The present disclosure relates to the field of Hyperspectral Imaging (HSI). In particular, the disclosure proposes an apparatus for performing depth-resolved HSI and a corresponding method. The depth-resolved HSI provides a plurality of hyperspectral images, wherein each hyperspectral image resolves two spatial dimensions (width, height) and the plurality of hyperspectral images together resolve the third spatial dimension (depth). The HSI apparatus and method of the present disclosure can be used for monitoring and diagnostic purposes, for example, for process monitoring and tool diagnostics.
Diagnostic and monitoring methods, which utilize light emission, are well-established, especially in the semiconductor industry. Such methods are, for instance, used for characterizing and controlling the many steps in a semiconductor fabrication process. For example, the light emission of a process discharge in a process chamber, specifically a plasma chamber, may be analyzed.
For many process steps, an accurate measurement of the relative distribution of the atomic and molecular concentration in a process chamber is critical, in order to optimize the process parameters, as well as to reduce the variability between multi-chamber tools in use. For example, it has been reported in literature that there is a strong correlation between the yield of a plasma process and the spatial variation of the plasma parameters for a given instrument. It is also evident that reducing the variability between different instruments, which target identical recipes for a given process, is critical to improve the yield during production ramp up. Therefore, advancing spectral measurement techniques, e.g. for plasma discharge, plays a critical role in improving the semiconductor processes.
Among different example techniques, Optical Emission Spectroscopy (OES) is used for estimating the concentration of plasma content through measuring the spectral content (wavelength) of the light emitted from the plasma chamber. OES is a simple, nonintrusive, in-situ method, which can measure the emission intensity from various sources including atoms, radicals, and molecules.
However, OES provides only an ensemble measurement, and is in practice not capable of providing spatially resolved measurements. Some effort has been spent on improving the spatial resolution of OES systems. However, the solutions found require impractically long times to perform the measurements, due to their point-by-point scanning approach. Therefore, these solutions fail to provide an accurate dynamic measurement of the plasma content in practice, which is crucial to assessing the health of the plasma.
In view of the above-mentioned disadvantages, embodiments of the present disclosure improve upon the conventional solutions. The present disclosure provides an advanced hyperspectral measurement apparatus and method, which are able to measure with enhanced spatial resolution, in particular three-dimensional spatial resolution. The apparatus and method should thereby be able to provide accurate dynamic measurements, e.g. of a process chamber. The apparatus and method should require only short measurement times and should avoid scanning where possible.
The embodiments of the present disclosure are based on HSI. However, standard HSI may be too limited to provide a satisfactory solution.
However, the standard HSI shown in
According to the above, to the present disclosure provides the apparatus and method with the ability to provide an enhanced depth resolution. Embodiments of the present disclosure are to this end based on an advanced HSI system that provides spatial selectivity. The embodiments of the present disclosure are based on an HSI system (as shown in
A first aspect of the present disclosure provides an apparatus for depth-resolved HSI, the apparatus comprising an optical system configured to receive electromagnetic radiation and to: (i) set at least one determined focus distance, (ii) block received out-of-focus radiation, and (iii) pass received in-focus radiation, and the apparatus comprising an HSI sensor configured to produce a hyperspectral image based on the in-focus radiation passed by the optical system.
Since the out-of-focus radiation is blocked, and the in-focus radiation is passed, the hyperspectral image obtained by the HSI sensor effectively images only points from a certain distance, i.e. from at or near the determined focus distance. In this way, spatial selectivity regarding the depth direction along the optical axis is provided. If, for instance, a plurality of different determined focus distances are set by the apparatus, depth-resolved hyperspectral imaging can be performed. The apparatus is thus well-suited for monitoring, for example, a process chamber. In particular, it is able to provide spectral information from different width, height, and depth positions within the process chamber, and in a dynamic fashion.
A lateral spatial resolution achieved with the apparatus of the first aspect may be 200 μm or lower (i.e. width and/or height resolution) and a longitudinal resolution may be 10mm or less (i.e. depth resolution).
