Device for manufacturing power module and method for manufacturing power module

Abstract

The present invention provides a feature that makes it possible to improve power module producibility by shortening the time required for positioning when assembling a device for manufacturing a power module. The device for manufacturing a power module comprises a unit base, and a crimping blade unit having a crimping blade and a crimping blade base. The crimping blade has a plurality of vertically extending upper comb blades. The crimping blade base has a plurality of vertically extending lower comb blades that constitute the plurality of comb blades by being combined with the plurality of upper comb blades. A space into which a plurality of heat dissipation fins of a heat sink can be inserted is formed between adjacent comb blades. The crimping blade is fixed to an upper end of a portion of the crimping blade base where the plurality of lower comb blades are not provided. A lower part of the portion of the crimping blade base where the plurality of lower comb blades are not provided is fixed to an upper surface of the unit base.

Description

Power module manufacturing apparatus and power module manufacturing method

[0001] The present disclosure relates to a power module manufacturing apparatus and a power module manufacturing method.

[0002] Conventionally, a power module has been proposed in which a power module portion and a heat sink are integrated together.

[0003] Patent Document 1 describes a method for manufacturing a heat sink in which heat dissipation fins are attached to a metal base by a crimping process, which is part of the power module manufacturing process. Specifically, fin grooves and press grooves are alternately formed in the metal base. The heat dissipation fins are inserted into the fin grooves, and the press grooves are widened by pressing them using the crimping blade of a crimping jig. In this way, the heat dissipation fins are crimped and fixed to the metal base.

[0004] Japanese Patent Application Laid-Open No. 2019-166547

[0005] The crimping device described in Patent Document 1 has a configuration in which multiple crimping blades and multiple spacers are alternately combined and fixed with a shaft and screws, resulting in a large number of parts. As a result, each part needs to be positioned when assembling the crimping device, and the time required for positioning increases, resulting in a problem of reduced productivity of power modules.

[0006] Therefore, an object of the present disclosure is to provide a technique that can reduce the time required for positioning when assembling a power module manufacturing device and improve the productivity of power modules.

[0007] A power module manufacturing apparatus according to the present disclosure manufactures a power module by applying pressure to a heat sink having a power module section having a first uneven portion on one surface thereof, a heat sink base having a second uneven portion on a surface facing the power module section, and a plurality of heat dissipation fins provided on a surface of the heat sink base opposite to the surface facing the power module section, and engaging the first uneven portion with the second uneven portion, the power module manufacturing apparatus comprising: a unit base; a crimping blade base mounted on the unit base and having a crimping blade and an upper surface on which the crimping blade is fixed; and a crimping blade unit having the above-mentioned components, wherein the crimping blade has a plurality of upper comb blades extending in the vertical direction, the crimping blade base has a plurality of lower comb blades extending in the vertical direction and combining with the plurality of upper comb blades to form a plurality of comb blades, and a space is formed between adjacent comb blades into which the plurality of heat dissipation fins of the heat sink can be inserted, the crimping blade is fixed to an upper end of a portion of the crimping blade base where the plurality of lower comb blades are not provided, and a lower portion of the crimping blade base where the plurality of lower comb blades are not provided is fixed to the upper surface of the unit base.

[0008] According to the present disclosure, since the number of parts is smaller than that of conventional devices, it is easy to position each component when assembling the power module manufacturing device, which reduces the time required for positioning and improves the productivity of power modules.

[0009] The objects, features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description and the accompanying drawings.

[0010] FIG. 1 is a cross-sectional view of a power module manufactured using the power module manufacturing apparatus according to the first embodiment. FIG. 2 is a cross-sectional view showing an outline of a method for integrating a power module section and a heat sink. FIG. 3 is a front view of the power module manufacturing apparatus according to the first embodiment. FIG. 4 is a side view of the power module manufacturing apparatus according to the first embodiment. FIG. 5 is a top view of the power module manufacturing apparatus according to the first embodiment. FIG. 6 is an exploded perspective view of the power module manufacturing apparatus according to the first embodiment. FIG. 7 is a perspective view for explaining the assembly process of the crimping blade unit according to the first embodiment. FIG. 8 is a perspective view showing a first example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 9 is a side view showing a first example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 10 is a perspective view showing a second example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 11 is a side view showing a second example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 12 is a perspective view showing a third example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 13 is a perspective view showing a fourth example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 14 is a perspective view showing a fifth example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 15 is a top view showing a fifth example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 16 is a perspective view showing a sixth example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 17 is a perspective view showing a seventh example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 18 is a perspective view showing an eighth example of a method for fixing the crimping blade base according to the first embodiment to the unit base. FIG. 19 is a front view for explaining a process for attaching a heat sink to the crimping blade unit according to the first embodiment. FIG. 20 is a front view for explaining a process for integrating the power module section and the heat sink according to the first embodiment. FIG. 21 is a front view of a power module manufactured using the power module manufacturing apparatus according to the first embodiment.FIG. 22 is a front view showing a first example of the tip shape of the comb blades according to the first embodiment. FIG. 23 is a front view showing a second example of the tip shape of the comb blades according to the first embodiment. FIG. 24 is a front view showing a third example of the tip shape of the comb blades according to the first embodiment. FIG. 25 is a front view showing a fourth example of the tip shape of the comb blades according to the first embodiment. FIG. 26 is a top view of a manufacturing apparatus for a power module according to a first modified example of the first embodiment. FIG. 27 is a top view showing a state in which a heat sink is attached to a crimping blade unit in the first modified example of the first embodiment. FIG. 28 is a front view showing a state in which a heat sink is attached to a crimping blade unit in the first modified example of the first embodiment. FIG. 29 is a front view showing a state in which a power module is attached to a crimping blade unit in a second modified example of the first embodiment. FIG. 30 is a top view showing a state in which a power module is attached to a crimping blade unit in the second modified example of the first embodiment. FIG. 31 is a front view showing a state in which a power module is attached to a crimping blade unit in a third modified example of the first embodiment. FIG. 32 is a top view showing a state in which a power module is attached to a crimping blade unit in a third modification of the first embodiment. FIG. 33 is a front view of a power module manufacturing apparatus according to a second embodiment. FIG. 34 is a top view of a power module manufacturing apparatus according to the second embodiment. FIG. 35 is a top view showing a heat sink being attached to a crimping blade unit in the second embodiment. FIG. 36 is a front view showing a state in which a heat sink is attached to a crimping blade unit in the second embodiment. FIG. 37 is a top view showing a state in which a heat sink is attached to a crimping blade unit in the second embodiment. FIG. 38 is a top view showing a state in which a heat sink is attached to a crimping blade unit in a third modification of the second embodiment. FIG. 39 is a front view showing a state in which a heat sink is attached to a crimping blade unit in a third modification of the second embodiment. FIG. 40 is a front view of a power module manufacturing apparatus according to a third embodiment. FIG. 41 is a top view of a power module manufacturing apparatus according to the third embodiment. FIG. 42 is a front view showing a state in which a heat sink is attached to a crimping blade unit in the third embodiment.Fig. 43 is a front view showing a state in which a power module section is placed on a heat sink attached to a crimping blade unit in embodiment 3. Fig. 44 is a front view showing a state in which application of a press load to the power module section has begun in embodiment 3. Fig. 45 is a front view showing a state in which application of a press load to the power module section has been completed in embodiment 3. Fig. 46 is a front view showing a state in which the power module section and the heat sink are integrated in embodiment 3.

