System and method for signal processing for a workpiece surface inspection system

A surface inspection system, as well as related components and methods, are provided. The surface inspection system includes a beam source subsystem, a beam scanning subsystem, a workpiece movement subsystem, an optical collection and detection subsystem, and a processing subsystem. The signal processing subsystem comprises a series of data acquisition nodes, each dedicated to a collection detection module and a plurality of data reduction nodes, made available on a peer to peer basis to each data acquisition nodes. Improved methods for detecting signal in the presence of noise are also provided.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to technology for the inspection of a surface or surfaces of a workpiece, such as a semiconductor wafer, chip, or the like. More particularly, it relates to apparatus and methods for inspection of such workpiece surfaces using electromagnetic energy, e.g., light, to scan the surface to obtain characteristics of the surface or other information concerning the surface.

2. Description of the Related Art

There are a number of applications in which it is desirable or advantageous to inspect a surface or surfaces of a workpiece to obtain information about the characteristics and/or condition of that surface or surfaces. Examples of workpieces amenable to such application would include, for example, bare or unpatterned semiconductor wafers, semiconductor wafers with an applied film or films, patterned wafers, and the like. Characteristics and conditions of the surface that are commonly of interest include surface geometry such as flatness, surface roughness, etc., and/or the presence of defects, such as particles, crystal originated pits (“COPs”) and crystalline growths. Given the increasing drive over the years to reduce device size and density, there has been a need for increasing control over surface characteristics or properties at reduced dimensions, and an increasing demand for a reduction in the size of defects, the types of defects that are permissible, etc. Correspondingly, there is an enhanced need for resolution, detection and characterization of small surface characteristics, properties, defects, etc., and an enhanced need for increased measurement sensitivity and classification capability.

In the face of this demand, a number of systems and methods have emerged to provide this capability. One such system, for example, is disclosed in U.S. Pat. No. 5,712,701 (the “'701 patent”), which is assigned to ADE Optical Systems Corporation of Westwood, Mass. The '701 patent discloses a surface inspection system and related methods for inspecting the surface of a workpiece, wherein a beam of laser light is directed to the surface of the workpiece, the light is reflected off the surface, and both scattered and specular light are collected to obtain information about the surface. An acousto-optical deflector is used to scan the beam as the wafer is moved, for example, by combined rotation and translation, so that the entire surface of the workpiece is inspected.

As our understanding of the physics and phenomenology of optical scattering from surfaces has improved, a capability has been developed and refined in which detailed and high resolution information about defects on the surface can be ascertained. These phenomena largely are obtained from the optical energy that is scattered by the surface, as opposed to the energy in the main reflected beam or the “specular beam.” Examples of systems and methods that provide such defect detection capability include that of the '701 patent, as well as U.S. Pat. No. 6,118,525 and U.S. Pat. No. 6,292,259, all of which are assigned to ADE Optical Systems Corporation and all of which are herein incorporated by reference. Systems designed according to these patents have performed admirably and provided major advances over their predecessors. As the drive to smaller device dimensions and higher device densities has continued, however, the need also has continued for the ability to resolve and classify even smaller and smaller surface properties, defects, etc. A need also has developed to detect and characterize a greater range of surface characteristics and defects in terms of the types of defects, their extent or range, etc. Surface scratches are an example. Scratches on the surface of a workpiece often do not lie along a straight line. Surface scratches on semiconductor wafer surfaces, for example, can be the result of polishing, which can leave circular, curved or irregular scratch geometry. As the workpiece surface is moved relative to the beam, the orientation of the scratch relative to the oblique incident beam and collectors changes. This often causes changes in the amplitude and direction of scattered light from the scratch as the wafer rotates. As device dimensions decrease, the ability to detect and characterize the scratches and similar defects with improved sensitivity and reliability has become increasingly important.

Systems that are amenable to inspection and measurement of extremely small dimensions typically must operate in extremely clean environments. This commonly requires that they be contained and operated within a clean room. This highly controlled environment limits normal access to such machines and systems, which increases the difficulty and expense of their maintenance and repair. Accordingly, systems and methods are needed that are amenable to more efficient and effective replacement of precision-aligned optical sub-components within the machines.

OBJECTS OF THE INVENTION

Accordingly, an object of the present invention according to one aspect is to provide apparatus and methods for inspecting a surface of a workpiece with high sensitivity and reliability, e.g., for surface defects.

Another object of the invention according to another aspect is to provide apparatus and methods for inspecting a surface of a workpiece that enable an improved range of detection for surface characteristics, such as defects, defect type, etc., relative to known systems and methods.

Another object of the invention according to another aspect is to provide apparatus and methods for inspecting a surface of a workpiece that are accessible and/or amenable to efficient maintenance, repair, upgrade, and the like.

SUMMARY OF THE INVENTION

To achieve the foregoing objects, and in accordance with the purposes of the invention as embodied and broadly described in this document, a surface inspection system is provided for inspecting the surface of a workpiece. The surface inspection system comprises a base, a beam source subsystem, a beam scanning subsystem, a workpiece movement subsystem, an optical collection and detection subsystem, and a processing subsystem. The beam source subsystem comprises a beam source that projects an incident beam toward the surface of the workpiece. The beam scanning subsystem comprises means for receiving the incident beam and scanning the incident beam on the surface of the workpiece. The workpiece movement subsystem moves the surface of the workpiece relative to the incident beam. The optical collection and detection subsystem collects portions of the incident beam that are reflected or scattered from the surface of the workpiece and generates signals in response to the reflected portions of the incident beam. The processing subsystem is operatively coupled to the collection and detection subsystem for processing the signals.

Optionally but preferably, the beam source module comprises a beam source housing for fixedly supporting the beam source, and a beam source mounting means for fixedly mounting the beam source housing relative to the base so that the incident beam is projected at a pointing angle to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the surface of the workpiece. In addition, again optionally but preferably, the beam source module further comprises means for pre-aligning the incident beam to the pointing angle and the pointing position. In a presently preferred embodiment, the beam source housing mounting means comprises a plurality of pinholes and the beam scanning mounting means comprises a corresponding plurality of pins that mate with the plurality of pinholes. In another, the beam source housing mounting means comprises a plurality of pins and the beam scanning mounting means comprises a corresponding plurality of pinholes that mate with the plurality of pins. The beam source housing also may comprise a plurality of pinholes, and the beam scanning mounting means may comprise a corresponding plurality of pins that mate with the plurality of pinholes.

The beam scanning module preferably comprises a beam scanning module housing for supporting the beam scanning means, and beam scanning mounting means for fixedly mounting the beam scanning module housing relative to the base so that the beam is projected to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the surface of the workpiece. The beam scanning module also preferably comprises means for pre-aligning the incident beam to the pointing position. In a presently preferred embodiment, the base comprises a plurality of pinholes and the beam scanning mounting means comprises a corresponding plurality of pins that mate with the plurality of pinholes. In another embodiment, the base comprises a plurality of pins and the beam scanning mounting means comprises a corresponding plurality of pinholes that mate with the plurality of pins.

The optical collection and detection module preferably comprises a collection and detection module housing for supporting the optical collection and detection module, and collection and detection module mounting means for fixedly mounting the collection and detection module to the base. In a presently preferred embodiment, the base comprises a plurality of pinholes and the collection and detection module mounting means comprises a corresponding plurality of pins that mate with the plurality of pinholes. In another, the base comprises a plurality of pins and the collection and detection module mounting means comprises a corresponding plurality of pinholes that mate with the plurality of pins.

The collection and detection module, also known as collector detector module, preferably comprises at least one, and preferably two, wing collectors positioned to collect the portions of the incident beam that are scattered from the surface of the workpiece. The wing collector or wing collectors are disposed in a front quartersphere, outside an incident plane defined by the incident beam and a light channel axis, and at or near a maximum of the signal to noise ratio. According to another aspect, the wing collector or wing collectors are positioned in null, or a local minimum, in surface roughness scatter relative to defect scatter, for example, from a defect perspective, at a maximum in the signal to noise ratio of defect scatter to surface roughness scatter when the incident beam is P polarized, or, from a surface roughness scatter perspective, when the surface roughness is at a relative minimum in a bidirectional reflectance distribution function when the incident beam is P polarized.

In accordance with another aspect of the invention, a method is provided for assembling a surface inspection system having a base. The method comprises providing the base to include a first mating device, providing a beam source subsystem having a beam source that projects an incident beam and a beam source housing having a second mating device, wherein the beam source is mounted to the beam source housing, pre-aligning the beam source relative to the beam source housing prior to placement of the beam source housing on the base so that the incident beam is projected at a pointing angle to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the surface of the workpiece, and positioning the beam source housing on the base using the first and second mating devices, whereby the first and second mating devices automatically cause the incident beam to be in the pointing position.

In presently preferred implementations of this method, the first mating device may comprise a plurality of pinholes, and the second mating device comprises a plurality of pins that mate with the plurality of pinholes. The method also may be implemented so that the first mating device comprises a plurality of pins, and the second mating device comprises a plurality of pinholes that mate with the plurality of pins.

In accordance with another aspect of the invention, a method is provided for assembling a surface inspection system having a base. The method comprises providing a base having a first mating device, and providing a beam source subsystem having a beam source that projects an incident beam and a beam source housing having a second mating device, wherein the beam source is mounted to the beam source housing. The method also comprises providing a beam scanning subsystem having a beam scanning device that scans an incident beam on the surface of the workpiece, wherein the beam scanning subsystem comprises a beam scanning subsystem housing having third and fourth mating devices, and wherein the beam scanning device is mounted to the beam scanning housing. The method further comprises pre-aligning the beam source relative to the beam source housing prior to placement of the beam source housing on the beam scanning subsystem housing so that the incident beam is projected at a pointing angle to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the surface of the workpiece. The method still further comprises pre-aligning the beam scanning device relative to the beam scanning subsystem housing prior to placement of the beam scanning subsystem housing on the base so that the incident beam is projected to the pointing position. This method also comprises positioning the beam source housing on the beam scanning subsystem housing using the second and third mating devices, whereby the second and third mating devices automatically cause the incident beam to be in the pointing position and at the pointing angle. It also comprises positioning the beam scanning housing on the base using the first and fourth mating devices, whereby the first and fourth mating devices automatically cause the incident beam to be in the pointing position.

In accordance with another method according to the invention, a base having a first mating device is provided, as is a beam scanning subsystem having a beam scanning device that scans an incident beam on the surface of the workpiece. The beam scanning subsystem comprises a beam scanning subsystem housing to which the beam scanning device is mounted. The beam scanning housing comprises a second mating device. The method also comprises pre-aligning the beam scanning device relative to the beam scanning subsystem housing prior to placement of the beam scanning subsystem housing on the base so that the incident beam is project to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the surface of the workpiece. The method further comprises positioning the beam scanning subsystem housing on the base using the first and second mating devices, whereby the first and second mating devices automatically cause the incident beam to be in the pointing position.

In implementing this method, one may provide the first mating device to comprise a plurality of pinholes, and the second mating device may be provided to comprise a plurality of pins that mate with the plurality of pinholes. In another implementation, the first mating device comprises a plurality of pins, and the second mating device comprises a plurality of pinholes that mate with the plurality of pins.

In accordance with another aspect of the invention, a method is provided for assembling a surface inspection system having a base. The method comprises a base having a first mating device, and providing a collection and detection subsystem that comprises a collector module and a detector module mounted to a collection and detection subsystem housing for supporting the optical and detection subsystem. Prior to placement of the collection and detection subsystem housing on the base, the method includes pre-aligning the collector module and the detector module to receive reflected portions of an incident beam reflected from the surface of the workpiece. The method also includes positioning the collection and detection subsystem housing on the base using the first and second mating devices, whereby the first and second mating devices automatically cause the collector module and the detector module to be positioned to receive the reflected portions of the incident beam. In a presently preferred implementation, the first mating device comprises a plurality of pinholes, and the second mating device comprises a plurality of pins that mate with the plurality of pinholes. In another implementation, the first mating device comprises a plurality of pins, and the second mating device comprises a plurality of pinholes that mate with the plurality of pins.

In accordance with another aspect of the invention, a method is provided for affixing a beam scanning subsystem to a surface inspection system for inspecting a surface of a workpiece. The method comprises providing a beam scanning module, which beam scanning module scans a beam. After providing the beam scanning module, the method includes pre-aligning the beam as it is projected from the beam scanning module so that the beam is projected to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the workpiece. After this pre-alignment, the method includes fixedly mounting the beam scanning module with the pre-aligned beam to relative the base so that the beam automatically remains pre-aligned to the pointing position. The beam scanning module preferably is mounted to the base and is detachable. The mounting may be accomplished using mating pins and pinholes to mount the beam scanning module.

In accordance with still another aspect of the invention, a method is provided for affixing a collection and detection module to a surface inspection system for inspecting a surface of a workpiece. The method comprises providing the collection and detection module that comprises a collector and a detector module which respectively collect and detect light of a beam reflected from the surface. After providing the collection and detection module, the method includes pre-aligning the collection and detection module so that the collector module and detector module are at desired positions along a collection axis desired spot on the workpiece. After this pre-alignment, the method includes mounting the pre-aligned collection and detection module relative to the base so that the collector and the detector module remain pre-aligned to the desired positions. In preferred implementations of this method, the mounting is detachable. The mounting may comprise the use of mating pins and pinholes to mount the collection and detection module.

In accordance with another aspect of the invention, a method is provided for maintaining a surface inspection system used for inspecting a surface of a workpiece. The surface inspection system has a first beam source module coupled to a base. The method comprises de-coupling and removing the first beam source module from the base, and providing a second beam source module, which second beam source module projects a beam. After these, the method comprises pre-aligning the beam as it is projected from the second beam source module so that the beam is projected to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the workpiece, and after performing these, mounting the housing with the pre-aligned beam to the base so that the beam automatically remains pre-aligned to the pointing position. The mounting may comprise using mating pins and pinholes to mount the housing to the base so that that beam is in the pointing position.

In accordance with another aspect of the invention, a method is provided for maintaining a surface inspection system used for inspecting a surface of a workpiece, wherein the surface inspection system has a first beam source module coupled to a beam scanning housing. The method comprises de-coupling and removing the first beam source module from the beam scanning housing, and providing a second beam source module, which second beam source module projects a beam. After performing these, the method includes pre-aligning the beam as it is projected from the second beam source module so that the beam is projected to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the workpiece. This is performed by adjusting the position of the beam scanning module with respect to the target spot. After performing these, the method includes mounting the second beam source module with the pre-aligned beam to the beam scanning housing so that the beam automatically remains pre-aligned to the pointing position. The mounting may comprise using mating pins and pinholes to mount the housing to the beam scanning housing so that that beam is in the pointing position.

In accordance with yet another aspect of the invention, a method is provided for maintaining a surface inspection system used for inspecting a surface of a workpiece. The surface inspection system has a first beam scanning module coupled to a base. The method comprises de-coupling and removing the first beam scanning module from the base, and providing a second beam scanning module, which second scanning beam source scans a beam. After performing these, the method includes pre-aligning the beam as it is projected from the beam scanning module so that the beam is projected to a pointing position that is within about 50 micro radians of a target spot corresponding to a desired spot on the workpiece. After performing this, the method includes mounting the beam scanning module with the pre-aligned beam to the base so that the beam automatically remains pre-aligned to the pointing position. The mounting may comprise using mating pins and pinholes to mount the housing to the base so that that beam is in the pointing position.

In accordance with another aspect of the invention, a variable scanning speed acousto-optical deflector assembly is provided. It comprises an acousto-optical deflector, means operatively coupled to the acousto-optical deflector for varying the scan speed at which the acousto-optical deflector scans a beam passing through the acousto-optical deflector, and beam compensating means for compensating for astigmatism of the beam associated with the variation of scan speed.

In preferred embodiments of the variable scanning speed acousto-optical deflector assembly, a scanning speed selection device operatively coupled to the acousto-optical deflector selects one of a plurality of scan speeds, and compensating optics compensate for astigmatism of the beam associated with the variation of scan speed. The compensating optics comprise a plurality of lenses and a lens-positioning device operatively coupled to the plurality of lenses, for example, as described above, wherein the lens positioning device positions a selected one of the lenses in the beam at the output of the acousto-optical deflector, and each of the lenses provides a unique amount of compensation relative to others of the lenses. As noted, cylindrical lenses are optional but preferred.

The beam compensating means preferably comprises a plurality of lenses and a lens positioning device operatively coupled to the plurality of lenses, and the lens positioning device positions a selected one of the lenses in the beam at an output of the acousto-optical deflector. In this event, each of the lenses preferably causes the acousto-optical deflector to provide a unique amount of compensation relative to others of the lenses. The lenses in the plurality of lenses preferably comprise cylindrical lenses. Preferably there are two lenses, although this is not necessarily limiting and more such lenses may be provided. It also is preferred that the focal lengths of the lenses differ. The lens positioning device may comprise a housing for the plurality of lenses, wherein the housing moves the respective lenses into and out of the beam. The variable speed scanning device may include a pneumatic pressure source for moving the respective lenses into and out of the beam. The lenses may be rotated in and out using a carousel arrangement, or may be exchanged using a slide mechanism.

In a presently preferred embodiment, each of the lenses comprises a cylindrical lens having a longitudinal lens axis, the lens positioning device housing holds the lenses so that the longitudinal lens axes are substantially aligned, and the lens positioning device moves the cylindrical lenses in a direction parallel to the longitudinal lens axes. In another presently preferred embodiment, each of the lenses comprises a cylindrical lens having a longitudinal lens axis, and the lens positioning device housing moves the cylindrical lenses by rotating the respective lenses into the beam. In each of these preferred embodiments, it also is preferred that the lenses are positioned immediately adjacent to the acousto-optical deflector.

In accordance with another aspect of the invention, a method is provided for scanning a surface of a workpiece. The method comprises using an acousto-optic deflector to scan a beam on the surface of the workpiece at a first scanning speed, selecting a second scanning speed different than the first scanning speed, using the acousto-optic deflector to scan the beam on the surface of the workpiece at the second scanning speed, and compensating for changes to the beam caused by scanning at the second scanning speed relative to the first scanning speed. This typically will involve compensating for astigmatism of the beam associated with the change from the first scanning speed to the second scanning speed. The compensating preferably comprises selectively positioning a selected one of a plurality of lenses in the beam at the output of the acousto-optical deflector, wherein each of the lenses provides a unique amount of compensation relative to others of the lenses. This also preferably comprises using cylindrical lenses, and preferably at least two such lenses, each having a focal length that is unique relative to others lenses of the plurality of lenses. The compensating preferably comprises moving the respective lenses and the beam relative to one another so that one of the respective lenses is positioned within the beam. This preferably comprises moving the respective lenses, e.g., longitudinally or rotating the lenses into and out of the beam.

In accordance with another aspect of the invention, an optical collection system is provided for use in a surface inspection system for inspecting a surface of a workpiece. The surface inspection system has an incident beam projected through a back quartersphere and toward a desired spot on the surface of the workpiece so that a specular portion of the incident beam is reflected along a light channel axis in a front quartersphere. Inspection systems that comprise the optical collection system according to this aspect of the invention comprise an additional aspect of the invention. The incident beam and the light channel axis form an incident plane. The optical collection system according to this aspect of the invention comprises at least one wing collector positioned to collect a scattered portion of the incident beam. The wing collector or wing collectors are disposed in the front quartersphere, outside the incident plane, and at a maximum of the signal to noise ratio when the incident beam is P polarized and the collector incorporates a P-polarizing polarizer. The wing collectors also may be positioned in the front quartersphere, outside the incident plane, and at a null or a local minimum, in surface roughness scatter relative to defect scatter, for example, from a defect perspective, at a maximum in the signal to noise ratio of defect scatter to surface roughness scatter when the incident beam is P polarized, or, from a surface roughness scatter perspective, when the surface roughness is at a relative minimum in a bi-directional reflectance distribution function.

In presently preferred embodiments according to this aspect of the invention, the signal comprises a P-polarization component, and the wing collector is disposed at least one of the maximum of the signal to noise ratio of the P-polarization component, the null of the P-polarization component of the bidirectional distribution function, and/or the minimum, or a local minimum, of the P-polarization component of that function, when the incident beam is P polarized. This may and preferably is accomplished using a polarization analyzer orthogonal to the polarization of the surface roughness scatter.

It is preferred that two such wing collectors be used, although this is not necessarily limiting. Where two or more wing collectors are used, it is preferred but not required that they be substantially identical. It also is optional but preferred that they be located symmetrically with respect to the incident plane, and/or equidistant from the desired spot and/or from the surface. In presently preferred embodiments, a first wing collector has an azimuth angle with respect to the light channel axis of about 5 to 90 degrees, and a second wing collector has an azimuth angle with respect to the light channel axis of about −5 to −90 degrees. In these embodiments, the first wing collector has an elevation angle with respect to the surface of the workpiece of about 30 to 90 degrees, and the second wing collector also has an elevation angle of about 30 to −90 degrees. It is more preferred that the first wing collector has an elevation angle with respect to the surface of the workpiece of about 45 degrees and the second wing collector also has an elevation angle of about 45 degrees. In the presently preferred embodiments according to this aspect of the invention, each of the first and second wing collectors has a collection angle of up to about 40°, and more preferably the collection angle is about 26°. In the presently preferred embodiments, the optical collection further comprises a polarizing beamsplitter disposed in an optical path of the incident beam between the desired spot and at least one of the wing collectors. In these embodiments, the system further comprises a light channel collector positioned in the incident plane to receive the specular portion of the incident beam, and a central collector. These collectors may be positioned and configured, for example, as is described in the '701 patent. The system also preferably comprises at least one back collector, as will be described more fully herein below.

