Category Archives: Manufacturing

FlexTech, a SEMI Strategic Association Partner announced a new development project with PARC, a Xerox company, to develop a hybrid, highly bendable, paper-like smart tag, incorporating a thin audio speaker. The product is aimed at applications in packaging, wearables prosthetics, soft robotics, smart tags, and smart cities and homes.

PARC will use ink jet printing to build prototypes of the paper-like smart tags capable of producing audio signals, on a silver-printed polyethylene naphthalene (PEN) or polyimide (PI) substrate. They will develop and demonstrate a process for bonding chips, and printing active and passive components, as well as interconnects on the flexible substrate, essential in meeting the project goals for ruggedness and form factor. PARC will also focus on printing actuators to create thin film audio speakers. The technology will enable custom systems to be built on demand.

“Over the last 15 years PARC has been a pioneer in the exciting field of printed electronics.  We are pleased to continue our collaboration with SEMI-FlexTech in a project which takes advantage of the wide range of expertise on the PARC staff,” said Bob Street, project technical lead at PARC. “This new project is technically challenging because it combines a number of novel technologies needed to achieve stringent requirements, including the capability for a thin, paper-like film to produce clear speech audio.  We are looking forward to the challenge and implications for commercial products.”

In 2014, FlexTech awarded PARC with a project grant to develop printed sensors. Partly because of this work, it is now possible to print transistor circuits in a fully additive fashion, and to combine these with sensors, actuators and other electronic components.

“We have had a long, fruitful relationship with PARC and look forward to excellent results from this project which clearly advances innovation in flexible, printable electronics, enabling solutions that lead to safer, healthier lives,” said Melissa Grupen-Shemansky, CTO at SEMI-FlexTech. “In addition to pushing the boundaries in electronics, PARC pays attention to manufacturability and affordability, ensuring developments are scalable from R&D to production.”

PARC and SEMI-FlexTech staff envisage additive manufacturing delivering intelligence into electronics fabricated on demand, including smart packaging and wearable devices in conformal shapes. At the heart of this development are material science, novel printing technologies as well as process driven design that will deliver libraries of smart components and systems. The constituent “inks” of this technology are nanomaterials, molecular semiconductors, inorganic composites and silicon chiplets that together form circuits, sensors, light emitters, batteries, and more, integrated directly into products of all shapes, sizes and textures.

FlexTech’s R&D program is supported by the U.S. Army Research Laboratory (ARL), based in Adelphi, MD.

The number of connected Internet of Things (IoT) devices worldwide will jump 12 percent on average annually, from nearly 27 billion in 2017 to 125 billion in 2030, according to new analysis from IHS Markit (Nasdaq: INFO).

In a new free ebook entitled “The Internet of Things: a movement, not a market,” IHS Markit details how the IoT is revolutionizing the competitive landscape by transforming everyday business practices and opening new windows of opportunity.

According to the ebook, global data transmissions are expected to increase from 20 to 25 percent annually to 50 percent per year, on average, in the next 15 years.

“The emerging IoT movement is impacting virtually all stages of industry and nearly all market areas — from raw materials to production to distribution and even the consumption of final goods,” said Jenalea Howell, research director for IoT connectivity and smart cities at IHS Markit. “This represents a constantly evolving movement of profound change in how humans interact with machines, information and even each other.”

IHS Markit has identified four foundational, interconnected pillars at the core of the IoT movement: connect, collect, compute and create. The entire IoT is built upon these four innovational pillars:

  • New connections of devices and information
  • Enhanced collection of data that grows from the connections of devices and information
  • Advanced computation that transforms collected data into new possibilities
  • Unique creation of new interactions, business models and solutions.

“While internet-connected devices hold tremendous potential, many companies are having difficulty identifying a consistent IoT strategy,” Howell said. “The four Cs of IoT — connect, collect, compute, create — offer a pathway to navigate and take advantage of the changes and opportunities brought about by the IoT revolution.”

Piezoelectric materials are used for applications ranging from the spark igniter in barbeque grills to the transducers needed by medical ultrasound imaging. Thin-film piezoelectrics, with dimensions on the scale of micrometers or smaller, offer potential for new applications where smaller dimensions or a lower voltage operation are required.

Researchers at Pennsylvania State University have demonstrated a new technique for making piezoelectric microelectromechanical systems (MEMS) by connecting a sample of lead zirconate titanate (PZT) piezoelectric thin films to flexible polymer substrates. Doctoral candidate Tianning Liu and her co-authors report their results this week in the Journal of Applied Physics, from AIP Publishing.

