U.S. patent application number 12/551702 was filed with the patent office on 2009-12-31 for polarization imaging.
This patent application is currently assigned to Rudolph Technologies, Inc.. Invention is credited to Gang Sun.
Application Number | 20090324056 12/551702 |
Document ID | / |
Family ID | 38619156 |
Filed Date | 2009-12-31 |
United States Patent
Application |
20090324056 |
Kind Code |
A1 |
Sun; Gang |
December 31, 2009 |
POLARIZATION IMAGING
Abstract
A system and method for inspection a substrate for various
defects is herein disclosed. Polarizing filters are used to improve
the contrast of polarization dependent defects such as defocus and
exposure defects, while retaining the same sensitivity to
polarization independent defects, such as pits, voids, cracks,
chips and particles.
Inventors: |
Sun; Gang; (Mendham,
NJ) |
Correspondence
Address: |
DICKE BILLIG & CZAJA, PLLC;ATTN: CHRISTOPHER MCLAUGHLIN
100 SOUTH FIFTH STREET, SUITE 2250
MINNEAPOLIS
MN
55402
US
|
Assignee: |
Rudolph Technologies, Inc.
Flanders
NJ
|
Family ID: |
38619156 |
Appl. No.: |
12/551702 |
Filed: |
September 1, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11678407 |
Feb 23, 2007 |
7586607 |
|
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12551702 |
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60793858 |
Apr 21, 2006 |
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60844297 |
Sep 12, 2006 |
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Current U.S.
Class: |
382/145 |
Current CPC
Class: |
G01N 21/21 20130101;
G01N 21/88 20130101 |
Class at
Publication: |
382/145 |
International
Class: |
G06K 9/00 20060101
G06K009/00 |
Claims
1. A method of inspecting a substrate, comprising: capturing an
image of the substrate; accessing a model indicative of a
calibration substrate having a number of patterns formed thereon;
comparing pixel characteristics of the image of the substrate with
pixel characteristics of the model to identify differences between
the image and the model; and determining whether the differences
between the image and the model exceed a predetermined
threshold.
2. The method of claim 1 wherein the pixel characteristics of the
image and the pixel characteristics of the model comprise pixel
intensity values.
3. The method of claim 1 wherein the calibration substrate includes
a focus exposure matrix.
4. The method of claim 1 wherein the model is a golden die.
5. The method of claim 1, further comprising: forming a
differential image of differences between corresponding pixel
values of the image and the model.
6. The method of claim 1 wherein the patterns include at least one
of line structures, conductors, interconnects, vias and
streets.
7. The method of claim 1 wherein the pixel characteristics
correlate to geometry of the patterns.
8. The method of claim 1 further comprising repeating the comparing
and determining steps across substantially an entire wafer forming
the substrate.
9. A substrate inspection system, comprising: an optical sensor
adapted to capture an image of the substrate; a computer adapted to
access a model indicative of a calibration substrate having a
number of patterns formed thereon, compare pixel characteristics of
the image of the substrate with pixel characteristics of the model
to identify differences between the image and the model and
determine whether the differences between the image and the model
exceed a predetermined threshold.
10. The system of claim 9 wherein the pixel characteristics of the
image and the pixel characteristics of the model comprise pixel
intensity values.
11. The system of claim 9 wherein the calibration substrate
includes a focus exposure matrix.
12. The system of claim 9 wherein the model is a golden die.
13. The system of claim 9 wherein the computer is further adapted
to form a differential image of differences between corresponding
pixel values of the image and the model.
14. The system of claim 9 wherein the patterns include at least one
of line structures, conductors, interconnects, vias and
streets.
15. The system of claim 9 wherein the pixel characteristics
correlate to geometry of the patterns.
16. The system of claim 9 wherein the optical sensor is further
adapted to capture images across substantially an entire wafer
forming the substrate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/678,407, filed Feb. 23, 2007, entitled
"Polarization Imaging", and bearing Attorney Docket No.
A126.203.101, which claims priority under 35 U.S.C. .sctn.119(e)(1)
to U.S. Provisional Patent Application Ser. No. 60/793,858, filed
Apr. 21, 2006, entitled "Polarization Imaging," and bearing
Attorney Docket No. A126.193.101 and U.S. Provisional Patent
Application Ser. No. 60/844,297, filed Sep. 12, 2006, entitled
"Polarization Imaging," and bearing Attorney Docket No.
A126.199.101; the teachings of all of which are hereby incorporated
by reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to inspection and
metrology tools for used to ensure quality and improve yield in
semiconductor device manufacturing processes.
