DRIVING FORCES ON PACKAGING: 5 PHYSICAL INTERCONNECTS
The single most important element of the package and interconnect that influences the system clock speed, the performance density, and often the cost of a system, is how close together the devices can be placed. The term that best describes this is packaging efficiency. The three fabri- cation and assembly issues that constrain the packaging efficiency are:
¥ the I/O off the chipÑthe number, the form factor, the pitch ¥ the I/O off the packageÑthe number, the form factor, the pitch ¥ the interconnect substrateÑthe pad pitch, the via pitch, the line pitch, the number of layers
Pin Count Requirements and RentÕs Rule
As the number of gates on a single die has increased, the number of I/Os required to interface them to the outside world has also increased. In 1960, E.F. Rent of IBM identified a definite empir- ical relationship between the number of gates in a block, Ngates, and the number of I/Os they required, NI/O. This relationship, since coined RentÕs Rule, has been extended and generalized to encompass a variety of chip types and module sizes.
Figure 5-1 is a plot of the signal I/Os required for various gate arrays and microprocessors. In general, for every 4 to 10 signal I/Os, one power or one ground is used. As the clock frequency goes up, a higher fraction of power and ground pads are required to keep switching noise at acceptable levels. For clock frequencies over 250MHz, the ratio is closer to 3:1 signal to power/ground pads.
Empirically, the RentÕs Rule relationship between total signal I/Os required and gate count is:
NkN= p I/O gates where k and p are constants that depend on the architecture and the partitioning. RentÕs Rule graphically shows the ever greater demand for more I/Os as the number of gates increases.
INTEGRATED CIRCUIT ENGINEERING CORPORATION 5-1 Driving Forces on Packaging: Physical Interconnects
For the case of microprocessors: k = 0.82 p = 0.45
For the case of already committed gate arrays: k = 1.9 p = 0.5
The original values that Rent found applicable for his systems were: k = 2.5 p = 0.61
104
Bipolar Gate Array CMOS Gate Array Microprocessor SRAM DRAM 103
2
Number of Signal Pins 10
101 102 103 104 105 106 Number of Gates or Bits
Source: University of Arizona/ICE, "Roadmaps of Packaging Technology" 13651A
Figure 5-1. I/O Pin Count Versus Complexity
RentÕs Rule is a loose, empirical rule of thumb that can be used to roughly predict the number of I/Os a chip or module will need as the number of committed gates increases. Care must be exer- cised in using it. There is an explicit assumption that the partitioning will remain the same as the gate count increases. Of course, at some point, the functionality must reach the point where the I/O count decreases. After all, even the largest computer has at most a few hundred system-level I/Os for disk drive and keyboard access. The point at which the I/O requirements begin to fall under RentÕs Rule is a measure of the degree of partitioned functionality.
5-2 INTEGRATED CIRCUIT ENGINEERING CORPORATION Driving Forces on Packaging: Physical Interconnects
Decreasing the I/O count off chip without resorting to multiplexing or degrading signal integrity, will always increase the performance density per unit cost, if only by reducing the component and assembly costs. Partitioning of gates and chips into functional units that will bring the I/O count under RentÕs Rule is a critically important step in the design cycle. Integrating more functional- ity on chip will most often increase the performance/cost.
As the gate count available on gate arrays increases, the required I/O count will increase. From 2 the gate density, Dgate, in gates/in , the required I/O count for any die size can be calculated with RentÕs Rule. For gate arrays, the equation would be:
N = k D • A = 1.9 • N I/O gates chip gates
In Figure 5-2, this estimate of required I/O count is compared with a few representative examples of late 1980s vintage gate array families. It is clear that a consequence of smaller design rules and denser gates is more I/O required for the same size chips! This means either finer pitch periph- eral I/O or switching to the more efficient area array I/O.
2,000 1000K Gates/in2
1,500 500K Gates/in2 (486 density) Future Generation 1,000 250K Gates/in2 200K Gates/in2
I/O Required on CMOS Density 100K Gates/in2 500 One Micr
10K Gates/in2 0 0.0 0.2 0.4 0.6 0.8 1.0 √Die Size (inches)
Source: ICE, "Roadmaps of Packaging Technology" 15793
Figure 5-2. I/O Required Increases with Gate Density
For gate arrays fabricated with deep submicron design rules, the integration levels are high enough, and bussed I/O are sufficiently prevalent that RentÕs Rule no longer applies. For exam- ple, the 1996 generation ASICs, at 0.35 micron design rules, have a gate density of roughly 0.4M/cm2. The largest ASIC, 18mm on a side, would have about 3.2M gates, and by RentÕs Rule, require 3,400 I/O!