[0011] Embodiment 1. Embodiment 1 will be described below with reference to the drawings. Fig. 1 is a cross-sectional view of a power module 14 manufactured using a power module manufacturing apparatus according to embodiment 1. Fig. 2 is a cross-sectional view showing an outline of a method for integrating a power module section 12 and a heat sink 13.

[0012] First, a power module 14 manufactured using the power module manufacturing apparatus will be described. As shown in Fig. 1, the power module 14 is a heat sink-integrated power module, and includes a power module section 12 and a heat sink 13. The power module section 12 includes a plurality of semiconductor elements 1, a bonding material 2 such as solder, wiring 3, a metal conductor 4 such as a lead frame, an insulating material 5 such as an insulating sheet, a control terminal 6, a sealing material 7, a main terminal 8, and a fin base 9.

[0013] Multiple semiconductor elements 1 are mounted on the upper surface of a metal conductor 4 via a bonding material 2. The metal conductor 4 is arranged via an insulating material 5 attached to the upper surface of a fin base 9. The material of the semiconductor elements 1 is silicon (Si) or a wide bandgap semiconductor. Wide bandgap semiconductors include silicon carbide (SiC), gallium nitride (GaN), diamond (C), or the like. Similar effects can be obtained with any semiconductor material.

[0014] The control terminals 6 and the main terminals 8 are connected to the semiconductor element 1 via wiring 3. The sealing material 7 is made of an epoxy resin or the like, and seals the semiconductor element 1, the control terminals 6, the main terminals 8, the insulating material 5, and the fin base 9 so that one end sides of the control terminals 6 and the main terminals 8 and the lower surface (one surface) of the fin base 9 are exposed.

[0015] A first uneven portion 15a (see FIG. 2) is provided on the lower surface (one surface) of the fin base 9. The first uneven portion 15a is made up of a plurality of recesses and is provided across the width direction of the fin base 9 (the left-right direction in FIG. 1).

[0016] The heat sink 13 has a heat sink base 10 integrated with the underside (one side) of the fin base 9, and a plurality of heat dissipation fins 11 provided on the underside (the side opposite to the side facing the power module section 12) of the heat sink base 10.

[0017] A second uneven portion 15b (see FIG. 2) that can be fitted with the first uneven portion 15a is provided on the upper surface (the surface facing the power module portion 12) of the heat sink base 10 excluding the outer periphery. The second uneven portion 15b is made up of a plurality of protrusions and is provided across the width direction (left-right direction in FIG. 1) of the heat sink base 10 excluding the outer periphery.

[0018] The first uneven portion 15a on the fin base 9 and the second uneven portion 15b on the heat sink base 10 are integrated by pressing, achieving a grease-free design. Because no thermally conductive grease is placed at the connection between the power module portion 12 and the heat sink 13, there is low thermal resistance and no pumping out or bleeding of the thermally conductive grease occurs during use. As a result, the heat sink-integrated power module has excellent long-term reliability.

[0019] The fin base 9 is made of aluminum or an aluminum alloy by cutting, forging, casting, extrusion, or the like. However, the material of the fin base 9 is not limited to aluminum-based materials and may be copper or the like.

[0020] The heat sink 13 is a "crimped heat sink" in which the heat sink base 10 and the heat dissipation fins 11 are integrated by "crimping." The heat sink base 10 is made by cutting, die-casting, forging, extrusion, or the like, and is made of aluminum or an aluminum alloy.

[0021] Furthermore, it is possible to achieve both workability and heat dissipation by using a plate material (rolled material) such as aluminum or an aluminum alloy for the heat dissipation fins 11. The materials for the heat sink base 10 and the heat dissipation fins 11 are not limited to aluminum-based materials, and they may be a combination of different materials. For example, from the perspective of heat dissipation capacity, using a copper-based plate material, which has a higher thermal conductivity than aluminum-based materials, for the heat dissipation fins 11 will further improve heat dissipation capacity compared to aluminum-based materials.

[0022] Furthermore, when a crimped heat sink is used, there are no processing restrictions (aspect ratio) imposed by casting or extrusion, so the heat dissipation fins 11 can be freely designed. This allows the heat dissipation capacity of the heat sink 13 to be maximized. However, the heat sink 13 is not limited to a crimped heat sink, and similar effects can be achieved with heat sinks made by cutting, forging, extrusion, casting, or other processes.

[0023] In Figure 1, a convex portion is formed on the heat sink base 10 and a concave portion is formed on the fin base 9, and the two are integrated, but this is not limited to this. The same effect can be obtained by forming a concave portion on the heat sink base 10 and a convex portion on the fin base 9, or by combining these configurations and forming a combination of concave and convex portions on the heat sink base 10 and the fin base 9.

[0024] 2 is a cross-sectional view showing an outline of a method for integrating the power module section 12 and the heat sink 13. Note that in FIG. 2, the caulking blade unit 19 is shown in outline.

[0025] As shown in FIG. 2 , the heat sink 13 is set on a crimping blade unit 19 that supports a press load, and the power module section 12 is set at a position where the first uneven portion 15 a of the fin base 9 and the second uneven portion 15 b of the heat sink base 10 fit together. In this state, a press load is applied using a processing device such as a press (not shown), thereby integrating the power module section 12 and the heat sink 13.

