Semiconductor module with cooling mechanism and production method thereof

1. A semiconductor module comprising:

a plurality of resin molded packages each of which includes a resin mold, the resin molded packages being laid to overlap each other as a package stack, the resin mold having embedded therein a power semiconductor chip which has a first and a second surface opposed to each other and on which a semiconductor power device is fabricated, a first heat spreader, a second heat spreader, and electric terminals coupled electrically with the semiconductor power device, the first heat spreader having a first surface and a second flat surface opposed to the first surface and being disposed at the first surface thereof in connection with the first surface of the semiconductor chip, the second heat spreader having a first surface and a second flat surface opposed to the first surface and being disposed at the first surface thereof in connection with the second surface of the power semiconductor chip, a portion of each of the electric terminals being exposed outside the resin mold, the resin mold also having formed therein a coolant path that is a portion of a coolant path through which a coolant flows to cool the power semiconductor chip;

first and second insulating films disposed over the second flat surfaces of the first and second heat spreaders of each of the resin molded packages, respectively;

first and second fin heat sinks joined to the first and second insulating films of each of the resin molded packages, respectively, so that adjacent two of the resin molded packages are arranged to have the first and second fin heat sink facing one another;

a first cover disposed on a first surface of the package stack;

a second cover disposed on a second surface of the package stack; and

a fastener which fastens the first and second covers to hold the package stack,

wherein each of the first and second fin heat sinks is equipped with corrugated fins,

wherein the fins of the first fin heat sink of one of adjacent two of the resin molded packages are arrayed 180° out of phase with the fins of the second fin heat sink of the other of adjacent two of the resin molded packages,

wherein tops of the fins of the first fin heat sink of one of adjacent two of the resin molded packages are located away from those of the fins of the second fin heat sink of the other of adjacent two of the resin molded packages through a gap, and

wherein the fins of the first fin heat sink and the fins of the second fin heat sink are configured to generate a turbulent or eddy flow of the coolant.

2. A semiconductor module as set forth in claim 1 , wherein the first heat spreader has a first metal plate disposed on the semiconductor chip, the first insulating film disposed on a surface of the first metal plate that is the second surface of the first heat spreader, and a first metal film disposed on the first insulating film away from the first metal plate, wherein the second heat spreader has a second metal plate disposed on the semiconductor chip, the second insulating film disposed on a surface of the second metal plate that is the second surface of the second heat spreader, and a second metal film disposed on the second insulating film and electrically kept away from the second metal plate, and wherein the first and second fin heat sinks are welded to the first and second metal films, respectively.

3. A semiconductor module as set forth in claim 1 , wherein the fins are arrayed so that they are corrugated, as viewed in a direction perpendicular to the second flat surface of each of the first and second heat spreaders.

4. A semiconductor module as set forth in claim 1 , wherein the fins are arrayed so that they are also corrugated, as viewed on two planes which extend perpendicular to the second flat surface of each of the first and second heat spreaders and perpendicular to each other.