An overlay metrology tool may include an illumination source to generate a first illumination beam distribution with a first linear polarization and a second illumination beam distribution with a second linear polarization orthogonal to the first linear polarization, an illumination sub-system to sequentially illuminate two or more cell pairs of an overlay target on a sample having orthogonally oriented grating-over-grating structures, a collection sub-system with two collection channels to capture collected light from an illuminated cell pair and filtering optics to direct light from different cells in an illuminated cell pair to different collection channels for detection. The tool may further include a controller to generate separate overlay measurements for orthogonally-oriented grating-over-grating structures in the two or more cell pairs.

TECHNICAL FIELD

The present disclosure is related generally to overlay metrology and, more particularly, to scatterometry-based overlay metrology.

BACKGROUND

Overlay metrology generally refers to measurements of the relative alignment of layers on a sample such as, but not limited to, semiconductor devices. An overlay measurement, or a measurement of overlay error, typically refers to a measurement of the misalignment of fabricated features on one or more sample layers. In a general sense, proper alignment of fabricated features on multiple sample layers is necessary for proper functioning of the device. Demands to decrease feature size and increase feature density are resulting in correspondingly increased demand for accurate and efficient overlay metrology. Many existing overlay measurement techniques require separate measurement steps of multiple cells of an overlay target to generate overlay data for a particular direction and further require additional sets of measurement steps to generate overlay data for additional directions. However, the time required to perform such measurement steps may provide a limitation on the throughput of an overlay metrology system. There is therefore a need to develop systems and methods to overcome these deficiencies.

SUMMARY

An overlay metrology tool is disclosed in accordance with one or more illustrative embodiments of the present disclosure. In one illustrative embodiment, the tool includes an illumination source to generate a first illumination beam distribution with a first linear polarization and a second illumination beam distribution with a second linear polarization orthogonal to the first linear polarization. In another illustrative embodiment, the tool includes an illumination sub-system to sequentially illuminate two or more cell pairs of an overlay target on a sample. A particular one of the two or more cell pairs may include a first-direction cell with a grating-over-grating structure having periodicity along a first direction and a second-direction cell with a grating-over-grating structure having periodicity along a second direction orthogonal to the first direction. In another illustrative embodiment, the illumination sub-system simultaneously illuminates the first-direction cell with a first illumination beam distribution and the second-direction cell with a second illumination beam distribution. In another illustrative embodiment, the tool includes a collection sub-system with a first collection channel including one or more first-channel detectors at a first-channel detection plane, a second collection channel including one or more second-channel detectors at a second-channel detection plane, an objective lens to collect light from the sample as collected light, and one or more filtering optics to direct portions of the collected light associated with first-direction cells of the two or more cell pairs to the first collection channel and direct portions of the collected light associated with second-direction cells of the two or more cell pairs to the second collection channel. In another illustrative embodiment, the tool includes a controller to generate a first overlay measurement along the first direction based on data associated with the first-direction cells of the two or more cell pairs from the one or more first-channel detectors, and generate a second overlay measurement along the second direction based on data associated with the second-direction cells of the two or more cell pairs from the one or more second-channel detectors.

An overlay metrology tool is disclosed in accordance with one or more illustrative embodiments of the present disclosure. In one illustrative embodiment, the tool includes an illumination source to generate a first illumination beam distribution with a first linear polarization and a second illumination beam distribution with a second linear polarization orthogonal to the first linear polarization. In another illustrative embodiment, the tool includes an illumination sub-system to sequentially illuminate two or more cell pairs of an overlay target on a sample. A particular one of the two or more cell pairs may include a first-direction cell with a grating-over-grating structure having periodicity along a first direction and a second-direction cell with a grating-over-grating structure having periodicity along a second direction orthogonal to the first direction. In another illustrative embodiment, the illumination system includes a first illumination channel to direct a first illumination beam distribution to the first-direction cell of one of the two or more cell pairs, where the first illumination beam distribution includes one or more first illumination beams with a first linear polarization. In another illustrative embodiment, the illumination sub-system further includes a second illumination channel to direct a second illumination beam distribution to the second-direction cell of one of the two or more cell pairs simultaneously with the first illumination beam distribution, where the second illumination beam distribution includes one or more second illumination beams with a first linear polarization. In another illustrative embodiment, the tool includes a collection sub-system with a first collection channel including one or more first-channel detectors at a first-channel detection plane, a second collection channel including one or more second-channel detectors at a second-channel detection plane, an objective lens to collect light from the sample as collected light, and a polarizing beamsplitter to direct portions of the collected light associated with first-direction cells having the first linear polarization to the first collection channel and direct portions of the collected light associated with second-direction cells of the two or more cell pairs having the second linear polarization to the second collection channel. In another illustrative embodiment, the tool includes a controller to generate a first overlay measurement along the first direction based on data associated with the first-direction cells of the two or more cell pairs from the one or more first-channel detectors, and generate a second overlay measurement along the second direction based on data associated with the second-direction cells of the two or more cell pairs from the one or more second-channel detectors.