[0026] Next, a manufacturing apparatus for the power module 14 will be described. Fig. 3 is a front view of the manufacturing apparatus for the power module 14 according to the first embodiment. Fig. 4 is a side view of the manufacturing apparatus for the power module 14 according to the first embodiment. Fig. 5 is a top view of the manufacturing apparatus for the power module 14 according to the first embodiment. Fig. 6 is an exploded perspective view of the manufacturing apparatus for the power module 14 according to the first embodiment. Fig. 7 is a perspective view for explaining the assembly process of the caulking blade unit 19 according to the first embodiment.

[0027] As shown in FIGS. 3 to 5, the manufacturing device for the power module 14 is a fitting device for fitting the power module section 12 and the heat sink 13, and includes a unit base 20 and a caulking blade unit 19.

[0028] The unit base 20 is a plate-like member that is rectangular in top view. The crimping blade unit 19 is mounted on the unit base 20. Specifically, the crimping blade unit 19 is fixed onto the unit base 20 by screws 23.

[0029] As shown in FIG. 6 , the crimping blade unit 19 includes a crimping blade 17 and a crimping blade base 18 .

[0030] The crimping blade 17 is formed in a rectangular parallelepiped shape. The crimping blade 17 is provided with a plurality of upper comb blades 21a extending in the vertical direction. The plurality of upper comb blades 21a are arranged at intervals in the width direction (the left-right direction in FIG. 3 ). A portion 22 of the crimping blade 17 where the plurality of upper comb blades 21a are not provided is provided with two positioning holes 24 into which the upper portions of two positioning pins 26 for fixing to the crimping blade base 18 are respectively inserted, and a countersunk hole 25 for screw fastening.

[0031] The crimping blade base 18 is formed in a rectangular parallelepiped shape. The crimping blade base 18 is provided with a plurality of lower comb blades 21b extending in the vertical direction. The plurality of lower comb blades 21b are spaced apart in the width direction (left-right direction in FIG. 3 ). Two positioning holes 24a and a screw hole 25a are provided in the upper part of a portion 22a of the crimping blade base 18 where the plurality of lower comb blades 21b are not provided. The lower portions of two positioning pins 26 for fixing the crimping blade 17 are inserted into the two positioning holes 24a, respectively, of the crimping blade 17. The two positioning holes 24a of the crimping blade base 18 are located opposite the two positioning holes 24 of the crimping blade 17, and the screw hole 25a of the crimping blade base 18 is located opposite the countersunk hole 25 of the crimping blade 17.

[0032] The crimping blade 17 is fixed on the crimping blade base 18, and a plurality of upper comb blades 21a and a plurality of lower comb blades 21b are combined to form a plurality of comb blades 21. The number of upper comb blades 21a is the same as the number of lower comb blades 21b. A space is formed between adjacent comb blades 21 into which a plurality of heat dissipation fins 11 of the heat sink 13 can be inserted. The number of spaces between adjacent comb blades 21 is equal to the number of heat dissipation fins 11 so that all of the heat dissipation fins 11 can be inserted.

[0033] The positions into which the two positioning pins 26 are inserted and the positions of the countersunk hole 25 and the screw hole 25a may be positions other than those shown in Figures 5 and 6, and there is no limit to the number of them. However, if the positions into which the two positioning pins 26 are inserted and the positions of the countersunk hole 25 and the screw hole 25a are the positions shown in Figures 5 and 6, it will be difficult for the crimping blade 17 to rotate relative to the crimping blade base 18 due to misalignment during assembly or external force, and loosening of the screws that secure the two can be suppressed, so the positions shown in Figures 5 and 6 are recommended.

[0034] Furthermore, if the crimping blade 17 and the crimping blade base 18 are to be fixed more firmly, two or more countersunk holes 25 and two or more screw holes 25a may be provided. Furthermore, the crimping blade unit 19 will be more stable if the vertical lengths of the crimping blade 17 and the crimping blade base 18 are the same or if the crimping blade base 18 is larger than the crimping blade 17. In this case, the vertical length of the upper comb blade 21a is equal to or less than the vertical length of the lower comb blade 21b.

[0035] Furthermore, when the crimping blade 17 and the crimping blade base 18 are fixed, there is a possibility that the upper comb blade 21a and the lower comb blade 21b may become misaligned due to deviations caused by processing tolerances, so it is desirable to make the width of the upper comb blade 21a equal to or smaller than the width of the lower comb blade 21b to absorb the deviation.

[0036] As shown in Figure 7, when assembling the crimping blade unit 19, two positioning pins 26 are placed in the two positioning holes 24a of the crimping blade base 18, and the crimping blade 17 is placed on the crimping blade unit 19 so that the two positioning holes 24 of the crimping blade 17 align with the two positioning pins 26. Finally, the crimping blade 17 is fixed to the crimping blade base 18 with screws 27.

[0037] Fig. 8 is a perspective view showing a first example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20. Fig. 9 is a side view showing a first example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20.

[0038] For example, as shown in Figures 8 and 9, a screw hole may be provided on the surface of the crimping blade base 18 that comes into contact with the unit base 20, and the crimping blade base 18 may be fixed to the unit base 20 with a screw 23. Specifically, as shown in Figure 4, a screw hole 23a (see Figure 4) is provided in the lower part of a portion 22a of the crimping blade base 18 where the plurality of lower comb blades 21b are not provided, into which a screw is fastened to fix the unit base 20 to the crimping blade base 18. Note that a drilled hole or a countersunk hole may be used instead of the screw hole 23a.

[0039] Fig. 10 is a perspective view showing a second example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20. Fig. 11 is a side view showing a second example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20.

[0040] As shown in Figures 10 and 11, a screw hole may be provided on the underside of an extension 28 that extends the lower side surface of the crimping blade base 18 laterally, and the crimping blade base 18 may be fixed to the unit base 20 with a screw 23.

[0041] Fig. 12 is a perspective view showing a third example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20. Fig. 13 is a perspective view showing a fourth example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20. Fig. 14 is a perspective view showing a fifth example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20. Fig. 15 is a top view showing the fifth example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20.

[0042] 12 to 15, an extension 28 that is thinner than that in the case of Figures 10 and 11 may be provided on a side of the crimping blade base 18 other than the side where the multiple heat dissipation fins 11 are inserted, and a drilled hole 28a may be provided in the extension 28 to fix the crimping blade base 18 to the unit base 20 with a screw. Note that a countersunk hole may be used instead of the drilled hole 28a.

