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An article that explains the advantages and disadvantages of advanced packaging for Chiplets

Time: 2023-04-10 09:16:52

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One article explains the advantages and disadvantages of advanced packaging for Chiplets. One core conclusion is that advanced processes are limited, and there must be a trade-off between advanced packaging and Chiplets to improve computing power. Under the premise of technology availability, improving chip performance is the first choice for advanced process upgrades, while advanced packaging adds to the icing on the cake.

An article that explains the advantages and disadvantages of advanced packaging for Chiplets

1、 Core conclusion
1. Advanced processes are limited, and there must be trade-offs between advanced packaging and chiplet to improve computing power.
Under the premise of technology availability, improving chip performance is the first choice for advanced process upgrades, while advanced packaging adds to the icing on the cake.
2. In scenarios with high power consumption and computing power, advanced packaging/chiplets have application value.
3. China has very little reserve of advanced process production capacity, and advanced packaging/chiplets can help compensate for the scarcity of processes.
Advanced packaging/Chiplet can release a portion of advanced process capacity for use in more urgent demand scenarios.
2、 Crossing Moore's Law Limitations with Area and Stacking
The two eternal themes of chip upgrades: performance, volume/area. The development of chip technology is driving chips towards both high performance and thinness. The advancement of advanced processes and advanced packaging can both lead chips towards high performance and thinness. Faced with technological packaging in the United States, Huawei finds it difficult to gain a share of the advanced global processes. The supply of chips that require advanced processes, such as smartphones and HPCs, is severely hindered, and there is an urgent need to find a new path. Advanced packaging/chiplet and other technologies can to some extent compensate for the lack of advanced processes, exchanging area and stacking for computing power and performance.
Advanced processes are limited, and there must be trade-offs between advanced packaging and chiplet to improve computing power.
3、 What is advanced packaging?
Advanced packaging is a concept derived from advanced wafer processes, generally referring to packaging techniques that integrate different systems into the same package to achieve more efficient system efficiency. In other words, as long as the packaging technology can improve the overall performance of the chip (including transmission speed, computing speed, etc.), it can be considered as advanced packaging. Traditional packaging involves individually packaging each chip and then assembling these individual packaged chips onto a PCB motherboard to form a complete system. The information exchange between chips belongs to PCB level interconnection, also known as board level interconnection; Alternatively, different chips can be mounted on the same packaging substrate Substrate, and system level packaging can be completed. Communication between chips belongs to Substrate level interconnection. These two forms of packaging interconnection technology require information transmission between chips to be completed through PCB or Substrate wiring. In theory, the longer the information transmission distance between chips, the slower the information transmission, and the lower the performance of the chipset system. Therefore, at the same chip level, the overall performance of PCB level interconnect is weaker than that of Substrate level interconnect.
Before Moore's Law fails, the improvement of chip system performance can be completely dependent on the process improvement of the chip itself (process improvement leads to an increase in the number of integrated transistors in the chip). But with the failure of Moore's Law, the speed of chip process improvement has greatly slowed down, and the improvement of chip system performance can only be achieved by continuously optimizing the information transmission efficiency between each chip. The value of Wafer level packaging interconnection technology in circular crystals is highlighted.
Wafer level packaging interconnect technology integrates different SoCs onto TSV (Through silicon via) interposers. The interposer itself is made of silicon, which is the same as the substrate silicon of SoC. Through TSV technology and rewiring (RDL) technology, information exchange between different SoCs is achieved. In other words, the information transmission between SoCs is completed through the interposer. Interposer rewiring adopts circular crystal lithography technology, which is denser than PCB and Substrate rewiring, with shorter line distance and faster information exchange, thus achieving an overall improvement in the performance of the chipset. The example in Figure XX is a CoWoS package (Chip on Wafer on Substrate), where CPU/GPU die and Memory die are interconnected through an interposer. Information is directly transmitted through RDL wiring on the interposer without going through Substrate or PCB, resulting in fast information exchange and high system efficiency.

Since the semiconductor process entered 10nm, Moore's Law has expired, meaning that chip iterations no longer meet the requirement of "the number of transistors integrated on an integrated circuit chip doubles every 18 months; the performance of microprocessors doubles every 18 months, while prices double.". In the post Moore's Law era, advanced packaging is widely recognized as an effective way to continue "more than Moore" in the industry.

