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PROGRAMABLE DEVICES This is the broadest category of products we cover in one section as can readily be seen when considering that the parts reported on range in die size from 7 mm2 to 115 mm2. Technologies covered range from standard to antifuse, and some unusual combinations of process features occur. For example, the AT&T use of a salicide process which we regard as being quite advanced, on a die that looks quite primitive otherwise. None of these devices used any of the process features generally regarded as indicating advanced capability like more than two or three metal or poly layers, plugs for vertical interconnect, or chemical-mechanical planarization (CMP). 4-1 HORIZONTAL DIMENSIONS (DESIGN RULES) PROGRAMABLE DEVICES Actel AT&T Altera Altera Lattice AMD A1280A FPGA 9423 ATT3020 FPGA 9323 EMP5128LC EPLD 9349 EMP7032 EPLD 9401 GAL22V10 EPLA 9351 PAL22V10 EPLA 9402 Die size 10.5 x 10.9 mm (115 mm2) 4.2 x 5.3 mm (22 mm2 ) 6.9 x 8.1 mm (56 mm2 ) 2.7 x 4.0 mm (11mm 2) 2.4 x 2.9 mm (7mm 2 ) 2.6 x 4.4 mm (11mm 2) Min M2 width 1.5µm 1.3µm 2.2µm 1.0µm 1.5µm 2.0µm Min M1 width 1.8µm 0.7µm 1.5µm 0.6µm 1.0µm 1.8µm Min M2 space 1.9µm 1.6µm 1.7µm 1.0µm 1.4µm 2.0µm Min M1 space 1.1µm 1.1µm 1.5µm 0.6µm 1.1µm 1.4µm Min via 1.5µm 1.2µm 1.8µm 1.6µm 1.1µm 1.8µm 1.2µm 1.0µm 1.3µm 1.0µm 1.0µm 1.9µm Min Poly 2 1.7µm NA 0.7µm NA NA NA Min Poly 1 0.7µm 0.8µm* 1.4µm 0.45µm* 0.5µm 0.7µm Min gate - (N)† 0.7µm 0.8µm 0.75µm 0.45µm 0.5µm 0.7µm Min gate - (P)† 0.9µm 0.9µm 0.95µm 0.7µm 0.65µm 0.7µm Cell pitch 5 x 4.25µm NA 5 x 11µm 6.5 x 17µm Cell area 21µm2 NA 55µm2 110µm2 (Met. to Met.) Min cntct (Met. to Si) *Polycide †Physical gate length TABLE 4 - 1 12.4 x 15.9µm 197µm2 10.7 x 20.2µm 216µm2 VERTICAL DIMENSIONS PROGRAMABLE DEVICES Actel AT&T Altera Altera Lattice AMD A1280A FPGA 9423 ATT3020 FPGA 9323 EMP5128LC EPLD 9349 EPM7032 EPLD 9401 GAL22V10 EPLA 9351 PAL22V10 EPLA 9402 Final passivation 1.15µm 0.75µm 1.7µm 0.7µm 0.9µm 1.1µm Metal 2 1.1µm 1.1µm 1.25µm 1.15µm 0.85µm 1.5µm Metal 1 0.75µm 0.6µm 0.95µm 0.8µm 0.65µm 0.75µm Intermetal dielectric 0.7µm 0.6µm 0.75µm 0.6µm 0.4µm 0.75µm Poly 2 0.25µm NA 0.25µm NA NA NA Poly 1 0.25µm 0.4µm* 0.15µm 0.35µm* 0.3µm 0.3µm Recessed oxide 0.9µm 0.5µm 0.65µm 0.5µm 0.5µm 0.75µm N-well 3µm 1.5µm ?1 4µm 6.5µm 5µm P-well ?1 ?1 ?1 3µm 6.5µm 4.5µm Epi 7.5µm (P) 6.5µm (P) None None None None *Polycide TABLE 4 - 2 1Could not delineate DIE MATERIALS PROGRAMABLE DEVICES Actel AT&T Altera Altera Lattice AMD A1280A FPGA 9423 ATT3020 FPGA 9323 EMP5128LC EPLD 9349 EPM7032 EPLD 9401 GAL22V10 EPLA 9351 PAL22V10 EPLA 9402 Final passivation Nitride on glass Nitride on glass Nitride on glass Nitride Nitride on glass Glass Metal 2 Aluminum Titanium Aluminum Aluminum Titanium Aluminum Titanium-tungsten Titanium-nitride Aluminum Aluminum Metal 1 Aluminum Titanium-nitride Aluminum Titanium-nitride Titanium Titanium Aluminum Titanium-tungsten Titanium Aluminum Titanium-tungsten Titanium-nitride Aluminum Titanium-nitride Titanium Aluminum Titanium-nitride Titanium Intermetal dielectric Glass Glass Glass Glass Glass Glass Reflow glass BPSG BPSG BPSG BPSG BPSG BPSG Polycide metal NA Titanium NA Tungsten NA NA TABLE 4 - 3 TECHNOLOGY DESCRIPTION ACTEL A1280A FPGA (Antifuse) Introduction Ref. report SCA 9409-348 These parts were packaged in 172-pin, Ceramic Quad Flat Packs (CQFPs), date coded week 23 of 1994. All parts were fully functional production samples. This architecture provides 8,000 equivalent gate array gates or 20,000 PLD equivalent gates. The devices operate from a standard 5V power source. See tables for specific dimensions and materials identification and see figures for examples of physical structures. Unusual/Unique Features - Antifuse structure. - Relatively complex process including various length shallow source/drain extensions. Quality Quality of process implementation was normal. Metal thinning was significant but not of serious concern. In the area of layer patterning, both etch definition and control (depth) were good. Alignment/registration was also good. Packaging/assembly quality and workmanship was good as well. Technology These devices were made by a twin (multiple)-well CMOS process in a P-epi on a