Electroded thin-film PZT on a flexible polyimide substrate of relatively large area. Credit: Tianning Liu

Electroded thin-film PZT on a flexible polyimide substrate of relatively large area. Credit: Tianning Liu

“There’s a rich history of work on piezoelectric thin films, but films on rigid substrates have limitations that come from the substrate,” said Thomas N. Jackson, a professor at Penn State and one of the paper’s authors. “This work opens up new areas for thin-film piezoelectrics that reduce the dependence on the substrate.”

The researchers grew polycrystalline PZT thin films on a silicon substrate with a zinc oxide release layer, to which they added a thin layer of polyimide. They then used acetic acid to etch away the zinc oxide, releasing the 1-micrometer thick PZT film with the polyimide layer from the silicon substrate. The PZT film on polyimide is flexible while possessing enhanced material properties compared to the films grown on rigid substrates.

Piezoelectric devices rely on the ability of some substances like PZT to generate electric charges when physically deformed, or inversely to deform when an electric field is applied to them. Growing high-quality PZT films, however, typically requires temperatures in excess of 650 degrees Celsius, almost 300 degrees hotter than what polyimide is able to withstand without degrading.

Most current piezoelectric device applications use bulk materials, which hampers miniaturization, precludes significant flexibility, and necessitates high-voltage operation.

“For example, if you’re looking at putting an ultrasound transducer in a catheter, a PZT film on a polymer substrate would allow you to wrap the transducer around the circumference of the catheter,” Liu said. “This could allow for significant miniaturization, and should provide more information for the clinician.”

The performance of many piezoelectric thin films has been limited by substrate clamping, a phenomenon in which the rigid substrate constrains the movement of the piezoelectric material’s domain walls and degrades its properties. Some work has been done crystallizing PZT at temperatures that are compatible with polymeric materials, for example using laser crystallization, but results thus far have led to porous thin films and inferior material properties.

The released thin films on polyimide that the researchers developed had a 45 percent increase in remanent polarization over silicon substrate controls, indicating a substantial mitigation in substrate clamping and improved performance. Even then, Liu said, much work remains before thin-film MEMS devices can compete with bulk piezoelectric systems.

“There’s still a big gap between putting PZT on thin film and bulk,” she said. “It’s not as big as between bulk and substrate, but there are also things like more defects that contribute to the lower response of the thin-film materials.”

China IC industry outlook


October 17, 2017

SEMI, the global industry association and provider of independent electronics market research, today announced its new China IC Industry Outlook Report, a comprehensive report for the electronics manufacturing supply chain. With an increasing presence in the global semiconductor manufacturing supply chain, the market opportunities in China are expanding dramatically.

China is the largest consumer of semiconductors in the world, but it currently relies mainly on semiconductor imports to drive its growth. Policies and investment funds are now in place to further advance the progress of indigenous suppliers in China throughout the entire semiconductor supply chain. This shift in policy and related initiatives have created widespread interest in the challenges and opportunities in China.

With at least 15 new fab projects underway or announced in China since 2017, spending on semiconductor fab equipment is forecast to surge to more than $12 billion, annually, by 2018. As a result, China is projected to be the top spending region in fab equipment by 2019, and is likely to approach record all-time levels for annual spending for a single region.

Figure 1

Figure 1

This report covers the full spectrum of the China IC industry within the context of the global semiconductor industry. With more than 60 charts, data tables, and industry maps from SEMI sources, the report reveals the history and the latest industry developments in China across vast geographical areas ranging from coastline cities to the less developed though emerging mid-western regions.

The China IC industry ecosystem outlook covers central and local government policies, public and private funding, the industry value chain from design to manufacturing and equipment to materials suppliers. Key players in each industry sector are highlighted and discussed, along with insights into China domestic companies with respect to their international peers, and potential supply implications from local equipment and material suppliers. The report specifically details semiconductor fab investment in China, as well as the supply chain for domestic equipment and material suppliers.

Figure 2

Figure 2

Toshiba Corporation (TOKYO:6502) today announced that its board of directors has approved a further investment by Toshiba Memory Corporation (TMC), a wholly-owned subsidiary that manufactures Flash memory, in manufacturing equipment for the Fab 6 clean room under construction at Yokkaichi Operations. TMC will invest approximately 110 billion yen as a second investment in Fab 6 for the installation of additional manufacturing equipment in the Phase-1 clean room.

