Connection member with bulk body and electrically and thermally conductive coating
20190131218 ยท 2019-05-02
Inventors
- Wu Hu Li (Singapore, SG)
- Edmund Riedl (Wald, DE)
- Thomas Horedt (Haar, DE)
- Ali Mazloum-Nejadari (Unterhaching, DE)
Cpc classification
H01L23/49524
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2224/291
ELECTRICITY
H01L2924/20641
ELECTRICITY
H01L2924/13091
ELECTRICITY
H01L2224/2919
ELECTRICITY
H01L23/49568
ELECTRICITY
H01L2224/376
ELECTRICITY
H01L2224/2919
ELECTRICITY
H01L2924/00
ELECTRICITY
H01L2224/376
ELECTRICITY
H01L2924/00
ELECTRICITY
H01L23/36
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L21/4821
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/00012
ELECTRICITY
H01L2224/291
ELECTRICITY
H01L24/73
ELECTRICITY
H01L23/14
ELECTRICITY
International classification
H01L21/48
ELECTRICITY
Abstract
A connection member for connecting an electronic chip, wherein the connection member comprises a bulk body, and a coating at least partially coating the bulk body and comprising a material having higher electric and higher thermal conductivity than the bulk body, wherein a ratio between a thickness of the coating and a thickness of the bulk body is at least 0.0016 at at least a part of the connection member.
Claims
1. A connection member for connecting an electronic chip, wherein the connection member comprises: a bulk body; a coating at least partially coating the bulk body and comprising a material having higher electric conductivity and higher thermal conductivity than the bulk body; wherein a ratio between a thickness of the coating and a thickness of the bulk body is at least 0.0016 at at least a part of the connection member; wherein the coating comprises or consists of at least one of the group consisting of copper, a copper alloy, zinc, and zinc alloy.
2. The connection member according to claim 1, wherein at least a portion of the coating has a thickness in a range between 4 m and 100 m.
3. The connection member according to claim 1, wherein the coating has a thickness of at least 7 m.
4. The connection member according to claim 1, configured as a leadframe.
5. The connection member according to claim 1, configured as a clip.
6. The connection member according to claim 1, wherein a thickness of the bulk body is in a range between 100 m and 2500 m.
7. The connection member according to claim 1, wherein the bulk body comprises or consists of iron.
8. The connection member according to claim 7, wherein the bulk body comprises or consists of one of an iron alloy, a steel alloy, and steel.
9. (canceled)
10. The connection member according to claim 1, comprising at least one further coating on at least part of the coating, wherein the further coating and the coating are made of different materials.
11. The connection member according to claim 109, wherein the at least one further coating comprises at least one of the group consisting of Ag, Ni, Ni/NiP, Ni/NiP/Ag, Ni/Pd/AuAg, Ni/Pd/AuPd, Ni/Pd/Au, Sn, and SnPb.
12. The connection member according to claim 1, wherein the coating is applied directly on the bulk body.
13. The connection member according to claim 1, wherein the coating coats the entire surface of the bulk body.
14. A method of manufacturing a connection member for connecting an electronic chip, wherein the method comprises: providing a bulk body comprising iron; at least partially coating the bulk body by a coating ; forming at least a portion of the coating with a thickness between 4 m and 100 m, wherein the coating comprises a material having higher electric conductivity and higher thermal conductivity than the bulk body and the coating comprises or consists of at least one of the group consisting of copper, a copper alloy, zinc, and zinc alloy; forming the connection member with a ratio between a thickness of the coating and a thickness of the bulk body of at least 0.0016 at at least a part of the connection member.
15. (canceled)
16. The method according to claim 14, wherein forming the coating comprises at least one of the group consisting of plating, physical vapor deposition, chemical vapor deposition, rolling at least one copper comprising sheet onto the bulk body, and sputtering.
17. An electronic component, wherein the electronic component comprises: a leadframe comprising a non-copper bulk body at least partially coated with a coating comprising copper, the coating having a thickness of more than 4 m; an electronic chip coupled with the leadframe: and an encapsulant encapsulating part of the leadframe and the electronic chip; wherein a portion of the leadframe extending beyond the encapsulant comprises a further coating on the coating, wherein this further coating is not formed on another portion of the leadframe being encapsulated by the encapsulant.
