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A brief guide

04.10.2019

Press-Feature

Connected mobility

A brief guide

Semiconductors – one way, then another Semiconductors are chemical substances that have the properties both of electrical conductors and of non-conductors – hence semiconductors. As microchips, they are built into practically every kind of electrical system. They are a key technology of the connected world. Silicon/silicon carbide – the raw material of the connected world Silicon (Si) is the most frequently used semiconductor in microelectronics. In chip production, ultra-pure, monocrystalline silicon is used. With silicon carbide (SiC), carbon atoms are additionally integrated into the lattice structure of silicon during the manufacturing process. This serves to increase energy efficiency. Wafers – the semiconductor world in disc form In the world of semiconductors, the term “wafer” means a circular disc made of a material such as silicon or silicon carbide. In a drawing process, cylinders of the raw material of up to 300 millimeters in diameter and more than one meter in length are extracted from a molten bath of the semiconductors. These cylinders are then sawed into discs – the so-called raw wafers. These discs are thinner than a millimeter. In a manufacturing process lasting around 14 weeks, these discs are turned into semiconductor chips. MEMS – seeing, feeling, smelling Rectangular or square, smaller than a pinhead, and between one and four millimeters tall – the tiny MEMS sensors are hugely versatile all-rounders in the connected world. MEMS stands for microelectromechanical systems. They act effectively as sensory organs in a wide range of different applications in vehicles and supply the control units with important information, such as whether the car is spinning on a slippery road surface. Nowadays it is also impossible to imagine consumer and entertainment electronics without MEMS sensors. For example, they transform a simple cellphone into a smartphone that takes sharp photos with no shaking or jittering. MEMS sensors consist primarily of a MEMS element and an ASIC on a tiny circuit board. The whole lot is covered by a protective casing. ASICs – chips with built-in “intelligence” If MEMS sensors are the sensory organs of the connected world, then application-specific integrated circuits (ASICs) are the brains. They process the information from the MEMS sensors and trigger further actions. For instance, they tell the airbags in a vehicle when exactly they should deploy. On the silicon chips measuring just a few square millimeters, there are complex circuits with up to several million individual electronic functions. Power semiconductors – brimming with strength These special semiconductor components look after the controlling and switching of high electrical currents and voltages. To manage this, they are equipped with special switching and conducting properties, as the high currents and voltages would destroy ordinary semiconductor components. In electric and hybrid vehicles, they control the energy flow in the power electronics between the battery and the e-motor and ensure that the electricity is used as efficiently as possible. Clean rooms – not just clean, but squeaky clean In the manufacturing rooms for semiconductor production, it must be ensured that there is absolutely no dust or other contaminating particles present in the ambient air. Even the tiniest of particles can destroy semiconductor components. Therefore, the air is kept clean using special extraction and filtering technology. There are various clean room classes. Sensitive chip manufacturing requires the purest Class 1. For work clothing, this means: coverall, gloves, hood, and face mask. And make-up, lipstick, and eyeliner are a no-go.