P substrate. Two levels of metal and two levels of polysilicon were used. A normal recessed-oxide isolation was employed. No attempt to shorten the birdsbeak area was made. The cell array used poly 2 over diffusion with ultra thin oxide windows for programming. Both metal levels consisted of aluminum and were defined by standard dry etch techniques. Metal 2 used no cap but did have a relatively thick layer of titanium 4-2 underneath as an adhesion/barrier layer. Metal 1 used a titanium-nitride barrier on a very thin titanium adhesion layer, but also had no cap layer on top. No plugs were present at vias or contacts and no polycide or salicide source/drain treatment was used. No buried contacts were used. Metal 2 contacted metal 1, and metal 1 contacted diffusions and poly. Planarization of the intermetal dielectric was by deposited glass layers and planarizing etch. A spin-on-glass (SOG) was included. The dielectric under metal 1 was planarized by a reflow process. Poly 1 (no polycide) provided all gates on the die while poly 2 was used exclusively for program elements. All gates used oxide sidewall spacers that were left in place. In addition, various length, lightly doped, shallow N+ extensions were present at some Nchannel gates. In some cases, these were present on both sides of the gate, in others, only on one side. Also, of course, another totally separate diffusion is used in the memory array (see below). Both gate oxide and antifuse dielectric appeared to be normal grown oxides, but a thin layer of what appeared to be silicon nitride was present directly below the BPSG reflow glass (above poly 2). Since we found no cutouts that would indicate its use as a mask definition layer, we assume it is intended to mask the lightly doped very shallow diffusion extensions from possible doping effects of the reflow glass. Overall minimum feature measured anywhere on these dice was the 0.7 micron poly 1 width. Minimum physical gate lengths measured were 0.7 micron for N- channel and 0.9 micron for P-channel. Array Cell Structures These parts used round windows of ultra thin ruptureable oxide for programming. These windows were located between poly 2 and special N+ diffusion "program" lines in 8-bit groups between piggyback metal contacts. The array was in the form of an X-Y matrix. Cells are programmed by "zapping" the thin dielectric to establish a connection between the poly 2 line and the N+ diffusion line. Series resistance is kept low by connecting the N+ with piggyback metal 2 lines. Individual cell size including the overhead area caused by the piggyback connections, was 5 x 4.25 microns (21.25 microns2) although individual cells measure only 3.5 x 4.25 microns (<15 microns2). Diameter of the antifuse window was measured to be 1.25 micron. 4-3 Packaging/Assembly As mentioned, devices were packaged in standard 172-pin, CQFPs. All pins were connected. Die attach was by a silver glass or epoxy and standard ultrasonic wirebonds using aluminum wire were used. Two tiers of bond pads were used in the package. No special heatsink or other elements were used. No evidence of a die coat was found. 4-4 ® PIN 1 The Actel A1280 FPGA circuit die. Mag. 16x. ® EMBEDDING MEDIA section, Mag. 8000x POLY 1 GATE Mag. 3700x, 60° N+ Mag. 30,000x, 50° Actel A1280. SEM views illustrating device structures. TECHNOLOGY DESCRIPTION AT&T ATT3020-70 FPGA Introduction Ref. report SCA 9410-375 These parts were packaged in 84-pin, ceramic Pin-Grid Array (PGA) packages, date coded week 23 of 1993. Parts were fully functional production samples. These devices provide an architecture composed of configuration program store plus three types of configurable elements: perimeter I/O, core logic, and interconnect. The 3020 offers 8 x 8 configurable logic blocks and 2000 equivalent gates. They operate from a standard 5V power source. See tables for specific dimensions and materials identification and see figures for examples of physical structures. Unusual/Unique Features - Unusual combination of process features. Quality Quality of process implementation was less than desirable in the area of metal 1 step coverage at contacts where we found very severe metal thinning. Layer patterning and etch definition were good, but control (depth) was very poor at sidewall definition resulting in severe overetching of the recessed oxide. Alignment/registration was good. Packaging/assembly was normal to poor due to silicon chipouts at the edges of the die. Technology These devices were made by a twin (multiple)-well CMOS process, employing a P-epi on a P substrate. Two levels of metal and one level of polycide (titanium on polysilicon) were used. A severely etched-back, recessed-oxide isolation was employed, but birdsbeak areas were not particularly short. No evidence of any unusual gate oxide or dielectric layers was found. 