Integrated circuits are the foundation of most modern electronics. They function as the brains and heart of most circuits. This little black chip is almost in every circuit board. Integrated circuit has revolutionized the electronics technology as it has made it possible to embed millions of components in one single device.
As an engineer, it is crucial to understand how IC works. In every electronics project, there is always at least one IC. Therefore, it is important you understand everything about it.
What is an IC Chip?
An IC chip is a chip made of silicon that allows millions of transistors, capacitors, and other components to be embedded in it. Also, this small chip can serve a lot of purposes. It can store data and as well perform calculations. The number of transistors an IC could house has increased since its development.
Furthermore, an IC chip is simply a collection of electronic components embedded in a tiny chip. Before the advent of ICs, the basic technique of connecting electronic components on a circuit was by shouldering. Due to the high power consumption and big size of these devices, it was necessary to design a very small circuit that consumes less power.
Things became better after inventing transistors and semiconductors. However, the development of IC chips impacted electronics technology. Integrated circuits usually comprise several components. All these components work together to execute a particular task. Also, the integrated circuit is breakable. Therefore, a plastic package houses the IC.
An IC chip can function as microprocessors, amplifiers, or oscillators. Furthermore, an IC chip can be digital or analog based on its application. The transistors are the main components of an integrated circuit. Also, these components can be either field or bipolar effect based on the applications of the IC.
Integrated circuit chips comprise semiconducting materials. The manufacturing process often takes place in a controlled environment. Furthermore, the equipment operators in the room must protect themselves from any form of accidents. The light sources in this room are always filtered since some components can be sensitive to light.
Types of Integrated Circuits
There are two different types of integrated circuits. These are the analog IC and digital ICs.
Analog
The signals of the input and output of analog ICs are continuous. Also, the input signal level determines the output signal level. Analog ICs are commonly found in radio frequency amplifier and audio frequency amplifier. Furthermore, the IC chip is developed with the use of analog design process.
Digital
Digital ICs usually function with binary data like 0 or 1. In digital circuits, 0 means 0 V and 1 means +5V. Also, digital ICs are commonly integrated in some electronics projects. Examples of these ICs include logic gates, counters, and microprocessors.
IC Chip Manufacturing Process
The manufacturing process of an IC chip involves some steps. Also, this process can be a complex one. However, it is a straightforward process.
Wafer production
This step involves shaping pure silicon crystals in long cylinders and slicing them into thin wafers. Slicing involves cutting the silicon rods into very thin wafers. Some special internal blades help to achieve that. After this , you will need to clean the edges and surfaces of the wafer. Also, ensure you remove impurities and scratches form the sharp edges of this wafer.
Masking
The next step is masking. Here, you will need to heat the wafers to coat them in silicon dioxide. There are several layers installed in an IC. Also, a computer-aided drafting machine helps the design of each layer. You will need to place a drop of photoresist in the silicon wafer. Then the engineer spins the wafer to ensure the proper distribution of photoresist in the whole surface.
Etching
This step involves using chemicals to remove the photoresist. Therefore, this creates a template pattern that shows the desired area of p-type and n-type silicon. Also, you will need to mark out the wafers in several rectangular or square areas. Each of these makes up a silicon chip.
Doping
Doping involves the heating of etched wafers with gasses. These gasses comprise impurities to create the PC and N layers. Also, atomic diffusion can help to add dopants to create the N or P regions.
Testing and packaging
This is the final step in this process. All chips must undergo computer-controlled testing. Also, the functional chips are packaged in protective encasements.
Characteristics of IC Chips
IC chips are one of the most complex chips ever made. These chips comprise small silicon with microscopic patterns. Also, the patterns may feature millions of resistors, transistors, and other electronic components. These IC chips power cell phones, personal computers, etc. Chip designers have continued improving the functionality and performance of these chips.
IC Packaging
The IC package houses the integrated circuit die and make it easy to connect. Also, the IC chip is very small and delicate. Therefore, IC designers ensure these chips are well packaged. Each IC chip is individually bonded to aluminum wires and then set into a block of ceramic or plastic. This block features metal pins which leads to the wires inside. Also, the pins create an electrical and mechanical connection to other components in the chip.
The plastic block offers protection to the IC chip. The part number of the IC chip is always printed on the top. Furthermore, IC chip are available in different types of package. Examples of these packages are the dual-inline package, small outline package, and more. IC designers have included more pins in IC packages as the complexity of IC chips keeps growing.
Density
The semiconductor industry keeps increasing the number of transistors on a chip every two years since the 1960s. Some transistors on microprocessor chips measure about 45 nanometer on a side. The chips developed these days feature over 100 million transistors.
Materials
An IC chip comprises semiconducting materials. Silicon is surely the most frequently used material for producing IC chips. Furthermore, ultrapure silicon is usually mixed with some amounts of other elements to design electronic materials with various characteristics.