Production at Fab 6 will be entirely devoted to BiCS FLASH, Toshiba’s innovative 3D Flash memory. As Toshiba announced in its August 3, 2017 release “Update on Toshiba Memory Corporation’s Investment in Production Equipment for Fab 6 at Yokkaichi Operations”, TMC has previously invested approximately 195 billion yen in Fab 6 as its first investment covering the installation of manufacturing equipment in the Phase-1 clean room and the construction of the Phase-2 clean room.

Demand for TMC’s next generation 3D Flash memory devices is expected to increase significantly due to growing demand for enterprise SSDs in datacenters, SSDs for PCs, and memory for smartphones; TMC expects this strong market growth to continue in 2018. TMC’s investment timing will position it to capture this growth and expand its business.

The investment in Fab 6 will enable TMC to install manufacturing equipment for 96-layer 3D Flash memories, including deposition and etching equipment.

There is no change in the FY2017 Financial Forecast announced on Aug 10, 2017, as the impact of the additional investment will be realized after FY2018. However, the FY2017 investment plan for Toshiba Corporation Storage & Devices Solutions Segment will be revised from 330 billion yen, as announced on August 10, to 400 billion yen by accelerating a part of the investment previously planned for FY2018. This will be used with the remaining 40 billion yen in the FY2017 investment plan, bringing this second investment to 110 billion yen. As announced on March 17, 2016 announcement “Notice of Construction of New Semiconductor Fabrication Facility,” Toshiba decided on a construction and equipment investment plan for the new fabrication facility, with an estimated cost of approximately 360 billion yen from FY2016 to FY2018. The company will update its investments plans to reflect any subsequent changes.

TMC has recently asked SanDisk, its collaborator in three joint ventures for investment in manufacturing equipment at TMC’s Yokkaichi Operations, whether it intends to jointly participate in this second investment for the Phase-1 clean room in the Fab 6 facility.

By Yoichiro Ando, SEMI Japan

Shinzo Abe, the prime minister of Japan, plans to stage a Robot Olympics in 2020 alongside the summer Olympic Games to be hosted in Tokyo. Abe said he wants to showcase the latest global robotics technology, an industry in which Japan has long been a pioneer. Japan’s Robot Strategy developed by the Robot Revolution Initiative Council plans to increase Japanese industrial robot sales to 1.2 trillion JPY by 2020. This article discusses how the robotics industry is not just a key pillar of Japan’s growing strategy but also a key application segment that may lead Japan’s semiconductor industry growth.

Japan leads robotics industry

According to International Federation of Robotics (IFR), the 2015 industrial robot sales increased by 15 percent to 253,748 units compared to the 2014 sales. Among the 2015 record sales, Japanese companies shipped 138,274 units that represent 54 percent of the total sales according to Japan Robot Association (JARA). The robotics companies in Japan include Yaskawa Electric, Fanuc, Kawasaki Heavy Industries, Fujikoshi and Epson.

Source: International Federation of Robotics (global sales) and Japan Robot Association (Japan shipment)

Source: International Federation of Robotics (global sales) and Japan Robot Association (Japan shipment)

The automotive industry was the most important customer of industrial robots in 2015 that purchased 97,500 units or 38 percent of the total units sold worldwide. The second largest customer was the electrical/electronics industry (including computers and equipment, radio, TV and communication devices, medical equipment, precision and optical instruments) that showed significant growth of 41 percent to 64,600 units.

Semiconductors devices used in robotics industry

Robotics needs semiconductor devices to improve both performance and functionality. As the number of chips used in a robot increases and more advanced chips are required, the growing robotics market is expected to generate significant semiconductor chip demands.

FEA-RO-IA-R2000-SpotWeld-3

Semiconductor devices in robots are used for collecting information; information processing and controlling motors and actuators; and networking with other systems.

  • Sensing Devices: Sensors are used to collect information including external information such as image sensors, sound sensors, ultrasonic sensors, infrared ray sensors, temperature sensors, moisture sensors and pressure sensors; and movement and posture of the robot itself such as acceleration sensors and gyro sensors.

    Enhancing these sensors’ sensitivity would improve the robot performance. However, for robot applications, smaller form factors, lighter weight, lower power consumption, and real-time sensing are also important. Defining all those sensor requirements for a specific robot application is necessary to find an optimal and cost-effective sensor solution.