4-5 Both metal levels consisted of aluminum defined by standard dry etch techniques. Cap layers were not used on either metal 2 or metal 1, but metal 1 did make use of a barrier. It consisted of titanium-nitride on titanium. Standard vias and contacts were used (no plugs) and no buried contacts (poly to silicon) were present. Metal 2 contacted metal 1, and metal 1 contacted diffusions, and polycide. Planarization of the intermetal dielectric was by at least two layers of deposited glass and some minimal planarizing etch. The dielectric under metal 1 was planarized by a reflow process. Overall, planarization was minimal and poor. No spin-on-glass (SOG) was used and the severe overetching of the recessed oxide created very high steps at every polycide line where it crossed this oxide. These steps were accentuated rather than decreased by the subsequent attempt at planarization. All gates were formed by the layer of polycide and all used sidewall spacers that were left in place. A somewhat unusual feature present was the use of salicide on the sources/drains, which although certainly not unheard of, was unexpected on a die with the rudimentary process features present everywhere else. Overall minimum feature measured anywhere on these dice was the 0.7 micron metal 1 width. Minimum physical gate lengths measured were 0.8 micron for N-channel and 0.9 micron P-channel. Array Cell Structures These parts used large complex "cell" blocks consisting of many transistors, so transistor count and area measurement are meaningless for comparison purposes. Technology in this area was identical to rest of the die and no items of special interest were found. Packaging/Assembly Devices were packaged in standard 84-pin ceramic PGAs with metal lids. All but two pads on the die were connected. A single tier package land arrangement was employed and connected by gold wire and thermosonic wirebonds. Die attach was by gold-silicon eutectic. No die coat was used and no heatsink was present. 4-6 ®® The AT&T 3020-70 FPGA circuit die. Mag. 40x. ® METAL 2 section, Mag. 12,000x METAL 1 Ti SILICIDE POLYCIDE GATE INTERMEDIATE GLASS POLY Mag. 4000x, 60° DIFFUSION METAL 1 section, Mag. 30,000x POLYCIDE GATE AT&T 3020-70. SEM views illustrating device structures. TECHNOLOGY DESCRIPTION ALTERA EPM5128LC (MAX 5000) EPLD Introduction Ref. report SCA 9411-376 These parts were packaged in 68-pin, plastic leaded chip carrier (PLCC) packages, date coded week 49 of 1993. Parts were fully functional production samples. These devices are UV erasable when in window packages (one time programable in plastic). This specific device offers 128 macrocells and is capable of >60 MHz for pipelined data rates. These parts were apparently an Altera design, fabbed by Cypress according to package and die marking. They operate from a standard 5V power source. See tables for specific dimensions and materials identification and see figures for examples of physical structures. Unusual/Unique Features - Unique dielectric feature at vias. Quality Quality of process implementation was good, but parts failed latch-up tests. In the area of layer patterning, both etch definition and control (depth) were good. Alignment/registration was also good. Packaging/assembly was good as well. Technology These devices were made by a twin (multiple)-well CMOS process, employing an N substrate. No evidence of an epi layer was found. Two levels of metal and two levels of poly (no polycide) were used. A normal recessed-oxide isolation was employed. Both metal levels consisted of aluminum defined by standard dry etch techniques. Metal 2 employed a titanium barrier/adhesion layer and no cap layer. Metal 1 used a titanium cap and a titanium-tungsten barrier on a titanium adhesion layer. 