4、 What is Chiplet?

Chiplet, also known as small chip, refers to the process of breaking down a single "big" chip (Die) into several "small" chips at the wafer end. As a single "small" chip is functionally incomplete, it needs to be packaged and reassembled to restore the functionality of the original "big" chip. Chiplet can disassemble and design a large chip into several small chips with the same process, or it can be disassembled and designed into several small chips with different processes.


Chiplet can improve the yield of chip manufacturing. For wafer manufacturing processes, the larger the die size, the lower the yield of the process. It can be understood that there is a certain probability of failure points on each wafer. For the wafer process, it is difficult to reduce the number of failure points under the same technical conditions. If the chip being manufactured has a larger area, the probability of failure points falling on a single chip is higher, and therefore the yield is lower. If Chiplet's method involves disassembling a large chip into several small chips, the area of each chip will decrease, and the probability of failure points falling on a single small chip will be greatly reduced. The die size of the chip area is inversely proportional to the yield.
5、 Which is more significant in improving chip performance and thinness through advanced processes and packaging?

In terms of improving chip performance, the advanced process route is to reduce the feature size of individual transistors and improve transistor integration at the same die size level (with the same design framework, chip performance/computing power is positively correlated with the number of transistors); However, advanced packaging cannot change the size of individual transistors, and can only improve system efficiency from the perspective of bringing the CPU closer to Memory and computing closer to memory, thereby improving the computing and memory efficiency of each computation. The second is to integrate more components within a single chip package: signal transmission speed sorting, Wafer>IC substrate>PCB, where the communication efficiency of components within the chip is higher than at the board level, improving chip performance at the system level.

                                                                                                                             

   

In terms of chip lightweighting, advanced processes can achieve die size reduction by reducing the feature size of individual transistors without sacrificing the overall performance of the chip, while maintaining the same computational power and number of transistors; Advanced packaging, because it has no ability to miniaturize transistor size, can only achieve lightness and thinness through finer materials and denser structures. For example, the packaging of mobile phone AP processors often adopts the FCCSP packaging form, which includes a CSP carrier board. Fanout (TSMC collaborates with Apple, and Apple's A-series chips mostly use InFO technology packaging, i.e. Fanout) packaging, canceling the CSP carrier board (CSP carrier board is about 0.3 mm thick). The packaged chip is lighter and thinner, which significantly improves the overall (mobile phone) structural space margin.

                                                                                                                                                                                                                                                            


In terms of both high-performance and thinness, advanced manufacturing processes can achieve a balance, while advanced packaging has trade-offs. For example, when Apple's A-series chips were upgraded from A10 to A11, the process was increased from 16 nm to 10 nm, the chip area was reduced from 125 mm2 to 88 mm2, and the number of transistor integrations increased from 3.3 billion to 4.3 billion; When upgrading the A-series chips from A13 to A14, the wafer process was upgraded from 7nm to 5nm, the chip area was reduced from 98 mm2 to 88 mm2, and the number of transistor integrations increased from 8.5 billion to 11.8 billion, achieving a balance between performance improvement and thinness. Advanced packaging, on the other hand, aims to improve chip performance because it has no effect on reducing transistor size. Improving performance involves increasing the collaborative efficiency of various components within the chip, and stacking more components in a system (essentially improving transistor data within the system). The cost is that the system volume and area are larger, which means that the cost of advanced packaging to improve performance is sacrificing thinness, while achieving thinness is sacrificing performance improvement.

                                                                                                                                                                                                                                                         

Under the premise of technology availability, improving chip performance is the first choice for advanced process upgrades, while advanced packaging adds to the icing on the cake. What we usually see is that high-performance and high computing power chips will consider advanced packaging (2.5D, CoWoS, etc.), but these high computing power chips often also use advanced process technology. That is to say, advanced packaging/chiplet applications usually only appear in the packaging solution selection of top flagship chips, and are not a universal large-scale application solution. For example, the 7 nm AI training chip Siyuan 290 from the Cambrian period may adopt a "1+4" architecture, which is a chiplet packaging form with 1 CPU/GPU paired with 4 HBM storage. This chip is also one of the flagship chip products of the Cambrian period; The Huawei HiSilicon Ascend 910 chip adopts an advanced 7nm process technology. As can be seen from the promotional image, it also adopts a CoWoS structure with multiple stacked chips, which is also a form of chiplet. These chips are all based on advanced processes, and in order to further improve chip performance, CoWoS and other 2.5D advanced packaging technologies are adopted, indicating that advanced processes are superior to advanced packaging in terms of process route selection. Advanced processes are the first choice for upgrading chip performance, and advanced packaging is the icing on the cake.