18. The electronic component according to claim 17, wherein at least part of the coating is coated by a further coating.
19. The electronic component according to claim 17, configured as a power package.
20. The electronic component according to claim 17, wherein the electronic chip is a power semiconductor chip.
21. The electronic component according to claim 17, wherein the electronic chip is configured for an operation with a vertical current flow.
22. (canceled)
23. (canceled)
24. A method of manufacturing an electronic component, wherein the method comprises: providing a leadframe with a non-copper bulk body at least partially coated with a coating, the coating having a thickness of more than 4 m, the coating comprising a material having higher electric conductivity and higher thermal conductivity than the bulk body, and the coating comprises or consists of at least one of the group consisting of copper, a copper alloy, zinc, and zinc alloy, wherein a ratio between a thickness of the coating and a thickness of the bulk body is at least 0.0016 at at least a part of the bulk body; and coupling an electronic chip with the leadframe.
25. The method according to claim 24, wherein coupling the electronic chip with the leadframe comprises mounting the electronic chip on the leadframe.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The accompanying drawings, which are included to provide a further understanding of exemplary embodiments and constitute a part of the specification, illustrate exemplary embodiments.
[0047] In the drawings:
[0048]
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
DETAILED DESCRIPTION
[0055] The illustration in the drawing is schematically and not to scale.
[0056]
[0057] The connection member 100 is provided for electrically, mechanically and thermally connecting an electronic chip 102 in various applications (see for instance
[0058] Hence,
[0059] Besides steel bulk material with copper metallization, alternative materials for both the bulk material (for instance other metals or even non-conductive materials) and the metallization layer (for instance other metals) are also possible in other exemplary embodiments. Some examples are listed in Table 1.
TABLE-US-00002 TABLE 1 Overview of possible bulk materials and metallizations layer Metallization Bulk Material Layer (s) Preferred Iron, steel Cu or Cu-alloys (iron-alloy), (for instance steel-alloys CuZn, CuSn) Alternatives Various types of Zinc and zinc- steel, such as: alloys a) Carbon Steels b) Alloy Steels c) Stainless Steels d) Tool Steels
[0060]
[0061] In particular, further coating of one or more metal layers on a copper-coated steel leadframe surface makes it possible to adjust the properties of the connection member 100 for a respective application. Examples for such applications are wire-bonding, die attach or adhesion purposes.
[0062] For example, various plating procedures can be applied on the top of a steel leadframe with copper metallization, as shown for instance in
[0063] Thus, as shown in each of
[0064] Referring to
[0065] Referring to
[0066] Referring to
[0067] Referring to
[0068] Referring to
[0069] A further coating of metal layers on the external leads of a Cu-coated steel leadframe after molding and post-mold curing process (for solderability purpose) is possible as well. For the external leads after a molding and post-mold curing process, Sn or Sn/Pb plating can be applied at the external leads (see
[0070] The further coatings 108 shown in
[0071] Referring to
[0072]
[0073] Thus, the electronic component 114 shown in
[0074] A lower main surface of the electronic chip 102 is mounted on the mounting section 180 of the leadframe 110 to thereby establish an electrically conductive and thermally conductive connection between the electronic chip 102 and the leadframe 110. For instance, the electronic chip 102 may be configured as a transistor chip having a transistor (in particular field effect transistor) monolithically integrated therein. For example, a drain pad of the electronic chip may be located on the lower main surface and may be coupled with the leadframe 110 by the described mounting.
[0075] As mentioned above, the electronic component 114 additionally comprises, as the second connection member 100, the clip 112 which may also be formed on the basis of a punched and bent planar metal sheet. The clip 112 comprises an iron comprising (for instance steel) bulk body 104 with thickness, D, of for instance 250 m coated with coating 106 comprising copper and having a much smaller thickness, d, of for instance 10 m.
