This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2011-198656, filed on Sep. 12, 2011, the entire contents of which are incorporated herein by reference.
1. Field
Embodiments described herein relate to a pattern inspection apparatus and method.
2. Background
A conventional pattern inspection apparatus illuminates a wafer with light from a lamp light source, forms an image on a two-dimensional detector with the reflected light from the wafer so as to obtain the image, and compares pixel values obtained from corresponding places of a repetitive pattern on the wafer with each other, thereby determining whether the wafer includes a defect.
The wavelength of the light for the wafer illumination is set by selecting a wavelength range suitable for the structure and the defect of the wafer from a wide wavelength range of the lump light source by using a bandpass filter. In this case, the suitable wavelength changes due to variations of an underlying structure in the wafer plane, between wafers, and between lots, and variations of the heights of the defects. This often results in missing of the defects.
Furthermore, although the conventional pattern inspection apparatus illuminates the wafer with the light which illuminates a definite area, the wafer may be illuminated with a spot beam instead of such light. However, it is necessary in this case to scan the wafer with the spot beam. This results in a problem that the throughput is slow as compared with the case where the wafer is illuminated with the light illuminating a definite area.
Embodiments will now be explained with reference to the accompanying drawings.
An embodiment described herein is a pattern inspection apparatus including a light source configured to generate light, and a condenser configured to shape the light into a line beam to illuminate a wafer with the line beam. The apparatus further includes a spectrometer configured to disperse the line beam reflected from the wafer. The apparatus further includes a two-dimensional detector configured to detect the line beam dispersed by the spectrometer, and output a signal including spectrum information of the line beam. The apparatus further includes a comparison unit configured to compare the spectrum information obtained from corresponding places of a repetitive pattern on the wafer with each other, and a determination unit configured to determine whether the wafer includes a defect, based on a comparison result of the spectrum information.
The pattern inspection apparatus of
The light source 11 is a white light source having a wide wavelength band. In the present embodiment, a lamp light source is used as the light source 11. Examples of the lamp light source include an Hg (mercury) lamp, a Xe (xenon) lamp, a halogen lamp and the like.
White light generated from the light source 11 is converted into parallel light by the convex lens 12. The white light is further shaped into a line beam by the first cylindrical lens 13 to illuminate a wafer 21 with the line beam. The first cylindrical lens 13 is an example of a condenser.
The line beam reflected from the wafer 21 passes through the second cylindrical lens 14 which converts the light diverged by the scattering into parallel light, and then passes through the third cylindrical lens 15 to form an image on the grating 16. The line beam is then dispersed by the grating 16. The grating 16 is an example of a spectrometer.
The line beam incident on the grating 16 is white light, and therefore it contains light components of various wavelengths. The light components of the white light are changed in traveling angle according to the wavelengths by the grating 16 to illuminate the CCD sensor 17 with those light components. Therefore, the light receiving plane of the CCD sensor 17 detects information corresponding to a difference in wavelengths along a first direction, and detects information corresponding to a difference in positions in the line beam along a second direction perpendicular to the first direction. In
In this way, the CCD sensor 17 detects the line beam dispersed by the grating 16 as a whole. The CCD sensor 17 then outputs a signal including detected spectrum information of the line beam. The output signal is supplied to the comparison unit 18. The CCD sensor 17 is an example of a two-dimensional detector.
The pattern inspection apparatus of
The comparison unit 18 compares the spectrum information obtained from the corresponding places of the repetitive pattern on the wafer 21 with each other. Specifically, the repetitive pattern includes plural patterns having the same shape, and therefore the comparison unit 18 compares spectra obtained from the corresponding places of those patterns with each other. For example, the comparison process by the comparison unit 18 is conducted between adjacent IC chips fabricated on the wafer 21, or in a repetitive circuit pattern in one IC chip.
The determination unit 19 then determines whether the wafer 21 includes a defect, based on a comparison result of the spectrum information. In this way, in the present embodiment, it is possible to determine whether the wafer 21 includes the defect by comparing the spectrum information obtained from the corresponding places of the repetitive pattern on the wafer 21 with each other.