[0043] Fig. 16 is a perspective view showing a sixth example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20. Fig. 17 is a perspective view showing a seventh example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20. Fig. 18 is a perspective view showing an eighth example of a method for fixing the crimping blade base 18 according to the first embodiment to the unit base 20.

[0044] 16, an L-shaped plate 29 having a hole 29a may be attached to a side of the crimping blade base 18 other than the side where the heat dissipation fins 11 are inserted, and the crimping blade base 18 may be fixed to the unit base 20 with screws. Also, as shown in FIGS. 17 and 18, an L-shaped plate 29 having a hole 29a may be attached to the extension 28, and the crimping blade base 18 may be fixed to the unit base 20 with screws.

[0045] Next, a method for fitting the power module section 12 and the heat sink 13 will be described. Fig. 19 is a front view illustrating the process of attaching the heat sink 13 to the crimping blade unit 19 in the first embodiment. Fig. 20 is a front view illustrating the process of integrating the power module section 12 and the heat sink 13 in the first embodiment. Fig. 21 is a front view of the power module 14 manufactured using the manufacturing apparatus for the power module 14 according to the first embodiment.

[0046] As shown in Fig. 7, first, the crimping blade 17 is fixed onto the crimping blade base 18 with a screw 27 to form the crimping blade unit 19. Next, as shown in Fig. 9, etc., the crimping blade unit 19 is fixed onto the unit base 20 with a screw.

[0047] 19, when attaching the heat sink 13 to the crimping blade unit 19, the heat sink 13 is aligned at a position where the comb blades 21 of the crimping blade unit 19 and the heat dissipation fins 11 of the heat sink 13 are alternately arranged so that the heat dissipation fins 11 (see FIG. 2) fit into the spaces formed between adjacent comb blades 21 (see FIG. 3). Then, the multiple heat dissipation fins 11 of the heat sink 13 are inserted into the spaces formed between the adjacent comb blades 21 of the crimping blade unit 19.

[0048] Next, as shown in FIG. 20 , the power module unit 12 is placed at a position where the first uneven portion 15 a (see FIG. 2 ) of the fin base 9 and the second uneven portion 15 b (see FIG. 2 ) of the heat sink base 10 are fitted together, and a press load is applied from above the power module unit 12. The first uneven portion 15 a of the fin base 9 is fitted together with the second uneven portion 15 b of the heat sink base 10 (see FIG. 2 ), completing the power module 14 as shown in FIG. 21 . At this time, the comb teeth 21 are inserted between adjacent heat dissipation fins 11, and the press load is supported by the comb teeth 21. Therefore, the press load is supported directly below the second uneven portion 15 b of the heat sink 13. Therefore, the crimping process can be performed without deforming the heat sink base 10.

[0049] 22 to 25 are front views showing first to fourth examples of the tip shapes of the comb blades 21 according to the first embodiment, respectively.

[0050] 22 to 25, and may be selected to match the shape of the space between adjacent heat dissipation fins 11. Specifically, the tip shape of the comb teeth 21 may be a square shape as shown in Fig. 22, a chamfered shape as shown in Fig. 23, a triangular shape as shown in Fig. 24, or an arc shape as shown in Fig. 25.

[0051] Next, a modification of the first embodiment will be described. Fig. 26 is a top view of a manufacturing apparatus for a power module 14 according to a first modification of the first embodiment. Fig. 27 is a top view showing a state in which the heat sink 13 is attached to the crimping blade unit 19 in the first modification of the first embodiment. Fig. 28 is a front view showing a state in which the heat sink 13 is attached to the crimping blade unit 19 in the first modification of the first embodiment.

[0052] 26 to 28, a heat sink insertion opening 36 is formed on the side of the crimping blade unit 19, allowing multiple heat dissipation fins 11 of the heat sink 13 to be inserted into the space formed between adjacent comb blades 21. A positioning member 31 for abutting and positioning the heat sink base 10 may be provided on the opposite side of the heat sink insertion opening 36 on the top surface of the unit base 20. Note that A in FIG. 28 is the clearance between the comb blade 21 and the heat dissipation fin 11.

[0053] Fig. 29 is a front view showing a state in which the power module 14 is attached to the crimping blade unit 19 in Modification 2 of Embodiment 1. Fig. 30 is a top view showing a state in which the power module 14 is attached to the crimping blade unit 19 in Modification 2 of Embodiment 1.

[0054] 29 and 30 , a plurality of first holes 10a may be provided in the surface of the heat sink base 10 facing the power module unit 12. A plurality of positioning pins 34 for abutting and positioning the power module unit 12 can be attached to the first holes 10a. Two of the plurality of first holes 10a are provided on diagonal lines sandwiching the power module unit 12.

[0055] Fig. 31 is a front view showing a state in which the power module 14 is attached to the caulking blade unit 19 in the third modification of the first embodiment. Fig. 32 is a top view showing a state in which the power module 14 is attached to the caulking blade unit 19 in the third modification of the first embodiment.

[0056] 31 and 32 , the power module unit 12 may be provided with main terminals 8 as connection terminals connectable to an external device (not shown), and positioning pins 34 may be inserted into second holes 8a of the main terminals 8. Specifically, the multiple positioning pins 34 are inserted into the second holes 8a of some of the multiple main terminals 8.

[0057] In these cases, it becomes easier to position the heat sink 13 relative to the crimping blade unit 19 and to position the heat sink 13 relative to the components included in the power module section 12, further improving the productivity of the power module 14.

[0058] The crimping blade unit 19 is not limited to a configuration in which one crimping blade 17 and one crimping blade base 18 are combined, but the same effect can be obtained even if the configuration is a combination of two or more crimping blades 17 and crimping blade bases 18.

[0059] Next, the effects of the first embodiment will be described while comparing it with the conventional crimping device described in Patent Document 1.

[0060] The crimping device described in Patent Document 1 has a configuration in which multiple crimping blades and multiple spacers are alternately combined and fixed with a shaft and screws, resulting in a large number of parts. As a result, each part needs to be positioned when assembling the crimping device, and the time required for positioning increases, resulting in a problem of reduced productivity of power modules.