In accordance with another aspect of the invention, a method is provided for inspecting a surface of a workpiece. The method comprises scanning an incident beam on the surface of the workpiece so that a specular portion of the incident beam is reflected along a light channel axis in a front quartersphere, the incident beam and the light channel axis defining an incident plane. The method also comprises collecting a portion of the scattered light beam at a wing collector disposed in the front quartersphere, outside the incident plane, and at least one of a maximum of the signal to noise ratio, and/or null or a minimum in surface roughness scatter relative to defect scatter, for example, from a defect perspective, at a maximum in the signal to noise ratio of defect scatter to surface roughness scatter when the incident beam is P polarized, or, from a surface roughness scatter perspective, when the surface roughness is at a relative minimum in a bidirectional reflectance distribution function when the incident beam is P polarized. The method further comprises detecting the collected portions of the incident beam that are reflected from surface of the workpiece and generating signals in response, and processing the signals to obtain information about the surface. The beam scanning preferably comprises directing the incident beam through a back quartersphere and toward the desired spot on the surface of the workpiece at an oblique angle with respect to the surface.

In accordance with still another aspect of the invention, an optical collection system is provided for use in a surface inspection system for inspecting a surface of a workpiece. The surface inspection system has an incident beam projected through a back quartersphere and toward a spot on the surface of the workpiece so that a specular portion of the incident beam is reflected along a light channel axis in a front quartersphere. As noted herein above, the incident beam and the light channel axis form an incident plane. The optical collection system according to this aspect of the invention comprises a plurality of back collectors positioned in the back quartersphere for collecting scattered portions of the incident beam. In presently preferred embodiments according to this aspect of the invention, the plurality of back collectors consists of two back collectors. Preferably the collectors in the plurality of back collectors are positioned outside the incident plane. It also is optional but preferred that the plurality of back collectors are substantially identical. It also is optional but preferred that the two back collectors are located symmetrically with respect to the incident plane, and preferably equidistant from the incident plane and/or from the surface of the workpiece. In presently preferred embodiments, the two back collectors are positioned at an azimuth angle of up to about 90° with respect to the incident beam, more preferably at an azimuth angle of about 10 to about 90° with respect to the incident beam, and even more preferably at an azimuth angle of at least about 45° to 55° with respect to the incident beam. In the preferred embodiment described more fully herein below, two back collectors are positioned at an azimuth angle of about 55° with respect to the incident beam. The back collectors preferably have an elevation angle with respect to the desired spot on the surface of the workpiece of about 55°. In presently preferred embodiments, each of the back collectors has a collection angle of about 20 to about 60, and more preferably they have a collection angle of about 30.

In presently preferred embodiments according to this aspect of the invention, the system optionally comprises a polarizing beam splitter disposed in an optical path of the beam between the desired spot and each of the back collectors. Such embodiments also optionally but preferably comprise a light channel collector positioned in the incident plane to receive the specular portion of the incident beam, and a central collector.

Optical collection systems according to this aspect of the invention may be provided individually, or as part of a surface inspection system.

In accordance with yet another aspect of the invention, a method is provided for inspecting a surface of a workpiece. The method comprises scanning an incident beam on the surface of the workpiece so that a specular portion of the incident beam is reflected along a light channel axis in a front quartersphere, wherein the incident beam and the light channel axis define an incident plane. The method further comprises collecting scattered portions of the incident beam at a plurality of back collectors disposed in the back quartersphere, detecting the collected portions of the scatter and generating signals in response, and processing the signals to obtain information about the surface.

In presently preferred implementations of this method, one or more back collectors as described above, and as more fully described herein below, are used to collect scattered light from the surface of the workpiece. It is optional but preferred that the beam scanning comprises directing the incident beam through a back quartersphere and toward the desired spot on the surface of the workpiece at an oblique angle with respect to the vector normal to the surface.

In accordance with still another aspect of the invention, a surface inspection system is provided for inspecting a surface of a workpiece. The surface inspection system according to this aspect of the invention comprises an illumination subsystem that projects a beam to the surface of the workpiece. The beam comprises a collimated portion and a non-collimated portion. The illumination subsystem comprises an absorber for absorbing the non-collimated portion of the beam. The system also comprises a collection subsystem for collecting scattered portions of the beam scattered by the surface of the workpiece, and a processing subsystem operatively coupled to the collection subsystem for processing signals received from the collection subsystem to provide information about the surface of the workpiece.

The illumination subsystem preferably comprises an acousto-optic deflector or the like having an output, and the absorber preferably is positioned at the output of the acousto-optic deflector or its equivalent or substitute. The absorber preferably comprises baffling.

In accordance with another aspect of the invention, a surface inspection system is provided for inspecting a surface of a workpiece. The surface inspection system comprises an illumination subsystem that projects an incident beam to the surface of the workpiece, wherein the incident beam after interacting with the surface comprises a reflected (light channel) portion and a scattered (dark channel) portion. The system comprises a light channel that receives the reflected portion of the incident beam. The light channel comprises a beam receiving input and an attenuator at the beam receiving input. The system further comprises a collection subsystem that collects the scattered portion of the incident beam and generates signals in response, and a processing subsystem operatively coupled to the collection subsystem that processes the signals received from the collection subsystem to provide information about the surface of the workpiece. In related aspects of the invention, noise attenuating features may be provided, for example, by including baffling or the like at or in the optical path about objective lenses in the system, adding glare stops, and the like.

In accordance with another aspect of the invention, a surface inspection system is provided for inspecting a surface of a workpiece. The surface inspection system comprises an illumination subsystem that projects a beam to the surface of the workpiece. The illumination subsystem comprises a plurality of lenses, wherein each of the lenses has a surface roughness of that does not exceed a desired maximum roughness (such as about 5 Angstroms). The system further comprises a collection subsystem for collecting scattered portions of the beam scattered from the surface of the workpiece, and a processing subsystem operatively coupled to the collection subsystem for processing signals received from the collection subsystem to provide information about the surface of the workpiece. In addition or alternatively, the collection subsystem comprises a plurality of collection lenses, each of the collection lenses having a surface roughness of that does not exceed a desired maximum roughness (such as about 5 Angstroms).

Other aspects of the invention also are included herein and are further described herein below. These include, for example, a polarizing beamsplitter/analyzer, a virtual mask, and a switchable edge exclusion mask. In addition, processing subsystems and related methods are provided for processing signals obtained from a surface inspection system, and for obtaining useful information from the collected light.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND METHODS

Reference will now be made in detail to the presently preferred embodiments and methods of the invention as illustrated in the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not limited to the specific details, representative devices and methods, and illustrative examples shown and described in this section in connection with the preferred embodiments and methods. The invention according to its various aspects is particularly pointed out and distinctly claimed in the attached claims read in view of this specification, and appropriate equivalents.

Surface Inspection System

A surface inspection system10and related components, modules and subassemblies in accordance with various aspects of the invention will now be described. Surface inspection system10is designed to inspect a surface S or surfaces of a workpiece W, such as a silicon wafer. More specifically, these illustrative embodiments are adapted for inspection of unpatterned silicon wafers, with or without surface films. Systems according to the invention also would be suitable for inspecting other types of surfaces as well. They are particularly well suited for inspecting optically smooth surfaces that at least partially absorb and scatter the incident beam energy. Examples would include glass and polished metallic surfaces. Wafer W may comprise known wafer designs, such as known 200 millimeter (mm) wafers, 300 mm wafers, and the like.

System10is shown from various perspectives inFIGS. 1-4.FIG. 1shows a side perspective view block diagram of principal components of the system.FIG. 2shows the same type of block diagram, but from a top or plan view.FIG. 3provides a front perspective view of system10contained in its cabinet.FIG. 4shows a back view of system10in its cabinet.

System10is contained within a cabinet12. It includes an operator interface14comprising a keyboard or similar input device16, a mouse or similar pointing device18, and a display device20such as a video monitor. Other peripherals may be provided, such as a printer, network connection, and the like. An air filtration device30, such as a HEPA air filter, is provided for removing dust particles and purifying the air to desired specificity. An external wafer handling system32, also known as robotic wafer handling subsystem32and external workpiece handling system32, provides workpieces.

With reference toFIG. 4, within cabinet12system10includes a vibration isolation module40within a housing42. It is within this housing area that the workpieces W, shown inFIGS. 1 and 2, are iteratively inspected, as described more fully herein below.

System10includes a workpiece movement subsystem for movement of the wafer relative to the incident scanned beam. The manner of moving the workpiece may vary, depending upon the application, the overall system design, and other factors. A number of scan patterns, for example, may be implemented, as is described more fully below. Indeed, in some applications it may be desirable to move the beam or scanning subsystem instead of the wafer, i.e., while maintaining the wafer in a stationary location. As implemented in system10, an internal workpiece handling subsystem44, also known as robotic wafer handling subsystem44and a motorized γ-θ stage44, is provided which comprises a scanner gauge, not shown, and robot, not shown, are housed in cabinet12. This subsystem is configured to work in cooperation with external workpiece handling system32to receive the workpieces to be inspected. Internal workpiece handling subsystem44comprises a motorized linear stage46and a rotary stage48. It therefore is capable or both rotating and translating the workpiece (γ-θ), for example, to provide a number of scan patterns. This permits the wafer to be scanning in a variety of generally curved paths that provide full and efficient coverage of the entire wafer surface. It enables such scan patterns as concentric cylinder scans, spiral scans and the like. In the preferred embodiments and methods, a “hybrid scan” pattern is used in which the beam travels in a generally helical or Archimedes spiral scan, but in which the beam is oscillated in a series of short scans as the spiral is traced out. This pattern is disclosed in U.S. Pat. Nos. 5,712,701, 6,118,525, and 6,292,259, each of which is assigned to ADE Optical Systems Corporation. Subsystem44receives the workpiece and is used to perform appropriate calibration, as well as moving the workpiece according to one or more desired scan paths.

System10also includes appropriate support subsystems, such as a power supply50. A processor52and data acquisition subsystem54also are contained within cabinet12, as will be described more fully herein below.

With reference toFIGS. 1 and 2, the workpiece W, which in this illustrative example is a semiconductor wafer, resides in an inspection zone IZ within housing42during inspection, as will be described more fully herein below. Motorized γ-θ stage44is disposed so that the workpiece under inspection is positioned within this inspection zone IZ. The workpiece W is placed on this stage for inspection and remains there during the inspection.

Spatial Reference Frame Information and Nomenclature

To better illustrate the principles of the invention as manifested in the presently preferred embodiments and methods, some spatial reference frame information and nomenclature is useful. These geometric relationships are illustrated inFIGS. 5-7with reference toFIG. 1. The plane defined by the inspection stage, and which generally will be substantially coplanar with the surface of the workpiece, is referred to herein as the “inspection stage plane” or the “base plane” B. The “incident beam vector” IB is the vector or ray along which the incident beam propagates between the beam scanning subsystem and the surface of the workpiece. The center C of the inspection stage B is referred to herein as the “stage center of rotation.” In the presently preferred embodiments and methods as disclosed herein, a “target spot” TS corresponds to the center of scan position of the output scanner beam. All collectors point to or are configured to receive light emanating from this target spot TS. (The stage center of rotation C is located at the target spot TS when the center of the wafer is being scanned. During the spiral scan of the wafer, the spiral scan being described in more detail below, the target spot TS will move further away from the stage center of rotation C.) After the incident beam is reflected from the workpiece surface, it propagates along a light channel axis LC. The incident beam vector IB and the light channel axis LC define a plane of incidence PI. A normal plane NP is perpendicular to the base plane B and the plane of incidence PI. A vector normal N, corresponding to the z-axis, which is perpendicular to the base plane B and which is in the plane of incidence PI, goes through the target spot TS. In addition, the center collector axis is on the vector normal N, as will be described more fully herein below.

One may construct a hemisphere above the base plane, having a center at the target spot TS and having a radius approximately equal to the distance from the stage center of rotation C to the beam scanning subsystem output, or the collectors as described herein below. This hemisphere may be bisected into a back quartersphere BQ and a front quartersphere FQ. The back quartersphere BQ lies between the base plane B and the normal plane NP and contains the incident beam along the incident beam vector IB. The front quartersphere FQ lies between the base plane B and the normal plane NP, and contains the light channel axis LC.

Wafers are inserted into inspection zone IZ for inspection and retrieved from inspection zone IZ after inspection using the wafer handling subsystems32and44. In semiconductor inspection applications and others as well, the handling of the wafers within the housing preferably is done automatically, without contact by human hands, to avoid damaging or impairing the surface, e.g., with smudges, scratches, etc. Wafer handling subsystems32and44provide a plurality of wafers to be inspected. This may be done sequentially or, for system configurations designed to inspect multiple wafers simultaneously, it may provide multiple wafers in parallel. Robotic wafer handling subsystem44places the wafer or wafers on an inspection stage or table9within the inspection zone IZ of housing42. The robotic wafer handling subsystems32and44may comprise commercially available versions known in the industry. In the presently preferred embodiments, the robotic wafer handling subsystem44comprises a FX3000/2 robotic wafer handling subsystem, from Brooks Automation, Inc. (Chelmsford, Mass.). It uses one or more cassettes, with each cassette holding multiple workpieces (up to ten wafers). After placement on the inspection table9, the wafer is automatically aligned according to alignment techniques known to those of ordinary skill in the art.

System10comprises a base11that serves as a physical or mechanical support for other components of the system. As implemented in system10, the base11comprises an optics base plate60fixedly mounted within inspection zone IZ of housing42.FIG. 10provides a perspective view of base plate60.FIGS. 8 and 9illustrate its positioning and arrangement in system10.FIG. 21is a perspective view of the base for the system ofFIG. 1, with the collection and detection subsystem module attached. Base plate60in this embodiment is fabricated of black anodized aluminum. Its surface is coated with a light absorbing coating or treatment to eliminate or greatly reduce its optical reflectivity. Base plate60includes three kinematic interface points62for mounting to the vibration isolation module, or VIM40. The VIM40, which holds the motorized γ-θ stage44, rests on isolation mounts64to prevent vibration from disturbing the light channel signal. Base plate60also has vacuum lines64to remove particles that may be produced by the motorized assemblies located throughout the base plate60, and pressurized air line port to connect the pneumatic ports162for supplying air pressure to drive the drive shafts154of the AOD variable speed assembly104, described below.

The workpiece W provided for inspection is held in position approximately 1 inch below base plate60. Base plate60includes an aperture66approximately in its center and arranged to provide a viewpoint through which the workpiece is viewable. Thus, the workpiece W resides below aperture66during the inspection operations.

Modular Surface Inspection System

It has been noted herein above that, in accordance with an aspect of the invention, a modular surface inspection system is provided. Preferred systems according to this aspect of the invention comprise an illumination subsystem13having a beam source subsystem6for projecting a beam and a beam scanning subsystem8for receiving the incident beam from the beam source subsystem and scanning the incident beam on the surface of the workpiece, a workpiece movement subsystem15that moves the surface of the workpiece relative to the incident beam, an optical collection and detection subsystem7that collects the reflected beam and photons scattered from the surface of the workpiece and generates signals in response thereto, and a processing subsystem19operatively coupled to the collection and detection subsystem7for processing the signals. Any one or combination of these components may be modular, each may comprise a field replaceable unit811. A block diagram illustrating the use of field replaceable units811is shown inFIG. 74. For example, the beam source subsystem6preferably comprises a field replaceable beam source module70(also known as laser field replaceable unit70or LFRU70). Further, the beam scanning subsystem8preferably comprises a field replaceable beam scanning module92(also known as AOD field replaceable unit92or AFRU92). In addition, the collection and detection subsystem7preferably comprises a field replaceable collection and detection assembly200(also known as a collector-detector field replaceable unit or “DFRU”200). This modular design enables each such component to be assembled during original manufacture, or to be maintained or repaired, efficiently and cost effectively. This is particularly necessary in applications, such as semiconductor-related inspection applications, wherein it is important to minimize system downtime and to maintain critical optical component alignments in a clean or otherwise controlled environment. Semiconductor wafer inspection systems, for example, typically must operate in clean rooms. The use of pre-aligned modular components enables the inspection systems to be serviced or repaired while being maintained in these clean or otherwise controlled environments. In addition to their system configurations, each of the modular components as disclosed herein comprises separate aspects of the invention.

Beam Source Subsystem

The beam source subsystem6projects the beam used to illuminate the surface of the workpiece. The light propagating from the surface, both specular and scattered, is then used to characterize or otherwise provide useful information about the workpiece surface. The beam source subsystem6in this preferred embodiment is modular, and comprises a field replaceable beam source module70, also known as laser field replaceable unit70or LFRU70. Beam source module70is shown in exploded view inFIG. 11, and in assembled state with respect to the base plate60inFIG. 12.

Beam source module70comprises a beam source that projects an incident beam toward the surface S of the workpiece. Beam source module70has a beam source that preferably comprises a laser72that projects a beam having the desired quality and optical properties for the application at hand. The specific characteristics of the laser and the beam it projects may vary from application to application, and are based on a number of factors. In applications involving inspection of semiconductor wafers, suitable lasers comprise Argon lasers having a wavelength of about 488 nm, semiconductor laser diodes, at several wavelengths (e.g. GaN (405 nm), AlGaInP (635 nm-670 nm), and AlGaAs in the 780-860 nm range). Other lasers include diode-pumped laser such as frequency doubled Nd:YVO4, Nd:YAG, and Nd:YLF (532 nm) and quasi-CW diode pumped UV lasers (355 nm). The laser72may project a beam that is monochromatic, or which includes a plurality of frequencies, etc., depending upon the specific application, the desired surface features to be measured, etc.

As implemented in this embodiment, the beam source of beam source module70comprises a frequency-doubled Nd:YVO4 laser (Spectra Physics MG-532C) operating at 532 nm frequency. The beam comprises a substantially monochromatic beam having approximately a 532 nm frequency. The beam has a beam size at the laser output of 2 mm (full width at 1/e2level). The beam is outputted from laser72with a power of about 1-2 watts.

Beam source module70also comprises a beam source module housing74that provides structural support for other components of the beam source module70. In the presently preferred embodiment, beam source module housing74comprises a beam source module base plate76upon which laser72is fixedly disposed. Base plate76is constructed of black anodized aluminum.

Beam source module70also comprises laser unit optics78for receiving the beam outputted by the laser72and directing it to an appropriate pointing angle and pointing position. With reference toFIG. 13, the output of laser72passes through a laser shutter80, provided as a safety mechanism, through a pair of turn mirrors82and84, also known as turning mirrors or fold mirrors, and through an output aperture86. A set of baffles88is disposed in the beam path between the turning mirrors82and84for limiting light that is not contained within the main beam. The alignment of the laser output, the turning mirrors82and84and the output aperture86are such that the beam is projected from the output substantially at a precise pointing angle and pointing position. The pointing angle preferably is within 10 to 50 micro radians of the desired or ideal pointing angle that corresponds to placing the beam at a desired spot position and angle at the acousto-optic device100, (also known as “acousto-optic deflector”, “AO deflector” or “AOD” and described more fully herein below). The diffracted beam from the AOD100defines the spot position at the surface of the workpiece W.

Beam source module70further includes mounting means for mounting and fixing the beam source module housing74relative to the beam scanning module base90, described in more detail below. This mounting means preferably fixes the position of the beam source, and more particularly the beam projected from the output, relative to the base plate60so that, after the beam passes through the AOD100, the beam is projected by a pointing angle to a pointing position that is within about 10 to about 50 micro radians of the desired pointing angle into the AOD. The diffracted beam from the AOD100defines a target spot TS corresponding to a desired spot on the surface of the workpiece. The purpose of the “desired spot” and “desired angle” is to set and fix a point at which the laser beam is directed so that, when the system10is assembled and a workpiece W is under inspection, the beam is directed to the desired scanning location on the surface of the workpiece W. The “pointing position” refers to the location of the beam when it is pointed at the desired spot TS. The beam source module70in this modular embodiment is designed to be substantially automatically aligned when placed onto the base plate60, so that little or no additional alignment is required after placing the beam source module housing74in position. The beam source module housing74may be mounted directly and fixedly on the beam scanning module base90. Alternatively, the beam source module housing74may be fixed relative to the base90by other means, for example, by mounting it to another component that in turn is mounted to the base90. In the presently preferred embodiment according to this aspect of the invention, as shown particularly inFIG. 11, the beam source module base plate76is mounted to a beam scanning module92, which is a component of the beam scanning subsystem8, which in turn is directly mounted to the base plate60. This will be explained more fully below.

The mounting means for the beam source module housing74in accordance with this embodiment comprises a plurality of holes or pinholes94located in the housing74, preferably in the bottom portion of laser unit base plate76, designed, sized and configured to receive a corresponding plurality of pins or posts96disposed in or on another component to which the beam scanning module92is to be mounted, such as the beam scanning module base plate90, so that the pins or posts fit securely into pinholes94. Similarly, the mounting means may comprise a plurality of pins fixedly located in the beam source module housing74, e.g., in beam source module base plate76, and projecting outwardly from it that would mate to a corresponding plurality of holes located in the base plate90or other component to which the beam source module housing74is to be affixed. In system10, the mounting means comprises the plurality of holes94, as shown inFIG. 11, disposed in the bottom portion of laser unit base plate76and configured to mate with the corresponding plurality of pins96, as shown inFIG. 14, located on the upper surface or portion of the beam scanning module92, more specifically beam scanning module base plate90. The beam source module housing74is detachably locked into position using socket head cap screws (SHCS) (not shown).

