Abstract:
A circuit layout methology is provided for eliminating the extra processing time and file-space requirements associated with the optical proximity correction (OPC) of a VLSI design. The methodology starts with the design rules for a given manufacturing technology and establishes a new set of layer-specific grid values. A layout obeying these new grid requirements leads to a significant reduction in data preparation time, cost, and file size. A layout-migration tool can be used to modify an existing layout in order to enforce the new grid requirements.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to a circuit layout methodology for an integrated circuit (IC), and more particularly pertains to a circuit layout methodology for developing a layout for a very large scale integrated circuit (VLSI) with a set of reduced layout grid ground rules. The circuit layout methodology starts with the design rules for a given technology for fabricating an IC, and establishes a new set of layer-specific layout grid values. A circuit layout obeying these new layout grid requirements leads to a significant reduction in data preparation time, cost, and file size. The present invention can be used for migrating an existing VLSI layout to a set of reduced layout grid ground rules. A layout-migration tool can be used to modify an existing IC layout in order to enforce the new layout grid requirements. A layout-optimization application can be used to rescale data, thus changing the layout grid size, and also adjusting the minimum line widths and minimum line spaces, and a shapes-processing application can be used to adjust via sizes, locations and borders. 
   2. Discussion of the Prior Art 
   For any given technology for fabricating an IC on a wafer, (e.g. Intel Pentium™ microprocessor), a layout grid is defined for that technology. The layout grid represents the smallest dimensions that can be used by designers in layout data for each level in that technology. For a 130 nanometer (nm) generation technology, that value is approximately 0.01 microns. For wires and vias, this means that their widths and spacing are changed in 0.01 micron increments (e.g. 0.99, 1.00, 1.01 microns). 
   In addition, each technology for fabricating an IC specifies ground-rule values for minimum line width and minimum line spacing for each metal layer (M 1  (the first and lowest metal layer), M 2  (the second, next higher metal layer) and for each via layer (V 1  (the via layer connecting M 1  to M 2 ), V 2  (the via layer connecting M 2  to M 3 )), etc. For a 130 nanometer (nm) generation technology, these ground-rule values are: 
   M 1  minimum line width and line space=0.16 microns, 
   M 2  minimum line width and line space=0.20 microns, 
   M 3  minimum line width and line space=0.20 microns, 
   V 1  minimum line width and line space=0.20 microns, 
   V 2  minimum line width and line space=0.20 microns, etc. 
   For a 65 nm generation CMOS technology, the above values for a 130 nm generation CMOS technology are reduced by approximately one half. 
   It is apparent that the permitted feature sizes for wiring shapes are much smaller than the sizes actually required to draw wires in a VLSI layout, since for the exemplary 130 nm generation CMOS technology, the grid size is 0.01 microns and the M 2  minimum line width and line space is 0.20 microns. The resolution enabled by the manufacturing layout grid size is in some sense unneeded for wiring levels, since the minimum line space and minimum line width ground rules for wires are large multiples of this fine grid size. The grid size is much smaller than the minimum feature size to allow for the use of optical proximity correction (OPC). 
   The end result of using OPC is that data volume and processing runtime increase unduly during data prep. This ultra-fine grid is necessary for the mask layers that require extensive OPC (such as the layers involved in forming devices) to account for photolithographic and etch problems, but such extensive OPC processing and ultra-fine grids are not normally necessary for the wiring layers. 
   SUMMARY OF THE INVENTION 
   The present invention relates generally to a circuit layout methodology for an integrated circuit (IC), and more particularly pertains to a circuit layout methodology for developing a layout for a very large scale integrated circuit (VLSI) with a set of reduced layout grid ground rules. The circuit layout methodology starts with the design rules for a given technology for fabricating an IC, and establishes a new set of layer-specific layout grid values. 