BACKGROUND
[0003] In lithographic semiconductor device fabrication processes,
it is imperative that a stepper precisely focus an image of a
reticle on a semiconductor substrate or wafer. Where the image of
the reticle is out of focus, a state also known as defocus, the
structures of the resulting semiconductor device may be of the
incorrect size and form. For example, the edges of the resulting
structures may be relatively diffuse and indistinct, having rounded
or undercut surfaces in lieu of a more desired, often rectilinear
geometry. This state of defocus often leads to poor function and/or
inoperability in the semiconductor device in question. Measurement
of defocus is therefore an important means for allowing
semiconductor device manufacturers to ensure that a stepper
consistently focuses a reticle image on a wafer, thereby enabling
larger and more profitable yields from the manufacturing
process.
[0004] Another problem common to the formation of semiconductor
devices is that of exposure defects. Where the exposure of a photo
resist layer to light falls outside a range of acceptable light
dosages, the features that are to be formed on the semiconductor
substrate may be formed incorrectly. Accordingly, it is also
important to identify exposure defects where they exist.
[0005] In addition to inspecting a substrate or wafer for exposure
or defocus defects, it is important to inspect substrates and
wafers for process or material related defects commonly referred to
as "macro" defects. Macro defects are often defined as chips,
cracks, scratches, pits, delaminations, and/or particles that
appear on a substrate that have a dimension of about 0.5 u to 10 u
in size. Such defects can easily cause a failure in a semiconductor
device and can significantly reduce the yield of a manufacturer of
such devices. Note that the sizes of macro defects may depart up or
down from the size range stated above, which merely defines a
nominal size of such defects.
[0006] Traditionally, macro defects have been inspected using
dedicated inspection systems that have not been able to readily or
reliably identify the presence of exposure or defocus defects.
Exposure and defocus defects are usually identified using optical
critical dimension (OCD) techniques on any of a number of precision
metrology tools such as ellipsometers, reflectometers and
scatterometers. It would be desirable to combine the functions of
identifying the presence of exposure and defocus defects with
inspection of substrates for macro defects wherein the same optical
system is used for both functions.
SUMMARY
[0007] One embodiment of an inspection system for identifying
defects on a substrate includes a light source that directs light
onto a substrate that is to be inspected. A first polarizing
filter, or polarizer, is positioned between the light source and
the substrate. A second polarizing filter, or analyzer, is
positioned between the substrate and an optical sensor that
receives light reflected from the substrate. The polarizer and
analyzer, are angularly arranged with respect to one another such
that an image intensity of an image captured by the optical sensor
is at least partially correlated with the presence of polarization
dependent defects on the substrate under test. Polarization
dependent defects include, among other things, defocus and exposure
defects. Defects having a main dimension of approximately the
wavelength of incident light or smaller that are not defocus or
exposure defects may also be identified.
[0008] The light source may be of any useful type including, but
not limited to, a broadband incandescent light or a laser. Either
of these light sources may strobe and may be positioned to direct
light on the surface of the substrate at any useful angle of
incidence, including a normal angle of incidence. Lasers may be of
a fixed, monochrome variety or may be arranged to output light at
several different nominal wavelengths.
[0009] Where strobe illumination is used, the strobe will flash on
and off in a sequence that at least partially correlates with the
velocity at which a substrate is moved with respect to the
inspection system. This permits the inspection system to reliably
capture images of the substrate at the appropriate locations.
[0010] The optical sensor or imager may be a monochrome charged
capacitance device (CCD). In some instances, the optical sensor may
be a color imager of the Bayer type or a three-chip design. In yet
other instances, one or more light source and/or color filters may
be used in conjunction with a monochrome optical sensor to obtain
color data from the substrate. Both area scan and line scan optical
sensors may be used.
[0011] In addition to defocus and exposure defects, other types of
defects may be identified. These other defects may include pits,
voids, chips, cracks, particles, and scratches.
[0012] Inspection systems according to the present disclosure are
put into operation by first arranging the light source to direct
light onto the substrate. The first polarizing filter is positioned
between the light source and the substrate and the optical sensor
is placed to receive light reflected from the substrate. The second
polarizing filter is placed between the substrate and the optical
sensor and such that the first and second polarizing filters are at
a selected relative angle with respect to one another. The
inspection system is then used to capture images of the substrate
and comparative data is generated from these images to identify the
existence of exposure and/or defocus defects on the substrate, if
any. Arranging the polarizing filters to capture the required
images may involve rotating the first and second polarizing filters
together to a desired inspection angle whilst maintaining the
selected relative angle therebetween.
[0013] Comparative data may be obtained by first generating a
differential image for each captured image and then averaging pixel
intensity differences of the respective differential images over
the entire differential image to obtain an average image intensity
for each differential image. The average image intensity of each
captured image is evaluated with respect to a predetermined
threshold to determine the existence of at least one of exposure
and defocus defects on the substrate, if any.
