The present invention relates to the field of integrated circuit (IC) testing technology. Various implementations of the invention may be particularly useful for testing and characterizing interconnects of stacked integrated circuits.
Expanding into the third dimension enables chip manufacturers to continue shrinking transistors to boost speed without adding power leaks. However, chip stacking is limited by wiring-related problems. Today's interconnects do not run through the silicon itself but go millimeters around it, impeding speedy signaling and increasing power consumption along the way. 2-D (horizontal) real estate is also valuable. Even the thinnest interconnects must still be packed along the edges of a chip, imposing strict limits on how many input/output connections the chip can handle. Consequently, going vertical (3-D) by connecting one chip to another with lines that go straight through the silicon—commonly known as through-silicon vias (TSVs)—offers the numerous potential benefits. In particular, more connections can be packed side by side using much slimmer wires. Going through chips instead of around the side also reduces the length of interconnects from millimeters to microns or even less—as thin as individual wafers can be produced. It has been estimated that the switch to vertical interconnects may reduce power consumption in half, increase bandwidth by a factor of eight, and shrink memory stacks by some 35 percent.
As several hundreds of thousands of TSVs in a single package provide power/ground, clock, functional signals, as well as test access to logic blocks of different layers of the device, they become not only the key components of 3-D ICs but also make up a crucial test infrastructure. In order to form TSVs, one has to etch deep, narrow holes into a silicon wafer and then fill them with a nearly flawless layer of insulating material and then copper. But as a wafer heats up, copper expands at more than five times the rate that silicon does, exerting stress that can crack the wafer and render it useless. Because of such imperfect etching, ragged wafer surface, and potential wafer misalignments, certain TSVs in one wafer after thinning and polishing might not be completely exposed or aligned with their counterparts on the other wafer. Since the bonding quality of TSVs depends on the winding level of the thinned wafer as well as the surface roughness and cleanness of silicon dies, defective TSVs tend to occur in clusters, though even a single TSV defect between any two layers can void the entire chip stack, reducing the overall yield.
These mechanisms can lead to not only catastrophic defects but also parametric defects. There are two major parametric defects occurring at TSVs, resistive open defects and leakage defects. A resistive open defect occurs when a TSV has excessive resistance, which could result in extra delay across the TSV. Conventional at-speed test may detect it using transition fault test patterns when a large delay exists. However, for more elusive small delay, conventional at-speed test is unavailable. A leakage defect occurs when the conducting material of a TSV mistakenly penetrates the insulator between a TSV and its surrounding substrate. Such a defect causes leakage during the time when the TSV is being charged up to a high voltage. It could degrade the performance of the TSV and sometimes pose a reliability threat as the defect worsens over time. In the literature, it has also been called open-sleeve fault (defect), or short fault (defect).
A leakage test threshold is often used for testing leakage defects. Traditionally, an I/O (Input/Output) pin has a leakage defect if it has a leakage current above 1 μA. Most previous TSV test methods have employed leakage test thresholds in the range of 10-100 μA. Different methods cover different ranges of leakage test thresholds, and multiple methods may need to be combined to cover a wide range that satisfies different system-level requirements.
In general, there are two major types of methods for leakage test. The first type is referred to as L2VCC (Leakage to Voltage Conversion and then Comparison).
The L2VCC method has some major drawbacks. First, the method is not very easy to implement. Analog or custom circuitry might be required to perform analog voltage detection. Also, transmitting an analog reference voltage to each TSV, as needed, could be a daunting task. Second, the method usually targets leakage current in the range from 10 μA to 100 μA, and may not be very suitable for the detection of small leakage (e.g., less than 1 μA), because in that case the equivalent leakage resistance would be about 100 kΩ, assuming VDD=1 V and 2 kΩ for the pull-up device 110 and resulting stable voltage at the observation node 120 would be about 0.98 V. Detection whether a voltage is greater than this value with VDD=1 V is too challenging.
The second type of methods for leakage test is referred to as CAF-WAS (Chareg-up-and-Float, wait-and-Sample).
The voltage at the I/O pin 210 would dropped below VDD/2 at the end of the waiting period if the leakage current is larger than 1 μA. Accordingly, the sampled value at the output of the output buffer 230 would be a logic “0”, indicating the presence of a leakage fault. Otherwise, a logic “1” would be sampled, indicating a passing condition. The above procedure can be modified slightly to test if there is an unwanted conducting path to VDD at the I/O pin 210 by changing the charge value from “1” to “0”, and interpreting the sampled value inversely (i.e., “0” for passing and “1” for failing).