An overlay metrology method is disclosed in accordance with one or more illustrative embodiments of the present disclosure. In one illustrative embodiment, the method includes generating a first illumination beam distribution with a first linear polarization and a second illumination beam distribution with a second linear polarization orthogonal to the first linear polarization. In another illustrative embodiment, the method includes sequentially illuminating two or more cell pairs of an overlay target on a sample, where each of the two or more cell pairs includes a first-direction cell with a grating-over-grating structure having periodicity along a first direction and a second-direction cell with a grating-over-grating structure having periodicity along a second direction orthogonal to the first direction, and where the illumination sub-system simultaneously illuminates the first-direction cell with a first illumination beam distribution and the second-direction cell with a second illumination beam distribution. In another illustrative embodiment, the method includes collecting light from the sample as collected light. In another illustrative embodiment, the method includes directing portions of the collected light associated with first-direction cells of the two or more cell pairs to the first collection channel. In another illustrative embodiment, the method includes directing portions of the collected light associated with second-direction cells of the two or more cell pairs to the second collection channel. In another illustrative embodiment, the method includes generating a first overlay measurement along the first direction based on data associated with the first-direction cells of the two or more cell pairs. In another illustrative embodiment, the method includes generating a second overlay measurement along the second direction based on data associated with the second-direction cells of the two or more cell pairs.

DETAILED DESCRIPTION

Embodiments of the present disclosure are directed to systems and methods for generating parallel measurements of cells of an overlay target using scatterometry techniques. In some embodiments, two cells of an overlay target associated with overlay measurements along two different (e.g., orthogonal) directions are simultaneously illuminated, light from the two illuminated cells is simultaneously collected, and the collected light associated with the illuminated cells is directed to separate detection paths. In this way, measurements of multiple cells of an overlay target may be performed in parallel, which may beneficially increase the measurement throughput relative to sequential measurements of each cell on the target. Additional embodiments are directed to a multi-channel scatterometry overlay tool suitable for simultaneously illuminating multiple cells of an overlay target and separating the light from the multiple cells into separate detection channels.

For the purposes of the present disclosure, the term overlay is generally used to describe relative positions of features on a sample fabricated by two or more lithographic patterning steps, where the term overlay error describes a deviation of the features from a nominal arrangement. For example, a multi-layered device may include features patterned on multiple sample layers using different lithography steps for each layer, where the alignment of features between layers must typically be tightly controlled to ensure proper performance of the resulting device. Accordingly, an overlay measurement may characterize the relative positions of features on two or more of the sample layers. By way of another example, multiple lithography steps may be used to fabricate features on a single sample layer. Such techniques, commonly called double-patterning or multiple-patterning techniques, may facilitate the fabrication of highly dense features near the resolution of the lithography system. An overlay measurement in this context may characterize the relative positions of the features from the different lithography steps on this single layer. It is to be understood that examples and illustrations throughout the present disclosure relating to a particular application of overlay metrology are provided for illustrative purposes only and should not be interpreted as limiting the disclosure.

While in some applications overlay measurements may be performed directly on features of a fabricated device (e.g., device features), overlay measurements are commonly performed on dedicated overlay targets printed using the same lithography steps as the device features. In this way, the features of an overlay target (e.g., target features) may be specially designed to facilitate overlay measurements. Further, overlay measured at one fabrication step (e.g., after the fabrication of one or more sample layers) may be used to generate correctables for precisely aligning a process tool (e.g., a lithography tool, or the like) for the fabrication of an additional sample layer in a subsequent fabrication step.

In some embodiments, an overlay target suitable for scatterometry metrology as disclosed herein may include one or more cells having a grating-over-grating structure, where a grating-over-grating structure includes periodic features (e.g., grating features) on overlapping regions of two or more layers of interest. In this way, the various grating features on the layers of interest may contribute to the diffraction of incident illumination and an overlay measurement may be generated based on analysis of the diffracted light. For example, an overlay measurement may be generated based on pupil-plane data (e.g., associated with relative intensity differences between selected diffraction orders in a pupil plane). By way of another example, an overlay measurement may be generated based on field-plane data (e.g., associated with relative intensities of images of cells of the target generated with selected diffraction orders).

As used throughout the present disclosure, the term “sample” generally refers to a substrate formed of a semiconductor or non-semiconductor material (e.g., a wafer, or the like). For example, a semiconductor or non-semiconductor material may include, but is not limited to, monocrystalline silicon, gallium arsenide, and indium phosphide. A sample may include one or more layers. For example, such layers may include, but are not limited to, a resist, a dielectric material, a conductive material, and a semiconductive material. Many different types of such layers are known in the art, and the term sample as used herein is intended to encompass a sample on which all types of such layers may be formed. One or more layers formed on a sample may be patterned or unpatterned. For example, a sample may include a plurality of dies, each having repeatable patterned features. Formation and processing of such layers of material may ultimately result in completed devices. Many different types of devices may be formed on a sample, and the term sample as used herein is intended to encompass a sample on which any type of device known in the art is being fabricated. Further, for the purposes of the present disclosure, the term sample and wafer should be interpreted as interchangeable. In addition, for the purposes of the present disclosure, the terms patterning device, mask, and reticle should be interpreted as interchangeable.

In some embodiments, an overlay metrology tool simultaneously illuminates two cells of an overlay target with two illumination beams, where the two cells include grating-over-grating structures in which the orientations of the gratings in one cell are orthogonal to the orientations of the gratings in the other cell. For example, the overlay metrology tool may simultaneously illuminate an X-direction cell including a grating-over-grating structure having periodicity along an X direction with a first illumination beam and illuminate a Y-direction cell including a grating-over-grating structure having periodicity along a Y direction with a second illumination beam. It is to be understood that descriptions of X and Y directions are used herein solely for illustrative purposes to refer to arbitrary orthogonal directions on a sample. Further, the two cells may be illuminated with light having orthogonal linear polarizations (e.g., one cell is illuminated with linearly polarized light along the X direction and one cell is illuminated with linearly polarized light along the Y direction). In particular, the overlay metrology tool may illuminate each of the two cells with a distribution of one or more illumination beams (e.g., an illumination beam distribution), where the illumination beam distribution on each cell is smaller than the cell such that the cell is underfilled. Additionally, various aspects of the illuminating light on each cell such as, but not limited to, the spectrum (e.g., spectral bandwidth and/or center wavelength), intensity, illumination angle, an angular distribution of illumination, or focal position may be individually controlled or adjusted.