This modular beam source subsystem design provides the beam source subsystem in a self-contained and pre-aligned unit that is modular and field replaceable. By providing the modular mounting capability and beam pre-alignment, this design facilitates the ready installation or replacement of the unit on the system, quickly, efficiently, and without the need for substantial additional adjustments, alignments, etc. commonly required in prior known systems. A separate alignment fixture may be used to ensure that all of the laser source assemblies are co-aligned to ensure that no alignment is necessary in the field.

Beam Scanning Subsystem

System10also includes means for receiving the incident beam and scanning the incident beam on the surface of the workpiece. In this presently preferred embodiment, the beam scanning means comprises a beam scanning subsystem8, which, in this preferred embodiment, is modular and, in this illustrative modular system, comprises a field-replaceable beam scanning module92(also known herein as AOD field replaceable unit92or AFRU92).

The beam scanning module92receives the beam from the beam source module70and scans it on the surface S of the workpiece W in desired fashion. As noted herein above, a variety of different scan patterns are available, and the one used in a particular instance may vary from application to application.

Beam scanning module92is shown in perspective and exploded view relative to base plate60and beam source module70inFIG. 11. It is shown in its assembled stated mounted to base plate60inFIG. 12. A top view of beam scanning module92, shown separately, is provided inFIG. 14.

The beam scanning subsystem8comprises means198, mounted in a fixed position relative to the housing, for scanning the beam on the surface S of the workpiece W, also known as beam scanning means198and shown generally inFIG. 15. A number of alternative scanning means may be used to scan the beam in desired fashion. Examples include acousto-optic deflectors (AODs), rotating mirrors, and the like. In the presently preferred embodiments and method implementations, the beam scanning means198comprises an acousto-optic deflector (AOD)100, shown generally inFIG. 16.

The acousto-optic deflector100may be any acousto-optic deflector, including but not limited to those commercially available, that is capable of or suited for the beam and beam source to be used, the desired scanning parameters (e.g., beam and spot size, scan pattern, scan line dimensions, etc.), and other design requirements and constraints. The AOD100according to the presently preferred embodiment and method implementations comprises the ISOMET Model OAD-948R (488 nm) or, alternatively, the ISOMET OAD-971 (532 nm), both of which are available from Isomet Corporation of Springfield, Va.

The beam scanning module92also comprises a beam scanning module housing98fixedly coupled to or integral with base plate90for supporting the beam scanning means198. Housing98, shown inFIG. 14, comprises an AOD assembly102that houses the AOD100, which comprises an AOD crystal112and related components. AOD assembly102is mounted to or fixed to beam scanning module base plate90, or with which it forms an integral part.

Variable Speed AOD

With reference toFIG. 15, AOD assembly102comprises a variable speed assembly104for selecting or varying the scanning speed of the AOD100while maintaining good beam quality. Variable speed assembly104comprises a motor drive assembly106(if using an electric motor) or an air drive cylinder108(if driven pneumatically), and at least one drive shaft154. Referring toFIG. 16, which shows a cutaway view of a portion of the AOD assembly102, andFIG. 17, which shows a top view, AOD assembly102includes a beam input or aperture110at which AOD assembly102receives the incident beam from beam source module70. AOD assembly102also includes an AOD crystal112positioned in the optical path of the beam. An RF drive system (not shown) is provided to scan the output angle of the diffracted beam emitted by the AOD crystal. In operation, the RF drive system provides an acoustic signal across AOD crystal112, which causes the refractive index of the crystal to vary across its face. As the frequency of the RF drive system is changed, the light passing through the crystal interacts with the acoustic beam and is diffracted with an angle that is directly related to the frequency of the RF drive. This incident light also is split into separate beams, so that the zeroth order beam passes straight through the crystal112, but other orders, e.g., the 1st order, the −1st order, etc. are deflected. These orders are shown inFIG. 17at115. In the presently preferred embodiment, i.e., system10, the drive signal is varied in frequency in proportion to a sawtooth voltage signal, so the beam is deflected in the plane of the page forFIG. 17. Stops or baffles114in the form of well polished black glass are provided within AOD assembly102for blocking orders other than the +1storder, and for limiting and clipping the scan of the beam. These stops114are oriented with respect to the beam at the Brewster's angle to maximize the absorption of the unwanted diffracted beams from the AOD crystal112. An adjustable aperture116is located in the optical path of the beam. A wave plate118is disposed in the optical path to rotate the output polarization of the light. A telecentric lens120is positioned in the optical path after the wave plate118. This lens120focuses the beam down to a spot at the surface under test or inspection. The spot size in this preferred embodiment is nominally 50 microns in the in-scan direction and 120 microns in the cross-scan direction.

AOD SNR Improvement

The AOD assembly102also includes a beam scan absorbing system24for absorbing light that is not collimated in the beam. In this embodiment this beam scan absorbing system24comprises a series of apertures, baffles and threads, including optical baffling or optical threads122located in the snout124of the AOD assembly102near its output126. The beam is output from AOD assembly102at a beam output aperture126.

The beam scanning module92further includes beam scanning module mounting means196for fixedly mounting the beam scanning module housing98relative to the base11so that the beam is projected at a pointing angle to the pointing position. As was noted in connection with the beam source module70, it is desirable for the beam scanning module92to be easily mounted, pre-aligned, and to require a minimum of alignment or other adjustment to install it onto the system. Proper operation of a laser-based surface inspection system requires AOD alignment tolerances to be quite tight. It can be difficult to obtain the required diffraction efficiency and power uniformity necessary for proper AOD operation when aligning the AOD100during system assembly. Replacing the AOD assembly102in system10, as is occasionally necessary during servicing of surface inspection systems, requires duplicating the AOD alignment in order to obtain the same diffraction efficiency and power uniformity. Re-alignment could therefore result in loss of system sensitivity. Obtaining correct alignment, while critical, is made even more difficult when the AOD100must be replaced in the field. It is difficult to enable field replaceability of the AOD while ensuring that the laser beam will be aligned with respect to the AOD within such tight tolerances. The beam scanning module92according to the presently preferred embodiments therefore comprises a modular and field replaceable unit.

In this specific yet illustrative embodiment, the beam scanning module mounting means196comprises a plurality of pins96in the beam scanning module base90that mate a corresponding plurality of pinholes94in the beam source module base plate76. Alternatively, or in combination, the plurality of pinholes could be in another system component to which the beam scanning module92and the beam source module70are to be affixed. Also alternatively or in combination, the mounting means may comprise a plurality of pinholes in the surface of beam scanning module base90that would mate to a corresponding plurality of pins in the bottom surface or portion of the beam source module base plate76.

As noted above, beam scanning base plate90also comprises means196for mounting the beam scanning module92to base plate60or other system component through which the beam scanning module92is to be affixed to base plate60. In this presently preferred embodiment, the mounting means196comprise a plurality of pins128on the bottom surface of beam scanning module base plate90that mate with pinholes130in base plate60. Alternatively or in combination, the mounting means196may comprise a plurality of pinholes in the bottom surface of base plate90that would mate to a corresponding plurality of pins in the top surface or portion of base plate60.

In accordance with another aspect of the invention, a variable scanning speed acousto-optical deflector assembly194is provided. This assembly may be provided separately, or it may comprise a component in a surface inspection system. This assembly comprises an AOD100, means190operatively coupled to the AOD100for varying the scan speed at which the AOD100deflects a beam passing through the AOD100(the means196also known as the AOD scan speed varying means196), and beam astigmatism compensating means160for compensating for astigmatism of the laser beam associated with the variation of scan speed.

Beam scanning module92as described herein is designed to make better use of the relatively high detection-throughput capability of system10over prior known systems. “Detection-throughput” is analogous to the “gain-bandwidth product” known by those skilled in the art of electrical engineering. Detection-throughput determines how many wafers per hour a scanner can scan at a given detection sensitivity performance level. Alternately, it is the ultimate detection sensitivity the system can achieve at a given throughput level. As the detection-throughput capability increases, the wafer can detect smaller defects at higher throughput, thereby lowering the cost of ownership. Methods for increasing the overall detection-throughput include increasing the laser power, improving the collection efficiency of the detection collectors, and increasing the quantum efficiency of the detectors.

The ability of a beam scanning subsystem8to flexibly trade between detection sensitivity and throughput can be and often is very important. In some prior systems, the scan speed is fixed, and therefore the sensitivity that can be achieved also is fixed. If a system could scan more slowly, the system could effectively integrate more photons, thereby reducing the shot noise levels (described in more detail below) and improving the sensitivity of the system to smaller defects. If a system could be scanned more quickly, the throughput could be increased beyond its current speed, reducing the cost of ownership of the tool at the expense of defect sensitivity. By enabling such systems to scan multiple speeds, the user can advantageously trade off throughput for sensitivity in a flexible manner. By offering multiple or even many effective speeds, the user can choose the speed that is right for their particular process.

Multiple speed operation in surface inspection systems having short scanning capability can be achieved by two methods: 1) changing the cross-scan speed or the cross-scan pitch (slower stage rotational rate) in cooperation with cross-scan filtering to match the filter coefficients of the cross-scan pulse signal shape (see, e.g., U.S. Pat. No. 6,529,270, which is hereby incorporated by reference), and 2) changing the in-scan speed and adjusting the in-scan filter for proper matched filtering. Preferred systems and methods according to this aspect of the invention use both methods to provide a series of selectable scan speeds.

Method 1 does not require any changes to the optical design while Method 2 often will. Method 2 requires changing the AOD modulation frequency per unit time, requiring the AOD frequency chirp range (or scan length) to be reduced while holding the AOD scan time invariant in order to scan the spot more slowly during the same in-scan time base. The in-scan speed is controlled by the total change in the AOD modulation frequency per unit time. If the AOD scan length is reduced, the effective internal lens focal length in the AOD will also change, requiring the cylinder lens focal length to change in order to compensate for the new AOD in-scan focal length. If the active compensation is incorrect (i.e., the cylinder lens focal length does not match that of the AOD lens), the in-scan spot size will be too large at the wafer plane, and the effective sensitivity of the scanner will be reduced.

Reducing the AOD scan speed provides an improvement in particle diameter sensitivity, which is the result of quantum mechanical shot noise. It may be quantified as
[(√R)1/6]=,df/ds,where:

R is the ratio of a full scan speed to a slower scan speed;

dfis the diameter of the particle that is discernable at full speed; and

dsis the diameter of the particle that is discernable at the slower speed.

By using a combination of both Methods 1 and 2, a large selection of scan speeds can be chosen along the detection-throughput curve. For example, in an illustrative but not necessarily preferred embodiment, the AOD scan rate is 20 microseconds per AOD scan, with 16 microseconds for the AOD scan and 4 microseconds for the fly-back to the AOD scan start position, nominally 4, 3, 2, and 1 mm AOD scan lengths are selectable, and 23, 11, 6, and 3 micron AOD cross scan pitches are selectable. If the cross scan filter can support 23, 11, 6, and 3 micron cross scan pitches, and the in-scan beam scanning subsystem8can support 4, 3, 2, and 1 mm AOD scan lengths, the system10can operate at a total of 4×4=16 scan speeds. The 3 micron cross scan pitch, when utilized with the 1 mm AOD scan length, can provide the best sensitivity at the lowest throughput, while the 23 micron pitch and 4 mm scan length would provide the highest throughput. By providing 16 or more scan speeds along the detection-throughput curve, the user can select the optimal speed/sensitivity setting for their particular processes.

In the presently preferred yet merely illustrative embodiment, once an AOD scan speed is selected, it is maintained throughout the wafer scan. The setting does not vary within a given AOD scan.

A variable speed acousto-optic deflector assembly194according to a presently preferred yet merely illustrative embodiment of this aspect of the invention is shown inFIGS. 15-17and in block diagram form inFIG. 84. The acousto-optical deflector according to this aspect of the invention may comprise any AOD suitable for the application and capable of meeting the technical requirements at hand. The presently preferred AOD is AOD100of AOD assembly102.

The variable speed AOD assembly194also comprises means190operatively coupled to the AOD100for varying the AOD scan speed at which the acousto-optical deflector scans a beam passing through it. The specific means190that may be used to perform this task will depend upon the specific AOD used and in some cases other factors as well. It normally will involve drive electronics used to drive the AOD, such as that commercially available from AOD suppliers.

In the presently preferred embodiment, the AOD scan speed varying means190comprises digital drive circuitry180comprising a digital voltage controlled oscillator (“DVCO”)182, such as IDDS-1-SE Direct Digital VCO, and radio frequency (“RF”) power amplifier184, such as IA-100-3-826 RF Power Amplifier, both commercially available from ISOMET of Springfield, Va. It also comprises a gauge synchronization board186(also known herein as gauge synchronization control186) with synchronization signals that trigger the DVCO182to initiate AOD scans. The digital drive circuitry180includes a control188to selectively vary the scan speed of the AOD, and/or to select discrete scan speeds. The AOD scan speed varying means190has software controls181and stage servo controls189to accomplish the speed changes necessary when changing the cross-scan speed or the cross-scan pitch.

The AOD scan speed varying means190also has in-scan and cross-scan filtering circuitry183comprising electronic circuitry185, which may comprise digital circuitry. However, in the presently preferred yet merely illustrative embodiment, the filtering circuitry185comprises an analog low-pass filter187with an impulse function which matches the pulse width produced by the AOD scan to maximize signal to noise ratio in the in-scan direction.

Beam Compensating Means

The variable scan speed AOD assembly194also comprises has a beam compensating lens150that operates to produce a focal length difference between in-scan and cross-scan direction and a beam astigmatism compensating means160for varying the focal length difference in order to compensate for astigmatism of the beam associated with the variation in scan speed. As the scan speed of the AOD100is changed, the astigmatism of the beam also changes. This astigmatic effect usually is disadvantageous, for example, in that it spreads and defocuses the beam. The beam astigmatism compensating means160is used to compensate for this astigmatism so that its adverse effects can be offset or eliminated and the desired beam geometry can be obtained.

The focal length (L) for a selected AOD in-scan speed is a function of the laser beam size, the frequency shift across half of the laser beam, and the laser wavelength. It is calculated as follows:

The AOD Sweep rate (R) is calculated as:

R=Δ⁢⁢FP⁢(Hz/s),
whereΔF=Total frequency difference between lowest and highest frequencies during AOD sweep; andP=Sweep Period, defined to be the total time required for the AOD to sweep from lowest to highest frequency.
The time across beam (T) is calculated as:

T=BS;
whereB=Beam size, andS=Speed of sound in crystal.
The frequency shift across half of the beam (H) may be calculated as
H=R*T/2.
The focal length L for a selected AOD in-scan speed may then be calculated as

H=frequency shift across half of beam;

S=Speed of sound in crystal.

As noted above, the telecentric lens120is positioned in the optical path after the wave plate118and before the optical threads122near the optical threads122to convert the angular scan to a spot position scan at the workpiece surface, while simultaneously focusing the beam at the workpiece. The telecentric lens120, when it is properly matched to the effective lensing effect in the AOD (lens150), ensures that the in-scan and cross-scan waists are located at the same position along the optical axis. However, as the AOD scan speed varying means190varies scan speed, the focal length (L) changes and. Therefore, the effective lensing effect in the AOD100changes in response to the AOD scan speed, introducing an astigmatism. The beam astigmatism compensating means160performs an astigmatic correction. The beam astigmatism compensating means160operates to modify the effective lensing effect in the AOD100in order to allow the telecentric lens120to maintain focus of the beam at the workpiece W onto a spot position at the workpiece surface at varying scan speeds.

The beam astigmatism compensating means160may comprise any means in which the focal length of a lens system may be varied in response to a change in the index of refraction or lens surface curvature. For example, the beam astigmatism compensating means160may comprise a liquid lens, in which the surface curvature is changeable, or preferably a lens system192comprising a plurality of lenses in which the focal lengths of the respective lenses differ from one another and are selected to appropriately compensate for the beam deformation at each of the respective desired scan speeds. Cylindrical lenses are particularly preferred. The beam astigmatism compensating means160also preferably comprises a lens positioning device172operatively coupled to the plurality of lenses. The lens positioning device172is used to position a selected one of the lenses in the lens system192in the beam at the output of the AOD100, in the optical path of the beam. Each lens in the lens system192is designed to provide the desired beam compensation for a given AOD scan speed and provides a unique amount of compensation relative to that of others of the lenses in the lens system192. The lens positioning device172is used to alternately position the lens that corresponds to the selected scan speed into the beam path at or near the AOD output. When the AOD scan speed is changed, the current lens is moved away from this position, and another one of the lenses, this one being compatible with the newly selected AOD scan speed, is moved into position at or near the AOD output and in the beam path.

In the presently preferred embodiments, and with reference toFIGS. 15-17, the beam astigmatism compensating means160comprises a lens system192, having two cylindrical lenses150a,150bhoused in a lens housing152located between the AOD crystal112and near the optical threads within AOD assembly102, and a lens positioning device172for controlling the positioning of the lenses with a sliding plate158for moving the variable speed assembly cylindrical lens150A or150B into position. The lens positioning device172comprises a variable speed assembly104that uses a motor drive assembly106comprising an electric motor, not shown, or, alternatively, an air drive cylinder108, connected to drive shafts154that rigidly connect the motor drive assembly106to the cylinder lens housing152. Motor drive assembly106may comprise any drive assembly to move the lenses, e.g., such as those means noted herein above. In the presently preferred yet merely illustrative embodiment, the motor drive assembly106operates pneumatically and thus includes a pneumatic pressure source156and pneumatic ports162for supplying air pressure to drive the drive shafts154. A pair of springs164is positioned on drive shafts154to prevent the lens assembly192from being overdriven.

When AOD assembly102and its associated drive circuitry are set to scan at a first scan speed, variable speed assembly104, including motor drive assembly106, are used to position lens150a,150bin the beam path (the up position for variable speed assembly104as shown inFIG. 16). Lens150aprovides the amount of compensation appropriate to offset the astigmatism associated with the first scan speed. When AOD and its associated drive circuitry are set to scan at a second scan speed different from the first scan speed, in this case, slower than the first scan speed, the variable speed assembly moves the drive shafts down to position lens in the beam path. Lens150bis designed to provide the appropriate amount of compensation to offset the astigmatism associated with the second scan speed.

Another embodiment of a variable speed AOD in accordance with this aspect of the invention is shown inFIG. 18. In it, the beam astigmatism compensating means160comprises a lens housing170with a rotating carousel171that contains multiple lenses, preferably cylindrical lenses,170a,170band170c.Housing170selectively moves one of the plurality of lenses170a,170b,170cinto the beam path by rotating the carousel171.

In each of these embodiments, the lenses preferably but optionally are positioned immediately adjacent to the acousto-optical deflector100.

Scan Repetition Mode and Station

In accordance with another aspect of the invention, a method for inspecting the surface of a workpiece, in which an incident beam is projected toward the surface of the workpiece, and the surface of the workpiece is scanned to generate a scan output representative of the effects on the surface of the incident beam, comprises a method231for repeatedly scanning a selected scan region of a workpiece. As shown inFIG. 82, the scan repetition method231comprises the step215of moving a workpiece relative to the incident scanned beam and the step232of repeatedly scanning a selected scan region of the workpiece to produce a set of repeated scans.

In a further embodiment, the selected scan region has a plurality of sample locations, and the step231of repeatedly scanning a selected scan region of the workpiece further comprises a step233of generating a repeated scan output comprising, for each of said sample locations, generating a set of signals associated with the sample location over the set of repeated scans.

In a multi-collector surface inspection system such as system10, a surface scan produces, from each collector, a signal associated with each sample location, and the step233of generating a scan output comprises, for each of said sample locations, generating a set of signals associated with the sample location, from each collector and over the set of repeated scans.

In another embodiment, the step232of repeatedly scanning a selected scan region of the workpiece further comprises the step235of selecting a quantity of scan repetitions, for defining the number of scans to be run on a selected scan region of the surface, and a step234of selecting a scan region for defining a region of the workpiece to be scanned.

The resulting scan repetitions may be used to increase the Signal to Noise Ratio (SNR) of the selected scan region and thus reveal greater details of the surface under consideration. SNR may be improved by aggregating the output of a set of scans that are repeated on a selected region. Therefore, in another embodiment, the scan repetition method231further comprises the step236of aggregating the scan output. In one embodiment, the step of aggregating comprises the step237of averaging the scan output, for example finding the arithmetic mean of the scan output. In a more preferred embodiment, the step237of averaging the scan output comprises the step238of frame averaging the scan repetitions.

Frame averaging is a mathematical process in which several frames of identical scenes are coincided to produce an increase in detail and thereby resolution of the scene. In the context of scan repetition in a surface inspection system such as system10, frame averaging comprises averaging each of the sample signals associated with a sample location within a selected scan region over the set of repeated scans. In the context of scan repetition in a multi-collector surface inspection system such as system10, frame averaging comprises, for a sample location, averaging each of the sample signals associated therewith from each collector. A discussion of frame averaging may be found atThe Image Processing Handbook,3rd ed.,John C. Russ (CRC Press IEEE Press 1998). Frame averaging minimizes shot noise and enhances the signal from persistent scatter sources by lowering the signal value of shot noise in those locations where shot noise is present.

While the random nature of shot noise results in random signals during a scan, real surface scatter sources may produce a signal at the same location for each collector. Further, real surface scatter sources may produce a signal at the same location for each collector every time that a scan is repeated. When signals which are the output from a set of scans that are repeated on a selected scan region are averaged, signals from a real surface scatter source will more likely produce a higher average signal. However, shot noise signals from the region, which by definition generally do not repeat in the same locations, will result in a lower average signal. Thus the SNR will be improved by frame averaging a set of scans that are repeated on a selected scan region.

