PACKAGE
20220344241 · 2022-10-27
Inventors
- Noriyasu YAMAMOTO (Sanyo-Onoda-shi, JP)
- Yoshikazu MIHARA (Shimonoseki-shi, JP)
- Naoya SHIRAI (Mine-shi, JP)
Cpc classification
International classification
Abstract
A heat sink includes first to fifth layers. The first layer supports a frame made of ceramics, is made of copper, and has a thickness t.sub.1. The second layer is laminated to the first layer, is made of molybdenum, and has a thickness t.sub.2. The third layer is laminated to the second layer, is made of copper, and has a thickness t.sub.3. The fourth layer is laminated to the third layer, is made of molybdenum, and has a thickness t.sub.4. The fifth layer is laminated to the fourth layer, is made of copper, and has a thickness t.sub.5. A formula 3≤t.sub.1/t.sub.5≤5 is satisfied. A formula 3≤t.sub.3/t.sub.5≤5 is satisfied.
Claims
1. A package having a cavity to be sealed by a lid, the package comprising: a frame being made of ceramics and surrounding the cavity in plan view; and a heat sink having a support surface to support the frame, the heat sink including: a first layer having the support surface, being made of copper, and having a thickness t.sub.1; a second layer laminated to the first layer, being made of molybdenum, and having a thickness t.sub.2; a third layer laminated to the second layer, being made of copper, and having a thickness t.sub.3; a fourth layer laminated to the third layer, being made of molybdenum, and having a thickness t.sub.4; and a fifth layer laminated to the fourth layer, being made of copper, and having a thickness t.sub.5, wherein conditions below are satisfied: 3≤t.sub.1/t.sub.5≤5; and 3≤t.sub.3/t.sub.5≤5.
2. The package according to claim 1, wherein a condition below is satisfied: 3≤t.sub.1/t.sub.5≤4.
3. The package according to claim 1, wherein the ceramics of the frame have a coefficient of thermal expansion of 5 ppm/° C. or more and 8 ppm/° C. or less from 25° C. to 100° C., and have a coefficient of thermal expansion of 7.5 ppm/° C. or more and 8.5 ppm/° C. or less from 25° C. to 800° C.
4. The package according to claim 1, wherein a condition below is satisfied: 0.10 ≤(t.sub.2+t.sub.4)/(t.sub.1+t.sub.2+t.sub.3+t.sub.4+t.sub.5)≤0.13.
5. The package according to claim 1, wherein the lid is made of ceramics.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] An embodiment of the present invention will be described below with reference to the drawings. In description below, a coefficient of thermal expansion (CTE) at a temperature T (° C.) is defined as follows:
{(L.sub.T−L.sub.25)/(T−25)}/L.sub.25,
[0032] where L.sub.25 is the length at a temperature of 25° C. (room temperature), and L.sub.T is the length at the temperature T.
[0033] In the present description, the above-mentioned coefficient of thermal expansion is also referred to as a coefficient of thermal expansion from 25° C. to T (° C.). The coefficient of thermal expansion of a composite metal plate is calculated based on the length along an in-plane direction. The in-plane direction is herein a direction perpendicular to a direction of a stack (direction of the thickness) of the composite metal plate.
[0034]
[0035] The electronic device 90 includes a package 10 having the cavity CV, an electronic component 8 disposed within the cavity CV, wires 9, a lid 80, and an adhesive layer 70. The package 10 includes a heat sink 13, a frame 14, and metal terminals 15. The electronic component 8 is a high frequency power semiconductor element, for example, and, in this case, the package 10 is a high frequency package. The electronic component 8 may electrically be connected to the metal terminals 15 of the package 10 by the wires 9. The lid 80 is joined to the frame 14 by the adhesive layer 70 to seal the cavity CV.
[0036] The lid 80 may be made of ceramics. The ceramics may contain alumina as a major component. The ceramics may be the same as or different from those for the frame 14.
[0037] A material for the lid 80 is not limited to the ceramics. For example, the lid 80 may include a resin material. The resin material is a liquid crystal polymer, for example. Inorganic fillers may be dispersed in the resin material, and the inorganic fillers are silica particles, for example. The inorganic fillers dispersed in the resin material can enhance strength and durability of the lid 80.
[0038] In the package 10, the heat sink 13, the frame 14, and the metal terminals 15 may be joined together using a joining material (not illustrated). The joining material is silver solder, for example. Metal layers of tungsten, molybdenum, or the like may be disposed on surfaces of the frame 14 joined to the heat sink 13 and the metal terminals 15 to allow for junction between ceramics and metal using silver solder. The package 10 is typically plated after junction using the joining material.
[0039] The frame 14 is disposed on the heat sink 13, and surrounds the cavity CV in plan view. The frame 14 is made of ceramics. The ceramics may have a coefficient of thermal expansion of 5 ppm/° C. or more and 8 ppm/° C. or less from 25° C. to 100° C., and have a coefficient of thermal expansion of 7.5 ppm/° C. or more and 8.5 ppm/° C. or less from 25° C. to 800° C. The ceramics contain alumina as a major component, for example. The frame 14 typically has a greater flexural modulus than the adhesive layer 70.