[0061] In contrast, in the first embodiment, the manufacturing apparatus for the power module 14 includes a unit base 20 and a crimping blade unit 19 mounted on the unit base 20 and including a crimping blade 17 and a crimping blade base 18 to the upper surface of which the crimping blade 17 is fixed. The crimping blade 17 has a plurality of upper comb blades 21a extending in the vertical direction. The crimping blade base 18 has a plurality of lower comb blades 21b extending in the vertical direction and combining with the plurality of upper comb blades 21a to form a plurality of comb blades 21. A space is formed between adjacent comb blades 21 into which a plurality of heat dissipation fins 11 of a heat sink 13 can be inserted. The crimping blade 17 is fixed to the upper end of a portion 22a of the crimping blade base 18 where the plurality of lower comb blades 21b are not provided. The lower portion of the portion 22a of the crimping blade base 18 where the plurality of lower comb blades 21b are not provided is fixed to the upper surface of the unit base 20.

[0062] Therefore, the manufacturing device for the power module 14 is composed of the unit base 20 and the crimping blade unit 19 having the crimping blade 17 and the crimping blade base 18, and has fewer parts than conventional devices, making it easier to position each member when assembling the manufacturing device for the power module 14. As a result, the time required for positioning is reduced, and the productivity of the power module 14 can be improved.

[0063] Furthermore, in the crimping device described in Patent Document 1, if the crimping blades are not positioned perpendicular to the device, the crimping blades may buckle under a load lower than the intended load. If the crimping blades buckle, the load is used to deform the crimping blades, making it impossible to properly manufacture power modules. Furthermore, this can lead to deformation and breakage of the crimping blades, resulting in a loss of functionality as a crimping device. Therefore, adjustments must be made during assembly so that each crimping blade is positioned perpendicular, which takes time to assemble.

[0064] In contrast, in embodiment 1, the crimping blade 17 and the crimping blade base 18 are manufactured by cutting or wire electric discharge machining a metal block, for example, so that the perpendicularity between the comb blade 21 and the unit base 20 depends on the accuracy of the cutting process, and therefore no adjustment is required during assembly.

[0065] Furthermore, when a crimping blade needs to be replaced due to wear or damage, the crimping device described in Patent Document 1 requires approximately two to three hours to remove an assembly including multiple crimping blades, a shaft, and a spacer from the device, remove the crimping blades and spacers from the shaft, replace the worn or damaged crimping blade, and then reattach the assembly to the device.

[0066] In contrast, in embodiment 1, all that is required is to remove the screws 23, 27 and the positioning pin 26 and replace the crimping blade 17 having the multiple upper comb blades 21a or the crimping blade base 18 having the multiple lower comb blades 21b, which takes about 10 minutes, significantly reducing the time required for maintenance.

[0067] Furthermore, when the crimping blade 17 and the crimping blade base 18 are fixed, there is a possibility that the upper comb blade 21a and the lower comb blade 21b may become misaligned due to deviations caused by processing tolerances, but since the width of the upper comb blade 21a is equal to or smaller than the width of the lower comb blade 21b, the deviation can be absorbed.

[0068] Furthermore, since the vertical length of the upper comb blade 21a is less than or equal to the vertical length of the lower comb blade 21b, the vertical length of the crimping blade 17 is less than or equal to the vertical length of the crimping blade base 18, resulting in a stable crimping blade unit 19.

[0069] In addition, a heat sink insertion port 36 is formed on the side of the crimping blade unit 19, through which multiple heat dissipation fins 11 of the heat sink 13 can be inserted into the space formed between adjacent comb blades 21, and a positioning member 31 is provided on the opposite side of the heat sink insertion port 36 on the top surface of the unit base 20 to abut and position the heat sink base 10.

[0070] A first hole 10 a is formed in the surface of the heat sink base 10 that faces the power module section 12 , and a positioning pin 34 for positioning the power module section 12 can be attached to the first hole 10 a.

[0071] The power module section 12 is also provided with a main terminal 8 that can be connected to an external device, and the main terminal 8 is provided with a second hole 8a into which a positioning pin 34 can be inserted.

[0072] In these cases, it becomes easier to position the heat sink 13 relative to the crimping blade unit 19 and to position the heat sink 13 relative to the components included in the power module section 12, further improving the productivity of the power module 14.

[0073] Second Embodiment Next, a second embodiment will be described. Fig. 33 is a front view of a manufacturing apparatus for the power module 14 according to the second embodiment. Fig. 34 is a top view of the manufacturing apparatus for the power module 14 according to the second embodiment. Note that in the second embodiment, the same components as those described in the first embodiment are denoted by the same reference numerals, and description thereof will be omitted.

[0074] 33 and 34 , the second embodiment has a configuration in which a guide member 35 for guiding the heat sink 13 when inserting the heat dissipation fins 11 of the heat sink 13 into the spaces formed between adjacent comb blades 21 of the crimping blade unit 19 is added to the configuration of the first embodiment. The guide member 35 corresponds to a heat sink insertion guide.

[0075] The guide member 35 is provided around the heat sink insertion opening 36 in the unit base 20. Specifically, the guide member 35 is positioned from the side of the crimping blade unit 19 at a position calculated by subtracting the thickness of the comb blades 21 from the distance from the side of the heat sink base 10 to the side of the outermost heat dissipation fin 11. The guide member 35 is positioned so that, when the heat sink 13 is attached to the crimping blade unit 19, all of the heat dissipation fins 11 of the heat sink 13 can be inserted into all of the spaces formed between adjacent comb blades 21 of the crimping blade unit 19.

[0076] Next, a method of attaching the heat sink 13 to the crimping blade unit 19 will be described. Fig. 35 is a top view showing the heat sink 13 in the middle of being attached to the crimping blade unit 19 in embodiment 2. Fig. 36 is a front view showing the heat sink 13 attached to the crimping blade unit 19 in embodiment 2. Fig. 37 is a top view showing the heat sink 13 attached to the crimping blade unit 19 in embodiment 2.

[0077] 35, when the heat sink 13 is attached to the crimping blade unit 19 while the end of the heat sink base 10 is placed against the guide member 35, the outermost fin 11 of the heat sink 13 that is closest to the guide member 35 is inserted into the outermost space that is closest to the guide member 35 among the spaces formed between adjacent comb blades 21 of the crimping blade unit 19. Then, the other fins 11 are inserted in a chain reaction into the spaces that they should be in, and the heat sink 13 is attached to the crimping blade unit 19 as shown in FIGS.

[0078] As described above, in the second embodiment, the crimping blade unit 19 has a heat sink insertion opening 36 formed on the side thereof, through which the heat dissipation fins 11 of the heat sink 13 can be inserted into the space formed between the adjacent comb blades 21. Around the heat sink insertion opening 36 in the unit base 20, a guide member 35 is provided to guide the heat sink 13.