   The present invention provides a technique for eliminating the extra processing time and file-space requirements associated with the OPC of a VLSI design, and can use a layout grid size that is equal to or not much smaller than the dimensions of minimum size feature. A methodology is described that starts with the design rules for a given manufacturing technology and establishes a new set of layer-specific layout grid values. A circuit layout obeying these new grid requirements leads to a significant reduction in data preparation time, cost, and file size. Furthermore, a layout-migration tool can be used to modify an existing layout in order to enforce the new layout grid requirements. The penalty associated with these new grid requirements is that the chip size may increase because of the increased wire width and spacing. 
   The method proceeds as follows, for a given set of IC manufacturing ground rule values. 
   For the most critical layers such as PC (gate polysilicon conductor layer), RX (active silicon conductor layer that is surrounded by shallow trench isolation (STI) or field oxide) and M 1  (first metal layer), a fine layout grid is required for accuracy in OPC. Use a fine layout grid for these layers, but ensure that interfaces to the layers above and below obey the layout grid constraints for the layers above and the layers below (e.g. PC-C 1  (contact layer)-M 1  or M 1 -V 1 -M 2 ). 
   For each metal layer M 2 , M 3 , etc. in the IC technology, specify a new layout grid value Mx_grid equal to an integral fraction of the minimum line space and line width (Mx_space) ground rules for that layer. For example, the Mx_grid can be chosen to be ¼, ⅓, ½, etc. of Mx_space. All coordinates for Mx shapes in the circuit design must then be multiples of Mx_grid. 
   For via layer V 1  (first via layer), do not use an ultra-fine layout grid, use a layout grid that is a fraction (e.g. ¼, ⅓, ½, etc. of the M 2 _grid value. 
   For via layers V 2  (second via layer), V 3  (third via layer), etc., use the corresponding layout grid of the metal layer below. For example, use metal layer M 2 _grid for via layer V 2 ; metal layer M 3 _grid for via layer V 3 , etc. 
   For C 1  (contact layer between PC and M 1 ) and V 1 , do not use an ultra-fine layout grid. Use a layout grid that is a fraction (e.g. ¼, ⅓, ½) of the M 2 _grid value. 
   These steps permit a set of ground rules for any IC fabricating technology to be used to create a new “OPC-efficient” set of rules for the same technology. And for a given layout in the existing ground rules for the technology, use hierarchical layout optimization techniques of a layout-migration tool to enforce the new set of rules. 
   The present invention greatly simplifies design/layout rules, and has the potential to significantly decrease data volume and mask designs with less complex OPC. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing objects and advantages of the present invention for a circuit layout methodology may be more readily understood by one skilled in the art with reference being had to the following detailed description of several embodiments thereof, taken in conjunction with the accompanying drawings wherein like elements are designated by identical reference numerals throughout the several views, and in which: 
       FIG. 1  illustrates a simplified example of a mask for an original wire and via layout before OPC. 
       FIG. 2  illustrates the wire and via layout of  FIG. 1  after OPC, as is generally known in the art, in which some areas are added and other areas are removed. 
       FIG. 3  shows an illustrative starting first embodiment of the present invention for a 65 nm generation mask having different wire features A–D, with connecting vias  1 – 7 . 
       FIG. 4  illustrates a modified second embodiment (modified relative to the first embodiment) having the same general wire features A–D and same general connecting vias  1 – 7  and a much smaller grid size. 
       FIG. 5  illustrates a modified third embodiment having the same general wire features A–D and same general connecting vias  1 – 7 . 
       FIG. 6  illustrates a modified fourth embodiment having the same general wire features A–D and same general connecting vias  1 – 7 . 