[0040] The metal terminals 15 are joined to the frame 14. The metal terminals 15 form an electrical path connecting the interior and the exterior of the cavity CV sealed by the package 10 and the lid 80. In the cavity CV, the electronic component 8 is electrically connected to the metal terminals 15 by the wires 9. The wires 9 are bonding wires, for example.
[0041] The adhesive layer 70 is disposed on the package 10 to surround the cavity CV. Referring to
[0042] The adhesive layer 70 is formed of a thermosetting adhesive in a cured state. The thermosetting adhesive may include at least any of an epoxy resin, a phenolic resin, and a silicone resin as a major component. In particular, the epoxy resin is preferred in terms of a balance of thermal resistance, mechanical strength, and chemical resistance. To suitably have the above-mentioned properties, the thermosetting adhesive in the cured state preferably has a content of the epoxy resin as the major component of 20 wt % to 40 wt % (weight percent), and may include a minor component, such as a curing agent, as the remainder. Specifically, the minor component may be a curing agent of 1 wt % to 10 wt %, inorganic fillers of 50 wt % to 70 wt %, a coupling agent of 0.5 wt % to 2 wt %, a catalyst of 0.5 wt % to 2 wt %, and a low stress agent of 0.1 wt % to 5 wt %, for example. A phenoxy resin compound may be used as the curing agent. Silica may be used as the inorganic fillers. Organic phosphorus or a boron salt may be used as the catalyst. Silicone may be used as the low stress agent.
[0043] A bottom surface BT (
[0044] As illustrated in
[0045] A method of manufacturing the electronic device 90 will be described below.
[0046] The package 10 is prepared. The electronic component 8 is mounted on the heat sink 13 of the package 10. For example, the electronic component 8 is soldered onto the heat sink 13. Next, the electronic component 8 is electrically connected to the metal terminals 15 by the wires 9.
[0047] Next, the lid 80 is mounted over the package 10. Specifically, the lid 80 is attached to the frame 14 of the package 10 through the adhesive layer 70 in a semi-cured state. Next, the lid 80 is pressed against the package 10 at a predetermined load. An appropriate load is dependent on dimensioning of the package 10, and is 500 g or more and 1 kg or less, for example. The adhesive layer 70 is heated during pressing at the load. The heated adhesive layer 70 changes to a softened state first. The viscosity of the adhesive layer 70 is thus reduced. As a result, the adhesive layer 70 wets. With the progress of a curing reaction by heating thereafter, the adhesive layer 70 changes to the cured state. As a result, the lid 80 is joined to the package 10. The cavity CV is thereby sealed.
[0048] The electronic device 90 can be obtained as described above.
[0049]
[0050] Measurement results of the amount of warpage described later were obtained by a scheme of bringing the tip of a stylus into direct contact with the surface of a sample. A profilometer (SURFCOM480B from TOKYO SEIMITSU. Co., LTD.) was used as a measurement apparatus.
[0051] The top of
[0052] The bottom of
[0053]
[0054]
[0055] When high thermal conductivity of approximately 330 (W/m.Math.K) or more and 360 (W/m.Math.K) or less at 25° C. as a reference temperature is intended, the coefficient of thermal expansion of the composite metal plate is adjustable between and around the coefficient of thermal expansion CTE.sub.A and the coefficient of thermal expansion CTE.sub.B depending on the material design. Specifically, properties of a coefficient of thermal expansion in a range of 9 ppm/° C. or more and 15 ppm/° C. or less from 25° C. to 100° C. and properties of a coefficient of thermal expansion in a range of 7.5 ppm/° C. or more and 8.5 ppm/° C. or less from 25° C. to 800° C. can easily be obtained. When the heat sink 13 has a coefficient of thermal expansion of 15 ppm/° C. or less from 25° C. to 100° C., an excessive difference in expansion/contraction between the heat sink 13 and the frame 14 can be avoided.
[0056] The coefficient of thermal expansion CTE.sub.B of the composite metal plate is much higher than the coefficient of thermal expansion CTEx of the ceramic material for the frame in a temperature range in a heating cycle (−65° C. to +150° C. in a typical test). Expansion/contraction EX1 is thus much greater than expansion/contraction EX2 as shown in
[0057] To secure reliability of the above-mentioned junction, it is preferable to perform material design of the heat sink 13 so that the heat sink 13 has a lower coefficient of thermal expansion at approximately 100° C. as indicated by an arrow VC (
[0058]
[0059] A broken line in each of
[0060] The ceramic composition X has a coefficient of thermal expansion of 5.76 ppm/° C. from 25° C. to 100° C., and has a coefficient of thermal expansion of 7.80 ppm/° C. from 25° C. to 800° C. The ceramic composition Y has a coefficient of thermal expansion of 7.10 ppm/° C. from 25° C. to 100° C., and has a coefficient of thermal expansion of 8.30 ppm/° C. from 25° C. to 800° C. The ceramic composition X is mainly made of alumina, and, specifically, contains alumina at a ratio of 90 wt % or more. The ceramic composition Y contains zirconia at a ratio of approximately 20 wt % while containing alumina as a major material to have a higher coefficient of thermal expansion than the ceramic composition X.
