Semiconductor Heat Dissipating Unit Embedded Copper for Thermal Stability

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Solution Overview

Problem

The peeling of epoxy resin from heat dissipating units in semiconductor devices due to thermal cycling, caused by significant differences in linear expansion coefficients between the sealing member and the heat dissipating unit, leads to a decrease in reliability.

Innovation Solution

A semiconductor device design where a heat dissipating unit with a primary part made of aluminum and an embedded part made of copper or a copper alloy is used, with the embedded part having a lower linear expansion coefficient than the primary part, and the sealing member's expansion coefficient difference with the embedded part is minimized to prevent peeling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a composite heat dissipating unit with aluminum primary part and copper embedded part is used, then weight is reduced and cost is lowered, but peeling of the sealing member occurs due to thermal expansion coefficient mismatch

Engineering Contradiction:
Improveweight of heat dissipating unitVSAvoidpeeling resistance of sealing member
Core Design Contradiction:
Weight of moving objectVSReliability

Solution Approach 1:

The patent applies local quality by embedding copper material specifically in the sealed region where the sealing member contacts the heat dissipating unit, while the primary part remains aluminum. This creates a localized material property change that matches the thermal expansion coefficient in the critical bonding area, preventing peeling without requiring the entire heat dissipating unit to be copper, thus maintaining weight reduction and cost benefits.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining aluminum primary part with copper embedded part in a hybrid structure. The aluminum provides lightweight properties and cost effectiveness, while the copper embedded in the sealed region provides thermal expansion compatibility with the sealing member. This composite approach resolves the contradiction by integrating materials with complementary properties in a unified structure.

Inventive Principle:
Principle #40Composite materials

2Temperature

If copper is used as the main constituent of the heat dissipating unit, then heat dissipating characteristics are improved, but weight increases and cost increases

Engineering Contradiction:
Improveheat dissipating characteristicsVSAvoidweight of heat dissipating unit
Core Design Contradiction:
TemperatureVSWeight of moving object

Solution Approach 1:

The patent applies local quality by placing copper material specifically in the sealed region where heat dissipation is critical and thermal expansion matching is needed, rather than using copper for the entire heat dissipating unit. This localized copper embedding provides improved heat dissipating characteristics in the critical area while maintaining the lightweight advantage of aluminum for the bulk structure.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent uses partial action by embedding copper only in the sealed region rather than using copper throughout the entire heat dissipating unit. This partial application of copper provides sufficient heat dissipating improvement in the critical bonding area while avoiding the excessive weight and cost that would result from full copper construction.

Inventive Principle:
Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design effectively prevents peeling of the sealing member from the heat dissipating unit, enhancing the reliability and longevity of the semiconductor device while maintaining lightweight and cost-effective characteristics.

Implementation Method 1

the linear expansion coefficient of the second metal material is less than a linear expansion coefficient of the first metal material, and an absolute difference of the linear expansion coefficient of the second metal material and a linear expansion coefficient of the sealing member is less than or equal to 25% of a value of the linear expansion coefficient of the sealing member

Methodology Applied
Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

a front surface of the heat dissipating unit having a mounting region on which a rear surface of the substrate is mounted so as to dissipate heat generated by the semiconductor element

Methodology Applied
Scientific EffectHeat dissipation: Heat Sink

Data Source

PatentUS10262953B2Semiconductor device
Publication Date: 2019.04.16 FUJI ELECTRIC CO LTD
  • US10262953B2 patent drawing
  • US10262953B2 patent drawing
  • US10262953B2 patent drawing

AI summary

A semiconductor device includes a heat dissipating unit that includes a primary part made of a first metal material and an embedded part that is embedded in a front surface of the primary part and that is made of a second metal material, a front surface of the heat dissipating unit having a mounting region on which a rear surface of a semiconductor element substrate is mounted so as to dissipate heat generated by the semiconductor element; and a sealing member that seals the semiconductor element, the substrate, and a sealed region of the front surface of the heat dissipating unit, wherein the embedded part is formed in the sealed region, and an absolute difference of the linear expansion coefficient of the second metal material and that of the sealing member is less than or equal to 25% of a value of the linear expansion coefficient of the sealing member.