In accordance with another aspect of the invention, a scan repetition system38is provided. The scan repetition system38, which may be provided separately, or which may comprise a component in a surface inspection system, comprises a workpiece movement subsystem15for movement of the wafer relative to an incident scanned beam and a system31operatively coupled for repeatedly scanning a scan region of the workpiece. The scan repetition system38is shown inFIG. 83.

In a further embodiment, the selected scan region has a plurality of sample locations, and the system31operatively coupled for repeatedly scanning a scan region of the workpiece further comprises a system33for generating a repeated scan output, which generates, for each of said sample locations, a set of signals associated with the sample location over the set of repeated scans. In a multi-collector surface inspection system, the system33for generating a repeated scan output generates, for each of said sample locations, a set of signals associated therewith from each collector and over the set of repeated scans.

In a further embodiment, the scan repetition system38further comprises a scan repetition quantity selector35, for defining the number of scans to be run on a surface, and a scan region selector45for defining a region of the workpiece to be scanned.

The scan repetition system38may comprise any scan repetition system suitable for the application and capable of meeting the technical requirements at hand. The scan repetition system38preferably comprises software controls37and stage servo controls39. In addition, each of the specific implementations of the system31for repeatedly scanning a scan region of the workpiece scan, the repetition quantity selector35, and the scan region selector45will depend upon the specific workpiece movement subsystem15used and in some cases other factors as well. In the presently preferred embodiment, the repetition scan system31and its systems33,35,45,36,47,49are operable using software controls37and stage servo controls39.

In a further embodiment, the scan repetition system38further comprises a scan output aggregator36to aggregate the output of a set of scans that are repeated on a selected region. In one embodiment, the scan output aggregator comprises a system47for averaging scan output. In a more preferred embodiment, the system47for averaging output comprises a system49for frame averaging for averaging each of the sample signals of each collector from each of the sample locations within the repetition region.

Using the scan repetition system38and scan repetition method231, the surface inspection system may scan an entire wafer and then make multiple scans of sub-regions of the wafer wherever there are defects of interest. Use of the scan repetition system38and method231can allow detection of defects with <30 nm PSL equivalent sizes.

Optical Collection and Detection Subsystem

In accordance with another aspect of the invention, an optical collection and detection subsystem7is provided. The optical collection and detection subsystem7may be provided as an independent assembly, or it may be incorporated into a surface inspection system, for example, such as system10. It comprises a collection system380and a detection system480. The collection system380comprises components used to collect the beam portions reflected from the surface of the workpiece and scattered from the surface due to surface roughness, defects in the surface, and the like. The detection system480is operatively coupled to the collection subsystem380and works in conjunction with it to detect the collected light and convert it into corresponding signals, e.g., electrical signals, that can be utilized by the processing subsystem to obtain information pertaining to the surface of the workpiece.

Architecture

The optical collection and detection subsystem7(FIG. 21) in accordance with the presently preferred embodiment of this aspect of the invention operates to collect portions of the incident beam that are scattered and reflected from the surface of the workpiece and generates signals in response to them. As implemented in system10and shown inFIG. 20, the collection and detection subsystem7comprises an optical collector subsystem380and a detector subsystem480, and the signals comprise electrical signals, each of which having a voltage that is proportional to the optical power illuminating the detector subsystem480. The collection and detection subsystem7in its various implementations as described herein and claimed herein below, comprise additional aspects of the invention, in the system embodiments as well as separately.

The optical collection and detection subsystem7comprises means250for developing a light channel, for collecting the beam reflected from the surface of the workpiece into a light channel, and means260for developing a dark channel, for collecting the portions of the beam scattered from the surface into a dark channel collector. The means260for developing a dark channel further comprises components of the optical collection and detection subsystem7, described in more detail below.

As shown inFIG. 1, the optical collection and detection subsystem7comprises a series of collection and detection assemblies200(also known as collection and detection modules200), each assembly200comprising components of the optical collection subsystem380and the detection subsystem480and each assembly200organized into a collector module300(also referred to herein as “collector”) for collecting portions of the beam, and a detector module400associated therewith. The means250for developing a light channel comprises the components of the collection and detection assemblies200for collecting and detecting the specular beam and, the means260for developing a dark channel comprises the components of the collection and detection assemblies200for collecting and detecting the scattered portions of the beam,

In the illustrative but not necessarily preferred embodiment and as shown inFIGS. 1 and 2, the series of collection and detection assemblies200comprises a front collection and detection module230, a center (or central) collection and detection module220, a pair of wing collection and detection modules210A,210B, and a pair of back collection and detection modules240A,240B.FIG. 19provides a perspective view of optical collection and detection subsystem7.FIG. 20shows a side cutaway view of it.FIG. 21shows the subsystem7attached to base plate60.FIG. 22shows a bottom view of the collection and detection subsystem7.

Although all of the collector-detector assemblies200need not necessarily all be of the same design and construction, in this preferred embodiment each of them has the same basic design, which is illustrated by back collector-detector assembly240A inFIGS. 23-26.FIG. 23provides a perspective view of the assembly240A from a first or front perspective,FIG. 24provides a perspective view from a view opposite the first or front perspective, andFIG. 25is a side cutaway view.

Referring toFIG. 25, the collector-detector assembly240A comprises a collector module300that includes a collection optics subassembly390mounted in a barrel housing394. A variety of lens designs may be used, for example, depending upon the specific application, the budget, etc. In other embodiments, the collector module300could comprise arrangements other than lens assemblies. For example, mirrors could be used to direct the scatter to a detector. In the illustrative but not necessarily preferred embodiment, the collection optics subassembly390comprises collector objective lens optics392having aspheric lenses L1, L2. Objective lens optics392focuses the incoming beam to a slit396. Lens L1collimates the light scattered from the workpiece, while L2focuses the light to the slit396, which operates as a field stop to absorb scatter outside of the region being scanned by the laser spot. When the collector objective lens optics392comprise aspheric lenses, a wide collection angle, such as about a 60 degree total angle) may be achieved while a small image spot Point Spread Function (“PSF”) is produced at the slit396. Alternatively, the collector objective lens optics392could comprise doublet lenses.

A detector module400is mounted to the collector module300. Detector module400includes a detector module barrel housing494that mates with collector module barrel housing394adjacent to slit396and a relay lens assembly490. Relay lens assembly490comprises a relay optic collimating lens L3that is disposed in housing in the beam path adjacent to slit396, a relay optic focusing lens L4that is positioned at the opposite end of housing494, and a lens L5(between L4and the final slit496) that produces the desired spot size on the photocathode surface.FIG. 26is a perspective view of collector module300and a portion of the detector module400, excluding the detection units shown inFIG. 25. As shown inFIG. 26, a slit496also is provided in the relay lens assembly490near the detection unit.

A first detection unit492is mounted to detector barrel housing494adjacent to the focusing relay optics lens L4. Detection unit492comprises a detector497, such as a photo-multiplier tube (“PMT”), such as the Hamamatsu H6779-20, or an Avalanche Photodiode (APD) Detector (e.g. Advanced Photonix 197-70-74-581), or other type of detector that is sensitive to receive and detect portions of the light beam passing through a lens. A second detection unit493is provided at the side of detector barrel housing494. Second detection unit493according to this embodiment is substantially identical to first detection unit492, and includes a detector499such as the PMT identified above (although it is permitted in the illustrative embodiment that the PMTs found in detection units492or293may be different in design, hereinafter a PMT may be referred to generally as PMT495). Each of the detectors497,499detects a specific polarization orientation. For example, while one PMT495collects scattered light that is polarized in the “P” orientation, the other PMT495collects light in the “S” orientation. This is because each PMT495is positioned to collect the “P” and “S” polarized light that is emitted by the polarizing beam splitter cube472that is located in the relay lens assembly490.

PMT at a Telecentric Plane and Stationary Laser Spot

In accordance with another aspect of the invention, one or more of the detectors497,499is designed so that the photomultiplier tube495or other detection device is located at a telecentric plane or stop498with respect to the collection optics. This can help to ensure that the laser spot is stationary on the PMT photocathode surface during the AOD scan, or is limited in movement on the detector. This correspondence can help to eliminate detector-induced banding effects across the scan. As implemented in the presently preferred embodiment, the plane of each detector497,499in collector and detector assemblies200is located at a telecentric plane498with respect to the collection optics392. Referring toFIG. 25, which shows a back collector-detector assembly240A but is illustrative of the other collector-detector assemblies200as well, telecentric planes or stop locations498are imaged at P1, P2, P3so as to ensure minimal spot movement at the detector, thereby reducing background signal non-uniformity. Refer to pages 142-143of Modern Optical Engineering,2nded., Warren J. Smith (McGraw-Hill, 1990), for a description about telecentric stops.

Optical Collection and Detection Subsystem, Contd.

Variable Polarization

In accordance with yet another aspect of the invention, the collection and detection assembly200comprises a relay assembly490(FIG. 72) further comprising a polarizing relay assembly450positioned between the collection optics subassembly390and the detectors497,499. In a further aspect of the invention, the polarizing relay assembly450further comprises a variable polarizing assembly470. This variable polarizing assembly470, also known herein as rotational analyzer470and rotational polarization filter470, is capable of selectively passing solely P polarization, or solely S polarization, or combinations thereof. Referring to the back collection and detection assembly240A illustrated inFIG. 25, a presently preferred variable polarizing assembly470according to this aspect of the invention will now be described. Variable polarizing assembly470in this embodiment is integrated into the detector module400. Assembly470, in this embodiment also known herein as dual channel variable rotational analyzer assembly470, comprises a motor-driven rotational polarizer analyzer461(also known as dual detector polarization analyzer461) having a beamsplitter cube472and dual detectors497,499. The polarizing beamsplitter472is fixedly positioned in a chamber473of detector module400, in the light scatter path. The beamsplitter472is positioned so that a transmitted portion of the scattered light passes through the beamsplitter472and impinges upon a first detector497in first detector unit492as a flux of photons having a first selected polarization, and a reflected portion of the scattered light passes through the beamsplitter472and impinges on a second detector499in a second detector unit493as a flux of photons having a second selected polarization, for dual PMT implementations. A rotational mechanism474, such as motor, rotates the chamber473and thus the polarizing beamsplitter472to alter the polarization of the light impinging on the detection units492,493. Second detector499is fixed with respect to first detector497, and thus second detector499also rotates with the assembly470. A motor476or similar drive mechanism is provided which, upon actuation, causes the chamber473, including beamsplitter472, and second detector499to rotate.

To illustrate the construction and operation of this assembly470, assume that the incident photons are unpolarized, and that beamsplitter472is oriented in chamber473, and chamber473is oriented, so that polarizing beamsplitter472transforms a portion of the unpolarized beam into P polarized light for transmission to the first detector497. Simultaneously, polarizing beamsplitter472transforms a portion of the photons' S-polarized light for transmission to the second detector499. If a different polarization mix is desired, motor476causes the assembly470, including chamber473, polarizing beamsplitter472, and detectors497,499to rotate. This causes the polarizing beamsplitter472to transform the portion of the scattered light impinging on the first detector497into a first selected mixture of P polarized light and S polarized light. This also causes the polarizing beamsplitter472to transform the portion of the scattered light impinging on the second detector499into a second selected mixture of P polarized light and S polarized light. Preferably, the polarizing beamsplitter472according to this aspect of the invention has multiple selectable polarization settings, and more preferably are infinitely selectable over a desired range.

The motor476may causes the assembly to rotate to any desired polarization mix, or it may be arranged to step through selected polarization mixes. Alternatively, the assembly470may have a programmed polarization mix mechanism478, which may be any known combination of hardware and software elements, that is arranged to provide a combination of infinitely selectable mixes and stepped polarization mixes, with the stepped polarization mixes changeable at the option of the user.

A variable polarization assembly470according to a second preferred embodiment, shown inFIG. 71, comprises an optional motor-driven rotating carousel polarization analyzer451with a rotating carousel453that contains multiple glass cubes. Carousel453selectively moves one of the plurality of cubes475,477,479into the beam path. In an illustrative but not necessarily preferred embodiment of the present invention, the motor-driven rotating carousel polarization analyzer451comprises three glass cubes262: one polarization beamsplitter cube (“PBS”)475oriented for local P-polarization, one PBS cube477oriented for S-polarization, and one non-polarizing cube479for unpolarized light. By using a glass cube479for the unpolarized light, the effective optical path length through the relay lens assembly is maintained. This is required to maintain the same spot shape at the PMT photocathode. Incorporating three cubes into the rotating carousel polarization analyzer451simplifies the assembly design, and enables the analyzer to change polarization states quickly and accurately. This analyzer451can be easily interchangeable with the fixed polarizer relays. As noted herein, different virtual masks131, which are described in more detail below, can be switched in and out using this assembly as well.

Rotational carousel analyzers451as described herein can be used to electronically select each of a plurality of cubes475,477,479, each of which can utilize a different virtual mask131shape and size. This enables the detection subsystem480to have a refined angular resolved scatter defect detection capability in a versatile manner by either selectively blocking or passing angular sub-regions of scatter that are collected by a collection optics subassembly390.

FIG. 72is a block diagram showing some of the relay lens assemblies490contemplated by the present invention. As seen inFIG. 72, the types of relay assemblies490, using glass cubes462to pass the beam of light into the detection units, may be used at each collector-detector assembly200include: 1) unpolarized relay assembly483, using an unpolarizing cube452, 2) a fixed polarizing relay assembly454that is oriented in a fixed polarization state, and 3) a variable polarization device470, such as a rotational PBS analyzer461. The fixed polarizing relay assembly454and variable polarization device470, collectively known as polarizing relay lens assembly450, may use either a polarizing beamsplitter, such as cube472or a polarizing non-beamsplitter cube such as cube456. The variable polarization device470in turn may comprise, for example, a carousel cube assembly, such as rotating carousel polarization analyzer451, for selecting between “P”, “S”, and “unpolarized” detector polarization states.

When inspecting surfaces bearing a film, however, such as semiconductor wafers with applied films, the three fixed detector polarization states provided by the rotating carousel polarization analyzer451may be insufficient, because some films require ±45° as well as other intermediate polarizer orientation angles in order to achieve the best SNR. One approach to address this is to adjust the polarization of the incident beam in coordination with the detector polarization angle to achieve the optimal detector performance. The optimal SNR is related to both the particle signal peak amplitude and the background level obtained from the film surface. These parameters change for each type of film that is present on the wafer surface. In accordance with another aspect of the invention, new rotational analyzer assemblies are provided to permit the intermediate polarizer orientation angles that are necessary to achieve the optimal SNR when the surface produces circularly polarized scatter. The rotational cube analyzer461and rotational waveplate, fixed PBS analyzer471both described in detail below, both provide increased variation in polarizer orientation angles.

FIG. 27shows a cut-away of a collector detector module200according to the presently preferred embodiment described herein above, and which comprises a dual detector rotational polarizing cube analyzer461that provides P polarization, S-polarization and no polarization, as well as the opportunity to provide combinations therebetween. The analyzer461, referred to inFIG. 72, has a single polarizing beamsplitter472and dual detectors497,499. The collector detector assembly200on the right hand side is a back collector detector module, such as back collector detector module240A, and the one on the left is a wing collector detector module, such as wing collector detector module210A. The assembly in the center is the center collector detector module220. The front collector detector module230also is shown. The PBS cube472in each dual PMT assembly461can rotate around the detector collector optical axis.

Dual detector rotational polarizer analyzer461comprises a single polarization beam-splitter cube472and two PMT photodetectors497,499. The cube472can be rotated to the desired rotational angle around the detector optical axis by manual means, not shown, or motorized means476. Therefore the PMT signals are directly associated with the orthogonal polarization states. If the polarizer is oriented so that PMT #1sees “P” light, then PMT #2will detect “S” light. If PMT #1detects “+45°” light, then PMT #2will detect “−45°” light. Furthermore, by electrically adding the signals from both the PMTs495, the resulting signal is effectively the same as that obtained with no polarizer present (assuming the polarizer is lossless). Consequently, the assembly470can simultaneously detect “P”, “S”, and “Unpolarized” light, or “+45°”, “−45°”, and “Unpolarized” light, or, more generally, “θ”, “θ−90°”, and “Unpolarized” light during a single scan of the wafer or surface. The “unpolarized” signal is useful, for example, for scanning bare silicon surfaces and for some film inspection applications.

By adding the signals from the PMTs495for the unpolarized signal, one can eliminate the need to mechanically exchange the polarized cube472with an unpolarized cube452. The equivalent optical path should be maintained in the relay lens assembly470by including the unpolarized cube452. If the polarized cube472were removed and not replaced with an unpolarized cube452, the spot would size would not be imaged correctly onto the PMT495. The sides of the cube472or452are painted black as well, and it therefore acts as a baffle structure to further reduce stray light. By eliminating the need to exchange the cube472or452, the mechanical design can be simplified and this facilitates modularization.

Detection of COPs Using Polarization Information

The incorporation of an optical collection and detection subsystem7comprising a series of collection and detection modules200into the surface inspection system10enables more optimal use of the beam scanning subsystem8. For example, some defects (such as scratches) are more readily detectable in signals from a channel600formed from output associated with a wing collector310A,310B, when it is operated using “S” polarization, than signals from a channel600formed from output associated with the wing collector310A,310B, when it is operated using “P” polarization, while particles are more readily detected in signals from a channel600formed from output associated with the wing collectors310A,310B, when they are operated using “P” polarization than signals from a channel600formed from output associated with the wing collector310A,310B, when it is operated using “S” polarization. By simultaneously providing both signals, the overall defect detection performance of the inspection system10can be improved.

When scanning bare polished wafers, the dual detector rotational polarization analyzer461preferably is oriented so that one PMT495is “P” and the other is “S.” In some applications, a variable polarizing assembly470is not necessary. In others, however, for example, such as some film inspection applications, polarizer orientation can be and is changed routinely.

In summary, the collection and detection assembly200comprises a collector-detector field replaceable unit (“DFRU”)811configuration of the preferred embodiment of the present invention that is particularly useful in inspecting polished bare wafers using a fixed “P” and “S” relay assemblies454in each wing detector module410A,410B and unpolarized relay assemblies483(comprising unpolarized glass cubes452) in all of the other detector modules420,430,440A,440B. The DFRU811configuration of the preferred embodiment of the current invention that is particularly useful in inspecting wafers on which films are deposited uses variable polarizing relay assemblies470such as motorized dual PMT rotational polarization analyzers461, in the back detector modules440A,440B and wing detector modules410A,410B, and unpolarized relay assemblies483(comprising unpolarized glass cubes452) in the center detector module420and front detector module430.

A variable polarization analyzer470according to a further embodiment is shown inFIG. 28. In this analyzer design, the analyzer470comprises a rotational waveplate, fixed beamsplitter polarization analyzer471having a polarization beamsplitter (“PBS”) cube472C and dual detectors495that are rotationally fixed. A rotatable quarter waveplate (“QWP”)486and half waveplate (“HWP”)488are located in front of the PBS cube472C. This enables the suppression of the background light, as described in U.S. Pat. No. 6,034,776, which is herein incorporated by reference. By using a QWP/HWP combination, linear as well as elliptical polarized light can be substantially attenuated in one of the detectors497,499. By making the QWP/HWP combination rotatable, both linear and elliptical polarized light of selectable polarization mixes can be presented to the detectors497,499. As before, an unpolarized detector signal can be generated by adding signals from the two PMTs495.

The polarization filters450,470and non-polarizing assemblies483as described here can be used in connection with any of the collectors used in system10, or any combination of them.

Front Collectors

As noted above, the optical collection and detection subsystem7comprises means250for developing a light channel, for collecting the specular beam reflected from the surface of the workpiece into a light channel650, and means260for developing a dark channel, for collecting the scatter from the workpiece surface S into a dark channel655. The means260for developing a dark channel further comprises a series of collection and detection modules200, one of which comprises a front collection and detection module230. The front collection and detection module230and the means250for developing a light channel are both generally positioned in the path of the reflected incident beam.

Front collection and detection module230comprises a collector and detector assembly having a front collector assembly330and a front detector assembly430. Front collection and detection module230is similar to the back collector and detector assembly240A shown inFIGS. 23-26. Objective lens optics392in the front collector330focus the incoming scattered (not specular) light to a slit396, which operates as a field stop to absorb scatter outside of the illuminated localized region of the wafer being scanned. Light then passes to a relay lens assembly490in the front detector assembly430. The front collector330is similar to the back collector430shown inFIG. 25, with the exception that the slit396in the front collector330is disposed at the appropriate Schiempflug angle, to match the angle of the image of the wafer surface W.FIG. 25, which shows the back collector and detector module240A, shows the slit396also arranged at the Schiempflug angle that corresponds to the angle of the back collector340A with respect to the wafer normal. The Schiempflug angle will be different for the back, front, and wing collectors since they are positioned at different angles with respect to the wafer normal. The center collector330(or central collector330) does not have a Schiempflug angle, because it is disposed normal to the wafer surface, and therefore has no Schiempflug condition. For more information about the Schiempflug condition and how the Schiempflug angle is calculated, refer to FIG. 2.21 inModern Optical Engineering,2nded., Warren J. Smith (McGraw-Hill, 1990).

Specular Beam Guiding System

In addition, the objective lens optics392in the front collector330differs from the objective lens optics392in the back collector340A in that front collector objective lens optics292also has a light channel assembly253comprising an aperture (or hole)251(FIG. 22), which is positioned in the front collector objective lens optics292at the intersection of the light channel axis LC to permit the specular beam to pass through the optics292.