       FIG. 7  illustrates a modified fifth embodiment having the same general wire features A–D and same general connecting vias  1 – 7 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   For virtually all non-block mask layers/levels, i.e. wiring, vias, RX, PC, etc., layout grid sizes that are approximately 1/20th of a ground rule are commonly used to allow the use of optical proximity correction (OPC). For a 90 nm generation CMOS technology, the minimum ground rule is about 100 nm, and accordingly a layout grid size of 5 nm is used. Typically massive OPC is used to provide the densest possible wiring. 
   The present invention uses a coarse layout grid size with increased spacing between individual structures on each mask layer to avoid problems with electrical opens and shorts. 
     FIGS. 1 and 2  illustrate a simplified example of a mask before and after OPC processing.  FIG. 1  illustrates a simplified example of a mask for an original wire and via layout before OPC.  FIG. 2  illustrates the wire and via layout of  FIG. 1  after OPC in which the areas  10  are added, and the areas  12  are removed. The OPC improves the lithographic printing of the wires, thus decreasing via to wire opens and wire to via shorts 
   Typically in OPC, as illustrated by  FIGS. 1 and 2 , shapes are either added to or removed from structures on a mask, with the shapes being defined by an integral number of grid points. For example, a line end extension might be added, ranging from 1 to 10 grid points (5 nm to 50 nm), depending upon how much space there is to an adjacent line. 
   In addition, mask comps are commonly employed to slightly increase or decrease the width of mask shapes (typically &lt;5 grid points). This conversion of simple shapes to more complicated shapes significantly increases the data volume and complexity, with resulting increased data preparation cost, increased mask build cost, and increased risk of making an error which results in a higher defect density on the wafer. The benefit of the conversion is that wire width and spacing requirements can be increased without increasing the chip size. 
   The present invention provides a set of migratable design rules that allow the use of a layout grid size equal to the minimum ground rule for a given technology. For simplicity, the explanation focuses on wiring masks and via masks, although the subject invention is applicable to all mask levels. 
   More specifically, the present invention provides a methodology for simplifying a circuit layout with layout rules that provide a layout grid size customized for each level based upon the pitch and minimum ground rules for that level. 
   In a broad aspect, the present invention: 
   1. develops a set of layout rules that selects a layout grid size for a given level based upon the pitch and minimum ground rules for that level. 
   2. applies the layout rules developed in step  1  to customize the layout grid size (for at least one and normally more levels). 
   In a more detailed aspect, the present invention: 
   1. identifies the minimum line width/space (as defined for example by ½ the minimum pitch). 
   2. selects a layout grid size having a value that, 
   a) is greater than a minimum required offset for manufacturing features (such as vias), and also 
   b) is a factor of the minimum line width/space, generally between the minimum line width/space and ¼ the line width space (¼, ⅓, ½, or 1×) 
   3. lays out all wires using the selected grid size for developing a new circuit layout, or for modifying an existing circuit layout. 
   4. provides a minimum line width/space, with one (1) additional grid point spacing being provided around manufacturing features (such as wires under or over vias). 
   5. performs an optional data prep, which generally examines the overall mask design and equalizes the pattern factor, which is a ratio of print to non-print across the chip, by adding dummy shapes to the mask, as is generally known in the art. 
   In cases where OPC is needed, start with steps  1 – 5  above, and add an additional second pass adjustment of the layout and the data prep with approximately 1/10 the line width/space grid to allow for rudimentary OPC. 
   The following is a discussion of several specific embodiments. 
   The contacted polysilicon (PC) level pitch defines the ground rules needed for wiring masks and via masks. For a 65 nm generation CMOS technology, the contacted PC level pitch is 160 nm (i.e. 80 nm line/space). Typically, for a CMOS BEOL (back end of line processing) with multilevel wiring, the wiring width/space/pitch are given in the following table. 
   In the following table, 1X via is the via layer that connects 1X wire (metal M) to 2X wire, 2X via is the via layer that connects 2X wire to 4X wire, and 4X via is the via layer that connects 4X wire to 6X wire, etc. 
   
