Transcript How Chips Are Made? May 21st, 2013

How Chips Are Made?
May 21st, 2013
Agenda
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Introduction
How Chips are made?
How Transistors are made?
How Chips are made?
Question and Answers
A Little Company History
• Founded in July 18, 1968 by
Gordon Moore, and Robert
Noyce
• Based in Santa Clara California
• No. of employees ~110,000
• Serves ~Worldwide
• Products: Bluetooth chipsets,
flash memory, microprocessors,
motherboards chipsets, and
network interface cards
A Little Chip History
• First chip built in 1971 called Intel®
4004 processor
• Initial clock speed: 108KHz
• Transistors: 2,300
• Manufacturing technology: 10 micron
42 years later
• In 2012 3rd generation Intel® Core™
processor
• Initial clock speed: 2.9GHz
• Transistors: 1.4 billion
• Manufacturing technology: 22nm
How Chips Are Made? From Sand to Silicon
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Sand:
25% silicon
2nd frequent chemical found on earth
Base ingredients for semiconductor mfg
• Melted Silicon
• Wafer level ~300 mm/12in
• Purified through mfg/chemi process to
electronic grade si, 1 ailen atom/one
billion si atom
• The crystal Product results in mono crystal
called Ingot
• Mono-crystal Si Ingot
• Electronic Grade si
• Weights 100Kg, with purity
99.9999%
Cutting
Ingot Silicon
Cut into individual si discs
called wafer
Polished to flawless surface
UV Exposing
• Applying Photo (print) resist
• A thin/even Blue liquid , photo resist
finish, is poured to make a layer
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Just like what happens to film material in
a film camera when you press the shutter
button
When photo exposedSoluble
The exposure is done using circuit masks
pattern
Each die on each wafer contains millions
of transistors
How A transistor is made?
• What is a transistor?
• A transistor acts as a switch, controls the flow
of electrical current
• Intel makes 30m of them on the head of a pin
• Washing Off of Photo Resist
• The liquidly photo resist is dissolved by a
solvent, revealing patterns made by mask
• finish, is poured to make a layer
• Etching (Cutting) & Removing Photo Resist
• Extra material is cut, but photo resist is
left
• Photo resist is removed by chemicals and
desired shape becomes visible
How A transistor is made?
• Applying Photo resist
• The area is exposed to photo resist material so
should not get ions implanted. Ions are
electrically charged atoms, +/- electrons
• Ion Implantation
• To increase conductivity, ions are added
(doped) at very high speed to wafer
(300,000 km/hr)
• Removing Photo Resist
• The green material is the doped material
with alien atoms implanted
How A transistor is made?
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Ready Transistor
Insulation layer (magenta) is added
Three holes are dogged & filled copper
The filled copper is used to connect to other
transistors
• Electroplating
• The si wafer is put into a copper sulphate
• The copper ions travel from positive
terminal (anode) to negative terminal
(cathode). This is called electroplating
• After Electroplating
• On the surface the copper ions settle as a
thin layer of copper
How A transistor is made?
• Polishing
• The excess material is polished off.
How Chips Are Made? From Sand to Silicon
• Metal Layer
• Transistors are placed next to each other
according to design/architecture
• Metal layers are created to wire between
transistors
• Chips are made of several different wire
layers, just like a multi-layered highway
• Wafer Sort Test
• Functional test are run through each chip,
test response is compared to the right
answer. If no correct answer, debug or scrap
How Chips Are Made? From Sand to Silicon
• Wafer Slicing
• The wafer is cut into pieces of passed (good) dies
Chip Diagram
How Chips Are Made? From Sand to Silicon
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Individual Die
An individual die cut through slicing
Packaging
The substrate, the die and the
ehatspreader are put together
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Processor
Complete process