[0079] Therefore, the guide member 35 can prevent the multiple heat dissipation fins 11 from being inserted into a position other than the space where they are supposed to be, making it easy to position the heat sink 13 relative to the crimping blade unit 19. Furthermore, it is possible to reduce the number of incorrect insertions of the multiple heat dissipation fins 11 caused by human error, thereby improving the productivity of the power module 14.

[0080] Next, a modified example of embodiment 2 will be described. Fig. 38 is a top view showing a state in which the heat sink 13 is attached to the crimping blade unit 19 in the modified example of embodiment 2. Fig. 39 is a front view showing a state in which the heat sink 13 is attached to the crimping blade unit 19 in the modified example of embodiment 2.

[0081] 38 and 39 , positioning pins 35A are provided on the upper surface of the unit base 20 to position the heat dissipation fins 11 of the heat sink 13 so as to guide them into the spaces formed between adjacent comb blades 21, and holes 35a into which the positioning pins 35A can be inserted may be provided in the heat sink base 10. The holes 35a are provided in two or more of the four corners of the heat sink base 10. In this case, as in the above case, it is possible to easily position the heat sink 13 relative to the crimping blade unit 19, and the productivity of the power module 14 is improved.

[0082] Third Embodiment Next, a third embodiment will be described. Fig. 40 is a front view of a manufacturing apparatus for the power module 14 according to the third embodiment. Fig. 41 is a top view of the manufacturing apparatus for the power module 14 according to the third embodiment. Note that in the third embodiment, the same components as those described in the first and second embodiments are designated by the same reference numerals, and description thereof will be omitted.

[0083] 40 and 41, in the third embodiment, an upper plate 37, an intermediate plate 38, and an elastic member 39 are added to the configuration of the first embodiment. Note that the upper plate 37, the intermediate plate 38, and the elastic member 39 may also be added to the configuration of the second embodiment.

[0084] The top plate 37 is formed in a rectangular shape when viewed from above, and has the same contour as the contour of the unit base 20 when viewed from above. The top plate 37 is disposed at the upper end of the crimping blade unit 19 and is capable of supporting the peripheral edge of the heat sink base 10.

[0085] The intermediate plate 38 is formed in a rectangular shape when viewed from above, and has the same outline when viewed from above as the outline when viewed from above of the unit base 20. The intermediate plate 38 is disposed between the upper plate 37 and the unit base 20.

[0086] The elastic members 39 are respectively disposed between the upper plate 37 and the intermediate plate 38 and between the intermediate plate 38 and the unit base 20. The elastic members 39 are, for example, springs.

[0087] A heat sink insertion opening 36 (see FIG. 26 ) is formed on the side of the crimping blade unit 19, allowing multiple heat dissipation fins 11 of the heat sink 13 to be inserted into the space formed between adjacent comb blades 21. A heat sink insertion section 41 that communicates with the heat sink insertion opening 36 is provided on the part of the top plate 37 on the side of the heat sink insertion opening 36. A space 40 for removing a product is formed on the part of the top plate 37 that is perpendicular to the heat sink insertion section 41 in a top view.

[0088] Next, a method of fitting the power module unit 12 and the heat sink 13 will be described. FIG. 42 is a front view showing a state in which the heat sink 13 is attached to the crimping blade unit 19 in the third embodiment. FIG. 43 is a front view showing a state in which the power module unit 12 is placed on the heat sink 13 attached to the crimping blade unit 19 in the third embodiment. FIG. 44 is a front view showing a state in which application of a press load to the power module unit 12 has begun in the third embodiment. FIG. 45 is a front view showing a state in which application of a press load to the power module unit 12 has finished in the third embodiment. FIG. 46 is a front view showing a state in which the power module unit 12 and the heat sink 13 are integrated in the third embodiment. Note that in FIGS. 42 to 46, the power module unit 12 and the heat sink 13 are shown in cross section.

[0089] As shown in Fig. 7, first, the crimping blade 17 is fixed onto the crimping blade base 18 with screws 27 to form the crimping blade unit 19. Next, as shown in Fig. 9 etc., the crimping blade unit 19 is fixed onto the unit base 20 with screws. Next, as shown in Figs. 40 and 41, an upper plate 37, an intermediate plate 38, and an elastic member 39 are attached between the crimping blade unit 19 and the unit base 20.

[0090] 42, the heat dissipation fins 11 of the heat sink 13 are inserted into the spaces formed between adjacent comb blades 21 of the crimping blade unit 19 at a height such that the tips of the comb blades 21 do not come into contact with the bases of the heat dissipation fins 11. At this time, the peripheral edge of the heat sink base 10 is supported by the upper plate 37.

[0091] Next, as shown in FIG. 43, the power module section 12 is placed at a position where the first concave-convex portion 15a of the power module section 12 and the second concave-convex portion 15b of the heat sink 13 fit together.

[0092] Next, as shown in Figure 44, a press load is applied in this state using a processing device such as a press (not shown). In the initial stage of pressing, the power module section 12 receives the press load, and the first concave-convex portion 15a of the power module section 12 begins to fit into the second concave-convex portion 15b of the heat sink 13. At this time, the press load is also transmitted to the top plate 37, and the top plate 37 moves in the compression direction, i.e., downward, against the elastic force of the elastic member 39.

[0093] As the applied load increases, the heat sink 13 comes into contact with the comb teeth 21 of the crimping blade unit 19 and begins to support the load. As the applied load increases further, the first uneven portion 15a of the power module portion 12 fits into the second uneven portion 15b of the heat sink 13, as shown in Figure 45, and the power module portion 12 and the heat sink 13 are integrated together, completing the power module 14.

[0094] 46, the upper plate 37 moves upward due to the elastic force of the elastic member 39 when the load is removed, and the upper plate 37 and the heat sink 13 return to their original height positions. Finally, the power module 14 is grasped and removed from the product removal space 40.

[0095] As described above, in the third embodiment, there are provided an upper plate 37 disposed at the upper end of the crimping blade unit 19 and capable of supporting the peripheral portion of the heatsink base 10, an intermediate plate 38 disposed between the upper plate 37 and the unit base 20, and elastic members 39 respectively disposed between the upper plate 37 and the intermediate plate 38 and between the intermediate plate 38 and the unit base 20. A heatsink insertion opening 36 is formed on the side of the crimping blade unit 19, allowing multiple heat dissipation fins 11 of the heatsink 13 to be inserted into spaces formed between adjacent comb blades 21, and a heatsink insertion portion 41 communicating with the heatsink insertion opening 36 is provided on the portion of the upper plate 37 on the side facing the heatsink insertion opening 36. In addition, a space 40 for removing a product is formed on the side of the upper plate 37 perpendicular to the heatsink insertion portion 41 in a top view.

