Semiconductor power module having an improved composite board and method of fabricating the same
First Claim
1. A semiconductor power module comprising:
- (a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board, said insulating layer comprising an epoxy resin; and
an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed,a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively;
(b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power, said power control semiconductor element including a plurality of insulated gate bipolar transistors;
(c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element, said control element outputting control signals to respective gate electrodes of said insulated gate bipolar transistors;
(d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; and
(e) a sealing resin injected into said case to seal said power control semiconductor element and said control element.
2 Assignments
0 Petitions
Accused Products
Abstract
An insulating metallic board 160 mounting IGBTs which control an electrical power and other circuit elements and an insulating board 170 mounting semiconductor elements which control the IGBTs and the other circuit elements are arranged adjacent to or closely parallel to each other, and combined by a frame 180 into one integral circuit board to define a composite board 150. Wiring patterns 161 and 171 on which the respective circuit elements are to be disposed are formed on major surfaces of the same side. Since the composite board 150 which includes the two different types of circuit boards can be treated simply as one board, it is possible to mount the circuit elements onto the two different types of boards at the same time in one fabrication step. Thus, the number of fabrication steps and a manufacturing cost are reduced.
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Citations
56 Claims
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1. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board, said insulating layer comprising an epoxy resin; and an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power, said power control semiconductor element including a plurality of insulated gate bipolar transistors; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element, said control element outputting control signals to respective gate electrodes of said insulated gate bipolar transistors; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; and (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board; and an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, said insulating member comprising a fiber reinforced epoxy resin, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power, said power control semiconductor element including a plurality of insulated gate bipolar transistors; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element, said control element outputting control signals to respective gate electrodes of said insulated gate bipolar transistors; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; and (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board; and an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power, said power control semiconductor element including a plurality of insulated gate bipolar transistors; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element, said control element outputting control signals to respective gate electrodes of said insulated gate bipolar transistors; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element; and (f) an electrically conductive heat sink member disposed between said first and second insulated gate bipolar transistors and said main circuit wiring pattern. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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40. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board; an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively; and a frame member for combining said insulating metallic board and said insulating board into one integral board; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; and (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element. - View Dependent Claims (41, 42, 43, 44, 45, 46, 47)
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48. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board; and an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, and an extending protrusion which has a through hole, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively, said insulating board of said composite board including an opening to receive said insulating metallic board for engagement, said opening extending from said major surface to an opposite major surface of said insulating board; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; and (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element.
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49. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board; an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively, said insulating board of said composite board including an opening to receive said insulating metallic board for engagement, said opening extending from said major surface to an opposite major surface of said insulating board; and a frame member for combining said insulating metallic board and said insulating board into one integral board, a groove being formed along a periphery of said frame member; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside, a ridge being formed along a periphery of said cylindrical case at said end thereof for engagement with said groove of said frame member; and (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element.
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50. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board; and an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively, said insulating board of said composite board including an opening to receive said insulating metallic board for engagement, said opening extending from said major surface to an opposite major surface of said insulating board, said opening including an extending protrusion at an end thereof so as to prevent said insulating metallic board from sliding toward said main circuit wiring pattern from its inserted position; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; and (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element.
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51. A semiconductor power module comprising:
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(a) a composite board which includes an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board; and an insulating board which includes an insulating member, a control circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said control circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed, a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively, said insulating metallic board and said insulating board of said composite board being disposed adjacent to each other and bonded to each other by an adhesive agent; (b) a power control semiconductor element disposed on said main circuit wiring pattern to control electrical power; (c) a control element disposed on said control circuit wiring pattern to control said power control semiconductor element; (d) a cylindrical case for receiving at an end thereof a peripheral portion of said composite board so as to contain said power control semiconductor element and said control element inside; and (e) a sealing resin injected into said case to seal said power control semiconductor element and said control element.
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52. A method of fabricating a semiconductor power module, comprising the steps of:
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(a) preparing a composite board which comprises; (i) an insulating metallic board which includes a metallic plate, a main circuit wiring pattern being disposed on an insulating layer which is formed on a major surface of said insulating metallic board through an insulating layer; and (ii) an insulating board which includes an insulating member, a sub circuit wiring pattern being disposed on a major surface of said insulating board, said insulating board being disposed adjacent to said insulating metallic board in such a manner that said major surface of said insulating board on which said sub circuit wiring pattern is formed is flush with said major surface of said insulating metallic board on which said main circuit wiring pattern is formed; a major surface of said metallic plate being exposed in a bottom surface of said composite board which is opposite said major surfaces of said insulating metallic board and said insulating board seating said main and said control circuit wiring patterns, respectively; (b) preparing a cylindrical case; (c) mounting a power control semiconductor element which controls electrical power and mounting a main terminal on said main circuit wiring pattern, said step (c) including the steps of; (c-1) applying a first solder on said main circuit wiring pattern; (c-2) placing said power control semiconductor element and said main terminal on said first solder; (c-3) heating said first solder after said step (c-2); (c-4) cooling said first solder down to room temperature after said step (c-3); (c-5) applying a third solder on said main circuit wiring pattern; (c-6) placing an electrically conductive heat sink member on said third solder; (c-7) applying a fourth solder on said heat sink member; (c-8) placing said power control semiconductor element and said main terminal on said fourth solder; (c-9) heating said third and said fourth solders after said step (c-8); and (c-10) cooling said third and said fourth solders down to room temperature after said step (c-9); (d) mounting a control element and a sub terminal on said sub circuit wiring pattern; (e) engaging an end portion of said cylindrical case with a peripheral portion of said composite board which mounts said power control semiconductor element and said control element so that said cylindrical case contains said power control semiconductor element and said control element therein; and (f) filling said cylindrical case with a sealing resin for sealing said power control semiconductor element and said control element in such a manner that an end of each of said main terminal and said sub terminal is exposed outside said sealing resin. - View Dependent Claims (53, 54, 55, 56)
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Specification