By comparison, the LSI Logic G10 family of gate arrays, at 0.35 micron design rules and slightly under 18mm on a side, has a maximum usable number of gates of about 2.5 million. However, it has a capacity of only about 800 I/O. This is significantly lower than the prediction from RentÕs
INTEGRATED CIRCUIT ENGINEERING CORPORATION 5-3 Driving Forces on Packaging: Physical Interconnects
Rule. Part of the reason is that 800 I/O were all that could be practically interconnected with cur- rent generation wirebonding equipment. This family is pad limited. Even so, there would never be designs requiring 3,400 I/O because of the high integration levels and the high level of func- tionality. Designs of greater than 200,000 gates are approaching the system-on-a-chip, and begin to fall significantly under RentÕs Rule.
The coefficients for RentsÕ rule have been derived empirically based on a study of gate arrays built in the 1970s and 1980s. The predictions using these coefficients are a measure of the number of signal I/O to fully utilize all the gates as part of a larger ÒrandomÓ logic system. When there is significant integration and mostly busses as the interface, RentÕs Rule should be used as an upper limit of the required number of I/O. Chips with this high an integration level do not have the same interconnect requirements as random logic.
The SIA roadmap for pin count takes into account the impact from higher integration levels and the implementation of bussed I/O. Figure 5-3 contrasts the SIA prediction for I/O with RentÕs Rule prediction, based on the SIA values for chip size and gate density. The large and growing discrepancy is a measure of the impact from the two factors of integration functionality and bussing. Even so, the off- chip I/O count is predicted to grow considerably.
80,000
70,000
Rent's Rule I/O 60,000 SIA Prediction SIA Rent's Rule
50,000
40,000 I/O Off-Chip 30,000
20,000
10,000
0 1994 1996 1998 2000 2002 2004 2006 2008 2010 Year of Introduction Source: ICE, "Roadmaps of Packaging Technology" 22196
Figure 5-3. SIA Off-Chip I/O Compared to RentÕs Rule
5-4 INTEGRATED CIRCUIT ENGINEERING CORPORATION Driving Forces on Packaging: Physical Interconnects
Based on the SIA roadmap predictions, we can estimate the new values for RentÕs Rule that match the SIA roadmap. A good approximation is obtained using:
k = 0.2 p = 0.5
The match to the projected SIA predictions with these coefficients to RentÕs Rule is also shown in Figure 5-3.
IMPLEMENTING OFF CHIP INTERCONNECTS
There are two configurations for I/Os off a chip:
1. a single row or two staggered rows around the periphery 2. an array of pads on a grid over the surface of the die
The maximum number of pads, Npads, on a chip is constrained by the pad pitch and perimeter for peripheral I/O,
4L N = chip pads P pads and the grid pitch and chip area for area array,
L2 N = chip pads P2 pads
This is diagrammed in Figure 5-4. The number of pads constrained by these two approaches is shown in Figure 5-5 for various pitches and for one and two rows of pads.
Using the die sizes and pin count predictions of the SIA roadmap, the pad pitches that would be needed can be estimated. For example, if a single peripheral row is used, a pad pitch of 80 microns is required for current generation ASICs. This is right at the capability of 1996 wirebonding in volume production. To meet future ASIC needs, this pitch must steadily decrease.
In contrast, if the I/O were to be on an area array, the pitch would only have to be 600 microns, or 24mils, a much more realistic effort. This is a strong driving force for area array off chip I/O. In addition to accommodating a higher I/O count without heroic mechanical feats, area array also offers the opportunity for better electrical performance by allowing more power and ground pads distributed over the surface of the chip, where they are needed the most.
INTEGRATED CIRCUIT ENGINEERING CORPORATION 5-5 Driving Forces on Packaging: Physical Interconnects
N gates PERIPHERAL PADS Chip
Lchip
4 L chip N = pads P pads P pads
AREA ARRAY PADS P pads
2 L chip N = pads 2 P pads Lchip
N gates = Number of available gates P = Pitch of the pads pads Lchip = Length of one side of the die
N I/O = Number of I/O required for the gates
N pads = Number of pads constrained by the geometry N gate D = Density of the gates = gates 2 L chip Source: ICE, "Roadmaps of Packaging Technology" 15794
Figure 5-4. Chip Pad Terms
INTERCONNECT DENSITY: REQUIREMENTS
Various factors will contribute to how closely the chips can be mounted on a board. This next level in the packaging hierarchy, the interconnect substrate, is a planar substrate that interconnects the chips either as bare dice, as in a multichip module or chip-on board (COB), or as packaged dice. Once placed, all the leads from all the chips will have to be interconnected.