[0014] Calibration of the output of the optical sensor with respect
to known levels of at least one of an exposure and a defocus defect
in a substrate is used to determine appropriate defocus and
exposure defect levels. In one embodiment calibration involves
capturing a plurality of images of a calibration substrate, wherein
each image is subject to a known degree of defocus and exposure
defects. As described above, a differential image is generated for
each captured image and the pixel intensity differences of the
differential images are averaged over the entire differential image
to obtain an average image intensity. The average image intensity
values for each captured image having a known degree of defocus and
exposure defect are recorded. A user may select any recorded
average image intensity value indicative of a particular degree or
magnitude of defocus and/or exposure defects as a threshold, may
interpolate between such recorded values or may simply use the
recorded values as a starting point to which modifiers specific to
the product are applied. It is entirely up to the user of an
inspection system to define suitable thresholds for defocus and/or
exposure defects.
[0015] Generating a differential image may involve averaging a
plurality of captured images on a pixel by pixel basis to obtain an
averaged image. This averaged imaged is then subtracted from each
captured image, on a pixel by pixel basis to produce a differential
image that can also be thought of as an array of pixel intensity
values or as an array of pixel intensity value differences.
[0016] Inspection of a substrate for defocus and/or exposure
defects may take simultaneous with inspection for other defects
such as pits, voids, chips, cracks, particles, and scratches.
Alternatively, inspection for these respective types of defects may
take place successively or even in a time shifted manner, i.e. at
times that are significantly separated from one another.
[0017] In another embodiment of the present disclosure, image
analysis techniques such as spatial pattern recognition (SPR)
techniques may be used to analyze a differential image to identify
the boundaries of layers on a substrate. Note that layer boundaries
such as the aforementioned ones may be part of layers that are an
intentional part of the substrate or may be related to residues
that are not intentionally part of the substrate, i.e. the layers
may be contaminants of one type or another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic view of one embodiment of an imaging
system of the present disclosure having a nominal angle of
incidence other than 90.degree..
[0019] FIG. 2 is a schematic view of one embodiment of an imaging
system of the present disclosure having a nominal angle of
incidence of substantially 90.degree..
[0020] FIG. 3 is an illustration, in vector form, of the relative
components of reflected light reflected from a substrate.
[0021] FIG. 4 is a chart showing the relative components of
reflected light before being passed through an appropriately
arranged analyzer.
[0022] FIG. 5 is a chart showing the relative components of
reflected light after having been passed through an appropriately
arranged analyzer.
[0023] FIG. 6 is a flow chart illustrating a method of setting up
an inspection system for inspection.
[0024] FIG. 7 is a flow chart illustrating a method of inspecting a
substrate.
DETAILED DESCRIPTION
[0025] In the following detailed description, reference is made to
the accompanying drawings that form a part hereof, and in which is
shown, by way of illustration, specific embodiments in which the
disclosure may be practiced. In the drawings, like numerals
describe substantially similar components throughout the several
views. These embodiments are described in sufficient detail to
enable those skilled in the art to practice the disclosure. Other
embodiments may be utilized and structural, logical, and electrical
changes may be made without departing from the scope of the present
disclosure. The following detailed description is, therefore, not
to be taken in a limiting sense, and the scope of the present
disclosure is defined only by the appended claims and equivalents
thereof.
[0026] The present disclosure involves a method and apparatus for
determining the presence of exposure and defocus lithographic
defects in a semiconductor substrate by measuring a change in the
polarization of light reflected from the surface of the substrate.
To simplify the following discussion, the term "defocus" will be
used herein to denote both exposure and defocus defects, though it
is to be understood that a given substrate may suffer from the one
defect or the other or both. Further, the term "defocus" shall be
construed broadly to encompass any defect or undesirable feature of
a substrate under inspection that has characteristic results
similar to exposure and/or defocus defects and which may be
identified or otherwise characterized by the inspection system of
the present disclosure. In general, defocus defects are
polarization dependent features, that is, defocus defects will
cause a change in the polarization state of light reflected
therefrom, though it is understood by those skilled in the art that
other aspects of defocus defects may affect the nature and extent
of such polarization changes.
[0027] As used herein, the term "substrate" shall be construed to
include any material or structure that may be inspected by the
inspection system of the present disclosure. Specifically, the term
"substrate" shall be construed to include, among other things,
semiconductor wafers of any construction or form or material,
including, but not limited to, whole wafers, unpatterned wafers,
patterned wafers, partially patterned wafers, broken wafers that
are wholly or partially patterned, broken wafers that are
unpatterned, sawn wafers in any form and on any support mechanism,
including film frames, JEDEC trays, Auer boats, die in gel or
waffle packs, multi-chip modules often referred to as MCMs, etc.
The terms "substrate" and "wafer" may be used interchangeably
herein.
[0028] The term "macro defect" as used herein will include all
unintentional features that appear on a substrate that are
essentially polarization independent. As noted above, macro defects
are traditionally described as being chips, cracks, pits,
particles, scratches and the like. Note that in some instances, the
size of macro defects may approach the wavelength of the incident
radiation being used for inspection purposes. In these instances,
macro defects may have an effect on the polarization state of light
reflected therefrom.