[0076] An upper main surface of the electronic chip 102 is connected with one terminal of the clip 112 having another terminal being mounted on the pin section 182 of the leadframe 110. Thereby, a further electrically conductive and thermally conductive connection is established between the electronic chip 102 and the leadframe 110 via the clip 112. As mentioned above, the electronic chip 102 may be configured as a transistor chip having both a source pad and a gate pad located on the upper main surface thereof, both of which being coupled with the leadframe 110 via the clip 112. In the shown embodiment, the electronic chip 102 may be configured for an operation with a vertical current flow, i.e. along a vertical direction of
[0077] A detail 184 in
[0078] Two types of simulations have been carried out to show that exemplary embodiments improve both the electric and thermal performance of connection members 100 and corresponding electronic components 114:
[0079] To assess the electric performance of exemplary embodiments, package RDSon simulations and actual sample evaluations were conducted. RDSon hereby refers to the source to drain resistance of an electronic component 114 of the type shown in
[0080] The simulation results are shown in Table 2. The thickness of clip materials and leadframe bulk material is the same, namely 250 m. The scenarios use Cu materials for the clip, while they use Fe material or SPCE materials as leadframe bulk materials. SPCE is one type of steel material (SPCE =Steel Plate Cold deep drawn Extra non-ageing) which has been used for actual sample evaluations. For some of the scenarios, Fe is considered as bulk material with the thickness of Cu metallization of 1.5 m, 7 m and 20 m, respectively. Similarly, for the other scenarios, SPCE is considered as bulk material with the thickness of Cu metallization of 1.5 m, 7 m and 20 m, respectively.
[0081] Table 2 shows that package RDSon reduces as the thickness of Cu metallization increases. In particular the results obtained for scenarios 2, 3, 5 and 6 are within the specification of many package types. When the thickness of the coating 106 is at least 4 m and/or the ratio between the thickness of the coating 106 and the thickness of the bulk body 104 is at least 1.6%, good results are obtained for many package types.
TABLE-US-00003 TABLE 2 Summary of simulation results vs. actual sample experiments Scenario 1 2 3 4 5 6 Leadframe Fe Fe Fe SPCE SPCE SPCE 250 m 250 m 250 m 250 m 250 m 250 m with with with with with with 1.5 m 7 m 20 m 1.5 m 7 m 20 m Cu Cu Cu Cu Cu Cu Clip Cu Cu Cu Cu Cu Cu 250 m 250 m 250 m 250 m 250 m 250 m Total 1.660 1.598 1.534 1.735 1.638 1.550 RDSONon (m) Measured 1.55-2.0 Ron range from experiments (m)
[0082] Hence, the RDSon simulation for TDSON 8 shows that, as the copper thickness increases, the RDSon decreases.
[0083] Moreover, thermal simulations have been performed using a TO263 package. Such a package or electronic component 114 is shown with encapsulant 116 in
TABLE-US-00004 TABLE 3 Summary of Rth simulation results (Rth relates to the bottom of the package fixed to 85 C.) Scenario 1 2 3 4 5 6 Leadframe Fe Fe Fe SPCE SPCE SPCE 1270/500 1270/500 1270/500 1270/500 1270/500 1270/500 m with m with m with m with m with m with 1.5 m Cu 7 m Cu 20 m Cu 1.5 m Cu 7 m Cu 20 m Cu Rth 1.346 1.329 1.292 1.716 1.687 1.624 [K/W]
[0084] The thickness of leadframe bulk material is the same. The various scenarios use Fe material or SPCE materials as leadframe bulk materials. For other scenarios, Fe is considered as bulk material with the thickness of Cu metallization of 1.5 m, 7 m and 20 m, respectively. Similarly, for the other scenarios, SPCE is considered as bulk material with the thickness of Cu metallization of 1.5 m, 7 m and 20 m, respectively.
[0085] The values in Table 3 show that, in particular with a sufficiently high thickness of the coating 104, the obtainable thermal resistance is compatible with specifications of many package types. In particular, the Rth simulation for TO 263-3 shows that as Cu thickness increases, the Rth of the electronic component 114 is advantageously reduced. A corresponding concept can also be applied to other power packages/devices, such as TO, TPAK, etc. This means that it is possible to use in particular a steel leadframe with Cu metallization to reduce the manufacturing effort while at the same time meeting the specification of many package types.
[0086]
[0087] The mounting base 118 comprises an electric contact 134 embodied as a plating in a through hole of the mounting base 118. When the electronic component 114 is mounted on the mounting base 118, electronic chip 102 of the electronic component 114 is electrically connected to the electric contact 134 via the leadframe 110 of the electronic component 114.
[0088] The electronic component 114 comprises an electrically conductive connection member 100 (here embodied as leadframe 110), the electronic chip 102 (which is here embodied as a power semiconductor chip) adhesively or by soldering mounted on the connection member 100 (see solder structure 158), and encapsulant 116 (here embodied as mold compound) encapsulating part of the connection member 100 and part of the electronic chip 102. As can be taken from
[0089] During operation of the power package or electronic component 114, the power semiconductor chip in form of the electronic chip 102 generates a considerable amount of heat. At the same time, it should be ensured that any undesired current flow between a bottom surface of the electronic component 100 and an environment is reliably avoided.