[0096] Therefore, after the power module section 12 and the heat sink 13 are integrated, the product floats from the crimping blade unit 19, making it easier to remove the product and improving the productivity of the power module 14.

[0097] Although the present disclosure has been described in detail, the above description is illustrative in all respects and is not restrictive. It is understood that countless variations not illustrated can be envisioned.

[0098] It should be noted that the embodiments can be freely combined, and each embodiment can be modified or omitted as appropriate.

[0099] Various aspects of the present disclosure are summarized below as appendices.

[0100] (Supplementary Note 1) A power module manufacturing device that manufactures a power module by applying pressure to a heat sink having a power module section with a first uneven portion provided on one surface thereof, a heat sink base with a second uneven portion provided on a surface facing the power module section, and a plurality of heat dissipation fins provided on a surface of the heat sink base opposite to the surface facing the power module section, and engaging the first uneven portion with the second uneven portion, the device comprising: a unit base; and a crimping blade unit that is mounted on the unit base and has a crimping blade and a crimping blade base on an upper surface of which the crimping blade is fixed, the crimping blade having a plurality of upper comb blades extending in a vertical direction, the crimping blade base having a plurality of lower comb blades that extend in a vertical direction and that constitute a plurality of comb blades by being combined with the plurality of upper comb blades, and spaces are formed between adjacent comb blades into which the plurality of heat dissipation fins of the heat sink can be inserted, The crimping blade is fixed to an upper end of a portion of the crimping blade base where the plurality of lower comb blades are not provided, and a lower portion of the portion of the crimping blade base where the plurality of lower comb blades are not provided is fixed to an upper surface of the unit base.

[0101] (Supplementary Note 2) The power module manufacturing apparatus according to Supplementary Note 1, wherein the width of the upper comb blade is equal to or less than the width of the lower comb blade.

[0102] (Supplementary Note 3) The power module manufacturing apparatus according to Supplementary Note 1 or Supplementary Note 2, wherein the number of the upper comb blades is the same as the number of the lower comb blades.

[0103] (Supplementary Note 4) The power module manufacturing apparatus according to any one of Supplementary Note 1 to Supplementary Note 3, wherein the vertical length of the upper comb blade is equal to or less than the vertical length of the lower comb blade.

[0104] (Appendix 5) A power module manufacturing apparatus as described in any one of Appendices 1 to 4, wherein a heat sink insertion port is formed on the side of the crimping blade unit, through which the plurality of heat dissipation fins of the heat sink can be inserted into the space formed between adjacent comb blades, and a positioning member is provided on the opposite side of the heat sink insertion port on the top surface of the unit base for abutting and positioning the heat sink base.

[0105] (Supplementary Note 6) The power module manufacturing apparatus according to any one of Supplementary Note 1 to Supplementary Note 4, wherein a first hole is provided in the surface of the heat sink base that faces the power module portion, and a positioning pin for positioning the power module portion can be attached to the first hole.

[0106] (Appendix 7) The power module manufacturing apparatus according to appendix 6, wherein the power module section is provided with a connection terminal that can be connected to an external device, the connection terminal is provided with a second hole, and the positioning pin can be inserted into the second hole.

[0107] (Appendix 8) A power module manufacturing apparatus as described in any one of Appendices 1 to 7, wherein a heat sink insertion port is formed on the side of the crimping blade unit, through which the plurality of heat dissipation fins of the heat sink can be inserted into the space formed between adjacent comb blades, and a heat sink insertion guide is provided around the heat sink insertion port in the unit base to guide the heat sink.

[0108] (Appendix 9) A power module manufacturing apparatus as described in any one of Appendices 1 to 7, wherein a positioning pin is provided on the upper surface of the unit base for positioning the plurality of heat dissipation fins of the heat sink so as to guide them into the space formed between adjacent comb blades, and the heat sink base is provided with a hole into which the positioning pin can be inserted.

[0109] (Appendix 10) A power module manufacturing device according to any one of Appendices 1 to 9, comprising: an upper plate arranged at the upper end of the crimping blade unit and capable of supporting the peripheral portion of the heat sink base; an intermediate plate arranged between the upper plate and the unit base; and elastic members respectively arranged between the upper plate and the intermediate plate and between the intermediate plate and the unit base; a heat sink insertion port is formed on the side of the crimping blade unit, into which multiple heat dissipation fins of the heat sink can be inserted into the space formed between adjacent comb blades; and a heat sink insertion portion communicating with the heat sink insertion port is provided on the part of the upper plate on the heat sink insertion port side.

[0110] (Supplementary Note 11) The power module manufacturing apparatus according to Supplementary Note 10, wherein a space for removing a product is formed in a portion of the upper plate that is orthogonal to the heat sink insertion portion in a top view.

[0111] (Supplementary Note 12) A method for manufacturing a power module using the power module manufacturing apparatus described in any one of Supplementary Note 1 to Supplementary Note 9, comprising: a step of configuring the crimping blade unit by fixing the crimping blade onto the crimping blade base with screws; a step of fixing the crimping blade unit onto the unit base with screws; a step of inserting the plurality of heat dissipation fins of the heat sink into the spaces formed between adjacent comb blades in the crimping blade unit; a step of positioning the power module part at a position where the first uneven portion of the power module part and the second uneven portion of the heat sink fit together; and a step of integrating the power module part and the heat sink by fitting the first uneven portion and the second uneven portion together by a press load.

[0112] (Supplementary Note 13) A method for manufacturing a power module using the power module manufacturing apparatus described in Supplementary Note 10 or Supplementary Note 11, comprising the steps of: configuring the crimping blade unit by fixing the crimping blade onto the crimping blade base with screws; fixing the crimping blade unit onto the unit base with screws; attaching the upper plate, the intermediate plate, and the elastic member between the crimping blade unit and the unit base; inserting the plurality of heat dissipation fins of the heat sink into the spaces formed between the adjacent comb blades of the crimping blade unit so that the tips of the comb blades are at height positions where they do not hit the bases of the heat dissipation fins; and arranging the power module part at a position where the first uneven portion of the power module part and the second uneven portion of the heat sink fit together. a step of applying a press load to move the top plate downward against the elastic force of the elastic member, thereby moving the tips of the comb teeth to a position where they come into contact with the bases of the heat dissipation fins, and further applying the press load to fit the first concave-convex portion and the second concave-convex portion together, thereby integrating the power module portion and the heat sink; and a step of removing the load to move the top plate upward due to the elastic force of the elastic member, thereby removing the power module.