    In addition, noise immunity is getting more important in selecting sensors as robot applications expand in various environments that include noises. Another new trend is active sensing technology that enhances sensors’ performance by actively changing the position and posture of the sensors in various environments.

  • Data Processing and Motor Control Devices: The information collected by the sensors is then processed by microprocessors (MPUs) or digital signal processors (DSPs) to generate control signals to the motors and actuators in the robot. Those processors must be capable of operating real-time to quickly control the robot movement based on processed and analyzed information. To further improve robot performance, new processors that incorporate artificial intelligence (AI) and ability to interact with the big data cloud database are needed.
  • As robotics is adapted to various industry areas as well as other services and consumer areas, the robotics industry will need to respond to multiple demands. It is expected that more field programmable gate arrays (FPGAs) will be used in the industry to manufacture robots to those demands.

    In the control of motors and actuators, power devices play important roles. For precise and lower-power operation of the robot, high performance power devices using high band gap materials such as Silicon Carbide and Gallium Nitride will likely used in the industrial applications.

  • Networking Devices: Multiple industrial robots used in a production line are connected with a network. Each robot has its internal network to connect its components. Thus every robot is equipped with networking capability as a dedicated IC, FPGA or a function incorporated in microcontrollers.

Ando--industrial-automation

Smart Manufacturing or Industry 4.0 requires all equipment in a factory to be connected to a network that enables the machine-to-machine (M2M) communication as well as connection to the external information (such as ordering information and logistics) to maximize factory productivity. To be a part of such Smart Factories, industrial robots must be equipped with high-performance and high-reliability network capability.

Opportunities for semiconductor industry in Japan

Japanese semiconductor companies are well-positioned in the key semiconductor product segments for robotics such as sensors, microcontrollers and power devices. These products do not require the latest process technology to manufacture and can be fabricated on 200mm or smaller wafers at a reasonable cost. Japan is the region that holds the largest 200mm and smaller wafer fab capacity in the world and the lines are quite versatile in these product categories.

The robotics market will likely be a large-variety and small-volume market. Japanese semiconductor companies will have an advantage over companies in other regions because they can collaborate with leading robotics companies in Japan from early stages of development. Also, Japan may lead the robotics International Standards development which would be another advantage to Japanese semiconductor companies.

For more information about the robotics and semiconductor, attend SEMICON Japan on December 13 to 15 in Tokyo. Event and program information will be available at www.semiconjapan.org soon.

TowerJazz, the global specialty foundry, and Crocus, a developer of TMR magnetic sensor technology and embedded MRAM, today announce volume manufacturing of Crocus TMR (Tunnel MagnetoResistance) sensors, using TowerJazz’s 0.13um CMOS process with a dedicated magnetic module in the Cu BEOL. With Crocus’ magnetic process, know-how and IP, and TowerJazz’s process technology and integration expertise, Crocus has successfully licensed the TMR technology to an automotive Tier 1 customer, bringing increased business to both companies.

According to a 2016 MarketsandMarkets report, the overall magnetic field sensors market was valued at USD $2.25 billion in 2015 and is expected to reach S4.16 billion by 2022, at a CAGR of 8.87% between 2016 and 2022. The growth of this market is driven by the rising demand for MEMS-based sensors across industry verticals, surge in the automotive industry, increasing demand for high-quality sensing devices, and continuous growth in consumer electronics applications.

Magnetic transducers which sense magnetic field strength are widely used in modern industry and electronics to measure current, position, motion, direction, and other physical parameters. Crocus’ TMR technology is a CMOS-based, robust technology capable of offering important advantages in sensitivity, performance, power consumption, size and full integration with CMOS to create monolithic single die ICs. Benefits to customers come in the form of low power, a robust design and high temperature performance. Crocus TMR solutions are ideally suited for many applications ranging from IoT to consumer, medical, automotive and industrial equipment.

“We selected TowerJazz because of their high flexibility and capabilities to adapt their TS13 platform to incorporate our TMR technology which includes magnetic materials that are typically not used in CMOS. TowerJazz’s vast manufacturing expertise is enabling us to successfully fulfill the needs of several market sectors combined with increased performance required in next-generation sensors. TowerJazz has been our development partner for many years and together we have achieved technology maturity leading to expanded business and successful licensing of Crocus IP,” said Michel Desbard, Crocus CEO.