This CAF-WAS method is elegant in that it uses only low-cost logic gates and its ability to detect very tiny leakage current (˜1 μA). However, two issues may prevent it from being applicable to the TSV leakage test directly. First, the capacitance of a TSV could be 100 times smaller than an I/O pin (e.g., 40 fF of a 5 μm-diameter TSV versus 3 pF IO pin). As to be analyzed in detail later, this CAF-WAS method uses 2˜3 test clock cycles as the waiting time period and may not be good for handling small capacitance. Second, the leakage test threshold may vary. If the leakage test threshold for a TSV is set to be 10 μA instead of 1 μA in another 3D circuit, then the CAF-WAS method needs to be modified to be flexible enough to accommodate the new leakage test threshold.
Various aspects of the present invention relate to techniques of testing interconnects in stacked designs for leakage defects.
In one aspect, there is a method, comprising: applying logic “1” or “0” to one end of an interconnect during a first pulse; and capturing, triggered by an edge of a second pulse, logic value at the one end, the first pulse preceding the second pulse by a time period, the time period being selected from a plurality of delay periods, the plurality of delay periods being generated by a logic device shared by a plurality of interconnects.
The interconnect may be a through-silicon via (TSV) or an interposer. A tri-state buffer may be used for the applying operation. A flip-flop may be used for the capturing operation.
The first pulse and the second pulse may be derived from two consecutive pulses of a signal. The first pulse may be generated by a flip flop and a gating device based on an early pulse of the two consecutive pulses and the second pulse may directly use a late pulse of the two consecutive pulses.
In another aspect, there is an integrated circuit, comprising: a first device configurable to apply logic “1” or “0” to one end of an interconnect during a first pulse; a second device configurable to capture, triggered by an edge of a second pulse, logic value at the one end, the first pulse preceding the second pulse by a time period, the time period being selected from a plurality of delay periods; and a third device, shared by a plurality of interconnects, configurable to generate the plurality of delay periods.
The first device may be a tri-state buffer. The second device may be a flip-flop. The integrated circuit may further comprise a fourth device configurable to generate a signal comprising two pulses, an early pulse of the two pulses being used to generate the first pulse, a late pulse of the two pulses being used as the second pulse.
In still another aspect, there is one or more non-transitory processor-readable media storing processor-executable instructions for causing one or more processors to create test circuitry in a design of an integrated circuit, the test circuitry comprising: a first device configurable to apply logic “1” or “0” to one end of an interconnect during a first pulse; a second device configurable to capture, triggered by an edge of a second pulse, logic value at the one end, the first pulse preceding the second pulse by a time period, the time period being selected from a plurality of delay periods; and a third device, shared by a plurality of interconnects, configurable to generate the plurality of delay periods.
Certain inventive aspects are set out in the accompanying independent and dependent claims. Features from the dependent claims may be combined with features of the independent claims and with features of other dependent claims as appropriate and not merely as explicitly set out in the claims.
Certain objects and advantages of various inventive aspects have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
Various aspects of the present invention relate to techniques of testing interconnects in stacked designs for leakage defects. Two examples of interconnects are TSVs for three-dimensional designs and interposers for two-and-half-dimensional designs. In the following description, numerous details are set forth for the purpose of explanation. However, one of ordinary skill in the art will realize that the invention may be practiced without the use of these specific details. In other instances, well-known features have not been described in details to avoid obscuring the present invention.
Some of the techniques described herein can be implemented in software instructions stored on one or more non-transitory computer-readable media, software instructions executed on a processor, or some combination of both. As used herein, the term “non-transitory computer-readable medium” refers to computer-readable medium that are capable of storing data for future retrieval, and not propagating electro-magnetic waves. The non-transitory computer-readable medium may be, for example, a magnetic storage device, an optical storage device, a “punched” surface type device, or a solid state storage device. Some of the disclosed techniques, for example, can be implemented as part of an electronic design automation (EDA) tool. Such methods can be executed on a single computer or on networked computers.
Also, as used herein, the term “design” is intended to encompass data describing an entire integrated circuit device. This term also is intended to encompass a smaller group of data describing one or more components of an entire device, however, such as a portion of an integrated circuit device. Still further, the term “design” also is intended to encompass data describing more than one microdevice, such as data to be used to form multiple microdevices on a single wafer.