The means250for developing a light channel also comprises a light channel assembly253that is positioned adjacent to the front collector330to receive the specular beam. As shown inFIG. 29, the light channel assembly253also comprises an input aperture251for receiving the specular beam. The beam passes through an absorptive attenuation filter252(composed of glass such as Schott NG4 from Schott Glass). After passing through the attenuator252, it passes through a 50/50 beamsplitter254, which splits or evenly divides the beam into transmitted and reflected components. The transmitted component passes through a cylindrical lens255, such as the SCX-50.8-127.1-C lens from CVI Corporation (Albuquerque, N.Mex.), and is then received at a Linear Position Sensitive Detector (LPSD)256, such as the SL15 detector from UDT Sensors, Inc. The LPSD256detects the centroid of the target spot TS. The cylindrical lens255ensures that the beam does not move during the AOD scan at the LPSD256, which is located at the telecentric plane.

The reflected portion of the beam from the 50/50 beamsplitter254passes through a spherical lens257, such as the Melles Griot 01LPX282 plano convex lens, and is then is received at a position sensitive detector258, such as the SPOT-9DMI segmented photodiode detector (or “quad cell”) from UDT Sensors, Inc. The quad cell detector258is sensitive to movement of the reflected spot caused by both radial and tangential tilt, which is useful for detecting slurry rings, slip lines, and other potentially non-scattering defects that exhibit low spatial frequencies.

Both differences in wafer height and wafer tangential tilt cause the spot to move on the LPSD256. By linearly combining signals from the quad cell detector258and the LPSD258, the signal component related to tangential tilt can be removed from the LPSD signal, leaving only the signal component related to workpiece height. Determining wafer height relative to the collection optics is important for properly computing the x,y coordinates of wafer defects, since their apparent position with respect to the beam changes with wafer height. Determining wafer height relative to the collection optics is also important to increase knowledge of the wafer and the processes in which the wafer is involved.

Back Collectors

The optical collection and detection subsystem7according to another aspect of the invention comprises one or more wing collection and detection modules positioned to collect at least one portion of the scattered light. It is preferable in some applications, such in particle detection, that there be two wing collection and detection modules240A,240B, having, respectively, a wing collector assembly340A,340B and its associated wing detector assembly440A,440B. In some applications, however, it is desirable to collect signal from only one such back collector, or more than two.

As with the center collector320and front collector330, the objective lens optics392in back collectors340A,340B focus the incoming photons to slits396, each slit396, as the slit396in the center and front collectors, operating as a field stop to absorb scatter outside the illuminated region of the wafer. Light then passes to the relay lens assembly490in the back detector assembly440A,440B, associated therewith. The slit396in the back collector340A,340B is disposed at the Schiempflug angle corresponding to the angle of the back collector340A,340B with respect to the wafer normal.

The back collector module or modules are disposed in the back quartersphere BQ, outside the incident plane PI, and at or substantially at a maximum in the signal-to-noise ratio of defect scatter to surface roughness scatter. The wing collectors310A,310B may be positioned at or near a null or a minimum in to provide a reduction of noise from Rayleigh scatter. The reduction of Rayleigh scatter is discussed in detail below.

Center Collector

Surface inspection system10further also includes a center collection and detection module220that, in this embodiment, comprises a center collector320located directly above the desired spot on the workpiece surface S (i.e., the center of the inspection table) whose optical axis is aligned to the vector that is normal to the surface S. The center collector320in this embodiment is part of a collection and detection subsystem7as shown inFIGS. 23-26.

Center collection and detection module220comprises a collector and detector assembly200having a center collector assembly320and a front detector assembly420. As with the front collector330, objective lens optics392in the center collector320focus the incoming photon flux to a slit396, which, as the slit396in the front collector, operates as a field stop to absorb scatter outside the region on the wafer that is illuminated by the scanned laser beam. Light then passes to a relay lens assembly490in the center detector assembly420. The center collector320is similar to the back collector340A shown inFIG. 21, with the exception that the slit in the center collector320is disposed normal to the light passing through it because the wafer is disposed normal to the light passing through the center collector320; therefore there is no Schiempflug condition.

Wing Collectors

The optical collection and detection subsystem7according to another aspect of the invention comprises one or more wing collection and detection modules positioned to collect a portion of the scattered light. It is preferable in some applications, such as those involving inspection of bare or unpatterned semiconductor wafers, that there be two wing collection and detection modules210A,210B, having, respectively, a wing collector assembly310A,310B and its associated wing detector assembly410A,410B. In some applications, however, including but not limited to bare or unpatterned wafers, it is desirable to collect signal from only one such wing collector, or more than two.

As with the center collector320and front collector330, the objective lens optics392in wing collectors310A,310B focus the incoming photons to slits396in wing collectors310A,310B, each slit396, as the slit396in the center and front collectors, operating as a field stop to absorb scatter outside the illuminated region of the wafer. Light then passes to the relay lens assembly490in the wing detector assembly410A,410B, associated therewith. A wing collector310A,310B is similar to the back collector340A shown inFIG. 21, with the exception that the slit396in the wing collector310A,310B is disposed at the Schiempflug angle corresponding to the angle of the wing collector310A,310B with respect to the wafer normal rather than at the Schiempflug angle corresponding to the angle of the back collector340with respect to the wafer normal.

The wing collector module or modules are disposed in the front quartersphere FQ, outside the incident plane PI, and at or substantially at a maximum in the signal-to-noise-ratio of defect scatter to surface roughness scatter. The wing collectors310A,310B may be positioned at or near a null or a minimum in surface roughness scatter relative to defect scatter for scattered light from the surface S, or the P component thereof. For example, wing collectors310A,310B may be positioned at about a minimum in the bidirectional reflectance distribution function (“BRDF”) for the surface when the incident beam is P polarized and the detector assembly400is also P-polarized. The calculation of the BRDF is discussed in detail below.

It is desirable to locate the wing collectors310A,310B at such locations, for example, because, at these locations, the haze, which may be defined to be the diminished atmospheric visibility that results, in the case of a surface inspection tool, from light scattered from a surface, and which determines background noise (due to BRDF) is minimized, but the defect scatter signals remain, preferably at or near a maximum relative to the noise. The haze or background noise (due to BRDF) is minimized because, when, as in the present invention, the collection optics contains a polarizer that is oriented in local “P” polarization, the light scattered from the surface has “S” orientation. The polarizer that is oriented in local “P” polarization thus counteracts the haze or background noise that has an “S” orientation.

Thus, collection at or near a null or a minimum in surface roughness scatter relative to defect scatter, for example, from a defect perspective, at a maximum in the signal to noise ratio of defect scatter to surface roughness scatter when the incident beam is P polarized, or, from a surface roughness scatter perspective, when the surface roughness is at a relative minimum for scattered light from the surface S resulting from the bi-directional reflectance distribution function (“BRDF”) of the surface S, or the P component thereof, when the incident beam is P polarized and the detector assembly400is also P-polarized, provides an enhanced signal to noise ratio for these signals. This is illustrated byFIGS. 30 and 31. These figures show a BRDF for P-polarized light incident on the workpiece surface S at 65° with respect to the normal vector N, and where beamsplitter472is configured to pass P-polarized scattered light to the detector while blocking S-polarized light.FIG. 30shows the BRDF using linear intensity, andFIG. 31uses log intensity. In both, the y-axis is representative of the spherical coordinate theta, or an angle of elevation, and the x-axis is representative of spherical coordinate phi, or an azimuthal angle. The location (0,0) is normal to the wafer, and pointing along the optical axis of the center collector320. From these graphs one may identify the local minima or nulls of the BRDF (hereinafter referred to as BRDFMIN), and correspondingly select a location for the wing collectors, in terms of azimuth and elevation. Referring particularly toFIG. 31, one can see BRDFMINas the darker region extending upward from the x-axis to the point (0,80) and then downward toward the x-axis again. Points910A,910B identify one combination of angles of elevation and azimuth for placing, respectively, the collectors310A,310B at locations in which haze which determines background noise is minimized. Specifically, the coordinates of points910A,910B define the angles of elevation and azimuth for such preferred placement. Once the decision is made to place the wing collectors310A,310B at a selected angle of elevation912, the collectors' azimuthal placement is determined by the x-coordinate of the two locations of the BRDFMINassociated with the elevation angle912s,namely azimuthal angles914,916, and the combination of desired angles are defined by the coordinates of points910A,910B.

The optical collection and detection subsystem7further comprises a pair of wing collection and detection assemblies210A,210B positioned in the front quartersphere FQ but outside the incident plane PI. Wing collectors310A,310B are substantially identical to one another. Each comprises a portion of a collection and detection assembly200as shown inFIGS. 23-26. Wing collectors310A,310B in this embodiment are located symmetrically with respect to the incident plane PI, and when they have identical focal lengths, they are equidistant from a point on the light channel axis LC and equidistant from the surface S of the workpiece W. This also applies where multiple pairs of wing collectors are used. Wing collectors310A,310B are positioned to receive a desired and preferably optimal or near optimal amount of light scattered from defects on the workpiece surface S. By positioning the wing collection and detection assemblies210A,210B out of the plane of incidence PI, the amount of light coupled into the wing detector assemblies410A,410B associated with wing collectors310A,310B due to Rayleigh air scatter is reduced, thereby reducing the background light and improving the signal to noise ratio (SNR).

The optical collection and detection subsystem7uses P-polarized incident light at 65° of incidence, as noted above. The scattered light from an optically smooth surface exhibits a minimum at a specific angle if the optical detector detects only P-polarized light since the surface roughness scatter from the wafer is S-polarized when the incident beam is P-polarized for the desired wing collector locations. This is only true for surfaces that exhibit Rayleigh-Rice scatter, as described inOptical Scattering Measurement and Analysis,2nd ed., John C. Stover, (SPIE Optical Engineering Press 1995) (hereinafter the Stover reference). This effect is shown in the plots inFIGS. 24 and 25. These plots were derived from Equations 4.1 and 5.12-5.17 inOptical Scatter.The null is the multi-dimensional equivalent of the Brewster angle. The location of the null, therefore, is dependent upon the index of refraction of the surface.

The wing collectors310A,310B of the wing collection and detection modules210A,210Bs of the optical collection and detection system7are also designed and placed to provide, along with the front collector330of the front collection and detection module230, symmetrical and nearly complete collection of forward scattered light. This can improve the scratch detection performance of the system.

The collection angle of wing collectors310A,310B in the present embodiment are about 26° (half angles of about 13°). As stated above, the spherical angle corresponding to the desired surface roughness scatter null will be dependent on the index of refraction of the material. For some types of surfaces, it may be desirable to increase the size of the wing collectors310A,310B to 30 degrees or more and adjust the angular position of the optical axis for optimal SNR. Note that the detector assembly400design incorporates selective subaperture masking (“virtual mask131,” described below), which can enable selective subaperture collection to collect light only from angular regions where the SNR is highest.

The first wing collector310A is positioned with an azimuth angle with respect to the light channel axis LC of about 5 to 90°, and the second wing collector310B is positioned at an azimuth angle with respect to the light channel axis LC of about −5° to −90°. The azimuth angles used in the presently preferred embodiments are about +50 and −50 degrees. It should be noted that, in referencing the positioning of the collectors300herein, the angular position of the collector300is measured to a central point on the central axis of the collector300, i.e., an optical axis of the lens corresponding to the axis of the optical path of the beam as it passes through the center of the lenses in the collector's objective lens optics392.

The wing collectors310A,310B preferably have an elevation angle with respect to the surface S of the workpiece W of about 30° to 90°. In the presently preferred embodiments and method implementations, the elevation angle of wing collectors310A,310B is about 45°.

In the preferred embodiments and implementations, a polarizing beamsplitter in each of the wing collection and detection modules210,210B, such as the beamsplitter472illustrated inFIGS. 23-26, is disposed in the relay lens assembly490at the input to each wing detector assembly410A,410B that is associated with a wing collector310A,310B, i.e., in the optical path of the region between the desired spot and the wing detector assembly associated with a wing collector or collectors310A,310B. This enables one of the detectors497,499of the collection and detection assemblies210A,210B to receive solely P-polarized radiation, and thereby take full advantage of this effect.

In accordance with this aspect of the invention, the method for locating the positions of the wing collectors310A,310B can be further explained and elaborated upon. U.S. Pat. No. 6,034,766 describes the use of a plurality of small solid-angle collectors over the surface of a scattering hemisphere to detect defects on a microrough surface. The patent indicates that large number of these collectors should be employed to cover a large solid angle. The patent also suggests that a polarization analyzer should be employed at each collector to be orthogonal to the scatter from microroughness so as to maximize signal-to-noise ratio.

The '776 patent fails to take into account two concerns that often are present in such systems. First, while each collector can be set to be “microroughness-blind,” the detectors will still be subject to Rayleigh scatter from the molecules of air near the surface of the workpiece. Rayleigh scatter is the scatter of light off the gas molecules of the atmosphere, principally Nitrogen for normal air. When surface inspection systems are operated in air, the illumination source generates Rayleigh scatter. This effect can be reduced by operating in partial vacuum, or by use of a gas with lower scattering cross-section such as Helium. Because both of methods for reducing Rayleigh scatter are difficult and expensive to implement, typically surface inspection systems are operated in air. Therefore, each collector in such systems has a constant background flux caused by Rayleigh scatter from the atmosphere. Even though Rayleigh scatter is a relatively small scatter component compared to surface roughness scatter, it is more significant, especially in the back collector of a multi-collector surface inspection system such as system10, when the surface scatter level is relatively low, for example when wafer surfaces with an extremely good polish are inspected. (See “A Goniometric Optical Scatter Instrument for Bidirectional Reflectance Distribution Function Measurements with Out-of-Plane and Polarimetry Capabilities”, Germer and Asmail, from “Scattering and Surface Roughness,” Z.-H. Gu and A. A. Maradudin, Editors, Proc. SPIE 3131, 220-231 (1997)). Second, building a system with a large number of collectors usually is expensive, difficult to set up and difficult to maintain. Furthermore, by setting the polarizer in each detector to minimize the background from surface roughness scatter, some detectors will also substantially reject important defect signal as well. The shot noise of the low level signals result in large defect voltage variations that could be confused with voltage signals representative of defects.

Because of the high cost associated with using a large number of collectors, it is desirable to reduce the number of collectors in the system. In accordance with this aspect of the invention, this objective can be achieved by placing the collectors at the locations on the scattering hemisphere where they can achieve the greatest advantage. Thus, the collectors are placed where they will have the highest signal-to-noise ratio for a selected range of workpiece surfaces and materials.

Because of the presence of the Rayleigh scatter from molecules in the atmosphere, each collector will have a constant background flux due to the Rayleigh scatter. Measuring photon flux has an inherent unavoidable noise associated with it called “shot noise.” It is expected that shot noise will be present in any surface inspection system. When the collectors are operated in air, the shot noise in the output associated with P-polarized wing collectors tends to be dominated by Rayleigh scatter. The shot noise in the output associated with the back collectors tends to be dominated by surface roughness scatter.

Shot noise consists of random fluctuations of the electric circuit in a photodetector, which are caused by random fluctuations that occur in the detector or by fluctuations in the number of electrons (per second) arriving at the detector. The amplitude of shot noise increases as the average current flowing through the detector increases. The flux measurement is really counting a rate of how many photons per second are collected by the detector. The longer the period of counting, the more accurately one can measure the rate. It can be shown that the power-equivalent noise from the Rayleigh scatter is given by:
σ2Rayleigh=2EphotonPRayleighχBW/QE,
where

σ2Rayleighis the variance of the measured Rayleigh scatter at the detector (in Watts2),

Ephotonis the energy of each photon in Joules,

PRayleighis the Rayleigh scatter present at the detector (in Watts),

QE is the quantum efficiency of the detector (dimensionless),

BW is the bandwidth of the measurement system (in Hz—equivalent to 1/sec), and

χ is the excess noise factor of the detector (dimensionless).

Furthermore, this noise is nearly Gaussian whenever

QE⁢⁢σi2Ephoton⪢1.
For practical scattering systems, this ratio is typically several hundred. We see that the RMS noise level (square root of variance) can be given by: σRayleigh=K√{square root over (PRayleigh)}, where K encompasses system contributions to noise, such as bandwidth, quantum efficiency, excess noise factor and photon energy. A defect particle will scatter with power Pparticle. To maximize the signal-to-noise ratio (SNR), we maximize

PparticleK⁢PRayleigh.
Note that the optical powers Pparticleand PRayleighare functions of incident wavelength, incident polarization, particle size, particle material, substrate material, incident declination angle, collector solid angle, collector declination angle and collector azimuth angle. These scatter powers are also controlled by the polarizer at the collector, which preferably is set to null the scatter from microroughness. For typical designs, the incident wavelength and incident declination angle are fixed. The collector solid angles are also fixed, and typically small. We now want to find the locations to place collectors300on the scattering hemisphere that maximize SNR.

In this illustrative example, silicon is used as the substrate or surface to be inspected. Using a beam having a wavelength fixed at 532 nm, an incident declination of 65 degrees, and p-polarization for the incident beam, the SNR plots for a small variety of particle sizes and materials can be shown. While the actual SNR values depend heavily on particle size and particle material, the scattering hemisphere locations of maximum SNR change very little. This can be used in accordance with this aspect of the invention to set the locations of the wing collectors310A,310B, e.g., using “microroughness-blind” collectors that are positioned according to their maximum SNR regions based solely upon incident wavelength, incident declination, incident polarization and substrate material.

Using this method, and in the particular case of a 532 nm beam source, a 65 degree incident declination, and p-incident polarization on a silicon substrate, the wing collectors310A,310B are placed in the regions of 40-70 degrees of declination, and either 40-70 degrees azimuth or 290-320 degrees azimuth to maximize SNR.

In order to fit the collectors300into the space above the wafer W, it may become necessary to cut sections out of the collectors300. Cuts may be seen inFIG. 22. As noted above, the output signal associated with the wing collectors310A,310B may be combined with output signals associated with selected other collectors300in order to provide improved defect detection and/or classification. Specifically, as will be described in further detail below, the back collectors340A,340B and P-polarized wing collectors310A,310B receive proportionately more signal from particles on the wafer surface than they receive from pits on the wafer when scanning defects <100 nm in size and using P-incident polarized light. Therefore, in order to facilitate the identification of pits on the surface of the wafer, it is preferable to cut as little as possible from the center collectors320(preferably no more than about 10%).

Collector System With Back and Wing Collectors

In accordance with another aspect of the invention, an optical collection system is provided for use in a surface inspection system10such as those described herein. In this aspect of the invention as in others, the surface inspection system10has an incident beam projected through a back quartersphere BQ and toward a spot on the surface S of the workpiece W so that a specular portion of the incident beam is reflected along a light channel axis LC in a front quartersphere FQ. The optical collection system according to this aspect of the invention preferably comprises a subsystem of a surface inspection system10. Thus, to illustrate and further describe this aspect of the invention, a presently preferred optical collection system embodiment will be described in the form of an optical collection subsystem380of system10. It will be appreciated, however, that the optical collection system is not necessarily limited in this respect.

In accordance with this aspect of the invention, an optical collection subsystem is provided that comprises a plurality of back collectors positioned in the back quartersphere BQ and outside the incident plane PI for collecting scatter from the workpiece surface. The number of back collectors may vary depending upon the application. Preferably there are two such collectors, such as collectors340A,340B. The back collectors340A,340B preferably are substantially identical to one another. Where more than two back collectors340A,340B are employed, it is preferred that they be used in pairs, and positioned symmetrically with respect to one another and with respect to the incident plane for a given pair. The back collectors340A,340B also preferably are located symmetrically with respect to the incident plane PI, and, when they have identical focal lengths, they are equidistant from the incident plane PI and the desired spot on the workpiece surface S, in general or at least for given pairs of the collectors340A,340B.

As with the center collector320and front collector330, objective lens optics392in the back collectors focuses the incoming beam to a slit396, which operates as a field stop to absorb scatter outside the illuminated scan region of the wafer being scanned. Light then passes to a relay lens assembly490in the detector assembly400. While the slit396in the center collector320was disposed normal to the light passing through it, in the back collector, the slit396is arranged at the Schiempflug angle, to accommodate for the angle of the back collector with respect to the wafer normal.FIG. 25, which shows the back collector340A, shows the slit396arranged at the Schiempflug angle corresponding to the angle of the back collector340A with respect to the wafer normal.

Back collectors340A,340B according to this aspect of the invention preferably are positioned at azimuth angles of up to about 90°, and more preferably about 10° to 90°, with respect to incident plane in the back quartersphere BQ. These angles equate to about 90° to 180° and about 90° to 170°, respectively, with respect to the light channel axis LC. Azimuth angles of at least about 45° to 55° are even more preferred, particularly in semiconductor wafer surface inspection systems, for example, such as system10.

The presently preferred elevation angles for back collectors340A,340B according to this aspect of the invention are about 35-60 degrees with respect to the workpiece surface S. More preferably, the elevation angles of the back collectors340A,340B are about 53° with respect to the workpiece surface normal vector.

The collection angle of back collectors340A,340B according to this aspect of the invention preferably are about 20° to about 60° (i.e., half angles of about 10° to about 30°), and more preferably about 60° (i.e., half angle of about 30°).

As implemented in the presently preferred embodiments, an optical collection subsystem is provided with two back collectors340A,340B. Collector340A is positioned at an azimuth angle of 55° with respect to the projection of the incident beam on the surface in the back quartersphere. Collector340B is positioned at an azimuth angle of about −55° with respect to this same incident beam projection. In this embodiment of an optical collection subsystem, collectors340A,340B are equidistant from the surface S of the workpiece W, and each has an elevation angle with respect to the desired spot on the surface S of about 53°. When scanning polished wafer surfaces, the relay lens assembly490in back detectors440A,440B associated with back collectors340A,340B uses unpolarized cubes. When scanning films, a rotating analyzer472such as described above can be used to minimize background from the film surface in some applications.