In some embodiments, an overlay metrology tool simultaneously separates collected light from the illuminated cells into separate detection channels for each cell. In this way, measurement data associated with the illuminated cells may be isolated from each other despite the simultaneous collection. A variety of techniques for separating the collected light into separate detection channels may be used within the spirit and scope of the present disclosure. For example, the collected light from the illuminated cells may be separated based on parameters such as, but not limited to, polarization, pupil-stop filters (e.g., spatial filters in a pupil plane to pass selected diffraction orders), or field-stop filters (e.g., spatial filters in a field plane to pass light from a selected cell).

In some embodiments, an overlay metrology tool includes beam control optics in illumination and/or collection paths to control various aspects of the illumination light or collected light. For example, the overlay metrology tool may include one or more scan mirrors to scan the illumination beams across the respective cells during a measurement, which may reduce noise associated with target imperfections. By way of another example, the overlay metrology tool may include beam control optics to control or adjust the separation between the two illumination beams, which may be used to match the illumination beam separation to the layout of the cells in a particular overlay target. Further, the overlay metrology tool may adjust illumination and/or collection field stops based on a selected illumination beam separation.

Additional embodiments of the present disclosure are directed to overlay targets suitable for parallel measurements by an overlay metrology tool. In some embodiments, an overlay target includes X-direction cells distributed along a first row and Y-direction cells distributed along a second row. In this way, cells associated with a particular direction may be illuminated sequentially with the same or similar illumination conditions (e.g., polarization, spectrum, intensity, angular distribution of illumination, focal position of the sample during illumination, or the like) simply by scanning the overlay target along the rows. For example, some overlay measurement techniques may require data capture from multiple cells with different intended offsets of the grating-over-grating structures. Accordingly, arranging the cells with common directions of periodicity along rows may reduce the burden on the overlay metrology tool such that illumination conditions may be the same or substantially the same as the target is scanned along the row direction.

Referring now toFIGS.1A-4, systems and methods for generating parallel measurements of cells of an overlay target using scatterometry techniques.

FIG.1Ais a block diagram view of an overlay metrology system100, in accordance with one or more embodiments of the present disclosure.

In some embodiments, the overlay metrology system100includes an overlay metrology tool102with a dual-channel illumination sub-system104to separately illuminate two cells106of an overlay target108on a sample110with spatially-separated distributions of one or more illumination beams112(e.g., illumination beam distributions) having orthogonal linear polarizations and a dual-channel collection sub-system114to separately detect light or other radiation emanating from the sample110(e.g., collected light116) associated with the two cells106.

In some embodiments, the sample110is disposed on a sample stage118suitable for securing the sample110and further configured to position the sample110with respect to the overlay metrology tool102. For example, the sample stage118may include any combination of linear, rotational, or angular (e.g., tip/tilt) actuators suitable for positioning the sample110in any selected orientation.

The overlay metrology tool102may be any type of overlay metrology tool known in the art suitable for generating overlay signals suitable for determining overlay associated with overlay targets on a sample110. For example, the overlay metrology tool102may collect pupil-plane data (e.g., one or more pupil-plane images or portions thereof) in which collected light116is analyzed at a pupil plane to characterize an angular distribution of radiation from the cells106(e.g., associated with scattering and/or diffraction of radiation by the cells106). By way of another example, the overlay metrology tool102may collect field-plane data (e.g., one or more field-plane images or portions thereof) based on selected diffraction orders from the cells106. Additionally, the overlay metrology tool102may characterize the cells106while the sample110is static (e.g., in a static or move-and-measure (MAM) mode) or while the sample110is in motion (e.g., in a scanning mode).

Referring now toFIGS.2A-2B, various configurations of an overlay target108suitable for parallel characterization of constituent cells106are described in greater detail in accordance with one or more embodiments of the present disclosure.

FIG.2Ais a side view of a grating-over-grating structure in a single cell106of an overlay target108, in accordance with one or more embodiments of the present disclosure. In some embodiments, a grating-over-grating structure in each cell106includes first-layer grating features202located on a first layer204of the sample110and second-layer grating features206located on a second layer208of the sample110oriented such that the regions including the first-layer grating features202and the second-layer grating features206overlap. In this way, the first-layer grating features202and the second-layer grating features206may each diffract incident illumination beams112into discrete diffraction orders. In general, any number of additional layers, not shown, may be located above, below, or between the first layer204, the second layer208, and a substrate210.

In a general sense, the first-layer grating features202and the second-layer grating features206may have the same or different distributions and may be intentionally offset from each other by any selected intended offset212. In some embodiments, the first-layer grating features202and the second-layer grating features206have the same pitch along the same direction such that the associated diffraction orders overlap in a pupil plane. In some embodiments, the first-layer grating features202and the second-layer grating features206have different pitches along a particular direction, which may result in Moiré fringes associated with a Moiré pitch larger than the pitches of the first-layer grating features202and the second-layer grating features206. Overlay metrology techniques utilizing Moiré effects are generally described in U.S. Pat. No. 9,182,219 issued on Nov. 10, 2015, U.S. Pat. No. 7,440,105 issued on Oct. 21, 2008, U.S. Pat. No. 7,349,105 issued on Mar. 25, 2008, U.S. Pat. No. 10,551,749 issued on Feb. 4, 2020, U.S. Patent Publication 2021/0072650 published on Mar. 11, 2021, U.S. patent application Ser. No. 16/935,117 filed on Jul. 21, 2020, and U.S. patent application Ser. No. 16/931,078 filed on Jul. 16, 2020, which are all incorporated herein by reference in their entirety.