[0029] With reference to FIG. 1, one embodiment of an imaging
system 8 includes an illuminator 10, a polarizer 12, an analyzer
14, and an optical sensor 16. The illuminator 10 directs light
along optical path P onto the polarizer 12, which transmits
substantially only light having a predetermined polarization angle.
The light transmitted by the polarizer 12 is then incident upon a
substrate S. In one embodiment, the substrate S is a silicon wafer
or a portion thereof having structures formed thereon. In some
embodiments, these structures form one or more semiconductor
devices on the substrate S. Other mechanisms and structures may
also be formed on the substrates S.
[0030] As can be seen in FIG. 1, optical path P is at a non-normal
angle of incidence with respect to the substrate S. In some
embodiments the illuminator 10, polarizer 12, analyzer 14, and
optical sensor 16, as well as other associated optical elements
such as objectives and the like, may be mounted so as to permit the
angle of incidence of light on the substrate S to be modified.
Mounting mechanisms of the type that would be useful in modifying
the angle of incidence of light in the system 8 are known to those
skilled in the art and may include a mounting plate(s) to which the
optical elements of the system 8 are mounted, the mounting plate(s)
being rotatable by a rotation means that can be one or more
actuators. The angle of incidence may be essentially fixed (as
shown) or may be modified for each product set-ups. Further, in
some embodiments, the angle of incidence may be modified during
inspection, as needed.
[0031] The illuminator 10 may be of any useful type, including a
broadband white light, a laser having a fixed wavelength output, a
laser arranged to output multiple wavelengths, or a plurality of
lasers arranged to direct light along the optical path P. The
intensity required of the illuminator may vary depending on the
application to which the system 8 is directed. In some
applications, a high intensity illumination is required and
conversely, in others, relatively lower intensities are required.
The illuminator 10 may be arranged to provide substantially
constant output or may be arranged to strobe so as to freeze the
motion of a substrate S in the system 8, thereby allowing the rapid
capture of images of the substrate S.
[0032] The light incident upon the substrate S is reflected
therefrom and this reflected light is incident upon an analyzer 14
which, being a polarizing optical element similar to polarizer 12,
passes only that light having a predetermined polarization angle.
What light passes through analyzer 14 is incident upon optical
sensor 16, which captures an image of the substrate S. Optical
sensor 16 is in one embodiment a two dimensional electronic optical
sensor such as charge-coupled device (CCD), though any device
capable of producing a two dimensional array of pixel intensity
values on a grayscale or color basis, such as a line scan or time
delay integration imaging (TDI) device or a CMOS optical sensor
array, may be used. In one embodiment, the optical sensor 16 is a
monochrome optical sensor wherein each pixel of the optical
sensor's 2D array of pixels registers a grey scale value of 0-256,
which pixels, taken together represent an image of the substrate S.
Where a monochrome optical sensor is used, one or more color
filters 18 may be positioned in the optical path P between the
illuminator 10 and the optical sensor 16 to pass only light within
the range of wavelengths to which the color filter corresponds. In
another embodiment, the optical sensor may be a color optical
sensor of the Bayer type or a three-chip color sensor having
separate optical sensors, each dedicated to a separate color, e.g.
one sensor for red light, one sensor of blue light, and one sensor
for green light.
[0033] Those skilled in the art will understand that the basic
elements of the system 8 described herein above may be used in
conjunction, or not, with other optical elements including, but not
limited to optical filters, lenses, mirrors, retarders and
modulators. One inspection system that may be adapted for carrying
out the present disclosure is marketed by Rudolph Technologies,
Inc. of Flanders, N.J. under the trade name WaferView.TM.. Further,
it is to be understood that the system 8 may be arranged to carry
out multiple functions, these multiple functions being carried out
in simultaneous or in temporally spaced arrangements. For example,
the system 8 may be adapted to carry out an inspection for macro
defects as well as an inspection for defocus defects. Further, the
system 8 can be arranged to carry out an inspection for macro
defects followed by an inspection for defocus defects, or vice
versa, or may carry out both inspections simultaneously.
[0034] Color filters 18 may be used in the system 8 as shown
schematically in FIG. 1. One or more color filters 18 may be placed
between the polarizer 12 and the substrate S, between the substrate
S and the analyzer 14, between the illuminator 10 and the polarizer
12, or between the analyzer 14 and the optical sensor 16. In one
embodiment, the color filter 18 may be a filter wheel of a type
known in the art wherein one of a group of color filters is affixed
to a rotating wheel placed in the optical path P such that the
color filters 18 are selectively positioned across the optical path
P. In another embodiment, a removable filter holder may be placed
in the optical path P to permit different color filters to be
placed in the optical path P. In yet another embodiment, a fixed
color filter may mounted in the optical path P. It is to be
understood that any filter media or mechanism suitable for
selectively passing a predetermined wavelength or range of
wavelengths may be used as a color filter.