[0061] Properties between and around the properties of the ceramic composition X and the properties of the ceramic composition Y can be obtained through adjustment of a material composition, and the material composition adjusted as described above may be used as a material for the frame 14. Specifically, properties of a coefficient of thermal expansion in a range of 5 ppm/° C. or more and 8 ppm/° C. or less from 25° C. to 100° C. and properties of a coefficient of thermal expansion in a range of 7.5 ppm/° C. or more and 8.5 ppm/° C. or less from 25° C. to 800° C. can easily be obtained.
[0062] It can be seen, from warpage of the packages 10A to 10D shown in solid lines in
[0063] Results of measurement of warpage described above are shown in a table below. The amount of warpage in each of conditions is an average value of values measured for four samples.
TABLE-US-00001 TABLE 1 COMPARATIVE EXAMPLE EXAMPLE EXPERIMENT NO. 1 2 3 4 5 6 7 8 9 10 STACK 10R 10D 10C 10B 10A STRUCTURE t.sub.1/t.sub.5 1 2 3 4 5 t.sub.3/t.sub.5 0.57 6 5 4 3 CERAMIC X Y X Y X Y X Y X Y COMPOSITION WARPAGE +43 +51 +23 +32 +25 +34 −4 +12 −37 −13 (μm) ABSOLUTE VALUE F F A B A B A A B A OF WARPAGE NEGATIVE A A A A A A B A C C WARPAGE TEMPERATURE F B B A B A B A B A CYCLE HEAT SINK A F B A A THERMAL CONDUCTIVITY
[0064] In the table above, in a row “ABSOLUTE VALUE OF WARPAGE”, results of evaluation of the absolute value of warpage are shown. “A” represents a most suitable value of less than 30 μm, “B” represents a slightly large value of 30 μm or more and less than 40 μm, and “F” represents an excessively large value of 40 μm or more. In particular, excessive positive warpage (top in
[0065] In the table above, in a row “NEGATIVE WARPAGE”, results of evaluation to preferably avoid excessive negative warpage (bottom in
[0066] In the table above, in a row “TEMPERATURE CYCLE”, results of a temperature cycle test at −65° C. to +150° C. to verify reliability of the junction in the heating cycle are shown. “A” represents a state in which reliability is secured in a hermeticity test after 500 cycles, “B” represents a state in which reliability is not secured in the hermeticity test after 400 cycles while reliability is secured in the hermeticity test after 300 cycles, and “F” represents a state in which reliability is not secured in the hermeticity test after 100 cycles. The lid 80 made of ceramics was used in the temperature cycle test.
[0067] Experiment Nos. 3 to 10 (asymmetric stack structure) are each expected to have a greater effect of mitigating stress obtained by distortion of Cu than Experiment Nos. 1 and 2 (symmetric stack structure) as a Cu layer facing the frame 14 has a greater thickness t.sub.1. Results of the temperature cycle test are thus considered to be substantially equivalent even when the lid 80 is made of resin.
[0068] In the table above, in a row “HEAT SINK THERMAL CONDUCTIVITY”, results of evaluation of heat dissipation performance from the cavity CV (electronic component 8) to the heat sink 13 are shown. A small thickness t.sub.1 means that a Cu layer of the heat sink 13 facing the cavity CV has a small thickness. In this case, a Cu layer having high thermal conductivity cannot be disposed at a location facing the cavity CV to have a sufficient thickness. As a result, heat dissipation performance from the cavity CV is less likely to be secured. “A” represents no such concern, “B” represents a small concern, and “F” represents a large concern.
[0069] When the results of evaluation shown in Table 1 are taken together, Experiment Nos. 5 to 10 are preferable, Experiment Nos. 5 to 8 are more preferable, and Experiment Nos. 7 and 8 are particularly preferable from among the experiment numbers shown in Table 1. The formulas 3≤t.sub.1/t.sub.5≤5 and 3≤t.sub.3/t.sub.5≤5 are required to be satisfied to avoid “F” representing unsuitable evaluation from each perspective.
[0070] Specifically, when a formula t.sub.1/t.sub.5≤5 is satisfied, excessive negative warpage (bottom in
[0071] Experiment Nos. 5 to 8 in each of which the formula 3≤t.sub.1/t.sub.5≤4 is satisfied are more preferable as there is only “A” or “B”, and there is not “C” in each of the evaluation items.
[0072]
[0073] 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 modifications and variations can be devised without departing from the scope of the invention.