Patent Application
20120086800
The present invention generally relates to lithography, and more particularly to surface inspection using a plurality of illumination sources.
Lithography is widely recognized as a key process in manufacturing integrated circuits (ICs) as well as other devices and/or structures. A lithographic apparatus is a machine, used during lithography, which applies a desired pattern onto a substrate, such as onto a target portion of the substrate. During manufacture of ICs with a lithographic apparatus, a patterning device (which is alternatively referred to as a mask or a reticle) generates a circuit pattern to be formed on an individual layer in an IC. This pattern can be transferred onto the target portion (e.g., comprising part of, one, or several dies) on the substrate (e.g., a silicon wafer). Transfer of the pattern is typically via imaging onto a layer of radiation-sensitive material (e.g., resist) provided on the substrate. In general, a single substrate contains a network of adjacent target portions that are successively patterned. Manufacturing different layers of the IC often requires imaging different patterns on different layers with different reticles or masks.
As the dimensions of ICs decrease and the patterns being transferred from the mask to the substrate become more complex, defects in the features formed on the mask become increasingly important. Consequently, defects in the features formed on the mask translate into pattern defects formed on the substrate. Mask defects can come from a variety of sources such as, for example, defects in coatings on mask blanks, the mask patterning process in a mask shop, and mask handling and contamination defects in a wafer fabrication facility. Therefore, inspection of masks for defects is important to minimize or remove unwanted particles and contaminants from affecting the transfer of a mask pattern onto the substrate.
Given the foregoing, what is needed is an improved mask/surface inspection system to support the minimization or removal of defects from mask patterns transferred onto a substrate. To meet this need, embodiments of the present invention are directed to a surface inspection system.
Embodiments of the present invention include an inspection system. The inspection system includes a plurality of illumination sources arranged around a surface of an object and configured to illuminate a target portion of the surface, a sensor, and an optical system configured to direct at least a portion of radiation from the target portion onto the sensor, the image sensor configured to detect an aerial image corresponding to the portion of the reflected radiation. The inspection system can also include an inspection stage configured to support the object during an inspection mode and an exposure mode of operation.
Further, the inspection system can include an analysis device configured to analyze the aerial image for defects. The analysis device can be configured to analyze the aerial image in one of three modes of operation: comparison of the aerial image to a previous aerial image detected by the inspection system; comparison of a first pattern area of the surface with a second pattern of the surface, wherein the first pattern are is substantially identical to the second pattern area; and, comparison of the aerial image to stored reference data.
Embodiments of the present invention additionally include an inspection method to detect defects on a surface. The method includes the following: directing radiation from a plurality of directions to reflect from a target portion of a surface of an object; receiving at least a portion of a reflected radiation from the target portion of the surface; and, detecting an aerial image corresponding to the reflected radiation. The method can also include analyzing the aerial image for surface defects.
Embodiments of the present invention further include a lithography system with two illumination systems, where a first illumination system can be used to pattern a substrate and the other illumination system can be used for mask defect inspection. The lithography system includes the following components: an illuminator configured to condition a radiation beam; a support constructed to support a patterning device, the patterning device configured to impart a pattern onto the radiation beam; a substrate table constructed to hold a substrate; a projection system configured to focus the patterned radiation beam onto the substrate; and, an inspection system. The inspection system includes an illumination system configured to illuminate radiation from a plurality of directions onto a target portion of the patterning device with a plurality of illumination sources arranged around the patterning device, an optical system configured to receive at least a portion of a reflected radiation from the target portion of the patterning device, and an image sensor configured to detect an aerial image corresponding to the portion of the reflected radiation.
Additionally, embodiments of the present invention include a system comprising a plurality of illumination sources arranged around a patterned surface of a reticle and configured to illuminate a target portion of the patterned surface from a plurality of directions. The plurality of illumination sources are configured to be selectively turned on and off to provide an illumination rotating around the reticle. The system includes a sensor configured to detect at least a portion of radiation reflected from the target portion. The system further includes an analysis device configured to analyze feature information in the portion of the reflected radiation for detecting defect and/or particulate contamination on the patterned surface of the reticle based on the feature information.
