How Chips Are Made? May 21 st, 2013. Agenda Introduction How Chips are made? How Transistors are...
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Transcript of How Chips Are Made? May 21 st, 2013. Agenda Introduction How Chips are made? How Transistors are...
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How Chips Are Made?May 21st, 2013
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Agenda
• Introduction• How Chips are made?• How Transistors are made?• How Chips are made?• Question and Answers
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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
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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
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How Chips Are Made? From Sand to Silicon• Sand:• 25% silicon• 2nd frequent chemical found on earth• Base ingredients for semiconductor mfg
• Mono-crystal Si Ingot• Electronic Grade si• Weights 100Kg, with purity
99.9999%
• 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
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Cutting
Ingot SiliconCut into individual si discs
called wafer Polished to flawless surface
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• Applying Photo (print) resist• A thin/even Blue liquid , photo resist
finish, is poured to make a layer
UV Exposing• Just like what happens to film material in
a film camera when you press the shutter button
• When photo exposedSoluble• The exposure is done using circuit masks
pattern• Each die on each wafer contains millions
of transistors
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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
• 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
• 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
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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
• Removing Photo Resist• The green material is the doped material
with alien atoms implanted
• Ion Implantation• To increase conductivity, ions are added
(doped) at very high speed to wafer (300,000 km/hr)
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How A transistor is made?• Ready Transistor• Insulation layer (magenta) is added• Three holes are dogged & filled copper• The filled copper is used to connect to other
transistors
• After Electroplating• On the surface the copper ions settle as a
thin layer of copper
• 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
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How A transistor is made?• Polishing• The excess material is polished off.
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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
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How Chips Are Made? From Sand to Silicon• Wafer Slicing• The wafer is cut into pieces of passed (good) dies
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Chip Diagram
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How Chips Are Made? From Sand to Silicon
• Individual Die• An individual die cut through slicing
• Processor• Complete process
• Packaging• The substrate, the die and the
ehatspreader are put together