Defect inspection apparatus and method

A defect inspection apparatus is disclosed that includes a stage, a photosensitive element, and a controller. The stage can support a semiconductor element that has a plurality of complete dies and partial dies surrounding the complete dies. The photosensitive element is located above the stage. The controller is electrically connected to the photosensitive element to drive the photosensitive element to inspect the defects of the complete dies and the partial dies.

FIELD

The present disclosure relates to a defect inspection apparatus and a defect inspection method.

BACKGROUND

With the development of science and technology, there are a wide variety of electric products provided in the consumer market. Therefore, different sizes of semiconductor elements are required for the electrical products.

When a wafer includes large dies or slender dies, there are partial dies (i.e., incomplete dies) surrounding complete dies formed at the edge of the wafer. However, since conventional defect scan tools can only focus on the complete dies of the wafer, additional devices, such as optical microscope (OM) and scanning electron microscope (SEM), are required to check if defects exist in the partial dies.

As result, if the wafers suffer from vibrations in the process, the conventional defect scan tools only can inspect the defect and collect defect information of the complete dies without the defect information of the partial dies at the same time. Technicians need to spend much more time confirming that the partial die area is defect free through the additional devices.

DETAILED DESCRIPTION

In the following description, specific details are presented to provide a thorough understanding of the embodiments of the present disclosure. Persons of ordinary skill in the art will recognize, however, that the present disclosure can be practiced without one or more of the specific details, or in combination with other components. Well-known implementations or operations are not shown or described in detail to avoid obscuring aspects of various embodiments of the present disclosure.

Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, implementation, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, uses of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, implementation, or characteristics may be combined in any suitable manner in one or more embodiments.

FIG. 1illustrates a perspective view of a defect inspection apparatus100in accordance with some embodiments of the present disclosure.FIG. 2illustrates a block diagram of the defect inspection apparatus100connected to a previous process tool210illustrated inFIG. 1. As illustrated inFIG. 1andFIG. 2, the defect inspection apparatus100includes a stage110, a photosensitive element120, and a controller130. The stage110can support a semiconductor element300, such as a wafer, but not limited in the present disclosure.

The photosensitive element120is located above the stage110, and may include a charge coupled device (CCD) camera. The controller130is electrically connected to the photosensitive element120. In operation, the controller130drives the photosensitive element120to inspect the defects of the semiconductor element300.

FIG. 3is a top view of the semiconductor element300when being inspected by the photosensitive element120shown inFIG. 1. As shown inFIG. 2andFIG. 3, the semiconductor element300has a plurality of complete dies312and partial dies314(i.e., incomplete dies), and the complete dies312are large dies. The partial dies314are at the edge portion of the semiconductor element300and thus surround the complete dies312. The controller130can drive the photosensitive element120to inspect the defects of the complete dies312and the defects of the partial dies314.

In some embodiments, the controller130includes a first driving module132and a second driving module134. The first and second driving modules132,134are electrically connected to the photosensitive element120. In operation, the first driving module132drives the photosensitive element120to inspect the defects of the complete dies312. Moreover, the second driving module134drives the photosensitive element120to inspect the defects of the partial dies314.

When the photosensitive element120inspects the semiconductor element300, the photosensitive element120may position an inspection area A1 on a portion of the complete dies312and a portion of the partial dies314. In some embodiments, the defect inspection apparatus100further includes a moving device125(seeFIG. 1andFIG. 2). The moving device125is connected to the photosensitive element120and electrically connected to the controller130. In operation, the controller130can drive the moving device125to move the photosensitive element120over the semiconductor element300in directions X, Y.

Moreover, the defect inspection apparatus100may further include an inspection setting device140. The inspection setting device140is electrically connected to the first and second driving modules132,134of the controller130. Users can choose a function on the inspection setting device140to inspect the defects of the complete dies312, the defects of the partial dies314, or the combinations thereof, such that an inspection signal may be sent to the photosensitive element120.

FIG. 4is a partial enlarged view of the semiconductor element300within the inspection area A1 of the photosensitive element120shown inFIG. 3. The inspection area A1 may be smaller than the semiconductor element300, but the present disclosure is not limited in this regard. However, referring toFIG. 1andFIG. 3, the inspection area A1 on the semiconductor element300can move along with the photosensitive element120, such that the defects of the complete dies312and the defects of the partial dies314can be scanned by the inspection area A1 of the photosensitive element300.

It is to be noted that the connection relationships of the elements described above will not be repeated in the following description.

FIG. 5is a top view of another semiconductor element300′ when being inspected by the photosensitive element120shown inFIG. 1.FIG. 6is a partial enlarged view of the semiconductor element300′ within an inspection area A2 of the photosensitive element120shown inFIG. 5. As shown inFIG. 5andFIG. 6, the semiconductor element300′ has a plurality of complete dies312′ and partial dies314′. The partial dies314′ surrounds the complete dies312′. That is to say, the partial dies314′ are at the edge portion of the semiconductor element300′.