[0035] In some embodiments, it is desirable to separate the output
of the optical sensor 16 with respect to predetermined color
channels wherein "color channel" is defined as a predetermined
wavelength or range of wavelengths. Separation of color channels
may be accomplished, as suggested above, by the use of color
filters, by the use of color optical sensors that incorporate
directly the ability to distinguish between respective color
channels as do three-chip optical sensors and Bayer optical
sensors, or by using an illuminator 10 that outputs light within a
pre-selected range of wavelengths. It should be understood that
some substrates S may be partially or wholly transmissive with
respect to certain ranges of wavelengths or colors. By way of
example only, a given substrate S may transmit or destructively
interfere a majority of all incident blue light having wavelengths
centered around 475 nm, but reflect a large portion of the red
light having wavelengths centered around 700 nm that is incident on
the substrate S. In this example, it may be useful then to be able
to use the signal output by the optical sensor 16 that results from
the red light incident on the optical sensor 16. The use of data
relating to a respective color channel will depend on what features
are being examined in the inspection being undertaken with the
system 8. In some embodiments, certain semiconductor substrates,
also known as products, will tend to have features that reflect
light in a known manner and accordingly, an inspection system 8 may
be set up specifically for a given product to optimize the
inspection of the product.
[0036] FIG. 2 illustrates another embodiment of the present
disclosure wherein an inspection system 30 has an illuminator 32
that directs light along optical path P though polarizer 36, filter
40 (optional), and beam splitter 42 onto substrate S in a
substantially normal arrangement. Light reflected from substrate S
on path P is directed by beam splitter 42 through filter 40
(optional) and analyzer 38 to optical sensor 34. Systems 8 and 30
are, aside from the presences of a beam splitter and differences in
the angle of incidence, substantially similar. In this embodiment,
optical path P is substantially normal to the substrate S.
[0037] It has been observed that defocus defects will modify the
reflectivity of a substrate S as defocus defects will modify the
geometry of the structures formed on a substrate S. Other factors
that will modify the reflectivity of a substrate S are the
properties of other film layers and the wavelength, polarization,
and angle of light incident upon the substrate. Using an inspection
system according to various embodiments of the present disclosure,
e.g. systems 8 or 30, it is possible to distinguish those
reflectivity changes that result from defocus defects and to do so
in a rapid and reliable manner.
[0038] In general, light from an illuminator 10, 32 is polarized to
a predetermined angle P by a polarizer 12, 36 and incident upon a
substrate S at a specified angle .theta.. Upon reflection, the
substrate S will modify the polarization state of the incident
light in relation to a number of characteristics thereof and
specifically defocus. From this modification of the polarization
information concerning defocus defects in the substrate S can be
obtained. The reflected light passes through analyzer 14 and is
incident upon optical sensor 16. The analyzer 14, when arranged as
described in more detail hereinbelow, helps ensure that the data
obtained from the optical sensor 16 includes information concerning
both the amplitude and the polarization change of the reflected
light and particularly information concerning the presence of
defocus defects on the substrate S.
[0039] In one embodiment, the light incident upon the substrate S
is linearly polarized by polarizer 12, 36 as this often presents
the simplest solution to the inspection problem at hand. In other
embodiments, incident light is elliptically or circularly
polarized, as needed. By setting the analyzer 14, 38 at an angle A
with respect to the polarizer 12, 36, the light that reaches the
optical sensor 16, 34 may be modulated. The angle between the
polarizer 12, 36 and the analyzer 14, 38 is given as P-A.
[0040] Referring now to FIG. 3, in general, when light is reflected
from the substrate S, portions of the incident light, E.sub.P, will
be reflected differently than other portions of the incident light.
A portion of the incident light E.sub.P is reflected from
polarization independent features on the substrate S surface
without any significant modification in its polarization as
illustrated in FIG. 3 at E.sub.1 and E.sub.2. Some examples of such
features that may be found on a semiconductor substrate S include,
but are not limited to, bright and dark appearing defects in the
substrate S such as chips, cracks, scratches, pits, voids, and
particles. Another portion of the reflected incident light,
E.sub.3, is reflected from polarization dependent features formed
on the substrate S that are arranged in such a way that they will
modify the polarity of the incident light. Some examples of the
polarization dependent features or structures found on a
semiconductor substrate S include, but are not limited to, line
structures, conductors, interconnects, vias and streets. Yet
another portion of the incident light reflected from the surface of
the substrate S is reflected by features or structures that modify
the polarization of the reflected light and which are also subject
to defocus defects. This light, E.sub.4, has a polarization state
that differs from E.sub.3. Structures that reflect light E.sub.4
may be structurally similar or identical to the nominal structures
from which light E.sub.3 described above is reflected except for
the fact that they are subject to defocus defects, the magnitude of
which will affect the intensity of light E.sub.4.