     
       
             
             
             
           
         
             
                 
                 
             
             
                 
               Level 
               minimum width/minimum space 
             
             
                 
                 
             
           
           
             
                 
               M1 metal 
                80 nm 
             
             
                 
               1× wire = 1× via 
               100 nm 
             
             
                 
               2× wire = 2× via 
               200 nm 
             
             
                 
               4× wire = 4× via 
               400 nm 
             
             
                 
               6× wire = 6× via 
               600 nm 
             
             
                 
                 
             
           
        
       
     
   
   Two options are presented, a first option of using 100 nm spacing and a second option of using 200 nm spacing. 
   One simple algorithm available to design a circuit layout and mask can use the ground rule width/space as the wiring layout and mask fabrication layout grid size (e.g. 80 nm for M 1 , 100 nm for 1X wires, etc.). 
   A potential problem with this approach is that OPC would not be possible. A solution to that problem is to relax the wiring width/space rules such that the wire and via width remain unchanged. 
   The following is a specific example of how all mask levels in a 65 nm generation CMOS design can be specified. It should be realized that there are an unlimited number of possible masks in different technologies by different manufacturers, and the following is a very specific example of a typical CMOS technology. 
   for very critical masks such as RX, PC and M 1 , use a traditional 5 nm grid size, but allow the layout to fit with a relaxed grid size for other mask levels by constraining interfaces between RX, PC, MI and front end of line processing (FEOL) block masks or CA/M 1  back end of line processing (BEOL) masks, 
   for FEOL block masks, use a 100 nm grid size, 
   for BEOL CA mask, use a 25 nm grid size, 
   for BEOL 1X wire masks (M 2 +), use a design grid size of 100 nm and a data prep grid size of 10 nm, 
   for BEOL 1X via masks (VI+), use a design grid size of 100 nm, 
   for BEOL 2X via and wire masks, use a design grid size of 200 nm, 
   for BEOL 4X via and wire masks, use a design grid of 400 nm, 
   for BEOL 6X via and wire masks, use a design grid of 600 nm. 
   Generically, considering the unlimited number of possible masks in different technologies by different manufacturers, the present invention classifies each mask according to four general parameters, minimum line size, minimum space size, minimum border for upper layers, and minimum borders for lower layers. 
   The following is a basic description of the present invention as used to develop a new circuit layout or to modify an existing circuit layout: 
   1) Define an integrated circuit containing N mask levels, where N&gt;&gt;1 (e.g. 50 for a 10 metal level chip). 
   2) Divide the masks into different groups, based on whether they are (a) used to provide connection between vertically adjacent levels (contact layers); or (b) used for horizontal patterning (wire layers); or (c) used to pattern alignment aids. Examples: 
   (a) vertical connection masks: vias between wiring levels; contacts to active or passive devices; MOSFET gates/source/drain; NPN emitter/gate/collector; passive resistors; passive capacitors; etc. 
   (b) horizontal patterning masks: gate conductors in MOSFET transistors; base or emitter conductors in NPN transistors; ion implant patterning mask; wire level mask; shallow trench isolation; etc. 
   (c) alignment aids: mask used to pattern and etch alignment aids for metal-insulator-metal (MIM) capacitors in the optical kerf, etc. 
   3) Define the critical dimension for each mask as the minimum resist line or space that must be printed using each mask. Determine the minimum critical dimension for each mask, and identify the overall mask set minimum critical dimension. Require that each mask be laid out using integer multiples of the minimum critical dimension. 
   4) Normalize the critical dimension for each mask by the overall mask set minimum critical dimension defined above in 3. This will result in each mask having a normalized critical dimensions &gt;=1. For a CMOS technology with multiple levels of hierarchical wiring, this will result in normalized critical dimensions in the range of 1–10, where numbers larger than one are not required to be integers. 
   5) For all of the masks defined above, use a grid size equal to the critical dimension for each mask (if the masks are greater or less, use with lithography exposure tools which are greater or less than 1:1, adust the grid size accordingly, as is known in the art). 