“As the demand for IoT applications in our daily life is ever-increasing, there is an even greater need for intelligent sensing, low power and improved performance. Crocus’ successful licensing of their IP, along with TowerJazz’s manufacturing capability and know-how, enables us to deliver highly-advanced and competitive embedded-solutions to multiple customers in various markets. Through our partnership with Crocus, we are broadening our presence in the sensors’ market, complementing our MEMS and image sensing programs,” said Zmira Shternfeld-Lavie, VP of TOPS BU and R&D Process Engineering.”

Crocus’s TMR magnetic sensor is expected to displace existing sensor technologies in many applications. Crocus’ TMR magnetic sensor product family includes multiple architectures which are based on its Magnetic Logic Unit, a disruptive CMOS-based rugged magnetic technology.

IDTechEx predict that 2017 will be the first billion dollar year for wearable sensors. These critical components are central to the core value proposition in many wearable devices. The “Wearable Sensors 2018-2028: Technologies, Markets & Players” report includes IDTechEx’slatest research and forecasts on this topic, collating over 3 years of work to provide a thorough characterisation and outlook for each type of sensor used in wearable products today.

Despite sales volumes from wearable products continuing to grow, creeping commoditisation squeezes margins, with hardware sales being particularly vulnerable. This has led to some consolidation in the industry, with several prominent failures and exits, and challenging time even amongst market leaders in each sector. As hardware margins are squeezed, business models are changing to increasingly focus on the valuable data generated once a device is worn. Sensors are responsible for the collection and quality of that data, so understanding the capabilities and limitations of different sensor platforms is critical to understanding the progress of the industry as a whole.

In the report, IDTechEx address 21 different types of wearable sensor across 9 different categories as follows: Inertial Measurement Units (IMUs), optical sensors, electrodes, force/pressure/stretch sensors, temperature sensors, microphones, GPS, chemical & gas sensors & others. Hundreds of examples from throughout the report cover a breadth of technology readiness, ranging from long-established industries to early proof-of-concepts. The report contains information about the activities of over 115 different companies, with primary content (including interviews, exhibition or site visits by the authors) to more than 80 different companies, large and small.

IDTechEx describe wearable sensors in three waves. The first wave includes sensors that have been incorporated in wearable for many years, often being originally developed for wearable products decades ago, and existing as mature industries today. A second wave of wearable sensors came following huge technology investment in smartphones. Many of the sensors from smartphones could be easily adapted for use in wearable products; they could be made-wearable. Finally, as wearable technology hype and investment peaked, many organisations identified many sensor types that could be developed specifically with wearable products in mind. These made-for-wearablesensors often remain in the commercial evaluation or relatively early commercial sales today, but some examples are already becoming significant success stories.

WearableSensors_Large

Click to enlarge.

Billions of wearable electronic products are already sold each year today. Many have already experienced significant hardware commoditisation, with tough competition driving prices down. Even as wearable devices become more advanced, introducing more sensors and better components to enhance value propositions, lessons of history tell us that hardware will always be prone to commoditisation. As this happens the role of sensors only becomes more important; with hardware prices being constantly squeezed, increasing proportions of the value that companies can capture from products will be from the data that the products can generate.

The key hardware component for capturing this data is the sensors, so understanding the development and prospects of sensors today is critical to predicting the potential for this entire industry in the future. “Wearable Sensors 2018-2028: Technologies, Markets & Players” is written to address the needs of any company or individual looking to gain a clearer, independent perspective on the outlook for various types of wearable sensor. The report answers detailed questions about technology, markets and industry trends, and supported by years of primary research investment collated and distilled within.

Understanding the impact of valve flow coefficient (Cv) in fluid systems for microelectronics manufacturing

BY STEPHANE DOMY, Saint-Gobain Performance Plastics,

When scaling up, or down, a high-purity liquid installation – many complex factors need to be considered from ensuring the integrity of the transported product to the cleanliness of the environment for both the safety of the process and the operator [1]. In my 15 years working in the semiconductor fluid handling component industry, I’ve learned that the Cv is a bit misunderstood. Given the Cv formula can be used for any flow component in a fluid line, most are familiar with it, yet few consider how it relates to their specific installation. Therefore, this article will focus on factors that pertain to achieving a specific flow performance and specifically the flow coefficient (Cv) as it relates to valves.