As described above, the defect detection in the present embodiment is conducted by using the spectrum information of the reflected light from the wafer 21. Therefore, as the light for the wafer illumination, the white light is used instead of the light whose wavelength is set in a wavelength area suitable for the structure and the defect of the wafer 21. According to the present embodiment, therefore, inspection can be conducted by using plural wavelengths at one time. Therefore, even if the structure and the defect of the wafer 21 vary to change a suitable wavelength, the defect can be detected with high precision.
Examples of variations of the structure of the wafer 21 include variations of a thickness of a layer on the wafer 21, variations of a line width or height of a circuit pattern, and variations of a substance of a layer on the wafer 21 which causes changes of a refractive index and an absorption index. Examples of variations of the defect of the wafer 21 include variations of a defect height and size, and a difference of materials of defects such as dielectrics or metals.
Furthermore, in the present embodiment, the light for the wafer illumination is not a spot beam but a line beam. Therefore, as compared with the case where the wafer 21 is scanned with the spot beam, the spectrum information in the wafer plane can be obtained fast by scanning the wafer 21 with the line beam. Therefore, the present embodiment can conduct a pattern inspection which is fast in throughput.
The light for the wafer illumination may be light other than the white light as long as the light has spread in wavelength range. As a result, it becomes possible to detect the defect with high precision even if the suitable wavelength changes due to variations of the structure and the defect of the wafer 21, similarly to the case where the white light is used.
(1) First Example of Pattern Inspection Method
A first example of a pattern inspection method of the first embodiment will now be described with reference to
Hereafter, an inspection position in
An example of a comparison method conducted by the comparison unit 18 includes a method of calculating a difference of spectra obtained from the corresponding places of the repetitive pattern on the wafer 21. In this comparison process, the difference is calculated, for example, between a first pattern on a first IC chip, and a second pattern having the same shape as that of the first pattern and located in the corresponding place on a second IC chip. In this case, each of the first and second patterns need not be the repetitive pattern. However, the repetitive pattern is formed by repeating plural patterns having the same shape as that of the first and second patterns among IC chips. Furthermore, in the comparison process, the difference is calculated, for example, between a first pattern which forms a repetitive pattern on an IC chip, and a second pattern having the same shape as the first pattern in the same repetitive pattern on the same IC chip.
If the first and second inspection positions include no defect, the difference intensity in
Therefore, the determination unit 19 determines whether the wafer 21 includes a defect based on the difference intensity shown in
When comparing intensities in two inspection positions with each other, the comparison unit 18 may set one inspection position to be an inspection position where the determination has been already completed, and set the other inspection position to be an inspection position where the determination has not been conducted yet. In this case, the determination unit 19 determines whether the second inspection position on the wafer 21 includes a defect.
Furthermore, when comparing intensities in two inspection positions with each other, the comparison unit 18 may set both of the inspection positions to be inspection positions where the determination has not been conducted yet. In this case, the determination unit 19 outputs a determination result, for example, “either of the inspection positions includes a defect” or “both of the inspection positions include no defect.”
If the structure and the defect of the wafer 21 do not vary, the intensity change shown in
Hereafter, the inspection position in
In this example, the second inspection position includes a defect. Therefore, in spectra in the second inspection position, the intensity changes at a certain wavelength as shown in
If there is such a change in the wafer structure, the conventional pattern inspection apparatus cannot detect a defect with high precision. In the present embodiment, however, it is determined that the wafer 21 includes a defect if the difference intensity is greater than a threshold at a wavelength. Therefore, even if there is a such a change in the wafer structure, the defect can be detected with high precision in the present embodiment.
(2) Second Example of Pattern Inspection Method
A second example of the pattern inspection method of the first embodiment will now be described with reference to
Hereafter, inspection positions in
The comparison unit 18 calculates a difference between spectra obtained from the corresponding places of the repetitive pattern on the wafer 21, similarly to the case of the first example.
Intensity changes in
If there is such a change in the defect structure, the conventional pattern inspection apparatus cannot detect a defect with high precision. In the present embodiment, however, it is determined that the wafer 21 includes a defect if the difference intensity is greater than the threshold at a wavelength. Therefore, even if there is such a change in the defect structure, the defect can be detected with high precision in the present embodiment.