4-7 No plugs were present at vias or contacts and no salicide source/drain treatment was used. No buried contacts were used. Metal 2 contacted metal 1, and metal 1 contacted diffusions, and poly 2. Planarization of the intermetal dielectric was by three layers of deposited glass including a spinon-glass. A unique and unexplained feature was present in the SOG at all via connections. The SOG material had different etch characteristics immediately around the via cuts (i.e., it appeared to be less dense). The only explanation for this seems to be that it is an effect of the etch used for the via cuts. We've never seen it before, but it appeared to have no affect on anything including quality. The dielectric under metal 1 was planarized by a reflow process. All gates were formed by a layer of standard polysilicon (poly 2) and all used oxide sidewall spacers that were subsequently removed. Redundancy fuses were present (but not activated) and were also made with the poly 2. No evidence of any unusual gate oxide materials was found. Overall minimum feature measured anywhere on these dice was the 0.7 micron poly width. Minimum physical gate lengths measured were 0.75 micron for N-channel and 0.95 micron P-channel. Array Cell Structures These parts used a two- transistor one-capacitor cell, all of which use the floating poly 1 so that both gate and capacitor oxide is the same. Dielectric between the poly 2 word line and poly 1 elements was an ONO (oxide-nitride-oxide), however. Bit lines were formed by metal 1. Poly 1 was defined after sidewall formation on poly 2, so it protrudes beyond the poly 2 word lines. Poly 1 did not use sidewall spacers. Gate length of these poly 1 floating gates was 1.3 micron. The cell size was measured to be 55 microns 2. Packaging/Assembly Devices were packaged in standard 68-pin J-lead PLCCs. All pins were connected. Die attach was by a silver-epoxy. No die coat was used and no heatsink was present. 4-8 ® The Altera EPM5128LC EPLD circuit die. Mag. 20x. ® section, Mag. 10,000x POLY 2 N+ OXIDE POLY 1 Mag. 9100x, 60° Q2 Q1 BIT 1 BIT 2 WORD VSS BIT 1 Q1 C BIT 2 Mag. 4000x, 0° POLY 2 ON POLY 1 Q2 Altera EPM5128LC. SEM views illustrating device structures. TECHNOLOGY DESCRIPTION ALTERA EPM7032 (MAX 7000) EPLD Introduction Ref. report SCA 9406-336 These parts were packaged in 44-pin, plastic leaded chip carrier (PLCC) packages, date coded week 1 of 1994. Parts were fully functional production samples. These devices reflect Altera's second generation MAX architecture with 125 MHz system speed and 7.5 nsec propagation delays. This specific device offers 600 usable gates and 32 advanced macrocells. They operate from a standard 5V power source. See tables for specific dimensions and materials identification and see figures for examples of physical structures. Unusual/Unique Features - Modern but relatively simple process. Quality Quality of process implementation was less than desirable in the area of metal 1 step coverage at contacts where we found significant aluminum thinning and a hint of possible cracking in the barrier metal. Subsequent analysis of this product type done at a later date and not related to this project indicated that these problems had been solved. Parts also failed latch-up tests. In the area of layer patterning, both etch definition and control (depth) were good. Alignment/registration was also good. Packaging quality was normal. Technology These devices were made by a twin (multiple)-well CMOS process, employing a P substrate. No evidence of an epi layer was found. Two levels of metal and one level of polycide (tungsten on polysilicon) were used. A fairly deep recessed-oxide isolation was employed, with birdsbeak areas kept short. 