V Advanced packaging/Chiplet has application value in scenarios with high power consumption and computing power

In situations where advanced processes are unavailable, product performance is maintained through chip stacking (advanced sealing/chiplet) and computational architecture reconstruction. Taking the A-series chip parameters of Apple as an example, A12, A10, and A7 chips use 7 nm, 14/16 nm (Samsung 14 nm, TSMC 16 nm), and 28 nm processes respectively. A-series mobile phone AP chips typically have a die size of approximately 100 mm2. On this 100 mm2 chip, A12, A10, and A7 chips integrate approximately 6.9 billion, 3.3 billion, and 1 billion transistors, respectively. Next, we will conduct a simple arithmetic conversion and discuss how the process of reducing production can maintain the computing power of the chip. If the chip process is reduced from 7 nm to 14 nm, the 7 nm process integrates 6.9 billion transistors on the A12 chip. If the 14 nm process is used to try to achieve similar computing power, the first step is to ensure that the number of transistors is consistent with the A12 chip, which is~7 billion. Without considering the significant improvement in the performance of individual transistors due to process improvement, the 14 nm process chip requires an area twice that of the 7 nm process, which is~200 mm2; If the chip process is reduced from 7 nm to 28 nm, the A7 chip with reference to 28 nm only integrates 1 billion transistors. To achieve the number of 7 billion transistors, the chip area needs to be expanded to~700 mm2. The larger the chip area, the lower the process yield, and the higher the manufacturing cost of a single chip obtained in actual manufacturing. Therefore, in the context where advanced processes are not available, reducing the process and stacking chips can indeed reduce computational disadvantages to a certain extent. However, to stack more chips, larger IC boards, more Chiplet chips, and more packaging materials are required, which also leads to increased power consumption, volume/area, and cost due to outdated processes. Therefore, for example, by stacking two chips at 14 nm, the performance of a 7 nm chip with the same number of transistors can be achieved; By stacking multiple 28 nm chips, achieve 14 nm chip performance. This stacking scheme may have practical value in the fields of HPC (server, AI inference) and base station based large chips, but for consumer electronics such as mobile AP chips and wearable chips, chip stacking is difficult to implement under strict spatial volume constraints in their application scenarios.

                                                                                                                                                                                                                                                                         

VI Our country has very little reserve of advanced process production capacity, and advanced packaging/chiplets can help compensate for the scarcity of processes

The globalization of cutting-edge technology is dead, and the production capacity of advanced processes in mainland China is extremely scarce and scarce. According to different wafer sizes, the production capacity of 6-inch wafers in mainland China accounts for nearly half of the global total, while the production capacity of 12 inch wafers is only about 10% of the global total. According to different process statistics, processes above 90 nm in mainland China account for about 20% of the world's total, processes between 20-90 nm account for about 10% of the world's total, and processes below 20 nm only account for about 1% of the world's total. The proportion of high-end manufacturing processes in mainland China is low, and there are obvious shortcomings in the industrial structure, with great potential for future expansion. The investment in high-end process expansion is large, with an investment of about $10 billion per 10000 pieces of production capacity for 3 nm process chips, which is much higher than the investment of about $700 million per 10000 pieces of 28 nm process chips. To make up for the shortcomings in the wafer industry structure in mainland China, it is necessary to focus on investing in high-end process wafer manufacturing capacity. This requires both technical breakthroughs and substantial investment support, which is a long and arduous task.                                                                                                                                                     

7、 Conclusion

Advanced packaging/Chiplet can release a portion of advanced process capacity for use in more urgent demand scenarios. From the above analysis, it can be seen that through process reduction and chip stacking, dependence on advanced processes can be reduced in some scenarios where there are no power and volume limitations, and chip costs are not sensitive. We can plan and apply the limited advanced process production capacity from a higher strategic perspective to the application needs that require more advanced processes.



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