The photosensitive element120(seeFIG. 1) may position the inspection area A2 on a portion of the complete dies312′ and a portion of the partial dies314′. The difference between this embodiment and the embodiment shown inFIG. 3andFIG. 4is that the complete dies312′ are slender dies.

As shown inFIG. 2andFIG. 5, the controller130can drive the photosensitive element120to inspect the defects of the complete dies312′ and the defects of the partial dies314′. In operation, the first driving module132electrically connected to the photosensitive element120drives the photosensitive element120to inspect the defects of the complete dies312′, and the second driving module134electrically connected to the photosensitive element120drives the photosensitive element120to inspect the defects of the partial dies314′.

When the photosensitive element120inspects the semiconductor element300′, the photosensitive element120may position an inspection area A2 on a portion of the complete dies312′ and a portion of the partial dies314′. Users can choose a function on the inspection setting device140to inspect the defects of the complete dies312′, the defects of the partial dies314′, or the combinations thereof, such that an inspection signal may be sent to the photosensitive element120.

As shown inFIG. 1andFIG. 5, the inspection area A2 may be smaller than the semiconductor element300′, but the present disclosure is not limited in this regard. However, the inspection area A2 on the semiconductor element300′ can move along with the photosensitive element120, such that the defects of the complete dies312′ and the defects of the partial dies314′ can be scanned by the inspection area A2 of the photosensitive element300.

FIG. 7is a schematic view of a data analysis device150when displaying a defect information shown inFIG. 2. As shown inFIG. 2andFIG. 7, the defect inspection apparatus100further includes the data analysis device150and a feedforward device160. The data analysis device150is electrically connected to the photosensitive element120, and the feedforward device160is electrically connected to the data analysis device150and a previous process tool210. Before the defect inspection apparatus100inspects the semiconductor element300(seeFIG. 1), the previous process tool210applies a treatment to the semiconductor element300. For example, the previous process tool210may be a CVD (chemical vapor deposition) equipment, a PVD (physical vapor deposition) equipment, or a CMP (chemical mechanical planarization) equipment.

After the photosensitive element120inspects the semiconductor element300, a defect information of the complete dies312and the partial dies314is received from the photosensitive element120. Thereafter, the data analysis device150analyzes the distribution of the defects316of the complete dies312and the partial dies314and displays a defect distribution graph of the defect information on the monitor thereof.

Furthermore, the data analysis device150can determine whether the defect information is in-spec or out-spec defined by users. When the defect information is in-spec, the data analysis device150may send a release signal to the controller130to release the semiconductor element300to a next process step. The defect information is in-spec means that the previous process tool210is under a normal operation. The data analysis device150may send a running signal to the previous process tool210, such that the previous process tool210keeps running. As a result, the previous process tool210can keep applying a treatment to other semiconductor elements300.

On the other hand, the defect information is out-spec means that the previous process tool210is under an error operation, such as the occurrence of hardware problems or process parameter problems of the previous process tool210. In some embodiments, the data analysis device150may send a stop signal to the previous process tool210, such that the previous process tool210stops running. As a result, the previous process tool210can stop applying a treatment to other semiconductor elements300. At this moment, users can check the hardware or process parameter problems of the previous process tool210.

In some embodiments, the data analysis device150does not send the stop signal to the previous process tool210, but sends a compensation value to the previous process tool210. The compensation value is formed in accordance with the defect information. As a result, the previous process tool210can tune process parameters in accordance with the compensation value that is sent from the data analysis device150. For example, the process parameters may include exposure energy, etching rate, polish time, and EBR (edge bead removal) range. After the process parameters are modified, the previous process tool210can recover to run product.

Referring back toFIG. 2andFIG. 3, the defect inspection apparatus100can inspect the complete and partial dies312,314of the semiconductor element300. Therefore, additional devices (e.g., OM or SEM) are not required to use to check the defects of the partial dies314. When the processes for manufacturing the semiconductor element300have vibrations, the defect inspection apparatus100can inspect the defects of the complete dies312and the partial dies314at the same time. As a result, the time for confirming the partial die area through additional devices may be reduced.

FIG. 8is a perspective view of a defect inspection apparatus100′ in accordance with some embodiments of the present disclosure.FIG. 9is a block diagram of the defect inspection apparatus100′ connected to the previous process tool210shown inFIG. 8. As shown inFIG. 8andFIG. 9, the defect inspection apparatus100′ includes the stage110, the photosensitive element120, the moving device125, the controller130, the inspection setting device140, the data analysis device150, and the feedforward device160.

The difference between this embodiment and the embodiment shown inFIG. 2is that the moving device125is electrically connected between the photosensitive element120and the controller130, such that the controller130can obtain the position information of the photosensitive element120through the moving device125.