Switchable Edge Exclusion Mask

In accordance with another aspect of the invention, a switchable edge exclusion mask132is provided in the front collector330in order to cover the region of the objective lens optics292between the specular beam hole251and the outer edge of the lens L1. It is frequently desirable to scan the edge of a workpiece W, e.g., a silicon wafer, to calculate or determine such things as the placement of the wafer with respect to the center of rotation, to look for edge chips, etc. Unfortunately, the wafer or workpiece edge typically is beveled in such a way that the laser beam may be reflected directly into the front collector330. This can cause the detector or detectors497,499in the detector430associated with the collector330to saturate, and can actually damage them in some cases, e.g., the anode of the PMTs495. To limit or prevent this, an edge exclusion mask132according to this aspect of the invention may be placed in front of the front collector330to absorb the specularly reflected beam as it scans across the edge of the wafer W.

In accordance with this aspect of the invention, switchable edge exclusion mask132is provided. In an illustrative but not necessarily preferred embodiment of this aspect of the invention, switching is performed electro-mechanically.

Using an edge exclusion mask132can substantially reduce the edge exclusion zone on the wafer (the region over which data can be reliably collected near the edge of the wafer). Unfortunately, however, it also can reduce the sensitivity of the front collector330to scratches that are perpendicular to the AOD scan direction. An example of this is shown inFIG. 32, which shows a scratch distribution plot. This problem can be minimized using a switchable edge exclusion mask132as described herein.

A mask132according to this aspect of the invention is illustrated inFIG. 33. Mask132is normally energized so that it is outside the collection field of the front collector330when scanning the interior of the workpiece surface S. This maximizes the front collector collection efficiency, and enables complete collection of scratches that are perpendicular to the AOD scan direction. When the AOD scan approaches within 1-3 mm of the edge of the scan, the mask132is electromechanically moved in front of the lens and blocks the scatter and reflection from the wafer bevel.

The mask132is designed to cover the region of the front collector lens between the specular beam hole and the outer edge of the lens. The mask132is connected to an electromechanical means133having an edge exclusion actuator137for moving the edge exclusion mask132. A sensor136is employed to sense the position of the mask, enabling the control computer500(described more fully herein below) to sense if the edge exclusion actuator137is working correctly. The electromechanical means133for moving the edge exclusion mask132could comprise a rotary motor, a two-position motor, a stepper motor, a DC servo motor, or a pneumatic means. In an illustrative but not necessarily preferred embodiment of this aspect of the invention, as illustrated inFIG. 33, the electromechanical means133comprises a drive mechanism134with a drive mechanism stage138and an air drive135for holding and moving the edge exclusion mask132.

Edge exclusion masks132in accordance with this aspect of the invention advantageously can enable one to obtain a small edge exclusion zone near the edge of the wafer or workpiece surface S without sacrificing overall front collector sensitivity.

Moveable, Switchable Virtual Mask

In accordance with still another aspect of the invention, a moveable, switchable virtual mask131is provided. Most of the optical scatter from a semiconductor wafer or similar workpiece is produced by the lowest spatial frequencies, and is therefore confined to a small angular range around the specular beam in the forward scatter direction. This background scatter tends to dominate the signal detected by the front collector PMT495, masking the presence of critical defects, such as microscopic scratches, that comprise higher spatial frequencies. Defects associated with higher surface structure spatial frequency content generally scattered light into larger angles with respect to the specular beam. It is possible to partially or fully absorb or otherwise exclude excessive scattered light associated with low surface structure spatial frequency from the wafer surface using an appropriate masking device.

In past inspection systems, in order to improve the defect detection performance of the front collector, an elliptical mask was installed in front of the lens to block this scatter. The mask was elliptically shaped in order to block the light scattered from surface structures of low spatial frequency relative to the collection geometry for the in-scan and cross-scan directions (based on the 2D grating equation expressions in the Stover reference, page 75). However, the placement of the black anodized aluminum mask in front of the lens in the front collector tended to reflect scatter back to the wafer, therefore introducing additional scatter into other detectors497,499.

In addition, when introducing such a mask, however, it is often undesirable to position the mask in front of the collection lens since this would scatter light back to the test surface. The mask in this instance can block desired light that includes important information about the surface. For example, it is desirable to detect “flat particles” shallow bumps or dimples whose aspect ratio is large, with diameters greater than 1 micron and heights of a few nanometers. These defects scatter light associated with a lower surface structure spatial frequency range (near the specular beam) than do typical spherical defects <100 nm in diameter. Therefore, when scanning a wafer for flat particles or dimples, it may be desirable to use a mask that blocks scattered light associated with higher or lower surface structure spatial frequencies than those associated with the defects of interest in the front collector but allows the scattered light associated with these particular defects to pass through to the detector497or499.

In order to enable the system to optimally detect either small particles or flat particle defects, a moveable, switchable virtual mask131is provided according to this aspect of the invention. Switching and moving a virtual mask131can allow the user to select the angular range of light that must be masked based on the surface structure spatial frequency content of the wafer or other like surface, and can allow optimization of defect sensitivity for defects that have unusual angular scatter distributions.

A virtual mask131according to a presently preferred yet merely illustrative embodiment of this aspect of the invention is shown inFIGS. 34 and 36. The virtual mask131comprises a black or otherwise light absorbing glass mask, preferably elliptical in shape, which is optically bonded to the glass cube462that is located in the detector relay lens assembly490of the detector module430. Alternatively, the mask131could comprise a black anodized aluminum sheet metal mask that is positioned in a correct optical imaging position in the detector module430, which is located along the beam path after the collector module330.

The virtual mask131is used to block the scatter near the specular beam. As shown inFIG. 34, scattered light from the wafer or other workpiece surface S is collected by the collector200over the solid angle subtended by the objective lens optics392. After the light travels through the objective lens optics392, it passes through a slit396, and then to the cube462, which may comprise polarizing beamsplitter472, polarizing cube456, or unpolarized cube452. Light that reaches the virtual mask131is blocked from reaching the PMT495.

Scatter that is reflected off of the mask131is minimized by the manner in which the virtual mask131is attached to the cube462and by the placement of the mask131after the slit396. Since the black glass piece that comprises the virtual mask131is bonded to the cube glass396with index-matching optical cement, the optical interface between the black glass mask131and cube396exhibits minimal scatter. In addition, any residual scattered light that bounces back from the mask131must pass through the slit396to pass back through the collector330and arrive at the wafer W, and is therefore substantially reduced relative to prior known systems.

In the presently preferred yet merely illustrative embodiment, as shown inFIG. 36, the black glass piece mask131is located at an x-y position within the front collector detector module230slightly off the optical axis, mapping the specular beam, in order to force the mask to be coincident on the specular beam hole251. The location of the black glass mask131at a z-position such that the real image of the black glass mask131is located between the two aspheric objective lenses L1, L2causes the glass piece to comprise a “virtual mask” rather than a physical mask that is in front of the objective lens optics assembly392of the front collector330.

The virtual mask131shown inFIGS. 34 and 36is fixed (bonded to the back of the cube). It may be rendered switchable by exchanging a mask (such as an aluminum mask) in/out of the desired position, for example, by manually replacing the glass cube362in the detector module430. The only way to move it is to either or Alternatively, the virtual mask131is rendered switchable and moveable by moving the glass cube362into another location, for example, using a carousel approach. As noted above, in the presently preferred yet merely illustrative embodiment of this aspect of the invention, the virtual mask131is a black glass piece, which is optically bonded to the glass cube362that is located in the relay lens assembly490of the detector module430. As noted above, in the presently preferred yet merely illustrative embodiment of this aspect of the invention, the polarizing beam splitter glass cube472is switchable to provide variable polarization. As the glass cube472is moved, so is the glass piece mask131attached to it.

Although the virtual mask131according to the presently preferred embodiment is depicted only in the front detector module430, it can be used in any of the detector assemblies400to either limit the solid angle collection range of the detector module400or to mask off unwanted solid angles. The solid angle range of collection is specified by the size and shape of the virtual mask131. Annular virtual masks can be used to reduce the effective solid angle of collection of the detector module400. Other shapes may be used to collect the desired light from a sub-region of the lens assembly. The virtual mask131could also be employed in the wing collection and detection modules210A,210B to limit collection of the scattered light associated with surface structure spatial frequency spectrum to only a defined sub-region of a workpiece region wing. The wing collection and detection modules210A,210B of preferred system10as described herein are optimized to detect light within the BRDF null (BRDFMIN) while achieving reasonable sensitivity to 45 degree scratch signals. As shown in the surface structure spatial frequency plot ofFIGS. 37-38, the wing collectors are designed to cover a portion of the surface structure spatial frequency spectrum between the front collector330and back collectors340A,340B.FIG. 37shows the front collector surface structure spatial frequency spectrum coverage143, the wing collectors' surface structure spatial frequency spectrum coverage141A,141B, and a portion of the center collector surface structure spatial frequency spectrum coverage142.FIG. 38shows the back collectors' surface structure spatial frequency spectrum coverage144A,144B and the remainder of the center collector surface structure spatial frequency spectrum coverage142.

If in a particular application it is desirable or necessary to achieve more complete wing collectors' surface structure spatial frequency spectrum coverage141A,141B in the region-between the front collector surface structure spatial frequency spectrum coverage143and back collectors' surface structure spatial frequency spectrum coverage144A,144B, in order to provide fuller coverage of this region, an aspheric lens design can be used in this region if the azimuth angle is increased to about 60 degrees. In certain semiconductor wafer applications there are primarily three reasons for collecting a sub-region of this region: 1) the BRDF null would be located to one side of the lens if the azimuth angle were set to 60 degrees, 2) the location of the BRDF null is dependent upon the index of refraction of the material, therefore it can move to slightly different locations for different materials, and 3) Rayleigh scatter adds an additional background contribution that can increase the overall background light collected by the wing (or other) collector and can partially shift the effective location of the BRDF null. It also may be desirable to use the virtual mask131in the relay to collect a sub-region of the wing collector surface structure frequency spectrum141A,141B to compensate for these three effects. As with the virtual mask131in the front collection and detection module230, the virtual mask131could be moveable or it could be selectable in a carousel fashion in order to collect a sub-region of the wing collector solid angle for optimal SNR.

Signal Processing Subsystem

Signal Processing Architecture

A number of the systems and their illustrative but not necessarily preferred embodiments as disclosed herein comprise a processing subsystem or module19operatively coupled to an optical collection and detection subsystem or module7for processing the signals generated by light detection. This processing module19performs processing on the signals obtained from the optical collection and detection subsystem7to provide desired information concerning the surface S of the workpiece W under inspection, such as its geometry, characteristics, defect information, and the like. The processing system19as implemented in the illustrative but not necessarily preferred embodiment comprises a controller such as system and processing unit500.

As best illustrated in the perspective view ofFIGS. 3 and 4, the surface inspection system10preferably is computer controlled. The system controller and processing unit500operates the inspection system10under the supervision and direction of a human operator, stores and retrieves data generated by the system10, and performs data analysis preferably responsive to predetermined commands. The relative position of the article being inspected is communicated to the system controller500via motors, not shown, and encoders, not shown, mounted thereto. The position data is transmitted to the gauge synchronization control186, which responsively drives the AO deflector100via an AOD scan driver950.

As understood by those skilled in the art, data signals from the collectors are conventionally electrically communicated to the processing electronics750. The processing electronics750could comprise digital electronics (not shown) and analog electronics comprising an Analog Combining Board (not shown) for processing the signals, such as that described in the '701 patent. In a presently preferred yet merely illustrative embodiment, the signals are processed digitally using the data processing system shown as system controller and processing unit500in block diagram form inFIG. 46.

As shown inFIGS. 46 and 48, a data processing subsystem or module19for use in inspecting a surface of a workpiece has a data acquisition system54comprising a plurality of data acquisition nodes570(DANs570) connected by a communication network to a data reduction system55comprising a plurality of data reduction nodes670(DRNs670). A system controller and processing unit500is connected to the data reduction system55via an interface or switch660arranged for a communication network or other system controller and processing unit500communication. The system controller and processing unit500is operated using keyboard16, mouse18, etc., and it presents output on display20or other suitable peripherals, e.g., a printer. The system controller and processing unit500outputs the data representative of the selected set of collectors to a channel analysis system520through System I/O530.

Channel Definition and Channel Combining

Output from the optical collection and detection subsystem7is organized into defined channels600.FIG. 47lists a set of channels600that could be formed for the presently preferred but merely illustrative embodiment described herein. Certain channels600comprise the set of data comprising the output associated with an individual collector module300, such as the center channel620formed from data from the center collection and detection module220and the front channel630formed from data from the front collection and detection module230.

Other channels600are formed from the set of data comprising the output associated with a combination of collection and detection modules200, such as the spherical defect channel615, which would be particularly sensitive to the detection of small spherical objects such as 50 nm polystyrene latex spheres (PSLs) and defects with like geometries, formed from data from the wing collection and detection modules210A,210B when operated in P-polarized format and the dual back collection and detection modules240A,240B. In addition, channels600comprise the set of output data associated with selected combinations of collector modules300operated in a selected format or in which the data are processed using a selected method. For example, back combined (CFT) channel641is formed from output data associated with back collection and detection modules240A,240B when they are combined using a selected signal combining CFT method812involving first combining, then filtering/thresholding the data (the method is described in more detail below). Similarly, the wing combined (CFT) P channel610P and wing combined (CFT) S channel610S are formed from data from the wing collection and detection modules210A,210B when the resulting data are operated in a selected polarization format (P or S, respectively) and the resulting data combined first by combining, then filtering/thresholding. Generally, channels C1through CN could be formed from the output data associated with any individual collection and detection module200or any desired combination of collection and detection modules200.

Light channels650are similarly formed with output data collected from the light channel assembly253, which has as input the specular beam reflected from the surface S of the workpiece W. Light channels650comprise, specifically, the extinction channel650EXT, the radial channel650R, the tangential channel650T, and the height/reflected power channel650H/RP.

As noted herein, an illustrative channel600could comprise the spherical defect channel615defined from the combination of wing modules210A,210B when operated in P-polarized format and the dual back modules240A,240B, which would be particularly sensitive to the detection of small spherical objects such as 50 nm polystyrene latex spheres (PSLs) and defects with like geometries. Channels are defined to comprise sets of collectors, using any of the combinations of collector sets described herein (such as channel615) or any other desired combination, and output signals associated with the sets of collectors are-combined according to any conventional methods or the methods described herein into output to be associated with the defined channel. The resultant output may be analyzed using any methods such as those described herein or any known defect detection method, such as those described in U.S. Ser. No. 10/864,962, entitled Method and System for Classifying Defects Occurring at a Surface of a Smooth Substrate Using Graphical Representation of Multi-Collector Data, which is assigned to ADE Corporation of Westwood, Mass. and which is herein incorporated by reference.

It should be noted that the present invention should not be limited to the embodiment of the present invention, in which channels600are formed from combinations of collectors200disposed at selected locations in the space above a workpiece surface. It should be noted that the present invention should not be limited to the collectors as described above. For example, collectors300have collection optics subassemblies390that direct the scatter to detectors400. Alternatively mirrors could be used to direct the scatter to detectors400. In addition, the present invention should not be limited to defining channels from collector response to light scattered from surface structural conditions.

Fundamentally, the invention involves combining signal representative of light of selected characteristics scattered from surface structural conditions, with characteristics comprising, for example, selected polarization and/or presence in a selected solid angles over a workpiece surface. As an example, the spherical defect channel615is preferably formed from signal representative of P-polarized scatter collected at a plurality of solid angles over a workpiece surface in the front quartersphere FQ and from signal representative of scatter collected at plurality of solid angles over a workpiece surface in the back quartersphere BQ of the space above a wafer, outside the incident plane PI.

Preferably, the plurality of solid angles in the front quartersphere FQ represent locations at or substantially at a maximum in the signal-to-noise ratio of defect scatter to surface roughness scatter, or, from a surface roughness scatter perspective, when the surface roughness is at a relative minimum in a bi-directional reflectance distribution function when the incident beam is P polarized. More preferably, the solid angles represent two locations, preferably substantially identical to one another and positioned symmetrically with respect to one another and with respect to the incident plane. In system10, such solid angles represent the location of the wing collectors210A,210B.

Preferably, the solid angles in the back quartersphere BQ represent two locations, preferably substantially identical to one another and positioned symmetrically with respect to one another and with respect to the incident plane. In system10, such solid angles represent the location of the back collectors240A,240B.

The communication network that is represented inFIG. 46as switch691could be any suitable communication system, such as an Ethernet™ communication system or, preferably, a Serial PCI compatible, switched interconnect communication system such as one based on the StarFabric™ open interconnect standard, “PICMG 2.17 CompactPCI StarFabric Specification” (ratified in May 2002).

Turning toFIG. 46, the data acquisition system54comprises a plurality of data acquisition nodes570connected by the serial PCI switch691to a data reduction system55comprising a plurality of data reduction nodes670. Each data acquisition node570is connected to and has associated therewith a collection and detection module200in the optical collection and detection subsystem7. Each light channel collection and detection module560and dark channel collection and detection module200has an output that is connected through an associated amplifier693to the input of a filtering unit comprising an A/D572(also known herein as an A/D converter572) and a Processing unit (PUs)574. The processing unit574comprises a microprocessor or, alternatively, a field programmable gate array (FPGA), and provide digital filtering and have outputs to the serial PCI switch691.

The light channel collection and detection module560has associated therewith elements of the quad cell detector258, specifically the extinction element, radial element, tangential element, and height/reflected power element. The dark channel collectors300comprise back left collection and detection module340B, back right collection and detection module340A, center collection and detection module320, and front collection and detection module330s,and further comprise right wing collection and detection module310A and left wing collection and detection module310B, each of which can be operated in P-polarized and S-polarized configurations.

The data reduction subsystem55comprises a selected number of data reduction modules670, also called data reduction nodes670. In the illustrative but not necessarily preferred embodiment, the data reduction nodes670comprise dual PC-type processors in the workstation class, specifically having a 64-bit architecture. The nodes670could also comprise a series of standard rack-mounted computers (blade processors). Each data reduction module670has an input that is connected to the serial PCI switch691. As mentioned above and described in more detail below, a data reduction module670may be provided for each of the desired combinations of collection and detection modules300to be processed into a channel600by the surface inspection system10.

The networking of a plurality of data reduction nodes670with a plurality of a data acquisition nodes570, each of which is dedicated to a collection and detection module200, provides a signal processing architecture in which multiple generic data recipients are available on a peer to peer basis to multiple sensors, thus essentially providing multiple computing destinations for the collector output. In addition, networking of DANs and DRN allows for simultaneous delivery of identical data to multiple destinations, thus allowing for simultaneous usage of the data product. For example, the signal processing architecture allows a user of system10to perform “Total Integrated Scatter”-based haze analysis in tandem with “Angle-Resolved Scatter”-based haze analysis, both of which are described in further detail below.

The resultant flexibility allows the system10to combine any suitable combination of collectors300into a channel600. The ability to define channels600using any desired set of collectors300allows for unprecedented flexibility in surface inspection system output, resulting in improved investigation of surface aberrations.

Referring toFIGS. 48 and 49, there is shown a block diagram showing data flow in the surface inspection system10of the presently preferred yet merely illustrative embodiment of the present invention. An optics plate60has a plurality of collector/detector assemblies200. In the preferred embodiment, the optics plate60has twelve collector/detector assemblies200, a plurality of PMT units495and associated preamplifiers, one quad cell detector258with three output signals (radial, tangential, and extinction) and associated preamplifier, and a LPSD256with associated preamplifier with output signals representative of wafer height changes.

In the embodiment of the present invention that is arranged for the inspection of bare semiconductor wafers, the optics plate60has eight PMTs495, one for each of the center collector/detector assembly220, front collector/detector assembly230, and back collector/detector assemblies240A,240B, and two for each wing collector/detector assembly310A,210B; each wing collector/detector assembly having one PMT495for its S-polarized configuration and one for its P-polarized configuration. In the embodiment of the present invention that is arranged for the inspection of semiconductor wafers with transparent films, the optics plate may have ten PMTs495(an additional two on the back collector/detector assemblies240A,240B).

The optics plate60is connected to a data acquisition subsystem54having a gauge synchronization board186that is connected to the plurality of data acquisition nodes (DANs)570. In the presently preferred yet merely illustrative embodiment, the gauge synchronization board186has a 25 MHz master clock and sends synchronization scan initiation signals to six DANs570. The DANs570comprise a low noise receiver A/D572, filters and processing units574that as a unit is operable to perform anti-aliasing filtering, a software-configurable in-scan filtering, analog compression, A/D conversion, digital decompression of analog compression function, data decimation, and preparation of the data for transmission. In an illustrative but not necessarily preferred embodiment, the filters are a component of the processing unit, which comprises a digital signal processor and programmable logic such as field programmable gate arrays (FPGA).

The DANs570are connected via a switch691to the data reduction subsystem55, which comprises a plurality of data reduction nodes (DRNs)670. The switch691maps output associated with the collector/detector assemblies200to processor inputs in the DRNs670. In the presently preferred yet merely illustrative embodiment, surface inspection system10comprises seven DRNs670that have a combination of hardware and software that is operable to perform linear combining, digital filtering, threshold/haze calculation, and data collation and formatting.