   option: the grid size could be equal to ½ (or ⅓, ¼, etc.) the minimum critical dimension for the mask and the layout rules described above would allow for horizontal features which are 1.5, 1.33, 1.25, etc. (or 0.7, 0.67, 0.75, etc.) times the minimum critical dimension for each mask. 
   6) The vertical connection masks, defined in 2a above, are used to fabricate vias or contacts between vertically adjacent levels on the wafer. To reduce or eliminate the possibility of either small contact area or opens (the via or contact partially contacting or missing the horizontal structure above or below), or unintended shorts between the contacts or vias and adjacent horizontal patterning features require: 
   option a) that the layout used for the horizontal patterning mask features contain borders above and below the contacts or vias which are equal to one grid point per edge as defined in 5 above and the via is greater or equal to 1 grid point away from all edges (i.e. the horizontal patterning feature which is coincident with a contact or via is bordered by one grid point on all sides of the via or contact). No data preparation or optical proximity correction would be employed prior to mask fabrication. 
   option b) that the minimum horizontal patterning mask feature width, for features that coincide with a contact or via above or below, be 2 grid points wider than the contact or via; and that the contact or via be centered in the horizontal patterning feature (i.e. the horizontal patterning feature which is coincident with a contact or via is bordered by one grid point on all sides of the via or contact). No data prep or optical proximity correction would be employed prior to mask fabrication. 
   option c) that the minimum horizontal patterning mask feature width be 2 grid points wider than the minimum critical dimension and that the contact or via be located such that it always is bordered by 1 or more grid points. 
   option d) that the minimum horizontal patterning mask space width between features be 2 grid points wider than the minimum critical dimension. 
   option e) that all features on the horizontal patterning mask have spaces between them greater or equal the minimum critical dimension defined in 3 above, plus 2 grid points; and that all contacts or vias be centered in the horizontal patterning feature. Prior to mask fabrication optical proximity correction would be employed. The OPC would consist of bordering each contact or via by one grid point on all sides, with the grid point defined in 5 above. 
   The present invention provides a method for developing or modifying a layout for fabricating a very large scale integrated circuit in a plurality of different layers having a plurality of masks for the different layers, in a given IC technology with a set of reduced ground rules for layout grids for the plurality of different layers. Following step 2) above wherein the plurality of masks are classified into different groups, depending upon which group a mask is classified into, use the design rules for the given IC technology to establish a layer-specific layout grid increment value for that mask, to develop a plurality of layer-specific layout grid increment values for the plurality of masks. Then use a layout-optimization application to scale data and select the size of the layout grid increment value for at least some of the plurality of different layers of the VLSI layout while also enforcing other constraints such as area growth or electrical properties. Then use a layout-optimization application to select minimum line widths and minimum line spaces for at least some of the plurality of different layers of the VLSI layout. Then use a shape-processing application to select via sizes, via locations, and via borders for at least some of the plurality of different layers of the VLSI layout. 
   In implementing the present invention, the layout database might be split across different files with different representations of minimum feature size. 
   Pursuant to the present invention, the grid size at any mask level of a multilevel IC should be an integer divisor of a larger grid size at another mask level. Moreover, at each mask level, the minimum line width and the minimum line space are preferably the same. If they are not the same, then the grid size should be an integer divisor into both the minimum line width and the minimum line space. For example, for a 200 nm minimum pitch level, the minimum line width and the minimum line space could be 100 nm. Alternatively, the minimum line width could be 125 nm and the minimum line space could be 75 nm, with a grid size of 25 nm which is an integer divisor into both 125 nm and 75 nm. 
   The following Table 1 refers to and describes embodiments 1–5 shown respectively in  FIGS. 3–7 , wherein embodiment 1 shown in  FIG. 3  is a starting point for embodiments 2–5 shown in  FIGS. 4–7 . 
   
