Optical Proximity Correction (OPC) is a compute-intensive process used to generate photolithography mask shapes at advanced VLSI nodes. Previously, we reported a modified two-step OPC flow which consists of a first pattern replacement step followed by a model based OPC correction step [1]. We build on this previous work and show how this hybrid flow not only improves full chip OPC runtime, but also significantly improves mask correction consistency and overall mask quality. This is demonstrated using a design from the 20nm node, which requires the use of model based SRAF followed by model based OPC to obtain the full mask solution.
At the 20nm technology node, it is challenging for simple resolution enhancements techniques (RET) to achieve sufficient process margin due to significant coupling effects for dense features. Advanced computational lithography techniques including Source Mask Optimization (SMO), thick mask modeling (M3D), Model Based Sub Resolution Assist Features (MB-SRAF) and Process Window Solver (PW Solver) methods are now required in the mask correction processes to achieve optimal lithographic goals. An OPC solution must not only converge to a nominal condition with high fidelity, but also provide this fidelity over an acceptable process window condition. The solution must also be sufficiently robust to account for potential scanner or OPC model tuning. In many cases, it is observed that with even a small change in OPC parameters, the mask correction could have a big change, therefore making OPC optimization quite challenging. On top of this, different patterns may have significantly different optimum source maps and different optimum OPC solution paths. Consequently, the need for finding a globally optimal OPC solution becomes important. In this work, we introduce a holistic solution including source and mask optimization (SMO), MB-SRAF, conventional OPC and Co-Optimization OPC, in which each technique plays a unique role in process window enhancement: SMO optimizes the source to find the best source solution for all critical patterns; Co-Optimization provides the optimized location and size of scattering bars and guides the optimized OPC solution; MB-SRAF and MB-OPC then utilizes all information from advanced solvers and performs a globally optimized production solution.
Model based optical proximity correction (MB-OPC) has been widely used in advanced lithography process today.
However controlling the edge placement error (EPE) and critical dimension (CD) has become harder as the k1 process
factor decreases and design complexity increases. Especially, for high-NA lithography using strong off-axis
illumination (OAI), ringing effects on 2D layout makes CD control difficult. In addition, mask rule check (MRC) limits
also prevent good OPC convergence where two segment edges are corrected towards each other to form a correction-conflicting
scenario because traditional OPC only consider the impact of the current edge when calculating the edge
movement. A more sophisticated OPC algorithm that considers the interaction between segments is necessary to find a
solution that is both MRC and convergence compliant.
This paper first analyzes the phenomenon of MRC-constrained OPC. Then two multiple segment correction techniques
for tolerance-based OPC and MRC-constrained OPC are discussed. These correction techniques can be applied to
selected areas with different lithographic specifications. The feasibility of these techniques is demonstrated by
quantifying the EPE convergence through iterations and by comparing the simulated contour results.
The steady march of Moore's law demands ever smaller feature sizes to be printed and
Optical Proximity Correction to correct to ever tighter dimensional tolerances. Recently
pitch doubling techniques has relieved the pressure on CD reduction, which instead of
being achieved lithographically are reduced by subsequent etching or chemical
interaction with spin-on layers. CD tolerance reductions, however, still need to match the
overall design rule shrinkage. The move to immersion lithography, where effective
Numerical Apertures now reach 1.35, has been accompanied by a significantly reduction
in depth of focus, especially on isolated contacts. To remedy this, RET techniques such
as assist feature placement, have been implemented. Certain local placements of assist
features and neighboring contacts are observed to result in highly elliptical contacts being
printed. In some layouts small changes in the aspect ratio of the contact on the mask leads
to strong changes in the aspect ratio of the printed contact, whereas in other layouts the
response is very weak. This effect can be described as an aspect ratio MEEF. The latter
type of contact can pose a significant challenge to the OPC recipe which is driven by the
need to place the printed contour within a small range of distance from target points
placed on the midpoint of edges of a nominally square contact. The OPC challenge
naturally will be compounded when the target layout is rectangular in the opposite sense
to the natural elliptical shape of the printed contact. Approaches to solving this can vary
from intervening at the assist feature placement stage, at the possible loss of depth of
focus, to accepting a certain degree of ellipticity in the final contour and making the OPC
recipe concentrate on minimizing any residual errors. This paper investigates which
contact layouts are most challenging, discusses the compromises associated with
achieving the correction target and results are shown from a few different approaches to
resolving these issues.
In this paper, we present some important improvements on our process window aware OPC (PWA-OPC). First, a CDbased
process window checking is developed to find all pinching and bridging errors; Secondly, a rank ordering method
is constructed to do process window correction; Finally, PWA-OPC can be applied to selected areas with different
specifications for different feature types. In addition, the improved PWA-OPC recipe is constructed as sequence of
independent modules, so it is easy for users to modify its algorithm and build original IPs.
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