[0113] 8 Main terminal, 8a Second hole, 10 Heat sink base, 10a First hole, 11 Heat dissipation fin, 12 Power module portion, 13 Heat sink, 14 Power module, 15a First uneven portion, 15b Second uneven portion, 17 Crimping blade, 18 Crimping blade base, 19 Crimping blade unit, 20 Unit base, 21 Comb blade, 21a Upper comb blade, 21b Lower comb blade, 31 Positioning member, 34 Positioning pin, 35 Guide member, 35A Positioning pin, 35a Hole, 36 Heat sink insertion port, 37 Upper plate, 38 Intermediate plate, 39 Elastic member, 40 Space, 41 Heat sink insertion portion.

Claims

1. A power module manufacturing device that manufactures a power module by applying pressure to a heat sink having a power module section with a first uneven portion on one surface thereof, a heat sink base with a second uneven portion on a surface facing the power module section, and a plurality of heat dissipation fins provided on the surface of the heat sink base opposite the surface facing the power module section, and engaging the first uneven portion with the second uneven portion, the device comprising: a unit base; and a crimping blade unit mounted on the unit base and having a crimping blade and a crimping blade base on whose upper surface the crimping blade is fixed, the crimping blade having a plurality of upper comb blades extending in the vertical direction, the crimping blade base having a plurality of lower comb blades extending in the vertical direction and combining with the plurality of upper comb blades to form a plurality of comb blades, and spaces are formed between adjacent comb blades into which the plurality of heat dissipation fins of the heat sink can be inserted, The crimping blade is fixed to an upper end of a portion of the crimping blade base where the plurality of lower comb blades are not provided, and a lower portion of the portion of the crimping blade base where the plurality of lower comb blades are not provided is fixed to an upper surface of the unit base.

2. The power module manufacturing apparatus according to claim 1, wherein the width of the upper comb blade is equal to or less than the width of the lower comb blade.

3. The power module manufacturing apparatus according to claim 1 or 2, wherein the number of the upper comb blades is the same as the number of the lower comb blades.

4. A power module manufacturing apparatus according to any one of claims 1 to 3, wherein the vertical length of the upper comb blade is equal to or less than the vertical length of the lower comb blade.

5. A power module manufacturing device as claimed in any one of claims 1 to 4, wherein a heat sink insertion port is formed on the side of the crimping blade unit, through which the plurality of heat dissipation fins of the heat sink can be inserted into the space formed between adjacent comb blades, and a positioning member is provided on the opposite side of the heat sink insertion port on the top surface of the unit base for abutting and positioning the heat sink base.

6. A power module manufacturing device according to any one of claims 1 to 4, wherein a first hole is provided on the surface of the heat sink base that faces the power module section, and a positioning pin for positioning the power module section can be attached to the first hole.

7. The power module manufacturing apparatus according to claim 6, wherein the power module section is provided with a connection terminal that can be connected to an external device, the connection terminal is provided with a second hole, and the positioning pin can be inserted into the second hole.

8. A power module manufacturing device as described in any one of claims 1 to 7, wherein a heat sink insertion opening is formed on the side of the crimping blade unit, allowing the multiple heat dissipation fins of the heat sink to be inserted into the space formed between adjacent comb blades, and a heat sink insertion guide for guiding the heat sink is provided around the heat sink insertion opening in the unit base.

9. A power module manufacturing device as claimed in any one of claims 1 to 7, wherein a positioning pin is provided on the upper surface of the unit base for positioning the heat dissipation fins of the heat sink so as to guide them into the space formed between adjacent comb blades, and the heat sink base is provided with a hole into which the positioning pin can be inserted.

10. A power module manufacturing device as claimed in any one of claims 1 to 9, comprising: an upper plate arranged at the upper end of the crimping blade unit and capable of supporting the peripheral portion of the heat sink base; an intermediate plate arranged between the upper plate and the unit base; and elastic members respectively arranged between the upper plate and the intermediate plate and between the intermediate plate and the unit base; a heat sink insertion port formed on the side of the crimping blade unit, through which the multiple heat dissipation fins of the heat sink can be inserted into the space formed between adjacent comb blades; and a heat sink insertion portion communicating with the heat sink insertion port is provided on the part of the upper plate on the side of the heat sink insertion port.

11. The power module manufacturing apparatus according to claim 10, wherein a space for removing a product is formed in a portion of the upper plate that is perpendicular to the heat sink insertion portion in a top view.

12. A method for manufacturing a power module using the power module manufacturing apparatus described in any one of claims 1 to 9, comprising the steps of: forming the crimping blade unit by fixing the crimping blade onto the crimping blade base with screws; fixing the crimping blade unit onto the unit base with screws; inserting the multiple heat dissipation fins of the heat sink into the spaces formed between adjacent comb blades in the crimping blade unit; positioning the power module part in a position where the first uneven portion of the power module part and the second uneven portion of the heat sink fit together; and integrating the power module part and the heat sink by fitting the first uneven portion and the second uneven portion together using a press load.

13. A method for manufacturing a power module using the power module manufacturing apparatus according to claim 10 or 11, comprising the steps of: forming the crimping blade unit by fixing the crimping blade onto the crimping blade base with screws; fixing the crimping blade unit onto the unit base with screws; attaching the upper plate, the intermediate plate, and the elastic member between the crimping blade unit and the unit base; inserting the plurality of heat dissipation fins of the heat sink into the spaces formed between the adjacent comb blades of the crimping blade unit at a height position such that the tips of the comb blades do not come into contact with the bases of the heat dissipation fins; and positioning the power module part at a position where the first uneven portion of the power module part and the second uneven portion of the heat sink fit together. a step of applying a press load to move the top plate downward against the elastic force of the elastic member, thereby moving the tips of the comb teeth to a position where they come into contact with the bases of the heat dissipation fins, and further applying the press load to fit the first concave-convex portion and the second concave-convex portion together, thereby integrating the power module portion and the heat sink; and a step of removing the load to move the top plate upward due to the elastic force of the elastic member, thereby removing the power module.

Images