The present disclosure also includes some hardware drawings. These drawings are only illustrative and are non-limiting. For illustrative purposes, the size of some of the elements in the drawings may be exaggerated and not drawn on scale, and some elements in the drawings may be omitted.
After a time period called wait time (390), a pulse of the LT Pulse signal 380 arrives with its rising edge (positive edge) triggering the sampling operation. The logic value captured by the flip-flop 360 indicates the binary pass/fail test result: “1” means “Pass” whereas “0” means “Fail”.
The wait time 390 should be selected with care as it is closely related to the leakage test threshold. Assuming 1 V of VDD and 40 fF of TSV capacitance (CTSV), the wait time needed for a particular leakage test threshold value (LTT) can be approximated by the following formula:
Wait time=(CTSV×0.5VDD)/LTT Eq. (1)
In principle, the wait time 390 is the time required for the node Y 370 to drop below 0.5VDD from VDD assuming that the leakage current is constant at the LTT value. If the LTT value is 10 μA as in the standard IO pin leakage test, the wait time will be about (40 fF×0.5V)/10 μA=2 ns. For a test running at 1 MHZ (or at a clock period of 1000 ns), this is only 1/500 of the clock cycle time, too small to be represented in multiples of the test clock cycle time used by the circuit (prior art) shown in
In
Δ=δ+programmable delay Eq. (2)
where δ represents the delay by the one-shot circuit 450.
Ideally, the wait-time should be solely determined by the programmable delay line. To achieve this goal, the δ-part is unwanted and needs to be calibrated away. This can be achieved to some extent by adding a δ-delay element such as a dummy delay δ 460 to the other path (i.e., the path from ‘WTG_in’ to LTE).
The one-shot circuit 450 is configured to generate a one-shot signal OS 470 and converts the pulse width of ‘WTG_in’ 440 to the desired pulse width of LT_Pulse 380.
The signals LTE 350 and LT_Pulse 380 may spend different amounts of time to arrive at a TSV because the physical routing paths may be different. This can affect the integrity of the wait time. In other words, it is very likely that a TSV may experience different wait time than the original one generated at the test controller. This problem can only become worse when there are many TSVs sharing the same LTE and LT_Pulse signals.
With some implementations of the invention, the same LTE and LT_Pulse signals are derived locally from two consecutive pulses of a signal. This signal is referred to as a self-timed timing control signal.
An internal signal, WTG in (440), is generated by a clock gating circuit from {TCLK (620) and Test_Enable (610)}. The clock gating circuit comprises a flip-flop 650 and an AND gate 660. Due to these two devices, when Test_Enable (610) is “1”, WTG_in (440) is a copy of TCLK (620) in those clock cycles and when Test_Enable (610) is “0”, WTG_in (440) remains “0”.
Event 1 (At the 1st rising edge (740) of ST_LTE 630): The voltage at node Y 370 will be sampled into the flip-flop 720. This is a false yet harmless sampling. The sampled value is not relevant and will be overwritten later by the 2nd sampling;
Event 2 (At the falling edge (750) of CAF 710): The pre-charged TSV 310 is left floating from this moment on until the end of the test cycle; and
Event 3 (At the 2nd rising edge (760) of ST_LTE 630): The voltage at node Y 370 will be sampled into the flip-flop 720 again. This is the real sampling for the leakage test.
There is a time delay between the first rising edge 740 of ST_LTE 630 and the falling edge 750 of CAF 710, due to the setup time of the flip-flop 720 and the delay of the AND gate 730. This combined delay, denoted as γ-delay, diminishes the original wait time. Fortunately, it is a constant term and can be pre-compensated during the wait time generation by the following process:
At wait-time generation:
Generated Wait-time=(Desired wait-time)+(γ-delay)
Actual wait-time as applied to each TSV:
If the substrate surrounding a TSV under test is biased at the supply voltage, instead of the ground voltage, logic ‘0’ signal, instead of logic ‘1’, needs to supplied to the input of the test-mode tri-state buffer 330. Also, the final ‘Pass/Fail’ result needs to be interpreted differently. For example, if at the final sampling time, the node Y 370 remains relatively low as its original discharged value, a sampled value of “0” indicates a “Pass”. On the other hand, it indicates a “Fail”.
While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims.
This application claims priority to U.S. Provisional Patent Application No. 61/771,767, filed on Mar. 1, 2013, and naming Shi-Yu Huang et al. as inventors, which application is incorporated entirely herein by reference.
Number | Date | Country | |
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61771767 | Mar 2013 | US |