[0090] For ensuring electrical insulation of the electronic chip 102 and removing heat from an interior of the electronic chip 102 towards an environment, an electrically insulating and thermally conductive interface structure 152 may be optionally provided which covers an exposed surface portion of the connection member 100 and a connected surface portion of the encapsulant 116 at the bottom of the electronic component 114. The electrically insulating property of the interface structure 152 prevents undesired current flow even in the presence of high voltages between an interior and an exterior of the electronic component 114. The thermally conductive property of the interface structure 152 promotes a removal of heat from the electronic chip 102, via the electrically conductive connection member 100 (of thermally properly conductive copper), through the interface structure 152 and towards a heat dissipation body 146. The heat dissipation body 146, which may be made of a highly thermally conductive material such as copper or aluminum, has a base body 154 directly connected to the interface structure 152 and has a plurality of cooling fins 156 extending from the base body 154 and in parallel to one another so as to remove the heat towards the environment.
[0091] As can be taken from a detail 177, a portion of the leadframe 110 extending beyond the encapsulant 116 comprises copper coating 106 on steel bulk body 104 and a further coating 108 on the coating 106. The further coating 108 may for example be made of tin. This further coating 108 is not formed on another portion of the leadframe 110 being encapsulated by the encapsulant 116 (see detail 179). The solderable material of the further coating 108 allows the formation of a solder connection between the leadframe 110 and the mounting base 118. The continuous coating 106 increases the electric and thermal performance of the electronic component 114, while the spatially selectively applied further coating 108 simultaneously promotes a reliable solder connection with the mounting base 118.
[0092] According to
[0093] With the migrating of bonding wires from gold to copper wire in recent years, leadframe materials become one of most costly materials in the package assembly. Thus, a reduction of the effort in terms of manufacturing of a leadframe becomes more and more important.
[0094] In order to reduce the effort for leadframe manufacture, leadframe materials may be changed. Also the manufacture of high density leadframes (such as larger strip size, etc.) is an option. It is also possible to convert an etched leadframe to a stamped leadframe for high volume parts. However, such concepts result only in a moderate reduction of the effort of manufacturing leadframes.
[0095] Exemplary embodiments implement bulk leadframe materials on the basis of iron, in particular steel and improve thermal and electric performance by an appropriate coating.
[0096] Steel can be obtained and processed with reasonable effort but involves the challenge of a lower electrical and thermal conductivity compared with copper material. In order to overcome this shortcoming, an exemplary embodiment provides a connection member such as a leadframe including an iron comprising bulk body with a coating or metallization (for instance manufactured by plating or by other methods). The coating may be made of a material which properly adheres on the iron comprising bulk body and at the same time increases the thermal and electrical conductivity of the manufactured connection member as a whole. The coating, which is preferably made of or comprises copper, may be applied directly onto a steel-based leadframe surface to improve the electrical and thermal performance of the leadframe. A correspondingly manufactured connection member can therefore be used also for power packages as well as other integrated circuit (IC) packages as examples of electronic components of exemplary embodiments.
[0097] Table 4 shows a comparison of electrical conductivity and thermal conductivity for copper and steel materials.
TABLE-US-00005 TABLE 4 Electrical conductivity and thermal conductivity at 20 C. Base Electrical Thermal conductivity Material conductivity [S/m] [W/(m*K)] Pure Cu 5.8 10.sup.7 385~401 Pure Fe 1.03 10.sup.7 72.7~79.5 Stainless 1.1 10.sup.6 16.3~24 steel Carbon 6.99 10.sup.6 36~54 Steel Zinc 1.69 10.sup.7 116
[0098] As seen in Table 4, the electrical conductivity of steel is about 50 times lower than that of copper material. The thermal conductivity of steel is about 5 to 10 times lower than that of copper material. In order to improve both electrical and thermal conductivity of a steel-based leadframe for power package application, a copper metallization may be applied onto the steel-based leadframe surface in an exemplary embodiment.
[0099] It should be noted that the term comprising does not exclude other elements or features and the a or an does not exclude a plurality. Also elements described in association with different embodiments may be combined. It should also be noted that reference signs shall not be construed as limiting the scope of the claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.