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Heterogenous Integration Sandia
Heterogenous Integration Sandia
SAND2020-10083C
PRiME
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1ES IC, .po
FreqUenCy(H,
RFOUT2
• Summary TRANSMITTER
RFIN2
RFOUT4
RFIN4
Ring Filters
RFOUT1
and PDs
RFOUT3
3
What Is Heterogeneous Integration (HI)?
From https://www.semi.org/en/heterogeneous-integration-roadmap
"Integration of separately manufactured parts into a higher assembly (SiP) that, in the
aggregate, provides enhanced functionality and improved operating characteristics."
HI Defines the Space Between Microfabrication and Packaging
Smaller than packaging, but coarser than microelectronics.
Allows integration of different optimized microtechnologies. • gstt,„
•.1 -
HI Challenges in Context of R&D/Prototyping. N./7,.#..
Minimal influence on component supply chain: little opportunity for customization.
High non-recurring costs of process development and dedicated fabrication runs.
Short time scales do not allow for in-depth process development.
R&D sponsors pay for results, not integration.
Objective: Develop HI Processes and Techniques Suitable for a Variety of COTS, Custom, and RaD
Technologies Without Requiring Substantial Development for Each Iteration.
4 HI @ Sandia's MESA Complex
MESA= Microsystems Engineering,Science and Applications
notechnnogy F.
PDK and Center for Integrated NanotechnDlogies (CIN Custom Epitaxial Growth & III-V Devices
8" Multi-Project Wafers (GaAs, InP, GaSb, GaN)
\\ ,/ 60+ Photonics Staff PDK and Multi-Project Wafers (InP)
Device Design, Modeling, Simulation
Semiconductor Device Fabrication
Microsystem Fabrication
Testing, Rad Effects, Cryo
Reliability
t-
Si Photonic circuits Photonic circuits Et Lasers
Si Photonics Platform w/ LiNb03 + InP
6 Outline 4X1 MMI
RFOUT2
• Summary TRANSMITTER
RFIN2
RFOUT4
RFIN4
Ring Filters
RFOUT1
and PDs
RFOUT3
Why HI? Electrically Short Interconnect
7
50
Z0=50 0
Long Length
r Must be electrically short
50 Ltrace
*—AAAt—*
i *-1\AAI—* ,fYYL.
1
4110
..1.. ,
I
.1
, 10
50
1
Cload
1Cload
Intimate integration from HI can allow high-frequency signaling across unterminated chip-to-chip
electrically short interconnect.
HI For Electrically Short Interconnect: RF
10 Simulation
8 ••.
oo
.
1 mm wirebond •• ,•
.7 . .•
V
•
*
__ 1 mm wirebond
-15
25 pm bump
-20
1E8 1E9 1E10 1E11
Frequency (Hz)
HI Enables Low-Power Chip-to-Chip GHz Signaling
HI For Electrically Short Interconnect: Eye Diagram Models
9 1
5 Gbps 20 Gbps 40 Gbps
0.6 0.13 0.6
0.4 0A
0.2 0.2
0.0
0.0 .t 0.0
-a2 -0.2
1.5 1.5
Wirebond Unteii mated
10 10 10
05- 0.5 05
Wirebond U
00 .2 a0 00
415
0.5 0.6 0.6
Bump Terminated
Bump Terminated
Bu•lip Terminated
04 1) 4
0.2 9.2 02
ao 00 00
-a2 -0.2
Bump Unlerminated
to_ 1,0
0.5-
0.5- 0.5-
.0
0.0 0.0
0.4 0.4
0.2 0.2
0.0 0.0
1.5 1.5
Wirebond Un1e i mated
1.0 10
0_5 05
Wirebond U
00
A AL 00
.0.5
Unterminated wirebonds
0.5 barely support 5 Gbps 0.6
Bump Terrnmaled
Bu•lip Terminated
04 4
0.2 02
aa
-a2 • 00
-02
to 1.5
Bump Unlerminated
Bump Unterrnmated
1,0
a5—
0.4 2 a4 0.4
43 0 2
1-
0.2 02
2
0.0 0.0 0.0
Terminated wirebonds—m"
1
-a2 -a2 -0.2
42
• ---z...%7--.argamp--
1.0 1.0
11.V
A _
dirr-
Wirebond U
111110
"-.
0.0 2 oo
Unterminated wirebonds Unterminated wirebonds
0.5 barely support 5 Gbps a5
worse ® 20 Gbps 06
ump Terminated
Bump Terminated
Bu•rip ler-minuted
04 04 0 4-
aa 00 00
■
-a2 Terminated Et Unterminated -0.2
1.6 1.5
Bumps Good ® 20 Gbps
Bump Untem-imated
Bump Unlerminated
Bump Linierminated
to
a5—
a5— 05-
a
a0 00
0.4 2 0.4 0A
0.2 I— 0.2 02
-2
0.0
.4elibi
1
0.0 .t 0.0
-a2 -a2
Terminated wirebonds—m" -0.2
Wirebond Unlei.iimated
11
1 11 .
