welding place of the terminals 30 and 33 with the aid of the protruding part and the recessed part. The recessed part can be a through hole.
(56) In some cases in the semiconductor device 200, two linear compression marks with a length of about 1 mm may be formed on the upper emitter terminal 33 at two places on either side of the welded part 34.
DESCRIPTION OF SYMBOLS
(57) 1: first welded member, first member 2: second welded member, second member 4: force 5, 34: welded part 6: irradiated surface 10: gap 21, 51: heat radiating base 22, 26, 28, 29, 52, 56: joining material 23, 53: rear surface conductor pattern 24, 54: DCB substrate 24a, 54a: ceramic insulated substrate 25, 55: front surface conductor pattern 27, 57: semiconductor chip 30: lower emitter terminal, first member 30a: rear surface 31: collector terminal 32: resin sealing material 32a: front surface 33: upper emitter terminal, second member 35: laser light 36 protruding part 37: recessed part 39: claw, pressing part 40: support column 42: sputtered particle 49: boundary region 58: terminal-inserted type resin casing 59, 60, 61: terminal 62: bonding wire 63: gel sealing material 100: laser welding jig 200: semiconductor device 500: power semiconductor module D1, D2: diameter L: length T: interval