FIG.2Bis a top view of an overlay target108, in accordance with one or more embodiments of the present disclosure. In some embodiments, an overlay target108includes two or more cells106associated with each measurement direction of interest. For example, different cells106associated with a particular measurement direction may include grating-over-grating structures with different intended offsets212.

FIG.2Billustrates an overlay target108having two cells106with periodicity along the X direction (e.g., X-direction cells106) for overlay measurements along the X direction and two cells106with periodicity along the Y direction (e.g., Y-direction cells106) for overlay measurements along the Y direction. The various cells106may generally be arranged in any suitable distribution. In some embodiments, as illustrated inFIG.2B, cells106with the same direction of periodicity are distributed in rows. For example,FIG.2Billustrates X-direction cells106along a first row214and Y-direction106cells along a second row216. As will be described in greater detail below, this configuration may facilitate efficient sequential illumination of cells106having the same direction of periodicity with the same or similar illumination conditions.

It is to be understood, however, that the overlay target108inFIGS.2A-2Band the associated description are provided solely for illustrative purposes and should not be interpreted as limiting. Rather, the overlay target108may include any suitable grating-over-grating overlay target design. For example, the overlay target108may generally include any number of cells106suitable for measurements along two directions. Further, the cells106may be distributed in any pattern or arrangement. For example, metrology target designs suitable for scanning metrology are generally described in U.S. patent application Ser. No. 16/598,146 filed on Oct. 10, 2019, which is incorporated herein by reference in its entirety.

Referring now generally toFIGS.1A-3B, parallel characterization of multiple cells106of an overlay target108is described in greater detail, in accordance with one or more embodiments of the present disclosure.

FIG.1Bis a schematic view of the overlay metrology tool102illustrating two illumination channels120and two collection channels122, in accordance with one or more embodiments of the present disclosure. In this way, the overlay metrology tool102may simultaneously characterize two cells106of an overlay target108such as, but not limited to, the overlay target108illustrated inFIGS.2A-2B. In some embodiments, the overlay metrology tool102simultaneously characterizes two cells106with orthogonal directions of periodicity (e.g., one X-direction cell106and one Y-direction cell106).

In some embodiments, the overlay metrology tool102includes at least one illumination source124configured to generate illumination126suitable for forming the illumination beam distributions to be directed to the cells106.

The illumination126from the illumination source124may include one or more selected wavelengths of light including, but not limited to, ultraviolet (UV) radiation, visible radiation, or infrared (IR) radiation.

The illumination source124may include any type of illumination source known in the art. In some embodiments, the illumination source124is a laser source. For example, the illumination source124may include, but is not limited to, one or more narrowband laser sources, a broadband laser source, a supercontinuum laser source, a white light laser source, or the like. In this regard, the illumination source124may provide illumination having high coherence (e.g., high spatial coherence and/or temporal coherence). In some embodiments, the illumination source124includes a laser-sustained plasma (LSP) source. For example, the illumination source124may include, but is not limited to, an LSP lamp, an LSP bulb, or an LSP chamber suitable for containing one or more elements that, when excited by a laser source into a plasma state, may emit broadband illumination. In some embodiments, the illumination source124includes a lamp source. For example, the illumination source124may include, but is not limited to, an arc lamp, a discharge lamp, an electrode-less lamp, or the like. In this regard, the illumination source124may provide illumination having low coherence (e.g., low spatial coherence and/or temporal coherence).

Each illumination channel120may direct a distribution of one or more illumination beams112(e.g., an illumination beam distribution) to a particular location on the sample110. An illumination beam distribution may generally include one or more illumination beams112or illumination lobes directed to a particular cell106with a selected distribution of illumination parameters such as, but not limited to, incidence angles (e.g., azimuth and polar incidence angles), spectra, or polarizations. For example, an illumination beam distribution may include, but is not limited to, a single illumination beam112at a selected incidence angle, a dipole distribution of illumination beams112, or a quadrupole distribution of illumination beams112. In this way, the illumination channels120may simultaneously provide different illumination conditions for different cells106on the overlay target108. Further, in cases where an illumination beam distribution includes multiple illumination beams112, these illumination beams112may be provided simultaneously or sequentially in a given measurement of a cell106.

In some embodiments, the illumination channels120provide illumination beams112with orthogonal linear polarizations. For example, one illumination channel120may provide a distribution of one or more illumination beams112with a linear polarization along a first direction (e.g., an X direction) and another illumination channel120may provide a distribution of one or more illumination beams112with a linear polarization along a second direction orthogonal to the first direction (e.g., a Y direction). It is contemplated herein that providing orthogonal linear polarizations in the illumination channels120may have various benefits such as, but not limited to, efficiently utilizing available power from the illumination source124, providing well-controlled diffraction by the grating-over-grating structures in each cell106, and/or facilitating the separation of the collected light146of the illuminated cells106into different collection channels122with a high extinction ratio to prevent cross-contamination of the signals.

Further, the various cells106of the overlay target108may be illuminated with any selected polarization direction. For example, the overlay metrology tool102may illuminate an X-direction cell106with linearly polarized light along the X direction and a Y-direction cell106with linearly polarized light along the Y direction, or vice versa.

The overlay metrology tool102may generally include any combination of optical components to simultaneously generate multiple illumination beam distributions.