1
.
1.0 1.0 1.0
11.V
A 0.5
door- 0.5
0.0 2 oo 00
Bump Terminated
Bu•lip Terminated
04 04 04
2
9.2 f
0.2 02
aa 00 A, E 00
Bump Unlerminated
10
0.5—
0.5- 05
a
0.0 — 00
-0 5 T I 05
0 20 40 60 86 100 120 140 160 180 ND 10 20 30
Silicon: high integration, large wafers III-V: moderate integration, faster turn
• Full suite of passive devices Et modulators • Full suite of active a passive devices
Photonics • Tight dimensional control a high density • Materials Et bandgap engineering
• But: No light emitters; requires compounds • Planar and vertical light emitters (lasers)
• -101° transistors • -104 transistors
Low entry cost with multi-project-wafers • Higher Performance Materials
Electronics
• Little opportunity for customization • Limited digital capability
• Limited drive voltage • Higher drive voltage
'0'
Silicon Electronics + Silicon Photonics: great III-V Electronics + III-V Photonics: somewhat
if you have control over both technologies lower cost of infrastructure, but moderate
and/or large development resources levels of integration
14 Why HI For Photonics? Combine The Best Technologies
Use HI to combine the best devices from each quadrant
Itii;1 glIllmuu .1
1 I
Silicon: high integration, large wafers Ill-V: moderate integration, faster turn
Lasers, gain, bandgap engineering
Very high density filters Et gratings
Photonics Higher performance materials
Minature high-impedance modulators
High-efficiency Photovoltaics
Single-chip digital, analog, RF, signal processing High-power voltage RF/optical drivers
Electronics i Direct interface with FPGA/memory/processor High-voltage point-of-load power conditioning 1
Silicon III-V
InGattsP/InP Photonic Integrated Circuit
Custom SNL Fabrication
Lasers
Modulators
Photonics Future Expansion
Combiners
Drop Filters
Photodiodes
Couplers
RFOUT2
• Summary TRANSMITTER
RFIN2
RFOUT4
RFIN4
Ring Filters
RFOUT1
and PDs
RFOUT3
1 RF Photonic Application: Multiplexed Radio-Over-Fiber
17
Modulator
Driver
Channelizing Filter
Through
Antenna
Elements 1.- - Drop
0
Driver NJ
Amplifiers 1.55 1.551 1.552 1.553 1.554 1.555
n Wavelength(pm)
RF1 RF2 RF3 RFN Optical
A1 RF1
Fiber
RECEIVER
A.2 RF2
Drop Filters
Lasers A.3 RF3
=N
Optical
xi„ Optical Combiner. IÀn RF
Modulators A.N RFN
Photodiodes
TRANSMITTER Transimpedance
Amplifiers
RF Beamforming and
Receiver Electronics
Laser
Photodiode
Rear Mirror Front Mirror
Phase Electroabsorption Modulator
18 InGaAsP/InP Multi-Wavelength Photonic Integrated Circuits
• Fabricated with multiple epitaxial growths & re-growths on InP substrate
• -1550 nm wavelength
• State-of-the-art discrete photonic component performance from a single chip
• Light generation, modulation, amplification, routing, switching, detection
411111111111ivol
1
25
20
15
10
5
0
-Gain (dB)
-Retum Loss(dB)
25
20
15
10
it
..,•••••:••••:. • •
'c''-.'t'7.7•• •
• u 1
o
5 T, Driver
10
15
20
Zload = 100 // 200 fF
-25 25
0 0.5 1 1.5 2 2.5 3 3 5 4 45 5
Frequency(GHz) 2 mm
20 Outline 4X1 MMI
RFOUT2
• Summary TRANSMITTER
RFIN2
RFOUT4
RFIN4
Ring Filters
RFOUT1
and PDs
RFOUT3
21
Flip-Chip Interconnect Scaling
MPW Chips Are
"Sweet Spot" Currently Limited
Diminishing Move MPW chips towards
-50 pm pitch bumps fine-pitch flip chip to Wirebonding
returns for this
1
application at
very fine pitch,
but good for FPAs 411lie / ‘/
Et stacked ASICs
.41M.
tki!