Integration
Devices such as LEDs and transistors comprise individual silicon chips. IC chips combine various devices on a single chip. Now, a single chip can perform the functions of many. For instance, a microcontroller integrates a memory, interface, and microprocessor in the same device.
Size
IC chips are available in different sizes which range from 1 sq.mm to over 200 sq.mm. Also, the plastic package that houses the chip is larger. Also, the thickness of the package can be a few millimeters.
IC Packages
IC packages are cases that protect the circuit material from physical damage or corrosion. Also, these packages enable the mounting of electrical contacts. There are different types of IC packages since there are different types of ICs. Different integrated circuits suit different packages.
Furthermore, the IC packaging is the final stage in IC production process. In this stage, the IC designer uses a package to cover the semiconductor block. This package is a case specially designed to protect the block. Since the 1970s, the IC packaging technology has continued to evolve. The most common package types are:
Dual inline package
This type of IC package comprises two rows of pins along the edges of a rectangular IC. Also, a dual inline package can mount to a PCB with a socket or a through-hole.
This is a flat IC component that has leads along all the four edges. Also, this type of package can’t be through-hole and the sockets are scarcely available for this package. The number of pins in a quad flat package can range from 32 to 304. However, this depends on the pitch range. Also, QFP have variants which are thin and low-profile.
Small outline package
This is an IC package that comprises a rectangular shape having small pins along the edges. Small outline packages are commonly used for ICs that power flash memory and RAM. On these packages, every pin has a space of about 0.05.”
A ball grid array (BGA) is commonly found in computing equipment. There are different from other IC packages. Also, this chip-carrying surface-mount package provides the highest speeds of all IC packages. You can find BGAs o USB cards, RAM sticks, etc. Furthermore, the soldering process on a BGA helps to offer precision.
Classes of IC Chips Based on Manufacturing Techniques
There are different types of IC chips according to the techniques used during manufacturing. These include thin and thick film, hybrid or multichip, and monolithic ICs.
Thin and thick film ICs
These integrated circuit types use components like capacitors and resistors. Also, these ICs are a combination of separated and integrated components. Thin and thick integrated circuits have related characteristics.
Hybrid or multi-chip ICs
These types of chip have more than one interconnected individual chip. Also, the active components such as diffused transistors or diodes often include these ICs. Multi-chip ICs are ideal for use in high-power amplifiers that range from 5W to 500 W. Also, these integrated circuits perform better than monolithic ICs.
Monolithic ICs
Monolithic ICs have the active, passive, and discrete components on a chip. This means that they can form the interconnections of the passive, active , and discrete components on the silicon chip. These ICs are usually found in amplifiers, computer circuits, and voltage regulators. Monolithic IC components usually have poor insulation.
What are the Commonly Used ICs?
IC chips are available in many forms. Here are some common ICs in electronics
Microprocessors and microcontrollers
Microprocessors and microcontrollers are a good example of ICs. They package thousands or millions of transistors in a tiny chip. Also, these components are available in a wide range in terms of size and functionality. Examples include 64-bit multi-core microprocessor and 8-bit microcontroller.
Sensors
Digital sensors such as gyroscopes, sensors, and accelerometers are all packed in an IC chip. Also, these chips are smaller than microcontrollers.
Logic gates
Logic gates can be well packaged in their own integrated circuit. Some logic gates comprise some gates in one package. Also, logic gates can connect in an IC to create shift registers, counters, and some basic logic circuitries. You can find the majority of these circuits in DIP packages and also SSOP.
Advantages and Disadvantages of IC Chips
Advantages
- IC chips offer a lot of advantages in modern electronic devices. They are responsible for the compact size of electronic devices. Also, these chips serve as the building block of most electronic devices.
- IC chips consume less power. These chips offer high performance at low power.
- Also, IC chips help to achieve compact electronic designs. These boards offer more functionality compared to discrete circuits.
- Integrated circuits function at high speeds because of their switching speeds.
- Furthermore, integrated circuits offer high reliability.
- Integrated circuits are small in size and millions of electronic components can be embedded in a single IC chip.
- It is easily replaceable from the mother PCB.
- IC chips are available in less cost due to their usage of low-cost material and fabrication technologies.
Disadvantages
Despite the benefits offered by IC chips, they have some drawbacks which include:
- Due to the small size of IC chips, there is no proper heat dissipation and current overflow can lead to IC damage.
- The range of power dissipation is about 10 watts
- Integrated circuits can’t obtain low noise and high voltage
- IC chips don’t allow the incorporation of electronic components like transformers and inductors
Frequently Asked Questions
What is the difference between a semiconductor and an IC chip?
IC chips are small devices that feature at least two semiconductor components. On the other hand, a semiconductor is an element that features electrical properties.
What are the use cases of IC chips?
IC chips are ideal for use in several electronic devices. These chips are available in computing equipment, mobile phones, medical devices and more.
Conclusion
IC Chips are available in almost every circuit. They are the foundational block of most electronic circuits. Also, these chips have contributed to the development of compact and miniaturized electronics.
