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INTRODUCTION
There is a saying in real estate; when land get expensive, multi-storiedbuildings are the alternative solution. We have a similar situation in the chip industry. For the past thirty years, chip designers have considered whether building integrated circuits multiple layers might create cheaper, more powerful chips. Performance of deep-sub micrometer very large scale integrated (VLSI) circuits is being increasingly dominated by the interconnects due to increasing wire pitch and increasing die size. Additionally, heterogeneous integration of different technologies on one single chip is becoming increasingly desirable, for which planar (2-D) ICs may not be suitable. The three dimensional (3-D) chip design strategy exploits the vertical dimension to alleviate the interconnect related problems and to facilitate heterogeneous integration of technologies to realize system on a chip (SoC) design. By simply dividing a planar chip into separate blocks, each occupying a separate physical level interconnected by short and vertical interlayer interconnects (VILICs), significant improvement in performance and reduction in wire-limited chip area can be achieved. In the 3-Ddesign architecture, an entire chip is divided into a number of blocks, and each block is placed on a separate layer of Si that are stacked on top of each other.
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1. Large scale integration of functionalities and disparate technologies on a single chip dramatically increases the chip area, which necessitates the use of numerous long global wires. These wires can lead to unacceptable signal transmission delays and increase the power consumption by increasing the total capacitance that needs to be driven by the gates. 2. Integration of disparate technologies such as embedded DRAM, logic, and passive components in SoC applications introduces significant complexity in materials and process integration. 3. The noise generated by the interference between different embedded circuit blocks containing digital and analog circuits becomes a challenging problem. 4. Although SoC designs typically reduce the number of I/O pins compared to a system assembled on a printed circuit board(PCB), several high performance SoC designs involve very high I/O pin counts , which can increase the cost per chip 5. Integration of mixed technologies on a single die requires novel design methodologies and tools ,with design productivity being a key requirement.
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Three-dimensional integration to create multilayer Si ICs is a concept that can significantly improve interconnect performance ,increase transistor packing density, and reduce chip area and power dissipation. Additionally 3D ICs can be very effective large scale on chip integration of different systems.
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In 3D design architecture, and entire(2D) chips is divided into a number of blocks is placed on separate layer of Si that are stacked on top of each other. Each Si layer in the 3D structure can have multiple layer of interconnects(VILICs) and common global interconnects.
ADVANTAGES OF 3D ARCHITECTURE
The 3D architecture offers extra flexibility in system design, placement and routing. For instance, logic gates on a critical path can be placed very close to each other using multiple active layers. This would result in a significant reduction in RC delay and can greatly enhance the performance of logical circuits. The 3D chip design technology can be exploited to build SoCs by placing circuits with different voltage and performance requirements in different layers. The 3D integration can reduce the wiring ,thereby reducing the capacitance, power dissipation and chip area and therefore improve chip performance. Additionally the digital and analog components in the mixed-signal systems can be placed on different Si layers thereby achieving better noise performance due to lower electromagnetic interference between such circuits blocks. From an integration point of view, mixed-technology assimilation could be made less complex and more cost effective by fabricating such technologies on separate substrates followed by physical bonding.
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Rents Rule:
It correlates the number of signal input and output (I/O) pins T, to the number of gates N, in a random logic network and is given by the following expressions : T=kNP -------------(i) Here k & P denote the average number of fan out per gate and the degree of wiring complexity (with P=1 representing the most complex wiring network), respectively, and are empirically derived as constants for a given generation of ICs.
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Where x is a variable of integration representing length and l is the length of the interconnect in gate pitches. The derivation of the wire-length distributed in a Ic is based on Rents Rule. To derive the wire length distribution I(l) of an integrated circuit, the latter is divided up into N logic gates, where N is related to the total number of transistor Nt in an integrated circuit by N=Nt/O where O is a function of the average fan-in(f.i0 and fan-out(f.o). The gate pitch is defined as the average separation between the logic gates and is equal to sqt(Ac/N) where Ac is the area of the chip. In order to derive the complete wire-length distribution for a chip, the stochastic wire-length distribution of a single gate must be calculated.