Cv empirical explanation and more

As we know, when working on a turbulent flow the Cv formula is: Cv= Q√(SG / ∆P) where Q is the flow going through the valve in gallons per minute (GPM), SG is the specific gravity of the fluid and ∆P is the pressure drop in PSI through the component. In the semiconductor industry, due to the low velocity of the transported fluid the high purity chemistry and slurries are mostly in a semi–turbulent state or a laminar state. Yet you’ll notice there is not a single link to the viscosity of the transported product in the Cv formula. This is significant given the viscosity directly impacts the Cv value when the flow is in a semi-turbulent or laminar mode. Consider that if you calculate the pressure drop in your system with the formula above you could end up with a result that is 4 to 5 times lower. No doubt this inaccuracy can cause significant issues in your installation.

To take this further, let’s analyze how pressure drop based on flow evolves through a valve by comparing a Saint-Gobain Furon® Q-Valve (1⁄2” inner flow path and 1⁄2” pipe connection) to a standard semiconductor industry valve of the same size. The Saint-Gobain valve, which meets the requirements of the semiconductor industry (metal free, 100% fluoropolymer flow path and so on), has a Cv of 3.5 – one of the best for its dimensions. To ease the calculation, we will use deionized (DI) water, which will free us of the specific gravity or impact of the viscosity if we are not in the right state.

As we can see on the graph in FIGURE 1, at a normal flow rate used in micro-e for 1⁄2” 5 to 10 lpm; the pressure drop difference between a standard valve and a Saint-Gobain valve is in the range of 0.1 to 0.3 PSI. At first glance, this does not appear to be much. However, let’s factor in a viscous product and that you have a number of these lines in your flow line — now the numbers start to accumulate. And by moving from a standard valve to a Saint-Gobain valve, as described above, you start to see a significant difference in pressure drop, which could occur across your installation. That being said, up to a certain limit (defined by another component in your installation, such as your pump pressure capability or some more delicate device) an “easy” counter is to increase the pressure through put of your pump but it is at the expense of wasting energy and adding the potential for additional shearing or particle generation in your critical fluid. Now that we have reviewed, the impact of the Cv on our flow and how this could impact our installation, let’s see what can potentially impact the Cv.

Screen Shot 2017-09-26 at 1.32.39 PM

Design impact on Cv and resulting trade-off

The first impact that may come to mind is a larger orifice – and it’s correct. The size of the orifice can benefit flow through and directly relates to the volume of your valve. However there are trade-offs for this improved Cv. The first is cost increase. A higher volume requires a larger valve, which can cost up to 50% more than the initial valve due to specific material and process requirements. Additionally, as highlighted in “Design Impact for Fluid Components” by increasing the size of the component (due to the specific micro-e material requirements), you could lose pressure rating performance [1]. Also when increasing the inner volume of your valve, you potentially increase volume retention as well as particle generation, given that using larger actuation systems results in more points of contact and creates a hub for generating particles. Another possible drawback is significant velocity loss, but that will have to be addressed in another article. The critical point to be taken here is the importance of choosing the right size orifice – too small and flow can be restricted too much and too big and you may end up paying for other problems.

Another potential impact to Cv is the difference in valve technology. Though there more, I’ll specifically cover stopcock/ball valves, weir style valves; and diaphragm valves. Other valve technologies, such as the butterfly valve, will not be discussed because their construction materials are generally not used for fluid handling components for the semiconductor industry.

Starting with the simplest design, the stopcock/ball valve provides by far the best Cv of the three technologies mentioned. Considering the premium Cv achieved, you would assume they are expensive. Instead they are generally the cheapest of the three values mentioned. One drawback in using stopcock valves is the need for a liquid oring on the fluid path which may create compatibility issues. The exception is the Furon® SCM Valve, a stopcock valve that employs a PFA on PTFE technology and allows for oring-free sealing. Additionally, stopcock valves can lower pressure/ temperature ratings and have a tendency to generate a great deal of particles when actuated. This occurs when the key or ball is rotating inside the valve body. Both drawbacks are related to the PTFE/PFA construction materials required for the flow path by the micro-e industry.

The weir style valve, if done properly, should provide a very good Cv – perhaps not as good as a stopcock/ball valve, but still very good. And although liquid orings are not an issue, these valves have other drawbacks. In a weir style valve the diaphragm is generally a sandwich structure consisting of a thin layer of PTFE that is backed by an elastomeric component in which a metal pin is embedded to connect the membrane to the valve actuating system. It is the sandwich materials that generate a number of potential issues when used on critical, high purity chemistry. Specifically, the delamination of the sandwich creates the possi- bility of multiple points of contamination to the liquid (metal & elastomer). In addition, the significant surface contact between the membrane and the valve seat, which is necessary to secure a full seal, generates a lot of particles – though significantly less than a stopcock/ball valve.