Further features and advantages of the invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with reference to the accompanying drawings. It is noted that the invention is not limited to the specific embodiments described herein. Such embodiments are presented herein for illustrative purposes only. Additional embodiments will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein.
The accompanying drawings, which are incorporated herein and form part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the relevant art(s) to make and use the invention.
The features and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, in which like reference characters identify corresponding elements throughout. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the corresponding reference number.
Embodiments of the present invention are directed to an EUV mask inspection system. This specification discloses one or more embodiments that incorporate the features of the present invention. The disclosed embodiment(s) merely exemplify the invention. The scope of the invention is not limited to the disclosed embodiment(s). The invention is defined by the claims appended hereto.
The embodiment(s) described, and references in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment(s) described can include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is understood that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
Embodiments of the present invention can be implemented in hardware, firmware, software, or any combination thereof. Embodiments of the present invention can also be implemented as instructions stored on a machine-readable medium, which can be read and executed by one or more processors. A machine-readable medium can include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computing device). For example, a machine-readable medium can include the following: read-only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; and, flash memory devices. Further, firmware, software, routines, instructions can be described herein as performing certain actions. However, it should be appreciated that such descriptions are merely for convenience and that such actions in fact result from computing devices, processors, controllers, or other devices executing the firmware, software, routines, instructions, etc.
Embodiments of the present inventions are directed to an EUV mask inspection system. The EUV mask inspection system can be used to measure an aerial image of features on a mask and identify potential mask defects. For instance, in a database comparison mode of operation, the EUV mask inspection system can be used by mask designers to obtain aerial images of a mask pattern as it would be used in a lithographic patterning process. These aerial images can be beneficial to mask design simulation tools to help accurately predict resulting features formed by a mask pattern (e.g., confirming the optical proximity corrections of the mask) and to optimize design of the mask.
Before describing such embodiments in more detail, however, it is instructive to present an example environment in which embodiments of the present invention can be implemented.
A. Example Reflective Lithographic System
The illumination system IL can include various types of optical components, such as refractive, reflective, magnetic, electromagnetic, electrostatic or other types of optical components, or any combination thereof, for directing, shaping, or controlling the radiation B.
The support structure MT holds the patterning device MA in a manner that depends on the orientation of the patterning device MA, the design of lithographic 100, and other conditions, such as for example whether or not the patterning device MA is held in a vacuum environment. The support structure MT can use mechanical, vacuum, electrostatic, or other clamping techniques to hold the patterning device MA. The support structure MT can be a frame or a table, for example, which can be fixed or movable, as required. The support structure MT can ensure that the patterning device is at a desired position, for example, with respect to the projection system PS.
The term “patterning device” MA should be broadly interpreted as referring to any device that can be used to impart a radiation beam B with a pattern in its cross-section, such as to create a pattern in the target portion C of the substrate W. In reference to
The patterning device MA can be reflective (as in lithographic apparatus 100 of
The term “projection system” PS can encompass any type of projection system, including refractive, reflective, catadioptric, magnetic, electromagnetic and electrostatic optical systems, or any combination thereof, as appropriate for the exposure radiation being used, or for other factors, such as the use of an immersion liquid or the use of a vacuum. A vacuum environment can be used for EUV or electron beam radiation since other gases can absorb too much radiation or electrons. A vacuum environment can therefore be provided to the whole beam path with the aid of a vacuum wall and vacuum pumps.
Lithographic apparatus 100 can be of a type having two (dual stage) or more substrate tables (and/or two or more mask tables) WT. In such “multiple stage” machines, the additional substrate tables WT can be used in parallel, or preparatory steps can be carried out on one or more tables while one or more other substrate tables WT are being used for exposure.