In some embodiments, the overlay metrology tool102may include a single illumination source124to generate illumination126for each illumination channel120. For example, the overlay metrology tool102may include a polarizing beamsplitter to split the illumination126into orthogonal linear polarizations directed to different illumination channels120. In some embodiments, the overlay metrology tool102includes a separate illumination source124for one or more of the illumination channels120.

The overlay metrology tool102may further include various optical components to generate selected illumination beam distributions for each illumination channel120. In some embodiments, as illustrated inFIG.1B, each illumination channel120may include, one or more illumination lenses128or one or more illumination control optics130to control various illumination parameters. For example, the illumination control optics130may include, but are not limited to, one or more field stops or filters, one or more pupil stops or filters, one or more polarizers, one or more spectral filters, one or more spatial filters, one or more beam splitters, one or more diffusers, one or more homogenizers, one or more apodizers, one or more beam shapers, or one or more mirrors (e.g., static mirrors, translatable mirrors, scanning mirrors, or the like). As an illustration, each illumination channel120may include an aperture stop to generate a distribution of one or more illumination beams112and/or a field stop to limit a spatial extent of the illumination beams112in that channel to an area equal to or smaller than a cell106such that the cell is underfilled with illumination.

In a general sense, each illumination channel120may provide independent control of the illumination parameters of one or more illumination beams112. In some embodiments, though not explicitly shown inFIG.1B, the overlay metrology tool102may include illumination lenses128and/or illumination control optics130to manipulate the illumination126prior to entering the illumination channels120. In this way, selected aspects of the illumination beam distributions may be consistent between the illumination channels120.

Further, the illumination parameters in each illumination channel120may be static or tunable. Tunable illumination parameters may be provided using any technique known in the art. The generation of tunable illumination parameters is generally described in U.S. Pat. No. 10,371,626 issued on Aug. 6, 2019 and U.S. patent application Ser. No. 17/076,312 filed on Oct. 21, 2020, both of which are incorporated herein by reference in their entirety.

In some embodiments, tunable illumination parameters are provided by selectively directing illumination126to one of multiple available optical paths having one or more static filters (e.g., spectral filters, neutral density filters, or the like). In some embodiments, tunable illumination parameters are provided by adjusting positions of one or more tunable filters (e.g., spectral filters, neutral density filters, or the like) in an illumination channel120. In some embodiments, tunable illumination parameters are provided by selectively controlling a position of illumination126from the illumination source124on one or more spatially-varying filters (e.g., spectral filters, neutral density filters, or the like).

FIG.1Cis a schematic view of a portion of the overlay metrology tool102illustrating two illumination channels120with separately configurable illumination conditions based on linearly-varying filters, in accordance with one or more embodiments of the present disclosure. Linearly-varying filters may include filters having filtering properties that vary along a linear filtering direction. For example, a linearly-varying neutral density filter may provide varying amounts of broadband intensity reduction based on spatial position of an input beam along the linear axis. By way of another example, a linearly-varying low-pass (or high-pass) filter may provide low-pass filtering with a cutoff wavelength that varies based on the spatial position of the input beam along the linear filtering direction. By way of another example, a linearly-varying filter may be formed as a polarizer, where the direction of polarization passed by the linearly-varying filter may differ at different directions along the linear filtering direction. It is contemplated that the systems and methods disclosed herein may utilize linearly-varying filters that modify any selected property of an input beam.

In some embodiments, the overlay metrology tool102includes an illumination source124with a spectral bandwidth covering a range of wavelengths of interest and a polarizer132to split illumination126from the illumination source124along two paths associated with two illumination channels120. For example, the polarizer132may be a polarizing beamsplitter to provide orthogonal linear polarizations in the two illumination channels120.

Each illumination channel120may include at least one tunable filter134providing tunable control of one or more illumination parameters. In some embodiments, a tunable filter134includes a pair of focusing optics136in a 4-f configuration, a linearly-varying filter138located at a pupil plane (e.g., a focal plane common to the focusing optics136), and angular scanners140located at the other focal planes of the focusing optics136as input and/or output couplers to the tunable filter134. In this way, the position of illumination126on the linearly-varying filter138, and thus the resulting filtering effect on the illumination126, may be controlled by adjusting an angle of an input angular scanner140to receive illumination126. Further, regardless of the angle of the input angular scanner140and the associated position on the linearly-varying filter138, the illumination126will be redirected to a common location on an output tunable filter134, which may direct the filtered illumination126along any desired optical path. For example, the input and output angular scanners140may be adjusted simultaneously to provide tunable filtering without modifying the output beam path and thus without impacting the alignment of additional optics of the overlay metrology system100.

Further, multiple tunable filters134may be arranged in series to provide tuning of multiple illumination parameters. For example,FIG.1Cillustrates three tunable filters134in each illumination channel120. Such a configuration may be suitable for, but is not limited to, adjusting the intensity and spectrum of the illumination126within each illumination channel120. For instance, one linearly-varying filter138may be a linearly-varying intensity filter, one linearly-varying filter138may be a linearly-varying low-pass spectral filter, and one linearly-varying filter138may be a linearly-varying high-pass spectral filter.

In some embodiments, the overlay metrology tool102includes one or more focus-control optics142to adjust or control a focal position of one or more illumination beams112in one or more illumination channels120. It is contemplated herein that focal position adjustments may be particularly useful for, but not limited to, measurements with different wavelengths or measurements of features at different depths. For example, illumination beams112in different illumination channels120may have different spectral ranges. By way of another example, measurement robustness may be improved by capturing data from each cell106at multiple different wavelengths. In either case, chromatic aberrations in the sample110and/or the overlay metrology system100may result in different focusing or imaging conditions at different wavelengths such that focal correction in one or more illumination channels120may be required.