The DRNs670, which comprise a master DRN672and at least one slave DRN674, with the master DRN672providing set up communications to the slave DRNs674, are connected via a switch660to a system controller and processing unit500, which comprises a combination of hardware and software that is operable to provide system control and monitoring, graphics user interface, and defect identification and sizing. The system controller and processing unit500is connected to a system I/O unit530that comprises a combination of hardware and software that is operable to provide subassembly control and monitoring and diagnostics.

The system controller and processing unit500is also connected to a motion servo controller696, which comprises a combination of hardware and software that is operable to perform stage control and AOD sweep initiation. The motion servo controller696is connected to the gauge synchronization board186in the data acquisition subsystem54, which is connected to the digital voltage controlled oscillator DVCO182to provide sweep line control to the AOD100.

FIG. 50is a block diagram showing data flow in the DANs570. As noted above, DANs570have a combination of hardware and software that is operable to perform digital filtering, and data collation and formatting. In the DANs570, clock, sync and sweep signals are transmitted to the A/D converters572and the Scan line assembly unit578. Also as noted above, raw data is transmitted from the collector/detector assemblies200to the DANs570, first arriving in the A/D converters572. The digital data are then transmitted at a rate of 400 Mbytes/sec (for 2 channels, 4× oversampling) to a filter/decimation unit580for filtering and decimation. The digital data are then transmitted a rate of 100 Mbytes/sec to a scan line assembly unit578.

Also as noted above, parameters and commands arrive at the DANs570at a low rate from the DRNs670via the StarFabric™ connection691. The commands are decoded by a command decoding unit584, which decodes commands from the signals and sends them to an address distribution unit586and scan line assembly unit578.

The decoded commands control the scan line assembly unit578in assembling scan lines from the digital data. The assembled digital data are then transmitted at a rate of 80 Mbytes/sec to a compression unit588for data compression, and then transmitted out as low voltage data signals via the Serial PCI switch691to the DRNs670. The address distribution unit586sends command signals to indicate the DRN destination of the newly compressed digital data.

FIG. 51is a block diagram showing the data flow in the Dark Channel Data Reduction Nodes670, which as described above, comprise a combination of hardware and software that is operable to perform linear combining, digital filtering, threshold/haze calculation, and data collation and formatting. The compressed digital data, which is assembled into scan lines, are transmitted at a rate of 80 Mbytes/sec (4 channel summing) to a decompression unit671. The data are decompressed at the data decompression unit671and then transmitted at a rate of 160 Mbytes/sec to a data combining unit673(in which channels are created as described in accordance with the present invention) and to DC Saturation logic678, for use in monitoring that will be described in more detail below.

The combined data are then transmitted at a rate of 40 Mbytes/sec (reduced to single channel) to a cross scan filter unit676for cross-scan filtering to be performed on the data in accordance with the methods described in the U.S. Pat. No. 6,529,270, which is hereby incorporated by reference, for background.

The cross-scan filtered data are then transmitted to a thresholding unit680, for use in the thresholding of data as described in detail above, and at a rate of 2 Mbytes/sec to a haze tracking algorithm unit684for haze analysis. In the presently preferred yet merely illustrative embodiment, an in-scan haze bucketing unit682is provided so that the cross-scanned filtered data may be prepared for haze analysis. In the in-scan haze bucketing unit682, the number of in-scan elements is reduced from 400 to 20, with each surviving element representative of 20 original elements and a haze1value comprising the mean scatter intensity value from surface roughness scatter, associated with the surviving element comprises an average of the haze values of the 20 original elements associated therewith. In the presently preferred yet merely illustrative embodiment, signals representative of the surviving elements are then transmitted to the haze tracking algorithm unit684for haze analysis.

The haze tracking algorithm unit684performs haze analysis in accordance with the methods described in the '701 patent, as well as U.S. Pat. No. 6,118,525 and U.S. Pat. No. 6,292,259. Haze analysis will be discussed in more detail below.

After the haze tracking algorithm unit684, the data are transmitted to the threshold calculation unit686for use in determining the threshold value. Thresholds can be calculated from the data using conventional methods such as averaging or by actual measuring noise levels and thresholding accordingly. As described in detail above, the threshold value may be calculated using a value γ determined by the accepted false alarm rate and a background level, of which haze is a part and the calculation of which the signals representing haze are used by the threshold calculation unit686.

The calculated threshold value is then transmitted to the thresholding unit680, where it is used in thresholding the data received from the cross-scan filtering unit676. The thresholded data are then transmitted to the data collation and formatting unit688, which is described in more detail below.

After the haze tracking algorithm unit684, the data also are transmitted to the line averaging unit690in order to perform cross-scan averaging of haze data. The haze output is then transmitted to the data collation and formatting unit688.

The DC saturation logic678operates to monitor the extent of saturation of the PMTs495. When the PMTs495receive too much haze signal, they start to become nonlinear and their size detection accuracy is diminished. Additionally, excess DC current through the PMT495causes premature aging of the detector. Therefore, an upper limit is set on the amount of current that may be obtained from the voltage output of the PMT495.

If a DRN670detects a current signal that is over a user-set limit, it will monitor the portion of the wafer that has gone over-limit. If it receives additional signal that is over the user-set limit, the PMT495will transmit an Abort scan signal, which will end the scan currently being performed. The scan may be re-initiated at a proper detection gain setting.

The DC saturation logic678performs that monitoring using data from individual PMTs, and so each PMT495is individually tracked for saturation.

The results of the PMT495saturation monitoring are input to the data collation and formatting unit688, along with the line averaged data and thresholded data. If no PMT saturation state is found, the data are collated and formatted and transmitted at a rate of 500 Kbytes/sec to the system controller and processing unit500.

Returning toFIG. 49, there is shown a block diagram showing communication flow in the surface inspection system10of the presently preferred yet merely illustrative embodiment of the present invention. The system controller and processing unit500communicates via the Ethernet Switch660with the Gauge Synchronization Board186, Motion Servo Controller696, Master DRN672and Slave DRNs674.

The system controller500sends DVCO set up, AOD Level, Enable scan, and Master Reset signals to the Gauge Synchronization Board186, which sends back Acknowledgement signals and (after a full wafer scan is complete) signals identifying the number of sweeps. The system controller500sends the following signals to the Motion Servo Controller696: Normal scan, Slow scan, Servo setup, Tuning commands, Start and Stop command, Stage commands, Trajectory setup and chuck commands. The motion servo controller696in turn sends back acknowledgment, scan position, and Motion status signals.

The system controller500sends the following signals to the Master DRN672: DRN Boot, DRN setup, DAN configuration and reset, scan control (such as start, enable, abort, end), acknowledgement. The master DRN672in turn sends acknowledgement of “Over Threshold and Haze” (OT&H) data, and it sends sensor calibration data signals to the system controller500. The slave DRNs674also send acknowledgement, OT&H data, and sensor calibration data signals to the system controller500.

The master DRN672and slave DRNs674are also interconnected-by the Ethernet switch660. The master DRN672sends the following signals to the Slave DRNs674: DRN setup, End scan, Abort scan, and Reset for new applications. The slave DRNs674send acknowledgement signals to the master DRN672. The Master DRN672and Slave DRNs674are connected via a StarFabric™ bus switch691to the DANs. The master DRN sends a switch setup signal to the StarFabric™ bus switch691.

The master DRN672also sends the following signals to the DANs570: Switch setup, DAN configuration, Enable scan, End scan, Abort scan, Diagnostic, Operational, DAN bootstrap commands, Switch configuration, Startup to run boot loader. The DANs570send detector setup and calibration signals to the collector/ detector assemblies200, which send raw data to the DANs570. The DANs570send filtered and decimated data to the master DRN672and the slave DRNs674, and they send Status and Acknowledgement signals to the master DRN672. The DANs570and gauge synchronization board186send low voltage data signals via a backplane960to each other: the DANs570sending DAN Acknowledgement signals and the gauge synchronization board186sending Reset, Clock, and Encoder signals.

The gauge synchronization board186and motion servo controller696communicate via a Differential bus962, the gauge synchronization board186sending Status signals and the motion servo controller696sending Trigger and Encoder signals. The gauge synchronization board186and digital voltage controlled oscillator (DVCO″)182communicate via an RS-232 bus964, the gauge synchronization board186sending Chirp command and Trigger signals and the DVCO182sending Acknowledgement and signals identifying the number of chirps (the DVCO chirps causing an AOD sweep).

Some components of haze actually collected and detected by surface inspection systems do not originate on or in wafer under inspection and therefore have nothing to do with wafer defects. The sensitivity of the surface inspection system10can be strongly influenced by the background noise in the system, especially when the system is used to detect extremely small surface characteristics, such as in semiconductor applications. The relative strength of the desired signal to the undesirable background noise is embodied in the signal-to-noise ratio (“SNR”). In semiconductor applications, Rayleigh scatter from the laser beam as it propagates through the air within the scanner is an important source of background light, and therefore quantum mechanical shot noise. Light reflected internally within the system from other components, for example, such as light reflected off of apertures or stop also can constitute unwanted noise. These noise sources are sometimes referred to as “instrument signature” (e.g., scattered light that comes from the instrument itself, and not from the workpiece under inspection). In addition, the electronic components of the surface inspection system could provide a certain amount of shot noise.

One approach to improving the SNR is to improve signal strength, for example, by increasing beam power, frequency, etc. Another approach to SNR improvement involves a reduction in system noise.

In accordance with still further aspects of the invention, a number of systems, apparatus and methods are provided for improving SNR. A number of presently preferred embodiments and method implementations of these will now be described. To aid in this description, and to simplify them, they will be described as implemented in system10. It will be understood and appreciated, however, that these aspects of the invention are not necessarily limited to system and its specific components and implementations as expressly described herein, and that they may be applied to other systems and embodiments.

In accordance with the preferred embodiments and implementations of these aspects of the invention, system10is designed to minimize instrument signature and other sources of unwanted background noise. The presently preferred embodiments and method implementations have been designed using, and based upon, a scatter tolerance budget within the system as a whole.

Illumination Absorbing System

To illustrate these aspects and principles of the invention, a surface inspection system10according to a presently preferred embodiment of these aspects of the invention will now be described. The system10is useful for inspecting one or more surfaces of a workpiece is provided. The surface inspection system10comprises an illumination subsystem13that projects a beam to the surface of the workpiece.

In a presently preferred embodiment and method implementation, the illumination subsystem13also comprises a beam scanning device, in system10called the beam scanning subsystem8, which preferably comprises an acousto-optic deflector such as AOD100. More preferably, this comprises beam scanning subsystem8or module92with variable scan speed AOD100as described herein above.

The system according to this aspect of the invention also comprises a collection subsystem for collecting scattered portions of the beam scattered from the surface S of the workpiece W. An illustrative but not necessarily preferred collection subsystem of the present invention has been described above as the collection subsystem380of which the optical collection and detection subsystem7is comprised. The collection subsystem380comprises collection optics of system10, which comprise components of the collection and detection module200above described, namely, a front collector module230with light channel assembly253, a center collector module220, a pair of wing collector modules210A,210B, and a pair of back collector modules240A,240B, all as described herein above with reference to system10.

The system according to these aspects of the invention further comprise a processing subsystem19operatively coupled to the optical collection subsystem380for processing signals received from the optical collection subsystem380to provide information about the surface of the workpiece.

The illumination subsystem13comprises a plurality of lenses or optical components through which the beam or its component portions pass. Such lenses or optical components have been described herein as components of the beam source subsystem6and the beam scanning subsystem8. Preferred embodiments of these lenses or optical components, such as objective lens optics392, have been described herein above.

Individual components of the illumination system13through with the beam passes, and preferably all of such lenses and optical components, have a surface roughness that does not exceed a selected value. In a presently preferred yet merely illustrative embodiment, the surface roughness does not exceed about 30 Angstroms; more preferably it does not exceed about 5 Angstroms. This limit on surface roughness limits scatter of the beam and correspondingly maintains a desired amount, preferably a maximum, of the beam energy collimated within the beam.

In addition, a reduction in system noise may be accomplished by providing the AOD and the collection system with instrument signature reduction systems employing, for example, combinations of baffles and relay lenses with glass stops that serve to reduce instrument signature.

In accordance with another aspect of the invention, the illumination subsystem13comprises an illumination absorbing system21comprised of components of the beam source subsystem6and the beam scanning subsystem8described above. As shown inFIG. 81, the illumination absorbing system21in this aspect of the invention comprises beam source absorbing system22at the beam source subsystem6and beam scan absorbing system24in the AOD100for absorbing scattered light. The laser beam comprises a collimated portion that lies within the main beam and a residual non-collimated portion, for example, that is scattered. The collimated beam portion is reflected off the surface of the workpiece W to provide the specular beam and the surface scatter that is collected by the front collector, wing collectors, and/or back collectors to detect and distinguish surface characteristics, such as defects. The uncollimated portion of the beam at the illumination subsystem typically comprises scattered light not useful in surface measurements. Some of the scatter comes from the Rayleigh scatter associated with laser beam itself, but most of the scatter comes from elements of the AOD100, such as the clean-up polarizing cube26seen inFIG. 16located between the cylinder lens150aand the black glass baffles114. By providing illumination absorbing system21, as is done here, generally undesirable light can be absorbed and removed from the system, so that it does not inadvertently enter the collectors and become an unwanted part of the measured signal. Scattered light from the AFRU92generally appears as increased background signal in the DFRU811channels.

As implemented in the illumination subsystem13, the beam scan absorbing system24comprises means for absorbing light that is not collimated in the beam, which are located both within and at the output of AOD.

Referring toFIG. 12, which is a top view of the AOD assembly102, andFIG. 13, which is a side view of the AOD assembly102, the means for absorbing light that is not collimated in the beam comprises a series of apertures, baffles and threads to absorb undesired scatter. The apertures are sized to allow the collimated portion of the laser beam to pass but operate as baffles for collecting scatter.

In the presently preferred yet merely illustrative embodiment and referring toFIGS. 16-17, the series of apertures, baffles and threads comprises the following:Aperture110is located at the opening of the AOD assembly102and is sized to allow the passing of the incoming laser beam.Aperture111is located at the input of the AOD100.Aperture113is located after the AOD100.Aperture117is located at the sliding plate158for moving the variable speed assembly cylindrical lens150A or150B into position.Aperture119is located at the input of the AOD beam splitting cube26(called the polarization clean-up cube26above) (which, being oriented at P polarization itself, itself substantially reduces the S-polarized stray light from the AOD).Aperture121is located after the beam splitting cube26.Baffles114, are located after aperture121and are preferably comprised of one or more pieces of black glass (e.g. Schott UGI) that are disposed at the Brewster angle for the particular absorbing glass type. These absorb the zero order laser beam when the AOD100is not on. When the AOD is on, the laser beam is diffracted away from the baffles114. However, the baffles114absorb the residual stray light scatter generated by the AOD100, cylinder lenses150A,150B, and cube26outside the laser beam scan aperture region.Aperture116is an adjustable aperture and is positioned immediately before the drive of the wave plate118.Aperture123is positioned at the interface where the beam comes into the AOD snout.Aperture125is located before the telecentric lens120.Threads122, which are located after the telecentric lens120and within the AOD snout124, operate as a baffle structure for collecting scatter.Aperture126is located at the end of the AOD snout.

Any further residual scatter then goes through the light channel specular beam aperture251and is absorbed either by the absorbing attenuator242in the light channel assembly253or by the Lyot stop770, both of which are components of the collector/detector absorbing means270described below.

Light Channel Absorbing Means

In accordance with still another aspect of the invention, a light channel absorbing means252is provided at the light channel assembly253for attenuating the light that propagates into the light channel.

As was described herein above, and as can be seen inFIG. 29, the light channel assembly253of system10uses a compact optomechanical design that splits the incident beam into two beams, directing them into the quad cell detector258and light position sensitive detector (LPSD)256. As shown inFIG. 85, the collector/detector absorbing means270has a light channel absorbing means252to transmit reflected light from the wafer into the light channel assembly. In the illustrated but not necessarily preferred embodiment, the light channel absorbing means252comprises an absorbing attenuator (OD=2.0, typical)242.

The attenuator242comprises an absorbing glass, for example, black glass, which further minimizes the amount of light that is reflected. Light that is incident on the attenuator in this embodiment and implementation is predominantly P-polarized. The attenuator242is oriented at the Brewster angle to maximize the amount of light that travels through the attenuator glass. The attenuator242does not have a coating of any type, in its preferred embodiment.

Light that is scattered from the mirror assemblies must pass back through the attenuator242in order to reach the wafer surface, therefore the light channel is optically isolated from the detection and collection subsystem. This can be an important noise attenuation approach given that the optical power entering the light channel can be many orders of magnitude higher than the amount of light that is collected by the collectors that are used to form the dark channel.

In accordance with yet another aspect of the invention, a surface inspection system10is provided, as generally described herein above, but which further comprises a collector/detector absorbing means270also having a Lyot stop770. As seen inFIG. 20, the Lyot stop770is located above the specular beam tube of the light channel assembly253and within the area containing the baffles B2in the collector module barrel housing394of the front collector330.FIG. 56illustrates the placement of the Lyot stop770relative to the lenses L1, L2and the telecentric lens120.FIG. 56is a beam trace of light emanating from the telecentric lens120to the wafer surface S at the telecentric plane498and scattering into the lenses L1, L2. Location I1is the image plane for light emanating from the AOD100. Location I2(between the location I1and the lens L2) is the image plane of light emanating from the telecentric lens120. The Lyot stop770is positioned between locations I1, I2.

The Lyot stop770is cup shaped. Preferably, it is formed of anodized aluminum and sized so that, in image space, the length of the Lyot stop770is longitudinally the length of the AFRU92optical system. In the present preferred yet merely illustrative embodiment, the Lyot stop770is sized and shaped so that scatter from the AFRU telecentric lens120is focused toward the back of the Lyot stop770, and scatter from the AOD100is substantially focused into the front of the Lyot stop770.

In addition, the Lyot stop770is also angularly separated from the specular beam to provide improved separation of the AFRU92scattered light from the scattered light that propagates into the front collector3301and light channel assembly253.

As shown inFIG. 25, the collector/detector absorbing means270also comprises a series of baffles and glare stops to absorb undesired scatter. As shown inFIG. 25, baffles B2in the collection optics subassembly390are provided above the objective lens L2to minimize stray off-axis light. Stray light that passes by the baffles B2will be further reduced by slit396.

Detector Slit Tracking

As noted above, and referring toFIG. 25, the collectors have a slit396through which the objective lenses L1, L2focus the incoming photons. The slit396operates as a field stop to absorb scatter outside the region illuminated by the laser spot. The width of the slit396is selected to so that the slit396is at least wide enough accommodate the imaged spot size on the wafer W.

In one embodiment, the width of the slit396is oversized to adjust for mechanical tolerances due to wafer height variations. As the wafer height changes due to wafer bow and warp, the intersection point where the laser spot and the wafer meet varies. This movement of the intersection point causes the scanned spot on the wafer to move from side to side as the wafer spins. The width of the slit396is selected to be oversized to allow the imaged spot to pass through the field stop as the local wafer height changes during the scan. In another embodiment, in order to minimize the Rayleigh scatter that an oversized slit396would allow into the collector300, the width of the slit396is matched to the beam size on the wafer W, and wafer tracking means, comprising a tracker398formed of known hardware and software elements, is provided to move the slit396to accommodate changes in the wafer height. The tracking means398comprises any suitable mechanism to move the slit396in any conventional way, such as linear stages or PZT or the like. For example, the tracking means398could comprise a control system that uses the signal from the light channel LPSD256to sense the local height of the wafer, and thereby move the slits396in each collector300to compensate for the associated imaged spot movement.

Stray light that passes through the slit396will be further reduced by the glare stops G1, G2, G3that are, respectively, located immediately before the collimating relay optics lens L3, after the collimating relay optics lens L3, and before the relay optics lens L4. Finally, any residual stray scatter light will be minimized by the field stop F2, immediately before the photocathode. In the two collector (dual PMT495) embodiment of the current invention, the field stop F2comprises a slit (such as detector slit496inFIG. 26). In the embodiment featuring a 90 degree collector, the field stop F2comprises a hole.

Beam Source Pre-Alignment System

In accordance with another aspect of the invention, a method and system is provided for assembling a surface inspection system10. This assembly may occur as part of a new system assembly, as part of a system maintenance or repair effort, or the like. A presently preferred implementation of this method and system will now be described. To simplify the description and illustration, this preferred method and system implementation will be described with respect to system10. It will be understood and appreciated, however, that neither the method nor the system is limited to this specific system embodiment, and that either the method or the system may be implemented using other embodiments, apparatus and implementations.

In accordance with the preferred assembly method, the beam source module70is aligned so that the laser beam is directed to the pointing position with 50 microradian accuracy. To facilitate this task, a beam source pre-alignment system824is provided.FIGS. 73 and 74are block diagrams showing implementations of the pre-alignment method contemplated by the present invention.FIG. 73shows an implementation of the beam source pre-alignment system824, which comprises a base, such as beam source module base plate76, apertures, such as aperture924,925, a reverse telescope826, and alignment detector838, also known as photodetector838(a digital camera or other optical-to-electrical conversion means). The pre-alignment system824also optionally but preferably includes a display922, and/or a signal processor926coupled to the photodetector838, for processing and/or displaying the beam alignment. The beam source pre-alignment system824further comprises a holding device920, also known as a beam source module mounting pad920, such as a jig that is identical with or similar to the base11to which the beam source and scanning mechanism will be attached.