4-9 Both metal levels consisted of aluminum defined by standard dry etch techniques, and both had thick titanium-tungsten barriers. Cap layers were not used on either metal 2 or metal 1. No plugs were present at vias or contacts and no salicide source/drain treatment was present. No buried contacts were used. Metal 2 contacted metal 1, and metal 1 contacted diffusions, and polycide. Planarization of the intermetal dielectric was by at least four layers of deposited glass (including two spin-on-glass layers) and planarizing etch. The dielectric under metal 1 was planarized by a reflow process. All gates were formed by the polycide (tungsten on polysilicon) and all used oxide sidewall spacers that were left in place. Redundancy fuses were not present. No evidence of any unusual gate oxide or dielectric materials was found. Overall minimum feature measured anywhere on these dice was the 0.45 micron polycide width. Minimum physical gate lengths measured were 0.45 micron for N-channel and 0.7 micron P-channel. Array Cell Structures These parts used a 3 transistor NMOS cell incorporating one capacitor. Programming uses a window of thin tunnel oxide. Metal 2 provided piggyback word lines, metal 1 was used for all the power connections, control and program lines. Polycide was used for all gates, capacitors and word lines. The cell size was measured to be 110 microns 2. Packaging/Assembly Devices were packaged in standard 44-pin PLCC packages with J leads. All pins were connected. Die attach was by a silver epoxy, and wirebonding used the thermosonic method with gold wire. No die coat was used and no heatsink was present. 4 - 10 ® PIN 1 The Altera EPM7032 EPLD circuit die. Mag. 55x. ® section, Mag. 11,000x OXIDE section, Mag. 5700x POLYCIDE SELECT GATE (1N) Mag. 2400x, 0° SECTION PGM TUNNEL AREA POLYCIDE Altera EPM7032. SEM views of device structures. TECHNOLOGY DESCRIPTION LATTICE GAL22V10C EPLA Introduction Ref. report SCA 9406-337 These parts were packaged in 28-pin, J-lead, Plastic Leaded Chip Carriers (PLCCs), date coded week 51 of 1993. All parts were fully functional production samples. This architecture provides ten output logic macrocells guaranteed to be 100 percent field programable and reportedly provide the highest performance available anywhere. Device operate from a standard 5V power source. See tables for specific dimensions and materials identification and see figures for examples of physical structures. Unusual/Unique Features - Short gates (0.5 micron). - Numerous mask modifications. - Unique metal 2 perforation design. Quality Quality of process implementation was normal except for significant metal thinning in a very few isolated areas. In the area of layer patterning, both etch definition and control (depth) were good. Alignment/registration was also good. Packaging/assembly quality and workmanship was good as well. Technology These devices were made by a twin (multiple)-well CMOS process on a P substrate. No evidence of an epi layer was found. Two levels of metal and one level of polysilicon were used. A normal recessed-oxide isolation was employed. The cell array used a single poly design with thin tunnel-oxide windows for programming. 4 - 11 Both metal levels consisted of aluminum and were defined by standard dry etch techniques. Both used titanium-nitride cap layers. Only metal 1 used a titanium-nitride barrier under the aluminum. As mentioned, metal 2 structures were somewhat unique. Besides the fact that there was evidence of many mask changes (such as isolated via contacts), the metal 2 power lines contained a complex array of slots and cutouts. This is normally done for stress relief but usually less elaborately. No plugs were present at vias or contacts and no salicide source/drain treatment was present. No buried contacts were used. Metal 2 contacted metal 1, and metal 1 contacted diffusions and poly. Planarization of the intermetal dielectric was by deposited glass layers and planarizing etch. A spin-on-glass (SOG) was included. The dielectric under metal 1 was planarized by a reflow process. The single layer of polysilicon (no polycide) provided all gates and program elements. All gates used oxide sidewall spacers that were left in place. No evidence of unusual gate oxide or dielectric materials was found. Overall minimum feature measured anywhere on these dice was the 0.5 micron poly width. Minimum physical gate lengths measured were 0.5 micron for N- channel and 0.65 micron for P-channel. Array Cell Structures These parts used a 3 transistor, 2 capacitor cell and a thin tunnel oxide window design for programming the macrocells. Metal 1 was used for the word lines and Program 2 lines. Metal 2 provided Bit, Enable and Program 1 lines. Poly was used for all gates and the capacitor areas on the floating gates. Round, very thin tunnel oxide windows were used for programming. It is possible that the capacitor and gate oxides are different thicknesses (would require TEM cross sections to verify). Size of these programable cells was 197 microns2. 