As an illustration,FIG.1Bincludes focus-control optics142in each of the illumination channels120to provide independent focus control for the associated illumination beams112. The focus-control optics142may include any type or combination of optical elements suitable for modifying a focal position of at least one illumination beam112such as, but not limited to, one or more deformable mirrors, one or more acousto-optic lenses, one or more voice coils, or one or more translatable lenses (e.g., any of the illumination lenses128). In some embodiments, the focus-control optics142may be designed to provide focus switching within a time required to tune one or more additional illumination parameters (e.g., spectrum, intensity, angular distribution of illumination, or the like) to facilitate high measurement throughput. In this way, the focus-control optics142may operate as fast focus controllers.

Referring again toFIGS.1A-1C, the overlay metrology tool102may generate or otherwise control the illumination beam distributions (e.g., the number and incidence angles of the constituent illumination beams112) using any technique known in the art.

In some embodiments, the overlay metrology system100includes one or more apertures (e.g., illumination control optics130) at an illumination pupil plane to define one or more illumination beams112. In some embodiments, the overlay metrology system100generates illumination beams112by providing light in two or more optical fibers, where light output from each optical fiber provided at or directed to an illumination pupil to provide an illumination beam112. In some embodiments, the overlay metrology system100generates one or more illumination beams112by diffracting illumination126from the illumination source124into two or more diffraction orders, where at least one of the diffraction orders forms at least one illumination beam112. Efficient generation of multiple illumination beams through controlled diffraction is generally described in U.S. Patent Publication US2020/0124408 published on Apr. 23, 2020, which is incorporated herein by reference in its entirety.

In some embodiments, the overlay metrology tool102includes an objective lens144to capture light or other radiation emanating from both illuminated cells106(e.g., collected light146). Further, an illumination beam112from any illumination channel120may generally be directed to the sample110through the objective lens144(e.g., in a through-the-lens (TTL) configuration) or outside a numerical aperture of the objective lens144(e.g., in an outside-the-lens (OTL) configuration). For example,FIG.1Billustrates a TTL configuration.

In some embodiments, the overlay metrology tool102includes one or more filtering optics to separate the collected light146from the two illuminated cells106into different collection channels122. For example, the filtering optics may selectively direct portions of the collected light116associated with the X-direction cell106to one collection channel122and collected light116associated with the Y-direction cell106to another collection channel122.

The one or more filtering optics may separate the collected light116associated with the two illuminated cells106using any technique or combination of techniques including, but not limited to, polarization filtering, pupil-plane filtering, or field-plane filtering.

In some embodiments, the filtering optics include one or more polarization filters such as, but not limited to, one or more linear polarizers or one or more polarizing beamsplitters to implement polarization filtering. It is contemplated herein that polarization filtering may be particularly effective when the illumination channels120provide illumination beam distributions with orthogonal linear polarizations since the collected light116may generally retain the polarization direction of the illumination.

For example, as illustrated inFIG.1B, the overlay metrology tool102includes a polarizing beamsplitter148in a location common to the illumination126and collected light116. In this configuration, the polarizing beamsplitter148may receive orthogonally linearly polarized illumination126from each of the illumination channels120and deliver this light to the objective lens144. This polarizing beamsplitter148may then receive the collected light116from both illuminated cells106and split this collected light116into the two collection channels122based on polarization.FIG.1Bfurther illustrates two non-polarizing beamsplitters150, one associated with each polarization direction, to separate illumination126and collected light116for that polarization direction.

By way of another example, though not explicitly shown, the overlay metrology tool102may include one or more linear polarizers in either or both of the collection channels122. For example, one collection channel122may include a linear polarizer aligned along the X direction and one collection channel122may include a linear polarizer aligned along the Y direction. In this configuration, the linear polarizers may implement polarization filtering, which may be achieved even if the illumination beam distribution does not have orthogonal linear polarizations. Further, polarizers in a collection channel122may provide a higher extinction ratio than provided by the polarizing beamsplitter148and may thus further reduce cross-talk between collected light116associated with different cells106.

In some embodiments, the filtering optics include one or more spatial filters in one or more pupil planes (e.g., pupil-plane filters). It is contemplated herein that a grating-over-grating structure will generate diffraction orders that are distributed in the direction of periodicity. Accordingly, diffraction orders from cells106having orthogonal directions of periodicity will be distributed in orthogonal directions in a pupil plane and may thus be filtered using pupil-plane filters.

FIGS.3A-3Billustrate the spatial distribution of diffraction orders from illuminated cells106of the overlay target108ofFIG.2B, in accordance with one or more embodiments of the present disclosure.FIG.3Ais a top view of a pupil plane illustrating a distribution of diffraction orders from an X-direction cell106of the overlay target108inFIG.2B, in accordance with one or more embodiments of the present disclosure. In particular,FIG.3Aillustrates 0-order diffraction302(e.g., specular reflection), X-direction −1-order diffraction304, and X-direction +1-order diffraction306within a pupil boundary308in response to a single illumination beam112at a normal incidence angle.FIG.3Bis a top view of a pupil plane illustrating a distribution of diffraction orders from a Y-direction cell106of the overlay target108inFIG.2B, in accordance with one or more embodiments of the present disclosure. In particular,FIG.3Billustrates 0-order diffraction302, Y-direction −1-order diffraction310, and Y-direction +1-order diffraction312within the pupil boundary308in response to a single illumination beam112at a normal incidence angle. As illustrated inFIGS.3A and3B, the nonzero diffraction orders from the X-direction cell106and the Y-direction cell106are non-overlapping in the pupil plane and may be isolated using pupil-plane filters. For example, one collection channel122may include a pupil-plane filter having apertures oriented to pass at least the X-direction −1-order diffraction304and X-direction +1-order diffraction306to isolate the collected light116from the illuminated X-direction cell106, and one collection channel122may include a pupil-plane filter having apertures oriented to pass at least the Y-direction −1-order diffraction310and Y-direction +1-order diffraction312to isolate the collected light116from the illuminated Y-direction cell106.