Did you know... Facts, figures, and amazing truths about semiconductors

04.10.2019

Press-Feature

Connected mobility

Did you know... Facts, figures, and amazing truths about semiconductors

The market In 2018, some 469 billion dollars (427 billion euros) worth of semiconductors were sold worldwide, an increase of around 15 percent over 2017 (source: World Semiconductor Trade Statistics). At 40 billion dollars (36 billion euros), memory chips make up the largest market share. The German semiconductor market grew by around 8 percent in 2018 and was worth 16 billion euros (source: ZVEI). While the semiconductor share in smartphones, tablet computers, PCs, and TVs will stagnate over the coming years, it will grow in vehicles as a result of increasing electrification, automation, and connectivity. Bosch today is one of the leading manufacturers of semiconductors for automotive applications and has been the leader in the manufacture of MEMS sensors since 2013.Production Semiconductor chips are manufactured on circular discs of silicon or silicon carbide, known as wafers. Up to 50,000 semiconductor chips fit on an eight-inch (200-mm) silicon wafer. Wafer production is carried out under cleanroom class 1 conditions. Every cubic foot (approx. 28 liters) of normal ambient air contains 100,000 particles. When manufacturing semiconductors, by contrast, there must be no more than one particle weighing half a microgram in every cubic foot of air. That is roughly the equivalent of having a single cherry pit in all of Lake Constance. In a complex production process lasting up to 14 weeks, the raw silicon wafers are made into semiconductor chips. In 1994, Bosch developed the “Bosch Process” for manufacturing MEMS sensors. For this work, the developers Jiri Marek, Michael Offenberg, and Frank Melzer received the German Future Prize. Bosch holds more than 1,500 patents and patent applications in the field of semiconductors, 1,000 of which are for MEMS technology. The development of semiconductor technology at Bosch Bosch has been manufacturing a wide range of semiconductor chips for nearly 50 years. These include application-specific integrated circuits (ASICs), power semiconductors, and microelectromechanical systems (MEMS). In the mid-1950s, Bosch research began to explore the development of particularly robust semiconductor components that are suitable for use on the road. In the 1960s, Bosch developed the first power semiconductor for cars. Back then, special generator diodes made generators more reliable and longer-lasting. At the end of the 1960s, Bosch built its first semiconductor factory in Reutlingen due to the growing demand for the components from within the Bosch Group. In 1970, Bosch launched the world’s first mass-produced ASICs for cars. Specifically, they were power transistors for voltage regulators and integrated circuits. When Bosch began producing its Motronic – a digital engine control system (ignition and injection in one control unit) – in 1979, it had an eight-bit microprocessor on board. Together with the erasable memory used, this was effectively the world’s first use of a computer in a car in a driving-relevant role. Bosch has been producing MEMS sensors for 25 years; the first model was a pressure sensor for the Bosch Motronic. In 2010, Bosch took its 200-millimeter semiconductor factory in Reutlingen into operation. With a total outlay of 600 million euros for the wafer fab, this was the biggest single investment ever made in the history of the Bosch Group. In June 2018, Bosch laid the foundation stone in Dresden for the construction of the Bosch Group’s most advanced semiconductor factory. The company is investing around one billion euros in this facility. In the plant, the company will manufacture semiconductors based on 300-millimeter technology. Use in vehicles In 2018, every new vehicle featured semiconductors worth 370 dollars (337 euros) on average. By 2021, this figure is set to rise to around 406 dollars (369 euros) (source: ZVEI). Experts predict that the biggest growth will be in the compact and middle-class segments, as typical high-end functions gradually seep into the mass market. Today’s vehicles feature around 50 MEMS sensors. Semiconductors account for some 75 percent of innovations in new vehicles. They can be found, for example, in the powertrain, in the cockpit, and in the infotainment and driver assistance and safety systems. In 2016, every car rolling off the production lines worldwide had on average more than nine Bosch chips on board, of which five were MEMS sensors. Use in consumer and entertainment electronics For more than ten years, Bosch MEMS sensors have also been used in consumer electronics. 2006 saw the market launch of the first MEMS sensor for consumer electronics. It enhanced the fun of games consoles. In 2018, more than 1.4 billion smartphones were sold (source: International Data Corporation (IDC)). In addition, wearables – the collective term for electronics that can be worn on the body, such as smart watches, fitness armbands, and data goggles – are growing in popularity. In 2018, sales of wearables were around 172 million units (source: IDC). All these devices contain sensors that evaluate a very wide range of information. On average, five MEMS sensors are built into every smartphone. They enable the mini-computers to recognize when the screen has been turned, and they stabilize photos and facilitate navigation. Every second smartphone has at least one Bosch semiconductor chip (MEMS sensor). Amazing but true When Bosch began the production of micromechanical sensors in 1995, the edge length of an acceleration sensor was 133 millimeters. The edge length of the smallest MEMS sensor currently in Bosch’s portfolio is 1.56 millimeters. That is smaller than a pinhead and represents a miniaturization of the sensor size by a factor of 85 within about 25 years – while simultaneously featuring more functions. More than 80 of these microchips would fit on a thumbnail. To date, Bosch has manufactured well in excess of 10 billion MEMS sensors in Reutlingen, with several million more added to the tally every day. On average, Bosch semiconductors are two millimeters thick. If the 10 billion semiconductors already manufactured by Bosch were laid end to end, the row of chips would be about 20,000 kilometers long. That is roughly the distance from the North to the South Pole. In consumer electronics, MEMS sensors are less than one millimeter in height. Some components inside the sensors measure a mere four micrometers – 17 times thinner than a human hair.