[0041] Referring to FIG. 4, it can be seen that for light that has
not passed through the analyzer 14, 38, there is little contrast
between the intensity of reflected light E.sub.3 and E.sub.4. As
can be appreciated, it is difficult to identify defocus defects
under these circumstances. However, once the reflected light
E.sub.1, E.sub.2, E.sub.3, and E.sub.4 is passed through a properly
arranged analyzer 14, 38, to obtain light signals E'.sub.1,
E'.sub.2, E'.sub.3, and E'.sub.4, the contrast level between light
signals E'.sub.3, and E'.sub.4 is sufficient to obtain useful
information concerning the presence of defocus defects. See FIG.
5.
[0042] In one embodiment, the angle P-A between the polarizer 12
and the analyzer 14 is determined experimentally. Referring now to
FIG. 6, with a test substrate S positioned in the system 8 for
inspection (step 50), the illuminator 10, which is in one
embodiment a strobe illuminator, is set to a predetermined
illumination level (step 52) that is preferably near the top end of
its intensity output, but may be of any suitable intensity. Light
E.sub.P from the illuminator or light source 10 is directed through
the polarizer 12 and onto the substrate S. Next, the polarizer 12
is set to an angle P (step 54). In one embodiment, the polarizer 12
is angularly oriented substantially perpendicular to any linear
structures present on the substrate S. As will be understood, where
the substrate S is a semiconductor wafer having semiconductor
devices formed thereon (in any state of completeness), such
structures typically, but not always, have significant linear
features. Reflected light (E.sub.1, E.sub.2, E.sub.3, and E.sub.4)
is passed through the analyzer 14 to obtain light signals E'.sub.1,
E'.sub.2, E'.sub.3, and E'.sub.4 on optical sensor 16. In instances
where there is no discernable orientation to linear structures on a
substrate S or where the substrate S has no linear structures
formed thereon, an arbitrary angle P may be chosen for polarizer
12.
[0043] The analyzer 14 is next rotated to an angle A (step 56) such
that sufficient illumination reaches the optical sensor 16 to
permit inspection of the substrate S for macro or polarization
independent defects as described in U.S. Pat. Nos. 6,324,298,
6,487,307 and 6,826,298, which are owned jointly herewith and which
are hereby incorporated by reference. Note that the analyzer 14
will be considered to be at the correct angle A when the
illumination not only allows for inspection of the substrate S for
defects, but also does so with a signal to noise ratio that permits
for an inspection of sufficient quality to satisfy an end user of
the system 8 that significant errors such as false positives and
missed defects do not occur in the inspection. The signal to noise
ratio of the system 8 is determined by analyzing the output of the
optical sensor 16 in a known manner.
[0044] Once the angles P and A at which the polarizer and analyzer
are positioned are known, the polarizer and analyzer are rotated
together through a series of inspection angles (step 58), keeping
the relative angle between the polarizer and analyzer (P-A)
substantially constant, to a desired angular position with respect
to the substrate S that will provide the necessary contrast between
light signals E'.sub.3 and E'.sub.4 as described above. During
rotation of the polarizer 12 and the analyzer 14, the intensity of
light incident upon the optical sensor 16 is recorded. Light
intensities at the optical sensor 16 are recorded for each of the
inspection angles or positions through which the polarizer 12 and
analyzer 14 are rotated. In one embodiment, the polarizer and
analyzer 14 are rotated in a more or less continuous manner and the
position of the polarizer and analyzer and the light intensity
present at the optical sensor 16 are recorded in small increments
of rotation of the polarizer and analyzer. Analysis of the data
obtained during rotation of the polarizer and analyzer is performed
to identify the optimal inspection angle or position for the
polarizer and analyzer with respect to the contrast between
reflected light E'.sub.3 and E'.sub.4.
[0045] The process of identifying an optimal setting for angles P
and A may be manual, wherein a user of the system 8 rotates the
polarizer 12 and analyzer 14 through a selected range of angles
while the optical sensor 16 records image data which is processed
by a computer C of a suitable type to determine the optimal angle
P-A. Alternatively, and preferably, the polarizer 12 and analyzer
14 will be automated such that the aforementioned computer can
control the rotation thereof while it records data from the optical
sensor 16 at various angles P-A. Automation of polarizers and
analyzers is well known to those skilled in the art. As suggested
above, the process of determining an optimal angle P-A angle
between the polarizer and analyzer may require multiple iterations,
both before and after the steps that are described immediately
hereinbelow. For example, once an entire calibration/set-up process
is completed, it may be useful to run the entire calibration/set-up
process multiple additional times to determine whether the
resulting system set-up is optimal.