In some embodiments, the filtering optics include one or more spatial filters in one or more field planes (e.g., field-plane filters). For example,FIG.1Billustrates field stops152in each of the collection channels122. In particular, a field stop152in a collection channel122may limit a collection area in that channel to a particular cell106.

In some embodiments, each collection channel122includes one or more detectors154configured to capture collected light116in the channel. Each collection channel122may further include one or more optical elements suitable for modifying and/or conditioning the collected light146from the sample110. In some embodiments, a collection channel122includes one or more collection-pathway lenses156(e.g., to collimate illumination, to relay pupil and/or field planes, or the like), which may include, but is not required to include, the objective lens144. In some embodiments, a collection channel122includes one or more collection-pathway optics158to shape or otherwise control the collected light146. For example, the collection-pathway optics158may include, but are not limited to, one or more field stops, one or more aperture stops, one or more polarizers, one or more spectral filters, one or more intensity filters, one or more beam splitters, one or more diffusers, one or more homogenizers, one or more apodizers, one or more beam shapers, or one or more mirrors (e.g., static mirrors, translatable mirrors, scanning mirrors, or the like).

A detector154may be located at any selected location within a collection channel122. In some embodiments, the overlay metrology tool102includes a detector154at a pupil plane (e.g., a diffraction plane) to generate a pupil image. In this regard, the pupil image may correspond to an angular distribution of light from the sample110on a detector154. For instance, diffraction orders associated with diffraction from grating-over-grating structures in a cell106may be imaged or otherwise observed in the pupil plane. In a general sense, a detector154may capture any combination of reflected (or transmitted), scattered, or diffracted light from the sample110. In some embodiments, the overlay metrology tool102includes a detector154at a field plane (e.g., a plane conjugate to the sample110) to generate an image of the sample110based on selected diffraction orders from the cell106.

The overlay metrology tool102may generally include any number or type of detectors154suitable for capturing light from the sample110indicative of overlay. In some embodiments, the detector154includes one or more detectors154suitable for characterizing a static sample. In this regard, the overlay metrology tool102may operate in a static mode in which the sample110is static during a measurement. For example, a detector154may include a two-dimensional pixel array such as, but not limited to, a charge-coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) device. In this regard, the detector154may generate a two-dimensional image (e.g., a field-plane image or a pupil-plan image) in a single measurement.

In some embodiments, the detector154includes one or more detectors154suitable for characterizing a moving sample (e.g., a scanned sample). In this regard, the overlay metrology tool102may operate in a scanning mode in which the sample110is scanned with respect to a measurement field during a measurement. For example, the detector154may include a 2D pixel array with a capture time and/or a refresh rate sufficient to capture one or more images during a scan within selected image tolerances (e.g., image blur, contrast, sharpness, or the like). By way of another example, the detector154may include a line-scan detector to continuously generate an image one line of pixels at a time. By way of another example, the detector154may include a time-delay integration (TDI) detector. A TDI detector may generate a continuous image of the sample110when the motion of the sample110is synchronized to charge-transfer clock signals in the TDI detector.

In some embodiments, the overlay metrology system100includes one or more beam-scanning optics160to control a position of one or more illumination beams112(or illumination beam distributions) on the sample110. As an illustration,FIG.1Bincludes beam-scanning optics160in each illumination channel120.

It is contemplated herein that beam-scanning optics160may be utilized in a variety of ways in accordance with one or more embodiments of the present disclosure.

In some embodiments, beam-scanning optics160located in both illumination channels120may scan in a synchronous pattern to scan the respective illumination distributions across the cells106. This synchronous scanning may beneficially mitigate noise associated with imperfections of the grating-over-grating structures and/or mitigating the impact of speckle associated with coherent illumination126. It is contemplated herein, however, that such speckle may be additionally or alternately mitigated using other techniques. For example, coherent illumination126may be scanned over an input face of a multi-mode fiber, where the output of the multi-mode fiber is imaged onto the sample110. Such a multi-mode fiber may be located prior to or within any of the illumination channels120.

In some embodiments, beam-scanning optics160in one or more of the illumination channels120are used to adjust or otherwise control a separation of the associated illumination beam distributions. In this way, the illumination beam distribution from each illumination channel120may be centered on different cells106. Further, this configuration may flexibly provide measurements for targets with any selected cell separation. For example, inFIG.1B, the beam-scanning optics160may tilt in a plane of the illustration to deviate the associated illumination beam distributions on the sample110in the plane of the illustration.

It is further contemplated herein that it may be desirable to ensure that illumination126and/or collected light116is centered in any field stops to avoid asymmetric diffraction during either illumination or collection. In some embodiments, the overlay metrology system100includes one or more adjustable field stops (e.g., field stops mounted to actuators, or the like), which may be, but are not required to be, synchronized to other components. For example,FIG.1Billustrates adjustable field stops152in both the illumination channels120and the collection channels122, which may optionally be synchronized to the beam-scanning optics160. In this way, the illumination126and collected light116may remain centered in the respective stops even as the positions of the illumination beam distributions on the sample110are adjusted.

Referring again toFIG.1A, various additional components of the overlay metrology system100are described in greater detail in accordance with one or more embodiments of the present disclosure.