Referring to
Referring to
In general, movement of the mask table MT can be realized with the aid of a long-stroke module (coarse positioning) and a short-stroke module (fine positioning), which form part of the first positioner PM. Similarly, movement of the substrate table WT can be realized using a long-stroke module and a short-stroke module, which foim part of the second positioner PW. In the case of a stepper (as opposed to a scanner) the mask table MT can be connected to a short-stroke actuator only or can be fixed. Mask MA and substrate W can be aligned using mask alignment marks M1, M2 and substrate alignment marks P1, P2. Although the substrate alignment marks (as illustrated) occupy dedicated target portions, they can be located in spaces between target portions (known as scribe-lane alignment marks). Similarly, in situations in which more than one die is provided on the mask MA, the mask alignment marks can be located between the dies.
Lithographic apparatus 100 can be used in at least one of the following modes:
1. In step mode, the support structure (e.g., mask table) MT and the substrate table WT are kept essentially stationary, while an entire pattern imparted to the radiation beam B is projected onto a target portion C at one time (i.e., a single static exposure). The substrate table WT is then shifted in the X and/or Y direction so that a different target portion C can be exposed.
2. In scan mode, the support structure (e.g., mask table) MT and the substrate table WT are scanned synchronously while a pattern imparted to the radiation beam B is projected onto a target portion C (i.e., a single dynamic exposure). The velocity and direction of the substrate table WT relative to the support structure (e.g., mask table) MT can be determined by the (de-)magnification and image reversal characteristics of the projection system PS.
3. In another mode, the support structure (e.g., mask table) MT is kept substantially stationary holding a programmable patterning device, and the substrate table WT is moved or scanned while a pattern imparted to the radiation beam B is projected onto a target portion C. A pulsed radiation source SO can be employed and the programmable patterning device is updated as required after each movement of the substrate table WT or in between successive radiation pulses during a scan. This mode of operation can be readily applied to maskless lithography that utilizes a programmable patterning device, such as a programmable mirror array of a type as referred to herein.
Combinations and/or variations on the described modes of use or entirely different modes of use can also be employed.
Although specific reference can be made in this text to the use of lithographic apparatus in the manufacture of ICs, it should be understood that the lithographic apparatus described herein can have other applications, such as the manufacture of integrated optical systems, guidance and detection patterns for magnetic domain memories, flat-panel displays, liquid-crystal displays (LCDs), and thin-film magnetic heads. The skilled artisan will appreciate that, in the context of such alternative applications, any use of the terms “wafer” or “die” herein can be considered as synonymous with the more general terms “substrate” or “target portion,” respectively. The substrate referred to herein can be processed, before or after exposure, in for example a track (a tool that typically applies a layer of resist to a substrate and develops the exposed resist), a metrology tool, and/or an inspection tool. Where applicable, the disclosure herein can be applied to such and other substrate processing tools. Further, the substrate can be processed more than once, for example, in order to create a multi-layer IC, so that the term substrate used herein can also refer to a substrate that already contains multiple processed layers.
In a further embodiment, lithographic apparatus 100 includes an extreme ultraviolet (EUV) source, which is configured to generate a beam of EUV radiation for EUV lithography. In general, the EUV source is configured in a radiation system (see below), and a corresponding illumination system is configured to condition the EUV radiation beam of the EUV source.
B. Example EUV Lithographic Apparatus
Collector chamber 48 includes a radiation collector 50 (which can also be called collector mirror or collector) that can be formed from a grazing incidence collector. Radiation collector 50 has an upstream radiation collector side 50a and a downstream radiation collector side 50b, and radiation passed by collector 50 can be reflected off a grating spectral filter 51 to be focused at a virtual source point 52 at an aperture in the collector chamber 48. Radiation collectors 50 are known to persons skilled in the relevant art(s).
From collector chamber 48, a beam of radiation 56 is reflected in illumination optics unit 44 via normal incidence reflectors 53 and 54 onto a mask (not shown) positioned on mask table MT. A patterned beam 57 is formed, which is imaged in projection system PS via reflective elements 58 and 59 onto a substrate (not shown) supported on wafer stage or substrate table WT. In various embodiments, illumination optics unit 44 and projection system PS can include more (or fewer) elements than depicted in
In an embodiment, collector mirror 50 can also include a normal incidence collector in place of or in addition to a grazing incidence mirror. Further, collector mirror 50, although described in reference to a nested collector with reflectors 142, 143, and 146, is herein further used as example of a collector.