The diaphragm valve is the most commonly used valve in the semiconductor industry as it offers a great balance in terms of the issues previously identified: potential contami- nation, materials and particle generation. The trade-off is that the construction of these valves is more complex and as a result they are priced higher than the average cost of the other valves. Additionally, the Cv performance is well below a stopcock/ball valve and slightly below a weir style valve. However, by using Saint-Gobain’s patented rolling diaphragm technology this does not have to be an issue. In fact, with this technology, we can offer the equivalent Cv of a weir style valve in combination with premium pressure and temperature capabilities as well as the cleanest valve technology – all of which allows for a system design with the lowest impact possible on the transported fluid.

As demonstrated in this document, understanding the Cv rating and the impacts that could affect that rating as it relates to valves is critical when optimizing an installation for fluid and energy efficiency. Cost aside, there are a number of issues that are unique to the semiconductor industry that ultimately guide and often restrict installation choices, such as: dead volume, particle generation, cleanliness as well as the physical and mechanical properties of appropriate polymers. Additionally, choosing the appropriate valve for your installation goes far beyond the simple notion that if “I need more flow, I will get a larger valve.” Most likely the residual effect of that choice will affect the performance of the system, particularly regarding cleanliness. Instead critical adjustments to your valve actuation mechanism and valve flow path designs as well as to your valve technology may allow you to achieve the required results – even if the installation still uses the same 1⁄2” valve…but more on this point in another article.

References

1. www.processsystems.saint-gobain.com/sites/imdf.processsystems. com/files/2015-12-03-part-one-design-impact-for-fluid-components.pdf

The latest update to the World Fab Forecast report, published on September 5, 2017 by SEMI, again reveals record spending for fab equipment. Out of the 296 Front End facilities and lines tracked by SEMI, the report shows 30 facilities and lines with over $500 million in fab equipment spending.  2017 fab equipment spending (new and refurbished) is expected to increase by 37 percent, reaching a new annual spending record of about US$55 billion. The SEMI World Fab Forecast also forecasts that in 2018, fab equipment spending will increase even more, another 5 percent, for another record high of about $58 billion. The last record spending was in 2011 with about $40 billion. The spending in 2017 is now expected to top that by about $15 billion.

fab equipment spending

Figure 1: Fab equipment spending (new and refurbished) for Front End facilities

Examining 2017 spending by region, SEMI reports that the largest equipment spending region is Korea, which increases to about $19.5 billion in spending for 2017 from the $8.5 billion reported in 2016. This represents 130 percent growth year-over-year. In 2018, the World Fab Forecast report predicts that Korea will remain the largest spending region, while China will move up to second place with $12.5 billion (66 percent growth YoY) in equipment spending. Double-digit growth is also projected for Americas, Japan, and Europe/Mideast, while other regions growth is projected to remain below 10 percent.

The World Fab Forecast report estimates that Samsung is expected to more than double its fab equipment spending in 2017, to $16-$17 billion for Front End equipment, with another $15 billion in spending for 2018. Other memory companies are also forecast to make major spending increases, accounting for a total of $30 billion in memory-related spending for the year. Other market segments, such as Foundry ($17.8 billion), MPU ($3 billion), Logic ($1.8 billion), and Discrete with Power and LED ($1.8 billion), will also invest huge amounts on equipment. These same product segments also dominate spending into 2018.

In both 2017 and 2018, Samsung will drive the largest level in fab spending the industry has ever seen. While a single company can dominate spending trends, SEMI’s World Fab Forecast report also shows that a single region, China, can surge ahead and significantly impact spending. Worldwide, the World Fab Forecast tracks 62 active construction projects in 2017 and 42 projects for 2018, with many of these in China.

For insight into semiconductor manufacturing in 2017 and 2018 with more details about capex for construction projects, fab equipping, technology levels, and products, visit the SEMI Fab Database webpage (www.semi.org/en/MarketInfo/FabDatabase) and order the SEMI World Fab Forecast Report. The report, in Excel format, tracks spending and capacities for over 1,200 facilities including over 80 future facilities, across industry segments from Analog, Power, Logic, MPU, Memory, and Foundry to MEMS and LEDs facilities.