In an example implementation of the apparatus, the optical system comprises at least one lens for setting the at least one determined focus distance. To this end, the lens may, for instance, be moved with respect to the sensor. The optical system and sensor of the apparatus may use components from a standard HSI camera, e.g. to provide the capability of focusing.
In an example implementation of the apparatus, the optical system comprises an aperture mask configured to block the received out-of-focus radiation. The aperture mask may comprise at least one aperture. This aperture may also be referred to as a pinhole, and may be dimensioned and positioned such that it blocks out-of-focus radiation, and lets in-focus radiation pass. The aperture may work like a pinhole arranged in a conventional confocal microscope before the detector. That is, the aperture mask may be positioned such that the lens of the optical system focuses each point on the focal plane into the aperture/pinhole. That means a distance between the aperture mask and the lens is the same as the determined focus distance. In other words, the aperture mask and the plane at the determined focus distance (focal plane) are confocal.
In another example implementation, instead of the aperture mask, at least one compound parabolic concentrator (CPC) may be used to block the out-of-focus radiation and pass the in-focus radiation to the HSI sensor. That is, the CPC may provide the spatial filtering function. In particular, the CPC is configured to collimate radiation beams falling into its entrance aperture, and output a beam, of which it controls the angularity. For instance, the angularity of the output beam may be controlled to be <2.5°.
Since multiple lateral positions can be resolved at the same time by the apparatus, no lateral scanning is necessary.
In an example implementation of the apparatus, the aperture mask comprises a plurality of regularly arranged apertures, each aperture being configured to pass only received in-focus radiation. Each aperture may act as a pinhole as described above. That is, the aperture mask may provide a multiple pinhole approach for blocking the out-of-focus radiation and passing the in-focus radiation, while allowing in total more light (a higher intensity of light) to pass through.
In an example implementation of the apparatus, the optical system comprises at least one optical element configured to provide the in-focus radiation passed by the aperture mask to the HSI sensor. The at least one optical element may be an arrangement of one or more lenses functioning as relay optics. The at least one optical element may focus the radiation onto the sensor, or may disperse the radiation to cover the sensor.
In an example implementation of the apparatus, the optical system is configured to subsequently set a plurality of different determined focus distances, and the HSI sensor is configured to produce a plurality of hyperspectral images, wherein each hyperspectral image is produced based on the in-focus radiation passed by the optical system for a different one of the focus distances set by the optical system. In this manner, the apparatus of the first aspect is able to produce multiple hyperspectral images, which provide depth-resolution. Since the multiple hyperspectral images can be obtained in a short timeframe, the apparatus is, for instance, able to monitor a plasma in a process chamber in a high-throughput and dynamic fashion.
In an example implementation, the apparatus is configured to acquire the plurality of hyperspectral images with an acquisition speed of 0.1-100 hyperspectral images per second, such as, for example, at least one hyperspectral image per second. Thus, a significant number of hyperspectral images can be taken in a very short time frame to provide a depth-resolution of 10 mm or less, e.g. over the whole depth of a process chamber, in a dynamic manner.
In an example implementation of the apparatus, the HSI sensor comprises a plurality of sensor units and a plurality of spectral filter units, each spectral filter unit being provided on one of the sensor units and being configured to pass a different sets of wavelengths in different spatial regions. Thus, the HSI sensor is able to produce spatially resolved hyperspectral images, i.e. 3D hyperspectral cubes including multiple monochromatic images representing different specific narrowband wavelength information.
In an example implementation of the apparatus, each spectral filter unit is divided into a plurality of columns arranged in parallel, and is configured to pass a different set of wavelengths in each of the columns.
In an example implementation of the apparatus, each spectral filter unit is divided into a plurality of blocks arranged in a mosaic pattern, and is configured to pass a different set of wavelengths in each of the blocks.
In an example implementation, the apparatus further comprises a calibration unit for calibrating the received radiation and/or a processing unit for post-correcting a hyperspectral image produced based on the received radiation, for example if the received radiation is transmitted through an optical window or viewpoint before it arrives at the apparatus. In this way, the apparatus is well suited for process chambers having viewports or other optical windows.