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The number of connections from the single logic gate in Block A to all other gate that are located at a distance of l gate pitches is determined using Rents Rule. The gates shown in the figure are grouped into three distinct but adjacent blocks(A,B&C), such that a closed single path can encircle one, two or three of these blocks. The number of connections between Block A and Block C is calculated by conserving all I/O terminals for blocks, A, B, and C, which states that terminals for blocks A, B, and C, are either interlock connections or external system connections. Hence, applying the principle of conservation of I/O pins to this system of three logic blocks, shown gives TA + TB + TC = TA to C + TA to B + TB to C + TABC .(iii) Where TA, TB, TC are the number of I/O blocks A, B, and C respectively. TA to C , TA to B, TB to C are the number of I/Os between blocks A and C, blocks A and B, and between blocks B and C, respectively. TABC represents the number of I/Os for the entire system comprising of all three blocks. From conservation of I/Os, the number of I /Os between adjacent blocks A and B, and between adjacent blocks A and B and between adjacent blocks B and C can be expressed as TA to B = TA + TB - TAB ...(iv) TB to C = TB + TC TBC ...(v) Substituting (iv) and (v) into (iii) gives TA to C = TAB + TBC TB - TABC (vi) Now the number of I/O pins for any single block or a group of blocks can be calculated using Rents Rule. If we assume that N, N, and N are the number of gates in blocks A, B, and C, respectively, then it follows that TB = k (NB)P (vii) TAB = k(NA + NB)P ....(viii) TBC = k(NB + NC )P .(ix) TABC = k(NA + NB +NC)P .(x) Where N = NA + NB + NC. Substituting (vii) (x) into (vi) gives TA to C = k [( NA + NB)P (NB)P + (NB + NC)P (NA + NB + NC)P] ..(xi) The number of interconnects between Block A and Block C (IA to C) is determined using the relation
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IA to C = k (TA to C) Where is related to the average fan out (f.o.) by = f.o. / (1+f.o.) Applying Rents Rule to all the layers, we have
Here, T is the number of I/Os for the entire design, Ti represents the number of I/O ports connecting n layers. Hence it follows that Tint = n (1- nP-1) k (N/n)P and Text,i = Ti Tint/n = knP-1 (N/n)P Here, Text,i , is the average of I/O ports per layer.
B) ESTIMATING 2-D AND 3-D CHIP AREA In integrated circuits that are wire-pitch limited in size, the area require by the wiring network is assumed to be much greater than the area required by the logic gates. For the purpose of minimizing silicon real estate and signal propagation delays, the wiring network is segmented into separate tiers that are physically fabricated in multiple layers. An interconnect tier is categorized by factors such as metal line pitch and cross-section, maximum allowable signal delay and communication mode (such as intra block, or inter block). A tier can have more than one layer of metal interconnects if necessary, and each tier or layer is connected to the rest of the wiring network and the logic gates by vertical vias. The tier closest to the logic devices (referred to as the local tier) is normally for short distance intra block communications. Metal lines in this tier will normally be the shortest. They will also normally have the finest pitch. The tier furthest away from the device layer (referred to as global tier) is responsible for long distance across chip inter block communications, clocking and power distribution. Since this tier is populated by the longest of wires, the metal pitch is the largest to minimize signal propagation delays. A typical modern IC interconnects architecture will define three wiring tiers: local, semi-global, and global. The semi-global tier is normally responsible for inter block communications across intermediate distances.
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The area of the chip is determined by the total wiring requirement. IN terms of gate pitch, the total area required by the interconnect wiring can be expressed as Arequired = Ac (PlocLtotal_loc+PsemiLtotal_semi+PglobLtotal_glob)/N Where, Ac N Ploc Psemi Pglobal Ltotal_loc Ltotal_semi Ltotal_glob Chip area ; number of gates; local pitch; semi global pitch; global pitch; total lengths of local interconnects; total length of semi global interconnects; total length of global interconnects;
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The total interconnects length for any tier can be found by integrating the wire-length distribution within the boundaries that define the tier. Hence it follows that Ltotal_loc= X li (l) dl Ltotal_semi=X li (l) dl Ltotal_glob = X li (l) dl Where X is a correction factor that converts the point to point interconnect length to wiring net length (using a linear net model, X=4/(f.o. + 3)
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reduced for the 3-Dchip. The significant reductions in chip area demonstrated by the 3-D results are a consequence of the fraction of wires that were converted from horizontal in 2-D to vertical VILICs in 3-D. it is assumed that the area required by VILICs is negligible. These results demonstrate, with given assumptions, that a 3-D IC can operate at the same performance level, as measured by the longest wire delay, as its 2-D counterpart while using up about 30% less silicon real estate. However, it is possible for 3-D ICs to achieve greater performance than their 2-Dcounterparts by reducing the interconnect impedance at the price of increased chip area as discussed next.
corresponding 2-D chip, which can be obtained by increasing the semi global pitch beyond that for the 4-GHz case. Two scenarios are considered 1) global pitch is increased to match the global pitch for the 2-d case and 2) global pitch is increased to match the chip area (footprint) for the 2-d case. Note that the delay requirements sets a maximum values of interconnect length are given tier. Therefore, as interconnect lengths are increased, lines which exceed this maximum length criterion for that particular tier need to be rerouted on upper ties. Beyond the maximum performance point for the 3-d chip, the performance gain becomes increasingly smaller in comparison to the decrease in performance resulting from the increase in chip area or reconnect delay. Furthermore, as the semi global wires need to be rerouted on the global tiers, which eventually leads to overcrowding of the global tier . Any further increases in the wiring density in the global tier forces a reduction in the global pitch.