The intensity in
(3) Effects of First Embodiment
Finally, effects of the first embodiment will be described.
As described above, in the present embodiment, the defect detection is conducted by using the spectrum information of the reflected light from the wafer 21. According to the present embodiment, therefore, it is possible to detect the defect with high precision even if the structure and the defect of the wafer 21 vary and consequently the suitable wavelength changes.
Furthermore, in the present embodiment, the light for the wafer illumination is not a spot beam but a line beam. According to the present embodiment, therefore, it is possible to conduct the pattern inspection with a faster throughput as compared with the case where the spot beam is used.
The optical system in the pattern inspection apparatus of
According to the second embodiment, it is possible to detect the defect with high precision even if the structure and the defect of the wafer 21 vary and consequently the suitable wavelength changes, similarly to the first embodiment, and it is possible to conduct the pattern inspection with a fast throughput.
In the first and second embodiments, a spectrum camera in which the grating 16 and the CCD sensor 17 are united in a body may be adopted as the grating 16 and the CCD sensor 17.
The pattern inspection apparatus shown in
The supercontinuum light source 31 is a white light source which generates wideband laser light called supercontinuum light as the white light. The supercontinuum light source 31 has a merit that the brightness can be made larger than that of the lamp light source 11, so that the signal-to-noise ratio can be improved. In the present embodiment, the supercontinuum light source 31 may be replaced with another white light source such as a superluminescent diode light source.
The prism 32 is a spectrometer which disperses the line beam reflected from the wafer 21, similarly to the grating 16. The CMOS sensor 33 is a two-dimensional detector which detects the dispersed line beam, similarly to the CCD sensor 17.
The first and third cylindrical lenses 13 and 15 may be replaced by a condenser and an imager other than cylindrical lenses, respectively.
In the present embodiment, a polarizer or an analyzer may be disposed on an optical path between the light source 31 and a setting position of the wafer 21, or an optical path between the setting position of the wafer 21 and the prism 32. As a result, for example, it is possible to select polarized light (such as p-polarized light, s-polarized light, right-handed elliptically polarized light, or left-handed elliptically polarized light) suitable for the detection of each defect, thereby improving the defect detection sensitivity.
For example, if a line cut defect (open-circuit defect) having a broken interconnect is inspected when inspecting an interconnect pattern, it is desirable to use polarized light which vibrates in parallel to the interconnect direction. On the other hand, if a bridge defect (short-circuit defect) having a short-circuit between interconnects is inspected, it is desirable to use polarized light which vibrates perpendicularly to the interconnect direction. When inspecting an interconnect pattern, therefore, polarized light suitable for the type of the defect may be selected.
If the polarizer or the analyzer is disposed, an intensity ratio or a phase difference between the p-polarized light and the s-polarized light obtained from the line beam may be detected in the CMOS sensor 33, instead of the intensity of the line beam.
A symbol P1 shown in
A symbol α shown in
Even if the incidence angle a and the output angle β are equal to each other, the dark field optical system can be constructed by disposing spatial filters of
The spatial filter 34 is disposed at, for example, the point P1 shown in
Furthermore, in the present embodiment, a spatial filter which emphasizes the defect or a spatial filter which reduces noise may be disposed on the optical path of the illumination optical system or the imaging optical system depending on the type of the defect, the structure of the underlying pattern or the like.
Furthermore, the pattern inspection apparatus of the present embodiment may include a component other than the above-described components. An example of such a component includes an optical element having a function of converting a magnification, such as a relay lens.
According to the third embodiment, it is possible to detect the defect with high precision even if the structure and the defect of the wafer 21 vary and to conduct the pattern inspection with a fast throughput, similarly to the first and second embodiments.
The configurations of the first to third embodiments may be partially combined. For example, in the first embodiment, only the lamp light source 11 among the lamp light source 11, the grating 16, and the CCD sensor 17 may be replaced by the supercontinuum light source 31.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel apparatuses and methods described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the apparatuses and methods described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
Number | Date | Country | Kind |
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2011-198656 | Sep 2011 | JP | national |