A second aspect of the present disclosure provides a method for depth-resolved HSI, the method comprising operating an optical system for receiving electromagnetic radiation to: (i) set a determined focus distance, (ii) block received out-of-focus radiation, and (iii) pass received in-focus radiation, and the method further comprising operating a HSI sensor to produce a hyperspectral image based on the in-focus radiation passed by the optical system.
In an example implementation, the method further comprises: (i) operating the optical system to subsequently set a plurality of different determined focus distances, and (ii) operating the HSI sensor to produce a plurality of hyperspectral images, wherein each hyperspectral image is produced based on the in-focus radiation passed by the optical system for a different one of the focus distances set by operating the optical system.
In an example implementation, the method is performed to obtain a plurality of depth-resolved hyperspectral images from within a process chamber, wherein each determined focus distance set by operating the optical system corresponds to a different depth-position in the process chamber, and each hyperspectral image produced by operating the HSI sensor resolves at least a part of a height and width of the process chamber.
In an example implementation, the method further comprises obtaining radiometric measurement data of the electromagnetic radiation received from the process chamber based on the plurality of hyperspectral images. For instance, absolute photon counts, i.e. a radiance, may be obtained from the process chamber, e.g. from plasma emission. This may be achieved through performing a known method of radiometric calibration of the HSI sensor such that the digital numbers read from the HSI sensor can be converted to radiance units. This calibration is usually done once per system.
The method of the second aspect and its example implementations achieve the same advantages as described above for the apparatus of the first aspect and its respective example implementations.
In summary, embodiments (example aspects and implementations) provide an apparatus and method configured for spatially resolved HSI, particularly also depth-resolved. The apparatus and method may be used to quantitatively assess, for example, a plasma process uniformity in a semiconductor manufacturing line. In particular, simultaneous measurements of spectral features at multiple spatial positions, for example in a process chamber, are possible. Thereby, the content of a plasma can be dynamically monitored at high speed and high sensitivity. The plasma radiation may be collected through an optical window situated on the process chamber, and thus the embodiments of the present disclosure may be compatible with conventional methods requiring no additional complexity of the tools.
The above described aspects and implementations are explained in the following description of embodiments with respect to the enclosed drawings:
The apparatus 10 shown in
In particular, the optical system 11 is configured to set at least one determined focus distance 12, i.e. it may also set successively multiple different focus distances 12. Further, the optical system 11 is configured to block received out-of-focus radiation 13, and to pass received in-focus radiation 14, as schematically indicated by the dotted and dashed lines in FIG. 1, respectively. That means, depending on the set determined focus distance, the optical system 11 lets only radiation received from or near the focus distance (at or near the focal plane) reach the optical sensor 15. For instance, as shown in
The HSI sensor 15 accordingly receives only the in-focus radiation 14 that is passed by the optical system 11, and produces the one or more hyperspectral images 30, 31 based on the received in-focus-radiation 14. Accordingly, the produced one or more hyperspectral images corresponds to points in a 2D plane in a certain depth from the apparatus 10, namely the currently set determined focus distance 12.
The apparatus 10 of
The at least one optical element 23, in
It can also be seen in
In an example of the apparatus 10 of
Specifically,
In the mosaic architecture shown in
The method 70 comprises a step 71 of operating an optical system 11 for receiving electromagnetic radiation. This step 71 may particularly include: setting 71a a determined focus distance 12, blocking 71b received out-of-focus radiation 13, and passing 71c received in-focus radiation 14. The method 70 further comprises a step 72 of operating an HSI sensor 15 to produce a hyperspectral image 30, 31 based on the in-focus radiation 14 passed by the optical system 11.
In summary, the example embodiments of the present disclosure enable depth-resolved HSI, and thus make new application scenarios feasible for HSI.
Number | Date | Country | Kind |
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18215229.8 | Dec 2018 | EP | regional |
The present application is a non-provisional patent application claiming priority to European Patent Application No. 18215229.8 filed Dec. 21, 2018, the contents of which are hereby incorporated by reference.