Further, instead of a grating 51, as schematically depicted in
The terms “upstream” and “downstream,” with respect to optical elements, indicate positions of one or more optical elements “optically upstream” and “optically downstream,” respectively, of one or more additional optical elements. Following the light path that a beam of radiation traverses through lithographic apparatus 200, a first optical element closer to source SO than a second optical element is configured upstream of the second optical element; the second optical element is configured downstream of the first optical element. For example, collector mirror 50 is configured upstream of spectral filter 51, whereas optical element 53 is configured downstream of spectral filter 51.
All optical elements depicted in
Radiation collector 50 can be a grazing incidence collector, and in such an embodiment, collector 50 is aligned along an optical axis O. The source SO, or an image thereof, can also be located along optical axis O. The radiation collector 50 can include reflectors 142, 143, and 146 (also known as a “shell” or a Wolter-type reflector including several Wolter-type reflectors). Reflectors 142, 143, and 146 can be nested and rotationally symmetric about optical axis O. In
Reflectors 142, 143, and 146 can include surfaces of which at least a portion represents a reflective layer or a number of reflective layers. Hence, reflectors 142, 143, and 146 (or additional reflectors in the embodiments of radiation collectors having more than three reflectors or shells) are at least partly designed for reflecting and collecting EUV radiation from source SO, and at least part of reflectors 142, 143, and 146 may not be designed to reflect and collect EUV radiation. For example, at least part of the back side of the reflectors may not be designed to reflect and collect EUV radiation. On the surface of these reflective layers, there can be an additional cap layer for protection, or as optical filter, provided on at least part of the surface of the reflective layers.
The radiation collector 50 can be placed in the vicinity of the source SO or an image of the source SO. Each reflector 142, 143, and 146 can include at least two adjacent reflecting surfaces, where the reflecting surfaces further from the source SO are placed at smaller angles to the optical axis O than the reflecting surface that is closer to the source SO. In this way, a grazing incidence collector 50 is configured to generate a beam of (E)UV radiation propagating along the optical axis O. At least two reflectors can be placed substantially coaxially and extend substantially rotationally symmetric about the optical axis O. It should be appreciated that radiation collector 50 can have further features on the external surface of outer reflector 146 or further features around outer reflector 146 such as, for example, a protective holder and a heater.
In the embodiments described herein, the terms “lens” and “lens element,” where the context allows, can refer to any one or combination of various types of optical components, including refractive, reflective, magnetic, electromagnetic, and electrostatic optical components.
Further, the terms “radiation” and “beam” used herein encompass all types of electromagnetic radiation, including ultraviolet (UV) radiation (e.g., having a wavelength λ of 365, 248, 193, 157, or 126 nm), extreme ultraviolet (EUV) radiation (e.g., having a wavelength less than 50 nm such as, for example, 13.5 nm), or hard X-ray working at less than 5 nm, as well as particle beams, such as ion beams or electron beams. Generally, radiation having wavelengths between about 780-3000 nm (or larger) is considered IR radiation. UV refers to radiation with wavelengths of approximately 100-400 nm. Within lithography, the teem “UV” also applies to the wavelengths that can be produced by a mercury discharge lamp: G-line 436 nm; H-line 405 nm; and/or, I-line 365 nm. Vacuum UV, or VUV (i.e., UV absorbed by air), refers to radiation having a wavelength of approximately 100-200 nm. Deep UV (DUV) generally refers to radiation having wavelengths ranging from 126 nm to 428 nm, and in an embodiment, an excimer laser can generate DUV radiation used within a lithographic apparatus. It should be appreciated that radiation having a wavelength in the range of, for example, 5-20 nm relates to radiation with a certain wavelength band, of which at least part is in the range of 5-20 nm.