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It can be observed that by using twice the number of metal layers the performance of the 3-D chip can be increased by an additional amount of 35% as compared to the 3-d chip with the same total number of metal layers as in 2-d . It can be observed that for the more aggressive technologies , the decrease in interconnect delay from 2-D to 3-D case is less impressive. This indicates that more than two active layers are possibly needed for those advanced nodes. The figure also shows the impact of moving only the repeaters to the second layer Si layer . It can also be observed that for more aggressive technologies , the decrease in interconnect delay from 2-D to 3-D case is less impressive This indicates that more than two active layers are possibly needed for those advanced nodes.
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Advantage
MOS on transistors fabricated on polysilicon exhibit very low surface mobility values [of the order of 10 cm/Vs]. MOS transistors fabricated on polysilicon have high threshold voltages (several volts) due to the high density of surface states (several 10 cm ) present at the grain boundaries.
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Disadvantage
This technique, however, may not be very practical for 3-D devices because of the high temperature involved during melting of the polysilicon. Difficulty in controlling the grain size variations.
Advantage
The quality of devices fabricated on these epitaxial layer can be as good as those fabricated underneath on the seed wafer surface, since the grown layer is single crystal with few defects.
Disadvantage
The high temperatures involved in this process cause significant degradation in the quality of devices on lower layers.
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Advantage
Devices on all active levels have similar electrical properties. Since all chips can be fabricated separately and later bonded ,there is independence of processing temperature.
Disadvantage
The lack of precision restricts the interchip communication to global metal lines.
Advantages
This technique offers flexibility of creating multiple active layers This is a low temperature technique
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Recently, interlayer (VLIC)metallization schemes for 3-d ICs have been demonstrated using direct wafer bonding. These techniques are based on the bonding of two wafers with their active layers connected through vias ,which serve as VILICs . One method is based on the bonding of a thinned top wafer to a bottom wafer with a organic adhesive layer of polyamide in between. Interchip vias are etched through the ILD(inter level dielectric ),the thinned top silicon wafer and through the cured adhesive layer ,with an approx depth of 20 m prior to the bonding
process .the interconnect chip via made of chemical wafer depositor (CVD). Tin liner and CVDW plug provides a vertical interconnect (VILIC)between the upper most metallization levels of both layers . the bonding between the two wafers is done using a flip-chip bonder with split beam optics at a temperature of 400 degree Celsius. A second technique realizes on the thermo compression bonding between the metal parts in each wafer. In this method, Cu-Ta pads on both wafers save as electrical contacts between the interchips via on the top thinned silicon wafer and the upper most interconnects on the bottom silicon wafer. The Cu-Ta pads can also function as small bond pads for wafer bonding. Additionally, dummy metal patterns can be made to increase the surface area for wafer bonding.
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The Cu-Ta bilayer pads with a combined thickness of 700 nm are fused together by applying a compressive force at 400 degree Celsius. This technique offers the advantage of a metal metal interface that will lower the interface thermal resistance between the two wafers (and, hence, provide better conduction) and can be beneficial as a partial ground plane for lowering the electromagnetic effects.
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APPLICATIONS
Portable electronic digital cameras, digital audio players, PDAs, smart cellular phones, and handheld gaming devices are among the fastest growing technology market for both business and consumers. To date, one of the largest constraints to growth has been affordable storage, creating the marketing opportunity for ultra low cost internal and external memory. These applications share characters beyond rapid market growth. Portable devices all require small form factors ,battery efficiency, robustness, and reliability. Both the devices and consumable media are extremely price sensitive with high volumes coming only with the ability to hit low price points. Device designers often trade application richness to meet tight cost targets. Existing mask ROM and NAND flash non volatile technology force designers and product planners to make the difficult choice between low cost or field programmability and flexibility. Consumers value the convenience and ease of views of readily available low cost storage. The potential to dramatically lower the cost of digital storage weapons many more markets than those listed above. Manufacturers of memory driven devices can now reach price points previously inaccessible and develop richer, easier to use products.
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CONCLUSION
The 3 D memory will just the first of a new generation of dense, inexpensive chips that promise to make digital recording media both cheap and convenient enough to replace the photographic film and audio tape. We can understand that 3-D ICs are an attractive chip architecture, that can alleviate the interconnect related problems such as delay and power dissipation and can also facilitate integration of heterogeneous technologies in one chip. The multilayer chip building technology opens up a whole new world of design like a city skyline transformed by skyscrapers, the world of chips may never look at the same again.
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REFERNCES
1. Proceedings of the IEEE, vol 89,no 5,may 2001: (a) Jose E Schutt-Aine , sung-Mo Kang, Interconnections addressing the next challenge of IC technology at page 583 (b) Robert h Have Mann, James A Hutch by, High performance interconnects: an integration overview at page 586. (c) Kaustav Banerjee, Shukri J Souri, Pawan Kapur and Krishna C Sara swath 3-D ICs: a novel chip design for improving deep sub micrometer interconnect performance and Soc integration at page 602. 2. Electronics today June 2002.
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