[0046] Once the system 8 has been appropriately set up as described
in conjunction with FIG. 6, inspection for defocus defects and if
desired, other defects, may take place. First, however, the system
8 must be calibrated. Calibration is preferably carried out using a
focus exposure matrix (FEM) wafer. An FEM is a substrate on which a
number of patterns or structures have been formed, each with a
different focal position and exposure (exposure) time. An FEM is
commonly created as part of calibrating a photolithography tool for
the production of semiconductor devices. The FEM embodies
structural changes in the patterns or structures formed on the
substrate S that result from changes in focal position and
exposure. Defocus and exposure data obtained from the FEM is used
as a comparator during inspection of substrate S. Note that the
patterns formed on the FEM may be different than those formed on
the substrates S under test, but are preferably the same.
[0047] As the method of obtaining defocus data is substantially the
same for calibration purposes as it is for inspection purposes, the
method of obtaining defocus data for calibration purposes will be
described as part of the inspection process. Differences between
calibration and inspection procedures will be noted where
appropriate.
[0048] During inspection, a substrate S of the type that is to be
inspected is obtained and placed on a wafer support or top plate
(not shown) that moves the substrate S relative to the optics of
the inspection system 8 in a known manner. Substrates S (product or
FEM) are in some embodiments inspected piecewise. In one embodiment
wherein the substrate S is a wafer on which semiconductor devices
are formed, the inspection of the substrate S is carried out on a
die level basis, that is, images of the individual die on the
substrate S are imaged by sensor 16 and those images are processed
as described hereinbelow. In other embodiments, inspection is
carried out on a field of view basis. The optics of a system 8 will
be arranged to capture images of a field of view whose size may
differ from that of an individual die or that of an individual
stepper shot. Where the field of view of a system 8 is smaller than
an individual die, multiple fields of view may be stitched together
to create composite images of individual die. The same stitching
technique may be used to form a composite image of an entire
stepper shot. It is to be understood that stitching images to form
a composite image is a technique that is well known in the art.
[0049] In other embodiments where the field of view is larger than
an individual die or larger than a stepper shot, the resulting
images may be cropped to show one or more die or stepper shots. It
is generally useful to not crop a larger image so as to include
multiple die from separate stepper shots as those die created by a
first stepper shot may be acceptable while those die created by a
second stepper shot may be defective. Cropping an image is a
technique well known to those skilled in the art.
[0050] In yet other embodiments, inspection of the substrate S is
accomplished by first capturing an image of an entire substrate S.
Where the substrate S is relatively small, this may be capture
using a system 8 operating on an area scan principle. Where the
substrate is larger than the field of view of an area scan system
8, multiple images of the substrate S may be obtained and stitched
together as suggested above. Stitching may be used in conjunction
with line scan as well as area scan type inspection systems 8 as
will be readily appreciated by those skilled in the art.
[0051] Once the appropriate polarizer/analyzer angle P-A is
obtained as described above, images of individual die on the
substrate S are captured by the optical sensor 16 (step 60). See
FIG. 7. The calibration and inspection processes described
hereinbelow will be described as taking place on a die by die
basis, though it is to be understood that other bases may be used.
The die on the substrate S that are imaged may be selected by a
user who determines that the die are sufficiently free of defects
such as chips, cracks, pits, color variation, particles or the like
to form a model. This determination is entirely up to the user of
the system 8 and can vary greatly depending on the nature and
intended use of the product on the substrate S. For example, a user
inspecting substrates S having semiconductor devices formed thereon
that are intended for use in pacemakers would likely impose very
stringent standards concerning the number of defects on a die that
is to be used for the purpose of creating a model. Conversely, a
user inspecting substrates S having identical semiconductor devices
formed thereon that are intended for use in an inexpensive and
essentially disposable consumer product would likely be willing to
accept a higher number of defects in die that are to be used for
the creation of a model. In short, it is up to the judgment of a
user of a system 8 as to what defines a `good` die for the purposes
of creating a model. While it is envisioned that images of all
`good` die on a substrate S may be obtained for the purpose of
creating a model, it is typically the case that only a
statistically significant number of `good` die; this number is
generally less than the total number of `good` die and may be on
the order of about 10-15. At a minimum, die having no more than a
modest number of random, relatively unobtrusive defects should be
chosen as small, random defects will not likely not have a
significant effect on inspection if a statistically significant
sample of such die are sampled, it being understood that large,
non-random defects will be more likely to skew an inspection
process.
[0052] Automated methods may also be used to obtain a useful model.
For example, a computer C that controls the system 8 may randomly
select a statistically significant number of die and capture images
thereof. These images are then used to form a model which is used
to inspect the individual images that formed the model. Where a
selected die is found to be defective under the user-selected
criteria, the defective image will be replaced by an image of
another randomly selected die. This process will be iterated until
a suitable model is created. Note that models created manually or
automatically may remain static, i.e. will not change over time, or
may be modified over time by adding new, good die to the model as
inspection progresses.