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5mil Area Array 10 4 10mil Area Array
(Current IBM C4) 2mil Peripheral MCA4 3mil Peripheral 10 3 4mil Peripheral 6mil Peripheral
MCA3
Number of I/O 10 2 25mil Area Array
10 1 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 √Die Size (inches) Source: ICE, "Roadmaps of Packaging Technology" 15795
Figure 5-5. How the Pad Pitch Constrains the Number of Possible I/O
In CAD terminology, each lead is called a node. The electrically connected nodes form one net. A generic board is diagrammed in Figure 5-6. The relevant terms are:
L total trace = total length of all the traces required Nnets = number of nets in the net list for the chips Nleads = number of leads per chip that must be interconnected Nfanout = number of input leads connected to one output Nchips = number of chips in the collection Pfootprint = pitch between chips on the board
There are many ways of describing the interconnect needs for a collection of chips. The method that offers the most generality and is easiest to understand uses the total length of trace, Ltotal trace, as the metric for interconnect. From this, other parameters such as inter- connect density and number of traces per linear inch can be derived.
The average number of nodes attached to a single net is roughly Nfanout+1. If there are three other leads to which an output driver goes, then the net consists of a total of four nodes: the output driver and the three input leads. Used in this way, the fanout number is a rough measure of the degree of bussing. If there is a lot of bus interconnect, Nfanout can be as high as 20. In general, for random logic, without knowing anything else about the architecture, a reasonable value of Nfanout is three.
INTEGRATED CIRCUIT ENGINEERING CORPORATION 5-7 Driving Forces on Packaging: Physical Interconnects
Single-Chip Package
Net Node Node Substrate (area, A)
Node Node
P Footprint
Source: ICE, "Roadmaps of Packaging Technology" 15797
Figure 5-6. A Net with 4 Nodes
The electrical design may influence the fanout number or the distribution of trace lengths. For example, in a transmission line environment, multiple nodes are connected as a daisy chain rather than a star. With a near-end, series terminated net, such as with the Motorola MCAIII STECL arrays, second incident switching is often used, and there is a greater use of point-to-point inter- connect to avoid excessive wiring delays.
Each fanout will require one interconnect trace segment. By definition, each of these traces will be electrically connected, and be contained on one net. Among the collection of Nchips, there will be a total of Nchips x Nleads nodes. The total number of nets among the collection of chips is given by:
N • N = chips leads Nnets Nfanout + 1
The total length of traces required by these nets will be the product of the number of interconnect trace segments per net, the total number of nets, and the average length of the trace segments,
5-8 INTEGRATED CIRCUIT ENGINEERING CORPORATION Driving Forces on Packaging: Physical Interconnects
IBMÕs studies suggest that a useful way to measure the average interconnect length,
< L >= R • P trace footprint
The average number of chip pitches of an interconnect trace segment, R, will obviously depend on the chip placement, routing algorithm, and interconnect architecture. IBMÕs studies indicate a rough approximation can be obtained using R = 1.5 chip pitches as an average trace length. This indicates that with proper layout, most of the routing runs to adjacent chips on a board.
The total length of interconnect required becomes:
N L = fanout N • N • (1.5) • P total trace N + 1 chips leads footprint fanout
The interconnect density required, Dinterconnect.R, is the length of trace required per unit area of the substrate to perform the required interconnect. For a collection of chips, the substrate area that contains all the traces, Asubstrate, is:
A = N • P2 substrate chips footprint
The interconnect density required is given by:
N 1 D = fanout • N • 1.5 interconnect.R N + 1 leads P fanout footprint
This relationship points out the important terms. It shows that the interconnect density required grows with the number of leads coming off each chip and increases as the footprint is reduced, as when the chips are moved closer together.
For the simple case when all the leads are on the periphery of the footprint, with a pitch of Pleads, the interconnect density required can be approximated by:
= 4 = 6 Dinterconnect.R 1.5 Pleads Pleads
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For example, to interconnect an array of 50mil pitch chip carriers, the interconnect density required is about 120in/in2. For the case of 11mil pitch leads, such as the outer leads of the single- chip packages of the now extinct ETA10 super computer, the required interconnect density is 540in/in2. This relationship is shown graphically in Figure 5-7, compared with a few examples of the interconnect density required in certain systems.
10 4
10 3 DEC Motorola
hes/sq in) Modules ETA/Honeywell 2 Packages (inc 10 25mil APS Chip 50mil
connect Density Required nChip Carrier Chip 100mil Modules Carrier Chip Carrier Inter 10 1 1 10 100 Peripheral Lead Pitch (mils) Source: ICE, "Roadmaps of Packaging Technology" 15798
Figure 5-7. Selected Interconnect Densities Required
INTERCONNECT DENSITY: IMPLEMENTATIONS
The earliest interconnect substrate, the printed circuit board, was stimulated by the need to reduce the cost of hand wiring vacuum tubes. The introduction of the first transistors in early 1950, with their finer pitch pins also accelerated the implementation of the printed circuit board. It has become conventional to call the bare board, before any components are assembled on it, a printed wiring board (PWB). After the components have been added, it is called a printed circuit board (PCB).