In some embodiments, the overlay metrology system100includes a controller162communicatively coupled to the overlay metrology tool102and/or any components therein. In some embodiments, the controller162includes one or more processors164. For example, the one or more processors164may be configured to execute a set of program instructions maintained in a memory device166, or memory. The one or more processors164of a controller162may include any processing element known in the art. In this sense, the one or more processors164may include any microprocessor-type device configured to execute algorithms and/or instructions.

The one or more processors164of a controller162may include any processor or processing element known in the art. For the purposes of the present disclosure, the term “processor” or “processing element” may be broadly defined to encompass any device having one or more processing or logic elements (e.g., one or more microprocessor devices, one or more application specific integrated circuit (ASIC) devices, one or more field programmable gate arrays (FPGAs), or one or more digital signal processors (DSPs)). In this sense, the one or more processors164may include any device configured to execute algorithms and/or instructions (e.g., program instructions stored in memory). In some embodiments, the one or more processors164may be embodied as a desktop computer, mainframe computer system, workstation, image computer, parallel processor, networked computer, or any other computer system configured to execute a program configured to operate or operate in conjunction with the overlay metrology system100, as described throughout the present disclosure. Moreover, different subsystems of the overlay metrology system100may include a processor or logic elements suitable for carrying out at least a portion of the steps described in the present disclosure. Therefore, the above description should not be interpreted as a limitation on the embodiments of the present disclosure but merely as an illustration. Further, the steps described throughout the present disclosure may be carried out by a single controller or, alternatively, multiple controllers. Additionally, the controller162may include one or more controllers housed in a common housing or within multiple housings. In this way, any controller or combination of controllers may be separately packaged as a module suitable for integration into overlay metrology system100.

The memory device166may include any storage medium known in the art suitable for storing program instructions executable by the associated one or more processors164. For example, the memory device166may include a non-transitory memory medium. By way of another example, the memory device166may include, but is not limited to, a read-only memory (ROM), a random-access memory (RAM), a magnetic or optical memory device (e.g., disk), a magnetic tape, a solid-state drive and the like. It is further noted that the memory device166may be housed in a common controller housing with the one or more processors164. In some embodiments, the memory device166may be located remotely with respect to the physical location of the one or more processors164and the controller162. For instance, the one or more processors164of the controller162may access a remote memory (e.g., server), accessible through a network (e.g., internet, intranet and the like).

The controller162may direct (e.g., through control signals) or receive data from the overlay metrology tool102or any components therein. The controller162may further be configured to perform any of the various process steps described throughout the present disclosure.

In some embodiments, the overlay metrology system100includes a user interface168communicatively coupled to the controller162. In some embodiments, the user interface168may include, but is not limited to, one or more desktops, laptops, tablets, and the like. In some embodiments, the user interface168includes a display used to display data of the overlay metrology system100to a user. The display of the user interface168may include any display known in the art. For example, the display may include, but is not limited to, a liquid crystal display (LCD), an organic light-emitting diode (OLED) based display, or a CRT display. Those skilled in the art should recognize that any display device capable of integration with a user interface168is suitable for implementation in the present disclosure. In some embodiments, a user may input selections and/or instructions responsive to data displayed to the user via a user input device of the user interface168.

Referring now toFIG.4,FIG.4is a flow diagram illustrating steps performed in a method400for overlay metrology, in accordance with one or more embodiments of the present disclosure. Applicant notes that the embodiments and enabling technologies described previously herein in the context of the overlay metrology system100should be interpreted to extend to the method400. It is further noted, however, that the method400is not limited to the architecture of the overlay metrology system100.

In some embodiments, the method400includes a step402of simultaneously illuminating a first-direction cell of a cell pair on an overlay target with a first illumination beam distribution with a first linear polarization and illuminating a second-direction cell of the cell pair with a second illumination beam distribution with a second linear polarization orthogonal to the first linear polarization. For example, an overlay target may include two or more cell pairs with grating-over-grating structures oriented in orthogonal directions as illustrated inFIGS.2A-2B.

The step402may include illuminating the first-direction and second-direction cells with any number or configuration of illumination beams, where the first and second illumination beam distributions may be separately controlled. In some embodiments, the step402may include underfilling both the first-direction and second-direction cells with the first and second illumination beam distributions. Further, the step402may include synchronously scanning the first and second illumination beam distributions across the first-direction and second-direction cells, which may mitigate target noise and/or speckle.

In some embodiments, the method400includes a step404of collecting light from the sample (e.g., the first-direction and second-direction cells) as collected light. In some embodiments, the method400includes a step406of directing portions of the collected light associated with first-direction cells of the two or more cell pairs to the first collection channel. In some embodiments, the method400includes a step408of directing portions of the collected light associated with second-direction cells of the two or more cell pairs to the second collection channel. In this way, collected light indicative of overlay for the first-direction cell and the second-direction cell may be collected in parallel. For example, step406and/or step408may be implemented using any combination of polarization filters, pupil-plane filters, or field-plane filters such as, but not limited to, those illustrated in the context of the overlay metrology system100.

In some embodiments, the method400includes a step410of generating a first overlay measurement along the first direction based on data associated with the first-direction cells of two or more cell pairs (e.g., based on repeating steps402-408for two or more cell pairs). In some embodiments, the method400includes a step412of generating a second overlay measurement along the second direction based on data associated with the second-direction cells of the two or more cell pairs.

It is contemplated herein that the method400may beneficially provide for parallel measurements of target cells with minimal or negligible cross-talk of the collected light. In this way, the method400may reduce the required number of sequential measurements of a given overlay target by a factor of two relative to techniques in which all cells are sequentially measured. Further, this throughput increase may not sacrifice the accuracy or sensitivity of the measurements.