The stage110can support the semiconductor element300, such as a wafer. The photosensitive element120is located above the stage110, and may include a charge coupled device (CCD) camera. The controller130is electrically connected to the photosensitive element120. In operation, the controller130drives the photosensitive element120to inspect the defects of the semiconductor element300.

As shown inFIG. 3andFIG. 9, the controller130can drive the photosensitive element120to inspect the defects of the complete dies312and the defects of the partial dies314. The controller130includes the first driving module132and the second driving module134. The first and second driving modules132,134are electrically connected to the photosensitive element120through the moving device125. In operation, the first driving module132drives the photosensitive element120to inspect the defects of the complete dies312, and the second driving module134drives the photosensitive element120to inspect the defects of the partial dies314.

When the photosensitive element120inspects the semiconductor element300, the photosensitive element120may position an inspection area A1 on a portion of the complete dies312and a portion of the partial dies314. The inspection area A1 on the semiconductor element300can move along with the photosensitive element120, such that the defects of the complete dies312and the defects of the partial dies314can be scanned by the inspection area A1 of the photosensitive element300.

The inspection setting device140is electrically connected to the first and second driving modules132,134of the controller130. Users can choose a function on the inspection setting device140to inspect the defects of the complete dies312, the defects of the partial dies314, or the combinations thereof, such that an inspection signal may be sent to the photosensitive element120.

FIG. 10is a flow chart of a defect inspection method in accordance with some embodiments of the present disclosure. As shown inFIG. 10, the defect inspection method includes the operations below. In step S1, a photosensitive element is positioned above a semiconductor element.

Thereafter in step S2, an inspection signal is sent to enable the photosensitive element for inspecting defects of a plurality of complete dies and partial dies of the semiconductor element. The inspection signal may be sent by an inspection setting device. Users can set a recipe in the inspection setting device for driving the photosensitive element to inspect the defects of the complete dies and the partial dies of the semiconductor element.

As a result, users can not only understand the defect contribution of the complete dies, but also understand the defect contribution of the partial dies, such that the state of previous process tools forming the defects of the complete and partial dies can be know by users.

FIG. 11is a flow chart of a defect inspection method in accordance with some embodiments of the present disclosure. As shown inFIG. 11, the defect inspection method includes the operations below. In step S1, a previous process tool applies a treatment to a semiconductor element. Next in step S2, the defects of the complete dies and the partial dies are inspected by the photosensitive element. Thereafter in step S3, the defect information of the complete dies and the partial dies obtained from the photosensitive element is received by a data analysis device. Next in step S4, the data analysis device determines whether the defect information is in-spec or out-spec.

Thereafter in step S5or S5′, if the defect information is in-spec, the semiconductor element is released to a next process step. If the defect information is out-spec, a feedforward device sends a compensation value in accordance with the defect information to the previous process tool.

Finally in step S6, the parameter of the previous process tool is tuned in accordance with the compensation value.

Compared with conventional scan tools, the defect inspection apparatus and method of the present disclosure can inspect the complete and partial dies of the semiconductor element. Therefore, additional devices (e.g., OM or SEM) are not required to use to check the defects of the partial dies. When the processes of the semiconductor element have vibrations, the defect inspection apparatus and method can inspect the defects of the complete dies and the partial dies at the same time. As a result, the time for confirming the partial die area through additional devices may be reduced.

In this document, the term “contact” is also used to indicate the term “via.”

In this document, the term “coupled” may also be termed as “electrically coupled”, and the term “connected” may be termed as “electrically connected”. “Coupled” and “connected” may also be used to indicate that two or more elements cooperate or interact with each other.

The above illustrations include exemplary operations, but the operations are not necessarily performed in the order shown. Operations may be added, replaced, changed order, and/or eliminated as appropriate, in accordance with the spirit and scope of various embodiments of the present disclosure.

In some embodiments, a defect inspection apparatus is disclosed that includes a stage, a photosensitive element, and a controller. The stage can support a semiconductor element that has a plurality of complete dies and partial dies surrounding the complete dies. The photosensitive element is disposed above the stage. The controller is electrically connected to the photosensitive element to drive the photosensitive element to inspect the defects of the complete dies and the partial dies.

Also disclosed is a defect inspection apparatus that includes a stage and a photosensitive element. The stage can support a semiconductor element that has a plurality of complete dies and partial dies surrounding the complete dies. The photosensitive element is disposed above the stage and has an inspection area. When the semiconductor element is on the stage, the inspection area is positioned on a portion of the complete dies and a portion of the partial dies.

A defect inspection method is also disclosed that includes the operations below. A semiconductor element and a photosensitive element disposed above the semiconductor element is provided. An inspection signal is sent to the photosensitive element. Defects of a plurality of complete dies and partial dies of the semiconductor element are inspected by the photosensitive element.

As is understood by one of ordinary skill in the art, the foregoing embodiments of the present disclosure are illustrative of the present disclosure rather than limiting of the present disclosure. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.