A variety of interconnect substrates have evolved over the last 50 years. Through the introduction of new design concepts, new materials, and new manufacturing processes, the complexity and value of the interconnect substrates have increased dramatically. In addition to the traditional FR4 (epoxy-glass) PWBs, there are substrates with multilayers composed of:
¥ thick-film polymer ¥ thick-film ceramic ¥ high temperature cofired ceramic ¥ low temperature cofired ceramic ¥ and thin-film metal, polymer or glass inner layer dielectrics, substrates.
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All of these variations are described in later chapters.
With all their differences, the interconnect capabilities of all the substrates can be described with the following terms:
Nlayers = the number of metal layers with signal traces Pvias = the closest center-to-center pitch between vias Ntracks = the maximum number of signal traces that will fit between vias at their closest spacing
An ultimate interconnect density can be defined, Dinterconnect ultimate, based on the total length of trace that can be patterned in the metallization per unit area. Based on these definitions, the ultimate interconnect density capability of an interconnect substrate is:
N • N = layers tracks Dinterconnect ultimate Pvias
For example, a low cost, double sided printed circuit board, with vias on 100mil centers, and having a line pitch such that two traces can fit between the via holes, will have an ultimate inter- connect density of 20 inches of trace per square inch of board area, per side, or 40in/in2. If a square inch were to be cut out of the board, and all the traces peeled off and placed end to end, they would extend 40 inches. Another way of looking at this is if all the traces were going in the same direction and a cut were to be made through the board, across the traces, it would cut through 40 traces per inch of cut.
More advanced circuit boards, commonly used for low end PC motherboards, typically use four metal layers. The inner two are power and ground and the outer two are signal layers. The via grid pitch is 50mils, with two tracks of conductors between them, at 5mil line and space. This board has an ultimate interconnect density of 40 inches/in2, with the added benefit of lower noise and lower EMI.
In contrast, at the other extreme of fine lines, the interconnect density on a chip, with a via pitch of 1 micron and one track routing on two metal layers would be 50,000in/in2.
The above analysis is based on the use of every routing channel possible. In practice, both rout- ing algorithms and technology choices limit the actual interconnect density capability, Dinterconnect.C, to no more than 50 percent of this ultimate:
N • N = • layers tracks Dinterconnect.C 0.5 Pvias
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In Figure 5-8, the interconnect density capabilities of various technologies are shown. There is a dramatic jump in density from a 12 signal layer PWB, with two tracks on a 100mil via pitch grid, having 120in/in2, to a thin-film substrate, with two signal layers, at one track on a 3mil via pitch grid, having 330in/in2. The latter interconnect density, which is quite large, is required to inter- connect a collection of bare dice closely spaced.
/in) 2,000 2 1,800 32 Layers- Traces 1,600 24 Layers- Traces 1,400
1,200 Fujitsu 1,000 nChip VP2000 12 Layers- IBM, 800 Traces TCM 600 8 Layers- Traces 400 2 Layers-
connect Density Capability (in 12 Signal Layer, 200 Traces DEC, 2 Track, High APS
Inter Performance PWB 0 0 1 2 10 10 10 Via Grid Pitch (mils) Source: ICE, "Roadmaps of Packaging Technology" 15799
Figure 5-8. Interconnect Density and Via Grid Pitch
Some technologies are less efficient than this. In interconnect substrates with only fixed through-hole vias, such as PWBs, using more than two tracks means that when a middle track makes contact with a via grid point, it will block the routing channel for some traces on other layers, which cannot use this via, thereby dropping the interconnect density capability, as the layer count grows.
INTERCONNECT DENSITY: PRICE
Each of the different interconnect technologies, printed wiring board, thick film, cofired ceramic, multilayer thin film, and on-chip multilayer, have a different interconnect density capability, a dif- ferent manufacturing cost, and a different level of maturity.
The associated prices for a particular technology are both dynamic and complex. Market forces affect prices as much as technical capability. Prices drop as products move up the learning curve, competition from multiple suppliers increases, and alternative technologies develop. Estimating prices is thus prone to be based on generalities, and should not be trusted to yield better than order of magnitude trends.
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George Messner has analyzed the prices of printed wiring boards. At the low end, a double-sided board with 50in/in2 of interconnect is priced at roughly $0.1/in2. This corresponds to roughly $0.002/in of trace. A four-layer board, with 100in/in2, is priced at $0.004/in of trace. As the board complexity increases, the price per inch of interconnect increases as well. A 14 signal layer board, for example, has a price of around $0.02/in of trace. These are summarized in Figure 5-9.
104 Multi-Chip Silicon Modules Interconnect Confired