[0053] As the term "model" may have different meanings to different
persons of skill in the art, it should be made clear that as used
herein, the terms "golden die" or "golden reference" are used to
describe an image whose constituent pixels have intensity values
obtained by summing the corresponding pixel values of a number of
die and obtaining an average of those values. Accordingly, the
golden die is simply an image of averaged die. The term "model" is
broader than the terms "golden die" or "golden reference" and in
some instances, will not incorporate or use golden die or golden
reference information.
[0054] A golden die is used in one embodiment of defocus inspection
(step 62). Similarly, golden die may form at least part of the
basis for a model used in macro defect inspection. Generally,
however, models used in macro defect inspection move beyond a
simple golden die by defining pixel intensity thresholds for each
pixel in an image. In macro defect inspection, if, upon evaluation,
pixel intensity values are found to fall outside of the range
defined by the thresholds, those pixels are deemed to be defective.
The thresholds themselves may be as simple as a standard deviation
calculated from a golden die, but more often include weighting
factors that take into consideration various features, variations
and characteristics of a substrate S and the user defined criteria
that apply to the product formed thereon. It is to be understood
that models used for defect inspection may be formed in myriad ways
and may or may not be based on a golden die in any way, the only
requirement for macro defect inspection models being that the
resulting inspection yields results that are satisfactory to the
user of the system 8. Where macro defect inspection is to be
carried out, a suitable model for such inspection may be obtained
(step 64) at more or less the same time that a golden die is
generated. As indicated by arrow 65, the formation of a model may
in some instances use golden die information. Once a model has been
created, subsequently captured images are compared with the model
to identify defects (step 72).
[0055] The golden die image obtained in the previous step is used
to remove the background of images captured during inspection for
defocus defects, resulting in what is referred to as a differential
image (step 66). The differential image consists of the differences
between individual corresponding pixel values of the golden die
image and an image of a die under inspection. The pixel intensity
values that make up the differential image, which can be positive,
negative or zero, are summed and averaged over the entire
differential image (step 68). The resulting averaged values are
then compared with similar averages obtained from inspecting an FEM
to determine whether the averaged values cross a predetermined
threshold set by a user of the system. In some embodiments it is
possible that FEM-derived differential image average values may be
directly compared with inspection derived differential image
average values to determine whether an unacceptable level of
defocus defects are present in a die.
[0056] As is understood by those skilled in the art, the polarizer
12 and analyzer 14 may be arranged angularly with respect to one
another so as to prevent the passage of substantially all light or
to permit the passage of substantially all light. In one embodiment
of the present disclosure, the polarizer 12 and analyzer 14 are
arranged angularly with respect to one another so as to prevent the
passage of substantially all light E.sub.1 and E.sub.2
therethrough. In this embodiment, and where the substrate S did not
affect the polarization state of the reflected light, the optical
sensor 16 would register substantially no image. However, since the
presence of features that modify polarity are generally present on
the substrate S and because at least some degree of defocus defects
are typically present, light E.sub.3 and E.sub.4 will be incident
upon the optical sensor 16.
[0057] The angular positioning of the polarizer 12 with respect to
the analyzer 14 will most often depend on the nature of the
substrate S being inspected, though other factors may be used,
including, but not limited to the nature of the light source 12,
physical properties of the optical system and the like. In one
embodiment, the polarization angle of the polarizer 12 is about
45.degree. to the linear structures present on the substrate S
being inspected. Accordingly, it is to be recognized that in some
embodiments, the polarization angle of the analyzer 14 may vary
depending on the nature of the substrate being inspected.
[0058] In some embodiments, a multiple scan inspection will be used
to determine the presence of defects on a substrate S. In one
embodiment, a first pass is undertaken with the polarizer 12 and
analyzer 14 in a setting that passes insufficient light for macro
defect inspection. This first pass is intended only to determining
whether defocus or exposure defects exist in the imaged area of the
substrate, generally one or more die or stepper shots. A second
pass involves finding macro defects such as chips, cracks,
particles, voids and scratches and is undertaken with the polarizer
12 and analyzer 14 arranged in a manner that allows a greater
amount of light to pass therethrough.
[0059] In another embodiment, the system 8 may be used to detect
changes in the thickness of, or the presence of, thin films on a
substrate. In some instances, unwanted residual films will remain
on all or portions of a substrate S after a processing step. Where
properly arranged, differential images of a substrate 8 will
identify the location and extent of residual films.
CONCLUSION
[0060] Although specific embodiments of the present disclosure have
been illustrated and described herein, it will be appreciated by
those of ordinary skill in the art that any arrangement that is
calculated to achieve the same purpose may be substituted for the
specific embodiments shown. Many adaptations will be apparent to
those of ordinary skill in the art. Accordingly, this application
is intended to cover any adaptations or variations. It is
manifestly intended that this disclosure be limited only by the
following claims and equivalents thereof.
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