For explanation purposes,
In a mask inspection tool operating based on scatterometry methods (e.g., light scatter defect inspection methods), light is typically illuminated onto a surface of the mask and an aerial image formed by light scattered from the surface of the mask is measured to detect defects in the mask pattern. The intensity of the light scattered by the defect is related to the wavelength of the illumination light and the size of the defect. As resolution of unwanted particles and contaminants decreases (e.g., a resolution less than 50 nm), mask inspection tools are faced with a challenge of detecting mask pattern defects at lower resolutions. For instance, in reference to
Embodiments of the present invention can be used to improve the detection of defects in a mask inspection tool. In particular, in reference to
EUV illumination source 310 is configured to project EUV inspection beam 370 onto a target portion of mask 360. An example of EUV illumination source 310 is radiation system 42 of
EUV illumination source 310 can be a standalone light source according to an embodiment of the present invention. In this embodiment, a lithographic apparatus integrating EUV mask inspection system 300 can be configured to operate in a mask inspection mode to analyze defects in a mask pattern (e.g., mask pattern 430 of
In another embodiment, EUV illumination source 310 is integrated into an illumination source used in a lithographic patterning process (e.g., illuminator IL in
In an embodiment, wafer patterning device 520 includes a mask 522 and a mask table 521 to support mask 522. Wafer patterning device 520 is configured to receive an EUV radiation beam 540, where EUV radiation beam 540 reflects off a patterned surface on mask 522 and is further processed by a projection system (not shown) in lithographic apparatus 500. The projection system receives a reflected EUV radiation beam 523 and projects a pattern imparted on reflected EUV radiation beam 523 by mask 522 onto a target portion of a substrate (as in lithographic apparatus 100 of
In an embodiment, EUV illumination source 510 includes an EUV light source 511 and a diverter device 512. EUV light source 511 is configured to direct an EUV radiation beam 513 to diverter device 512 and, in turn, diverter device 512 directs EUV radiation beam 540 to wafer patterning device 520 and an EUV radiation beam 550 to mask inspection device 530. In an embodiment, diverter device 512 includes a plurality of optical elements arranged to direct EUV radiation beam 513 to mask 522 (in wafer patterning device 520) and to mask 360 (in mask inspection device 530). Methods and optical element arrangements to direct a radiation beam, such as EUV radiation beam 513, to one or more directions are known to persons skilled in the relevant art(s). For instance, diverter device can be placed, for example, near virtual source point 52 of
Diverter device 512 can be configured to simultaneously direct EUV radiation beam 513 to both mask 522 and mask 360 (via EUV radiation beam 540 and 550, respectively) according to an embodiment of the present invention. For instance, as a substrate receives a patterned EUV radiation beam (e.g., via reflected EUV radiation beam 523), mask 360 in mask inspection device 530 can be inspected for mask defects.
In another embodiment, diverter device 512 can be configured to simultaneously direct EUV radiation beam 522 to mask 360 and mask 522 for the inspection of defects in masks 522 and 360. For instance,
In reference to
Diverter device 512 also directs EUV radiation beam 513 towards mask 360 in mask inspection device 530 during a mask inspection mode of operation. For instance, between patterning two or more substrates with mask 522 in wafer patterning device 520, diverter device 512 can direct EUV radiation beam 513 towards mask 360 and inspect mask 360 for defects while an already-patterned substrate is replaced with a substrate that requires patterning. Here, diverter device 512 does not direct EUV radiation beam 540 towards mask 522 when the already-patterned substrate is being replaced by the substrate to be patterned. In another example, diverter device 512 can direct EUV radiation beam 513 towards mask 360 and inspect mask 360 for defects when EUV beam 540 reaches an edge of mask 522 (e.g., change in scan direction) during a rasterization exposure of mask 522. That is, as EUV radiation beam 540 increments to the next row or column of mask 522 to expose with EUV radiation beam 540, EUV illumination source 510 can divert EUV radiation beam 513 towards mask 360 for inspection of defects as wafer patterning device 520 prepares for the next row or column of mask 522 to be exposed onto the substrate.