✓
S4890 3.0kV K3.00k SE(M)
SUN 3 C.D. •S • ON SE
Interconnect Pitch
DBI Bonding Indium Bumps Cu and Au pillars Solder Bumps Et Wirebonds
Oxide I 1
earner, Wafer
ilr
5. Solvent release die from EMC and die are ready for flip
7
Oxide —I* =
11 1- chip bonding using thermocompression, pillars, or solder
Gold
Hollowell, et al, "Die Level Microbumping and Flip Chip Bonding for MPW Die, SAND2019-3599C
https://www.osti.gov/biblio/1639613-die-level-microbumping-flip-chip-bonding-mpw-die
23
Flip-Chip Bonding of MPW Die
• After Underbump Metal is Deposited, Different Flip-Chip Approaches May Be Used
Bond to solder-capped copper Approaches plannedfor this integration
1
or gold pillar on interposer
Thermocompression Bond Bond with jetted solder balls 1 1
MPW Die ENIG UBM
to gold bump on interposer
1 or carrier
SnAg solder HDI
==j
Interposer -
Cu Pillar Solder
Ball
Interposer
10 pm
AICu
ECD SnAg
Passivation
30 pm
ECD Cu Pillar ENEPIG UBM
11111111P 411
• • •
• • • .
• • • • • • . • • •
• • • • • • • • • • • •
RF Test Structures
RFIC Flip-Chip Landing Structures 111111111111
25
I What About Passives?
• Passives are required for de- Wirebonded Single-Channel Optical Transmitter
coupling, matching, and power
supplies.
A single capacitor takes up
• Good passives (Resistors, almost as much area as an
Capacitors, Inductors) are hard entire integrated circuit
to integrate on-chip, so they go 1 - 1
The inductor is even bigger
on the PCB. 1
• State-of-the-art SMT
components are large but .The Microelectronics are here.
1
1,The rest of the board area is
difficult to assemble and spent on R, L, C's
I
integrate.
The actual useful active
• Possible Solutions: electronics & photonics only
• Integrate onto interposer take up these small areas
8 mm
26
Miniature Four-Channel WDM RF Photonic Link
• HI Approaches will allow a four-channel RF photonic link within the same volume as the single-
channel wirebonded transmitter.
• Integration platform is the InP photonic substrate: all optical interfaces are on-chip.
• Passives are either moved on-chip, eliminated with close interconnect, or wirebonded.
SLC capacitors
zes Four-Channel RF Photonic
los (4".7 Transmitter/Receiver Link
zos
zoss,0,5? et.?
Single-channel Driver + EAM (to scale) RECEIVER
RFIN1
A/
A,FIN3
RFOUT2
► TRANSMITTER RFOUT4
RF1N2
1044,
RF1N4 .1111110
!V,
*(t
RFOun
Ring Filters
and PDs
RFouT3
27 Outline 4X1 MMI
RFOUT2
• Summary TRANSMITTER
RFIN2
RFOUT4
RFIN4
Ring Filters
RFOUT1
and PDs
RFOUT3
28
HI: Lessons Learned
• There are a lot of things to coordinate, all with different schedules.
• Different teams (+ vendors) w/ different expertise, cultures, and design/fab/test cycles & schedules.
• Mitigate risk & reduce "serial" dependencies with modeling, test structures, pre-development, etc.
• Pay attention to early co-design of the physical and electrical interfaces.
• CMOS & optoelectronics make different assumptions: clarify the interfaces early.
• Negative voltages, unusual impedances, device model compatibility, biasing, etc.
• Don't forget about connectors and interfaces for electrical/optical power/signals
• 10x as many chips - 10x as many connections
• Must have passives for biasing, tuning, de-coupling, etc.
• HI has less appeal if the inductor/capacitor is as big as the integrated circuit.
• Affordable & accessible multi-layer high-density interposers are an R&D gap.
• HI needs -10 pm; PCBs struggle for -100 pm; vias make it worse.
• Most capability is focused on high-volume commercial product.
• Don't make things harder than they need to be...
• Only shrinking to 50 pm: avoid challenges of very high density flip-chip.
• Optical interfaces are on InP chip: avoid -dB losses and precision alignment.
• Separate device process flows: avoid multiplying yield fallout & adding cycle times & long ($) development.
29
Conclusions
• SNL is developing an ecosystem that allows intimate integration of COTS and foundry technologies.
• Electronics: Existing Si/GaAs/GaN die from vendors, Custom Si/GaAs/GaN MPW die from foundries.
• Photonics: III-V surface-normal or planar optoelectronics, Integrated Si photonics.
• Passives: SMT components, integrated passive die, magnetics, antennas, sensors, etc.
• Emerging Technologies: MEMS, NEMS, nanotechnologies, phase-change, multi-ferroics, etc.
• For R&D prototyping, MPW die-level bumping and handling is required.
• Move from mm-length bondwires and —100 pm pitch to smaller pads and bumps.
• —50 pm-pitch bumps can support unterminated interconnect to 80 Gbps.
• HI has the potential to enable order-of-magnitude SWaP improvement for integrated photonics.
• Reduce size from "book-sized" to "matchbox-sized".
• Open more application and insertion opportunities
Heterogeneous Integration of Silicon Electronics
and Compound Semiconductor Optoelectronics
for Miniature RF Photonic Transceivers
PRiME
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1ES IC, .po
FreqUenCy(H,