     
       
             
             
             
             
             
             
           
         
             
                 
             
             
                 
                 
               Via to 
                 
                 
                 
             
             
                 
                 
               adjacent 
             
             
                 
                 
               wire in a 
               Wire to 
             
             
                 
               Border 
               different 
               adjacent 
               Narrow 
             
             
               Embodi- 
               Surrounding 
               network, 
               wire min. 
               wire end 
               Grid 
             
             
               ment 
               via 
               min. space 
               space 
               comp 
               size 
             
             
                 
             
           
           
             
               1 (FIG. 3) 
               0 nm 
               100 nm 
               100 nm 
               0 
               100 nm  
             
             
               2 (FIG. 4) 
               25 nm  
               125 nm 
               100 nm 
               0 
               25 nm 
             
             
               3 (FIG. 5) 
               0 nm 
               125 nm 
               100 nm 
               0 
               25 nm 
             
             
               4 (FIG. 6) 
               25 nm  
                75 nm 
                50 nm 
               0 
               25 nm 
             
             
               5 (FIG. 7) 
               0 nm 
                75 nm 
                75 nm 
               25 nm 
               25 nm 
             
             
                 
             
           
        
       
     
   
     FIG. 3  shows an illustrative starting first embodiment of the present invention for a 65 nm generation mask having different wire features A, B, C and D, with connecting vias  1 ,  2 ,  3 ,  4 ,  5 ,  6  and  7 . Note the very large grid size of 100 nm represented by the spaced array of grid points  30 . The vias  1 – 7  are 100 nm diameter and have 0 nm borders, and the wire to wire minimum space is 100 nm. 
     FIG. 4  illustrates a modified second embodiment (modified relative to embodiment 1) having the same general wire features A–D and same general connecting vias  1 – 7 . Note the relatively smaller grid size of 25 nm represented by the spaced array of grid points  40 . The vias  1 – 7  are 100 nm diameter and have 25 nm borders, and the wire to wire minimum space is 100 nm. 
     FIG. 5  illustrates a modified third embodiment having the same general wire features A–D and same general connecting vias  1 – 7 . Note the small grid size of 25 nm represented by the spaced array of grid points  50 . The vias  1 – 7  are 100 nm diameter and have 0 nm borders, and the wire to wire minimum space is 100 nm. 
     FIG. 6  illustrates a modified fourth embodiment having the same general wire features A–D and same general connecting vias  1 – 7 . Note the small grid size of 25 nm represented by the spaced array of grid points  60 . The vias  1 – 7  are 100 nm diameter and have 25 nm borders, and the wire to wire minimum space is 50 nm. 
     FIG. 7  illustrates a modified fifth embodiment having the same general wire features A–D and same general connecting vias  1 – 7 . Note the small grid size of 25 nm represented by the array of grid points  70 . The vias  1 – 7  are 100 nm diameter and have 0 nm borders, and the wire minimum space is 75 nm. 
   
     
       
             
             
             
             
             
           
         
             
                 
             
             
                 
                 
               Minimum 
                 
                 
             
             
               Mask 
                 
               Nominal 
               Grid Size 
               Grid Size 
             
             
               Type 
               Mask Level 
               Feature Size 
               emb. 1 
               emb. 2 
             
             
                 
             
           
           
             
               1 
               RX DT PC 
                40 nm 
                20 nm 
                5 nm 
             
             
               2 
               Blocks, OP 
               100 nm 
               100 nm 
               25 nm 
             
             
               3 
               C1 M1 
                80 nm 
                20 nm 
               20 nm 
             
             
               4 
               1×-Via 1×-Wire 
               100 nm 
               100 nm 
               25 nm 
             
             
               5 
               2×-Via 2×-Wire 
               200 nm 
               200 nm 
               50 nm 
             
             
               6 
               4×-Via 4×-Wire 
               400 nm 
               400 nm 
               100 nm  
             
             
               7 
               Passive MIM bot. plate 
                2 μm 
                2 μm 
                1 μm 
             
             
                 
               Passive MIM top plate 
             
             
                 
               Passive thin film 
             
             
                 
               resistor 
             
             
                 
             
           
        
       
     
   
   Mask type  1  encompasses RX=the shallow trench isolation, DT=one or more masks used for fabricating deep trench capacitors, and PC=the polysilicon or silicon used for the MOSFET gate, NPN emitter, etc. 
   Mask type  2  encompasses Blocks=the ion implantations used for silicon or polysilicon doping, and OP=silicon without silicide (e.g. resistor, bipolar junction transistor, etc.) 
   Mask type  3  encompasses C 1 =the contact between PC and M 1 , and M 1 =the first wire level. 
   Mask type  4  encompasses 1X-Wire=the next and subsequent wiring levels with 100 nm minimum feature size, and 1X-Via=vias to connect adjacent wiring levels. 
   Mask type  5  encompasses 2X-Wire, 2X-Via. 
   Mask type  6  encompasses 4X-Wire, 4X-Via, etc. define relaxed pitch wire and via levels. 
   Mask type  7  encompasses passive components with a relatively large feature size such as passive capacitors, resistors, etc. 
   While several embodiments and variations of the present invention for a circuit layout methodology are described in detail herein, it should be apparent that the disclosures and teachings of the present invention will suggest many alternative designs to those skilled in the art.