In reference to
In yet another embodiment, inspection stage 350 is a standalone high-precision mask table that is integrated into a lithography system (e.g., lithographic apparatus 100 of
Optical system 320 is configured to receive at least a portion of a reflected EUV radiation beam 380 from a target portion of mask 360, according to an embodiment of the present invention. Optical system 320 is configured to condition, magnify, and direct reflected EUV radiation beam 380 onto image sensor 330. In an embodiment, the magnification factor of reflected EUV radiation beam 380 onto image sensor 330 depends on the size of a detector array located in sensor array 330 (described further below). Methods and optical element arrangements to condition, magnify, and direct reflected EUV radiation beam 380 onto image sensor 330 are known to persons skilled in the relevant art(s).
Image sensor 330 is configured to detect an aerial image corresponding to a portion of reflected EUV radiation beam 380 received by optical system 320, according to an embodiment of the present invention. In an embodiment, image sensor 330 includes a detector array. An example of a detector array is a silicon charge-coupled device array of sensors. Based on the description herein, a person skilled in the relevant art(s) will recognize that other types of sensors and detectors can be used in image sensor 330. These other types of sensors and detectors are within the scope and spirit of the present invention.
Design of the detector array can depend on several factors such as, for example, physical size and detection resolution of the array. For instance, the detector array can consist of 24,000 by 24,000 sensor cells, where each sensor cell in 5 μm by 5 μm. This example detector array would be in the order of 100 mm by 100 mm. In order to resolve a mask defect (e.g., mask defect 440 of
In another embodiment, inspection areas 730 and 830 can analyze patterns on mask 710 with substantially similar features. For instance, an upper portion of mask 710 can contain a pattern that is substantially similar to a pattern located in a lower portion of mask 710. An aerial image of the pattern in the upper portion of mask 710 can be compared to a corresponding aerial image of the substantially similar pattern in the lower portion of mask 710 to highlight potential defects (explained further below in pattern-to-pattern comparison mode of operation). Based on the description herein, a person skilled in the art will recognize that more than two inspection areas can be analyzed (e.g., in parallel) on mask 710.
In reference to
In an embodiment, data analysis device 340 is configured to analyze the aerial image from image sensor 330 according to the following modes of operation: (1) mask image comparison; (2) pattern-to-pattern comparison; and, (3) database comparison. The mask image comparison mode of operation scans and records image data of a mask at two or more different points in time. Here, data analysis device 340 is configured to compute an aerial image corresponding to the recorded image data, compare a current aerial image with a previous aerial image of the mask, and highlight any differences between the aerial images as a potential mask defect.
In the pattern-to-pattern comparison mode of operation, a first pattern area of a mask is compared to a second pattern area of the mask, where the first pattern area and the second pattern area are designed to be substantially identical to one another. Here, data analysis device 340 is configured to compute an aerial image corresponding to the first and second pattern areas of the mask, compare the aerial image of the first pattern area with the aerial image of the second pattern area, and highlight any differences between the aerial images as a potential mask defect. In an embodiment, data analysis device 340 can be configured to compare one or more features of the first pattern area with one or more corresponding features of the second pattern area of the mask.
The database comparison mode of operation scans and records image data of a mask. Here, data analysis device 340 is configured to compute an aerial image corresponding to the recorded image data, compare the aerial image to a reference aerial image stored in a design database, and highlight any difference between the aerial images as a potential mask defect. In an embodiment, the design database can include image data corresponding to a calculated or previously-measured aerial image of the mask. The design database can be located within EUV mask inspection system 300 (e.g., within data analysis device 340) or external to EUV mask inspection system 300 (e.g., a standalone computing system).
In an embodiment, during these exemplary instances of when the wafer is not exposed to the patterned radiation beam, an entire mask or portions of a mask can be inspected for defects. The portions of the mask that are inspected in a “piece-meal” manner every time the lithographic apparatus switches between the mask inspection mode and the wafer exposure mode of operation can be combined to construct an overall aerial image of the mask.