4 - 12 Packaging/Assembly As mentioned, devices were packaged in standard 28-pin, J-lead PLCCs. All except center pins on each side were connected. Die attach was by a silver epoxy and standard thermosonic wirebonds using gold wire were used. No evidence of a die coat was found. 4 - 13 ® PIN 1 The Lattice GAL22V10C EPLA circuit die. Mag. 73x. ® METAL2 CUTOUTS optical, Mag. 500x, 0° METAL 2 PASSIVATION METAL 2 METAL 1 POLY section, Mag. 11,000x OXIDE TUNNEL OXIDE N+ POLY PGM 2 N+ Mag. 2600x, 0° 3 Lattice GAL22V10C. Optical and SEM views of device structures. TECHNOLOGY DESCRIPTION AMD PAL CE22V10H-5JC/5 EPLA Introduction Ref. report SCA 9403-333 These parts were packaged in 28-pin, J-lead, Plastic Leaded Chip Carriers (PLCCs), date coded week 2 of 1994. All parts were fully functional production samples. This architecture provides 10 programable macrocells with 10 nsec propagation delays possible. Devices operate from a standard 5V power source. See tables for specific dimensions and materials identification and see figures for examples of physical structures. Unusual/Unique Features - None. Quality Quality of process implementation was normal. No significant areas of concern were found. In the area of layer patterning, etch definition was good and control (depth) was normal. Alignment/registration was good except for the thin tunnel-oxide windows which overlapped recessed oxide areas probably more than intended. Packaging/assembly quality was also good. Technology These devices were made by a twin (multiple)-well CMOS process on a P substrate. No evidence of an epi layer was found. Two levels of metal and one level of polysilicon were used. A normal recessed-oxide isolation was employed. The cell array used a single poly design with thin tunneling oxide windows for programming. Both metal levels consisted of aluminum defined by standard dry etch techniques. Metal 2 used no cap or barrier layers, but metal 1 used a titanium-nitride barrier on a titanium adhesion layer. 4 - 14 No plugs were present at vias or contacts and no salicide source/drain treatment was present. No buried contacts were used. Metal 2 contacted metal 1, and metal 1 contacted diffusions and poly. Planarization of the intermetal dielectric was by deposited glass layers and planarizing etch. A spin-on-glass (SOG) was included. The dielectric under metal 1 was planarized by a reflow process. The single layer of polysilicon (no polycide) provided all gates and program elements. All gates used sidewall spacers that were removed after use. No evidence of unusual gate oxide or dielectric materials was found, but some lifting was noted at the edges of the gates. Also, as mentioned, tunnel oxide windows appeared misaligned. Overall minimum feature measured anywhere on these dice was the 0.7 micron poly width. Minimum physical gate lengths measured were 0.6 micron for both N- and P-channel. Array Cell Structures These parts used a 3 transistor, 1 capacitor cell design with a thin tunnel oxide window for programming the macrocells. As shown in the figures, alignment of the thin oxide windows left something to be desired. The word lines were made with metal 2. Program 1, Enable and the bit lines used metal 1. Poly provided the Program 2 lines and all gates. Cell layout was not particularly efficient resulting in a cell size of 216 microns 2. Packaging/Assembly As mentioned, devices were packaged in standard 28-pin, J-lead PLCCs. All except the center pins on each side were connected. Die attach was by a silver epoxy and standard thermosonic wirebonds using gold wire were used. No evidence of a die coat was found. 4 - 15 ® The AMD PALCE 22V10H-5JC/5 circuit die. Mag. 55x. ® section, Mag. 10,000x N+ ENABLE POLY Mag. 3000x, 0° AMD PALCE 22V10H-5JC/5. SEM views of device structures.