In another embodiment, the EUV radiation beam simultaneously illuminates an EUV radiation beam onto a mask in a patterning device of a lithographic apparatus and onto a mask in a mask inspection device. EUV illumination source 510 of
In step 920, a portion (or the entire portion) of a reflected EUV radiation beam from the target portion of the mask is received by an optical system. The reflected EUV radiation beam can be received by, for example, optical system 320 of
In step 930, an aerial image corresponding to the portion of the reflected EUV radiation beam (from step 920) is detected by an image sensor. Image sensor 330 of
In step 940, the aerial image is analyzed for mask defects with a data analysis device. When analyzing the aerial image for mask defects, image data from the image sensor (from step 930) can be transferred to the data analysis device via a high-speed data connection such as, for example, a fiber optic-based data connection.
In one embodiment, surface inspection system 1000 can resolve features on a surface (e.g., mask 1060) to measure an aerial image of features on surface 1060 and to identify potential surface defects.
In various examples, the image sensor can be a camera, CCD or CMOS detector or array, or any other device that allows conversion of light characteristics to an electrical signal.
In one example, the plurality of illumination sources 1015 are coupled to or within stage 1050. In one example, the plurality of illumination sources 1015 can be arranged to be around the surface 1060 to be inspected. In one example, the one or more illumination sources 1015 are evenly spaced around a perimeter of inspection stage 1050, i.e., in a rectangular-like pattern. In another example, the plurality of illumination sources 1015 may be arranged in a circle encompassing inspection surface 1060 with the circle being centered at a center of surface 1060.
In one example, the plurality of illumination sources 1015 can be substantially in a same plane as surface 1060. In this example, radiation 1070 of the one or more illumination sources 1015 can be directed towards surface 1060 at very shallow, i.e., acute, angles.
In one example, there are one or more illumination sources 1015 each fixed at a relative position with reference to any point on surface 1060. In this example, radiation 1070 from each of the plurality of illumination sources 1015 will reflect off surface 1060 (shown in
In one example, the plurality of illumination sources 1015 are all turned on together. In another example, the plurality of illumination sources 1015 are turned on in groups. In still another example, each of the plurality of illumination sources 1015 illuminate individually. In another example, the plurality of illumination sources 1015 illuminate in a sequence, e.g., a temporal orbital sequence shown as arrow 1025.
In one example, data analysis device 1040 may capture a plurality of images of the surface pattern when the surface pattern is illuminated from a plurality of different directions. The plurality of images can then be combined into a composite aerial image of the surface pattern.
In one example, a method of illuminating surface 1060 can create images of anisotropic profiles and features associated with regular patterns depending on an angle of illumination, while irregular or globular features will appear more or less the same in all collected images (i.e., isotropic profiles). Combined processing of the collected images can reveal image features of specific interest, and facilitate discrimination of “regular” patterns from “particles” even on a surface with pattern relief. Several processing procedures can be utilized, e.g., those based on coincidence analysis: the repeating feature in every image will be noticed, while features that vary from frame to frame will be “eliminated.” Analysis of the collected images can allow topographical reconstruction of the resolvable pattern on the surface (e.g., reticle) and separate the resolvable pattern from irregularities (particles). Additionally, or alternatively, a definition of feature (particle) in-plane size, outline, and the actual feature (particle) height can be determined.
In one example, orbital illumination of mask 1060 allows for identification and measurement of substantially smaller features (e.g., particles). Therefore, discrimination of irregular features (e.g., particles) from regular patterns is enhanced.
The surface inspection system 1000 and associated methodology can be used as a stand-alone surface inspection system or can be combined with a mask inspection system (e.g., as shown in
In an embodiment, the aerial image can be analyzed in one of three ways. First, the aerial image can be analyzed by comparing the aerial image to a previously detected aerial image. Second, the aerial image can be analyzed by comparing a first pattern of the mask with a second pattern area of the mask, where the first and second patterns are substantially identical to each other. Third, the aerial image can be compared to reference data stored in a design database. It is to be appreciated that other analysis can also be used.
It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections can set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.
The present invention has been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
This application is a continuation-in-part of U.S. patent application Ser. No. 12/605,627, filed Oct. 26, 2009, which claims benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/138,389, filed Dec. 17, 2008, each of the above-referenced applications is incorporated herein by reference in its entirety.