In the illustrative yet not necessarily preferred embodiment of the beam source pre-alignment system and method according to this aspect of the invention, and with reference to the drawing figures, particularlyFIG. 13andFIG. 73, the method of pre-alignment may be performed using the holding device920to hold the beam source module base plate76in the position at which the beam source and scanning mechanism will be attached to the optics base plate60. As is known by persons of ordinary skill in the art, the turning mirrors82,84may be used to adjust the incident beam vector IB, with the reverse telescope826being used to magnify any small change in the position of the incident beam vector IB at the aperture924. The photodetector838is operated to detect the current pointing position of the laser after the aperture926, and its output is sent to the signal processor926, which identifies the current pointing position. The video display20to which the photodetector838is coupled displays the current alignment of the incident beam vector IB.

As part of the preferred assembly method for system, the beam scanning module92is pre-aligned to the pointing position as well. This is facilitated using a beam scanning pre-alignment system822, a presently preferred embodiment of which is shown in the drawing figures, particularly inFIGS. 11 and 74, and described above with reference to the design of the surface inspection system10, in which the beam scanning module92is mounted to the beam source module70by operation of pins96mating a corresponding plurality of pinholes94in the beam source module base plate76, and in which the beam scanning module92is mounted to the base11by operation of pins128on the bottom surface of beam scanning module base plate90mating a corresponding plurality of pinholes130in the optics base plate60.

Inspection Method

In accordance with another aspect of the invention, methods are provided for inspecting a surface of a workpiece, as noted herein above. Presently preferred implementations of these methods will now be described. For ease and simplicity of illustration, these preferred method implementations will be described in conjunction with the system10according to a presently preferred embodiment of the invention as it has been described herein above. It should be understood and appreciated, however, that these preferred method implementations are not necessarily limited to the systems, subsystems, components and assemblies as described herein with respect to the preferred embodiment.

In accordance with this aspect of the invention, a method is provided for inspecting a surface of a workpiece. The workpiece and the surface to be inspected are as have been described herein above. In this preferred but illustrative implementation of the method, the workpiece W comprises an unpatterned semiconductor wafer, and the surface S comprises one of the planar surfaces of the wafer upon which dies will be formed in subsequent processing.

In accordance with this preferred method, the wafer is positioned for inspection, preferably by using a robotic wafer handling subsystem such as workpiece movement subsystem15to place the wafer on inspection table 9.

This preferred method comprises providing an incident beam and scanning the beam on the surface of the workpiece so that a portion of the beam is reflected along a light channel axis LC in a front quartersphere FQ. The method further preferably but optionally comprises providing a light channel collection and detection assembly560, which is centered upon light channel axis LC. The channel developed from the output of the assembly560, referred to herein as the light channel650, receives the beam reflected from the workpiece surface S.

The method also comprises collecting a scattered portion of the incident beam at one or more wing collectors disposed in the front quartersphere FQ, outside the incident plane, and at a null or a local minimum, in surface roughness scatter relative to defect scatter, for example, from a defect perspective, at a maximum in the signal to noise ratio of defect scatter to surface roughness scatter when the incident beam is P polarized, or, from a surface roughness scatter perspective, when the surface roughness is at a relative minimum (BRDFMIN) of the BRDF when the incident beam is P polarized.

The method further comprises collecting scattered portions of the incident beam at a plurality of back collectors disposed in the back quartersphere BQ.

In addition, the method comprises detecting the collected portions of the incident beam and generating signals in response.

The method further comprises collecting scattered portions of the incident beam at a plurality of collectors300and identifying defects using signals from selected combinations of collectors300.

The method further comprises collecting scattered portions of the incident beam at a plurality of collectors300, comprising wing collectors340and dual back collectors310, and classifying defects on a workpiece W based on differences in the angular distribution of the light scattered from the workpiece.

In addition, the method comprises collecting angular components of scatter light that is collected by multiple collectors300arranged to collect light from multiple conical regions above a surface S in the laser-based surface inspection system10, and using the angular components to facilitate defect classification.

The method further comprises comparing the amount of light collected by one or a combination of collectors to the amount of light collected by one or more of the other collectors300.

In addition, the method comprises comparing the amount of light collected by one or a combination of collectors300to the amount of light collected by one or more of the other collectors300.

In the context of semiconductor wafer or chip inspection, and in like workpieces, a considerable fraction of the beam energy that is scattered from the workpiece surface is distributed outside the plane of incidence of the beam. The scattering of energy from a particle defect on a semiconductor wafer is known. It includes energy predominantly distributed in an annulus. For surface inspection systems wherein the detector lens assemblies are arranged solely in the plane of incidence, some of this energy may be missed. Inclusion of back collector and detector assemblies240therefore improve the ability of the system to take advantage of this energy to improve signal strength for defects. Moving the back collector detector assemblies240location to a position in the back quartersphere BQ that is 45° out of the plane of incidence improves back collector detection of polystyrene latex spheres (“PSL”s). When the back collector240was in the plane of incidence (as shown in U.S. Pat. No. 5,712,701), Rayleigh air scatter from the laser beam was coupled into the detector, thereby raising the background level and reducing the signal-to-noise ratio (SNR) of this collector. By moving the detector out of plane, less Rayleigh air scatter was coupled into the collector while the scattered light detected from particles on the wafer surface was nearly the same. As a result, the SNR substantially improved. A back collector orientation with an azimuthal angle of 235 degrees (0 degrees is outgoing laser beam propagation direction) and a meridional (or elevation) angle of 53 degrees is used in known prior systems.

Unfortunately, the single out-of-plane detector scheme described in U.S. Pat. No. 5,712,701 has some unfortunate drawbacks. Silicon wafers are normally polished with polishing pads to generate an extremely smooth surface. The pads also produce fine structure in the surface that behaves like a grating mirror when illuminated with a laser beam. As the wafer is scanned, the laser spot is diffracted by the grating surface in the direction perpendicular to the polisher-induced “groove” structure. The fundamental direction of the diffracted light changes as the wafer rotates, therefore the background scatter into the back collector varies with the rotation angle, producing a haze map with excessive amplitude variation, or “bow tie” effect. Users who want to sort wafers by surface roughness find it difficult to do so because of this effect. They would prefer a surface roughness map that has minimal “bow tie” effect and is more representative of the Total Integrated Scatter (TIS) from the wafer. In addition, the scanner exhibits lower sensitivity in the regions where the background level is higher, creating a sensitivity variation around the wafer.

It must also be noted that some kinds of defects may be undetectable when detection occurs in only one plane. Scratches are an example of a defect that falls into this category. A scratch having an orientation that is perpendicular to the AOD scan direction is detectable using a front collector if no edge exclusion mask is present. However, as the wafer rotates, the orientation of the scratch changes with respect to the AOD scan direction. When the orientation of the scratch is 45 degrees with respect to the AOD scan direction, much of the scratch signal is no longer collectable by any detectors. By positioning collectors outside of the plane of incidence in order to form “wing” channels, signal from scratches oriented 45 degrees with respect to the AOD scan direction can be detected, thereby improving complete scratch detection throughout the length of the scratch at various orientations to the incident beam.

It should be noted that methods of scatter detection that use a Total Integrated Scatter (TIS) collector system will not be as sensitive to these kinds of scratches since they inherently collect scatter from all directions at once. Since the scatter from the scratches is very directional in nature, these scratch defects will be “washed out” by the background signal from regions of the collection hemisphere where there is no scratch signal, thereby reducing the effective sensitivity of the system to scratches. By using separate angle-resolved detectors, the scratch signal can be localized to a particular detector and detected independently from the other collectors, thus avoiding the effective reduction of scratch signal that results from averaging signals from multiple collectors, some of which have collected scatter representative of workpiece locations where no scratch is present.

As described in the Stover reference incident laser light is scattered (or diffracted) from the surface in relation to the surface structure spatial frequency content of the surface roughness. The 2D grating equation relates the scattering angle (in spherical coordinates) to a specific 2D surface structure spatial frequency coordinate. The Angle Resolved Scatter (ARS) architecture described in the '701 patent, as well as U.S. Pat. No. 6,118,525 and U.S. Pat. No. 6,292,259 utilizes collection optics to collect scatter from specific angular regions of the collection sphere. These angular regions correspond to regions of the 2D surface structure spatial frequency spectrum.

Typically, surface inspection systems employ only an out-of-plane back collector to provide scatter information that is strictly in the out-of-plane or cross-plane surface structure spatial frequency region. In such systems, defects producing non-symmetrical scatter distributions can scatter light into space above the workpiece associated with surface structure spatial frequency ranges where no collection optics are located. In addition, non-symmetrical background surface structure causes the surface roughness scatter to change intensity and direction as the in-scan and cross-scan directions change with respect to the wafer surface as the wafer is rotated during the spiral scan.

The surface spatial structure frequency plot for the surface inspection system10of the present invention is shown inFIG. 52. As can be readily seen, the new design provides more complete collection of scattered light associated with the surface structure spatial frequency spectrum with the addition of channels. This enables simultaneous measurement of the Total Integrated Scatter (TIS) from the wafer and the Angle-Resolved distribution of the Scatter (ARS). By combining both TIS and ARS in one system, the scanner achieves both improved detection sensitivity and defect classification capability.

One may use wing collectors310A,310B, but no back collectors340A,340B, or back collectors340A,340B and no wing collectors310A,310B. Preferably both are used.

In order to determine the geometry of a defect, prior art surface inspection systems collected scattered portions of the incident beam at a plurality of detectors, applied a threshold separately to each, then evaluated the results for defect classification.

Signal Analysis

In accordance with the current invention, a system and method is provided for detecting the presence of defects by collecting scattered portions of the incident beam at a plurality of collectors300and identifying defects using signals from selected combinations of collectors300.

In one embodiment of the invention, the method, hereinafter known as the combined scatter method or CFT method812, further comprises the step860of combining output from selected collectors300, the step870of filtering and then threshold testing. In another embodiment, the method, hereinafter known as the individual collector processing method or FTC method814, further comprises the step870of filtering output from selected collectors300and threshold testing, and then the step860of combining the resultant output. Other methods of collector combining are envisioned in the scope of the present invention, and some of them will be discussed as examples in greater detail below.

The collectors300in the surface inspection system10of the present invention, shown in block diagram form inFIG. 39, comprise front collector330, center collector320, a pair of wing collectors310A,310B, each operable in P or S orientation, and a pair of back collectors340A,340B. The collectors300are positioned to collect scattered light components in a significant amount of the region in which scatter from defects are primarily distributed. Light detected by the various collectors300signifies a defect and surface roughness in or on the surface S of the workpiece W. Signals from the collectors300are selectively combinable using hardware and software elements to enable detection and classification of defects in the presence of noise.

FIG. 40is a block diagram showing an embodiment of the current invention of a method for detecting the presence of defects by collecting scattered portions of the incident beam at a plurality of collector detector assemblies200and identifying defects using signals from selected combinations of collector detector assemblies200. Specifically,FIG. 40shows one method for formation of a spherical defect channel chord815, which is particularly useful in identifying small spherical objects such as PSLs and defects with like geometries. The method illustrated comprises the combined scatter method of combining output from selected collectors (CFT method812), having the step860of combining output from selected collectors, and the step870of filtering and then threshold testing. Chords and the various method of combining channels, such as the CFT method812, are described in more detail below. In the channel combination example illustrated inFIG. 40, the selected combinations of collector detector assemblies200comprise the dual back collector detector assemblies240A,240B and wing collector detector assemblies210A,210B configured for P-polarization.

Detection of Defects in the Presence of Noise

Using Thresholding Based on Modeling Detector Module

As discussed below, summation of appropriately weighted output from collector detector assemblies200enables optimized detection of small defects, while other weighting schemes can optimize for detection of other defects, such as scratches. The output of the multiple and various collector detector assemblies200, for example, as are presented in system10, may be used to determine whether or not scatter from a Light Point Defect (“LPD”) is as opposed to noise. The following is a method that employs multiple and various collector detector assemblies200, for example, as are presented in system10, to detect Light Point Defects (“LPD”) in the presence of noise.

Recognizing that each collector detector assembly200will have associated with it a constant background light level and a level of background noise, the output of any single detector module400in a collector detector assembly200in the presence of an LPD is given by:
outputi=signali+Pi+noisei, E(noisei)=0,E(noisei2)=σi2, wheresignaliis the scattering power of a defect at detector i,Piis the constant background level; andNoiseiis the noise associated with the collector, such as shot noise, electronic noise or pick-up noise.

The output of a detector module400if no LPD is present is given by:
outputi=Pi+noisei, E(noisei)=0,E(noisei2)=σi2.

In accordance with this aspect of the invention, an “optimum” or ideal detector module400is constructed, in which a constant expected rate of “false alarms” is established and then the rate of detecting true LPD events is maximized. It can be demonstrated that the optimum detector module400is implementable by using a log-likelihood ratio threshold:

r→≡[output1output2⋮outputn],ln⁡(p⁡(r→|LPD⁢⁢present)p⁡(r→|LPD⁢⁢not⁢⁢present))>γ,
with the value γ determined by the accepted false alarm rate.

Whenever the log likelihood ratio exceeds γ, an LPD is declared to be present; and as long as the ratio is less than γ, no LPD event is declared. Rewriting the equation in terms of the individual detector modules400, the log likelihood ratio is given by:

Gi≡signaliσi2,
the log likelihood ratio test becomes a threshold test of

∑outputi⁢Gi-∑Pi⁢Gi>γ+∑signali⁢Gi2;
with Gibecoming a weighting value for the output of each collector.
Defining

Gi≡signaliσi2
provides a set of gains that also comprises the optimum gain weighting for maximizing the signal-to-noise ratio.

The first summation on the left side of the equation is a weighted sum of the individual collector outputs. The second summation on the left side of the equation is simply the background level of the weighted sum of the collectors. The right hand side of the inequality is a constant that may be pre-computed, and comprises the threshold value that, when exceeded by the weighted output of the collectors, causes an LPD to be declared present.

In one embodiment, a system and method for inspecting a surface of a workpiece by collecting scattered portions of the incident beam at a plurality of collectors and identifying defects using signals from selected combinations of collectors comprises the step combining the output of detector modules400associated with a set of collectors, filtering the combined output, and comparing the filtered combined output to a threshold value.

FIGS. 69 and 70show an illustrative but not necessarily preferred embodiment for a system and method for detecting a light point defect (LPD) greater than a selected size, comprising the following steps:

At Setup time (FIG. 69):

Step800: Determine the constant associated with the false alarm rate γ.Step802: Track the background levels Pifor a selected set of collectors.Step804: From the background noise, obtain the noise variance values σi2(including values for Rayleigh noise variance, non-Gaussian noise including Poisson, speckle noise, and local haze variation) that are associated with each collector in the selected set.Step806: Identify a selected scattering power value signaliassociated with each collector in the selected set, to obtain the scattering power of an LPD of a selected size s at each collector in the selected set.Step808: Derive collector weighting coefficients comprising a gain of

Gi≡signaliσi2,
associated with each collector in the selected set.,Step809: Divide the summed weighted scattering power values by 2

2⁢(∑signali⁢Gi2)
and add γ to obtain the LPD threshold value.

The set-up method shown inFIG. 69describes a theoretical way to find collector weighting factors. An alternative set up method comprises optimizing the collector gain coefficients (collector weighting coefficients) for optimal SNR empirically. In the empirical approach, coefficient computation comprises any conventional empirical method, such as 1) collecting raw data from a workpiece or a set of workpieces, 2) choosing a set of weighting coefficients, 3) measuring the SNR of the combined set of raw data, and 4) repeat steps 1) through 3) with different coefficients until the optimal SNR is found.

At Run time (FIG. 70):

Step900: Collect the output value outputifrom the detector module400associated with each collector300in the selected set. Apply the gain Gito each associated output value outputi(either digitally or with an analog circuit) to obtain the weighted output for each collector in the selected set.Step902: Sum the weighted output for each collector in the selected set (either digitally or with an analog circuit) to obtain the summed weighted output for the collectors in the selected set.Step904: Track the background level of the summed weighted output to obtain a tracked background level.Step906: Subtract the tracked background level from the summed weighted output to obtain a summed weighted background-independent output value.Step908: Compare the summed weighted background-independent output value to the LPD threshold value to determine the presence or absence of an LPD.

A set of contiguous elements554that have over-threshold summed weighted background-independent output values in the output of an AOD scan are formed into a channel chord552. The channel chords552so identified are analyzed by the channel analysis system520shown inFIG. 46, using currently known techniques to identify defects.

In the above-described combined scatter method (CFT method812) for detection of defects, the output of detector modules400associated with a set of collectors300is combined, filtered, and compared to a threshold value. In order to obtain optimum detection of LPD events, in the presently preferred yet merely illustrative embodiment, the selected set of collectors300comprises the set of collectors shown inFIG. 40, namely the dual back collectors340A,340B and the P-polarized wing collectors310A,310B.

It should be noted, however, that the invention in its broader aspects is not limited to combining the collectors300using the CFT method as shown inFIG. 40. The present invention contemplates methods of defect detection in which collector output is combined in other configurations in order to facilitate collection of other types of defects. For instance, the back collectors340A,340B could comprise a set of collectors to detect certain kinds of substrate defects to which the P-polarized wing collectors are less sensitive.

The combined scatter method for detection of defects, as shown inFIG. 40, is particularly useful in improving small particle sensitivity, providing additional information for classification. In addition, if combined scatter method is utilized to combine output associated with collectors as much as possible before input to feature (defect) process methods, gauge processing requirements will be minimized.

However, the combined scatter method is not preferable for detecting asymmetric defect scatter, such as produced by scratches in the workpiece surface. As noted above, the invention in its broader aspects is not limited to the combined scatter method. Another embodiment of the present invention comprises a method of defect detection in which the output associated with a collector is compared to a threshold value associated therewith, and then combined with (similarly threshold tested) output associated with at least one collector in order to facilitate detection of other types of defects.

Confidence Level Processing

In accordance with still another aspect of the invention, another surface defect detection method for defect detection in the presence of noise comprises identifying defects using the statistical significance of collector output. This method, and more particularly preferred implementations of the method, can be used with the surface inspection system10described herein above, or other systems such as noise-limited defect detection systems for which the background noise statistics are well known. Preferred implementations of this method can substantially extend the effective detection sensitivity of the system, enabling users to make good use of statistically significant data that otherwise may provide little benefit or even be discarded in known systems. Preferred implementations of this method may be used to augment signal processing methods such as those described in U.S. Pat. No. 6,529,270 (the “'270 patent”).

In the preferred embodiments and implementations disclosed in the '270 patent, signals from the photomultiplier tube detectors are filtered in the in-scan and cross-scan directions with a filter that is matched to the laser spot shape. A threshold is then applied to the filtered 2-dimensional data. Values above the threshold are deemed to be “real” defects while those below the threshold are discarded. Morphological processing is then performed to assess whether the defects are point, area, or line (scratch) defects. The defects are tabulated and displayed on a computer screen. Although the 2-dimensional filtered data exhibits an optimal signal-to-noise ratio (“SNR”) in a least-squares sense, the method for identifying defects from this data as described in the preferred embodiment and implementation of the '270 patent in some circumstances can be improved. In the preferred embodiment and method implementation of that patent, the threshold detector is applied to the 2-dimensional filtered data to determine if any defects are present. Due to the binary characteristics of this threshold detector, points that lie above the threshold are presented to the customer as real, and are implicitly assigned a 100% confidence level. All values below the threshold are ignored by the system, and are essentially assigned a confidence level of 0%. As a consequence, the threshold value is typically set relatively high with respect to the noise background in order to minimize false positive events. Because there can be over a billion voltage samples on a 300 mm silicon wafer surface, this implies that the threshold should be set at least 6 standard deviations above the background noise level (1×10−9probability level for a Gaussian distribution) to ensure that there are no more than a few false events. As a consequence, over 99% of the data is ignored, much of which is statistically significant and useful. This can cause essentially a mismatch between the statistical nature of the data and how it is presented to the system or method user.

One approach for a system user to accommodate this phenomenon is to lower the threshold below the 1×10−9level in order to see defects of interest. Where the false positive events due to background noise are displayed with the same statistical significance as the true defect events, however, this can result in a non-optimal display of “real” and “false” events. Although it is possible to attach a statistical significance and weighting factor to an event, typically the user assumes that a defect is either present or not present, without taking into account the statistical nature of the underlying data.

This implicates a need for a signal processing system and method that calculate the statistical significance of the data, and then faithfully represents this significance to the user. By allowing the user to weight the bins and displayed defects by the computed statistical significance, data that previously has been discarded can become useful to the user. This can extend the effective detection sensitivity range of the system and/or method by several nanometers in the context of semiconductor wafer or chip inspection, as will be described herein below.

To illustrate this aspect of the invention,FIG. 57is a defect map17depicting 2-dimensional (3.5 mm×5 mm, H×V) scanner data that has been collected using system10as described herein above to inspect a polished, unpatterned silicon wafer. Each pixel in the defect map17presents an intensity that is representative of a voltage level collected at the location on the map that is associated with the pixel. This data has been filtered in the in-scan and cross-scan directions in accordance with the preferred method described in the '270 patent. Two back collector maps and two P-polarized wing collector maps were averaged together to produce the map17shown inFIG. 57. A plurality of 50 nm polystyrene latex spheres (“PSLs”) were deposited onto the section of the silicon wafer depicted in the map17prior to scanning the surface. These particles can be readily seen in the map17as the bright locations along with the mottled background that is caused by residual shot noise.

FIG. 58depicts a voltage slice plot23that depicts one of these 50 nm particles. Although the particle peak P inFIG. 58appears to be substantially above the noise floor in this particular scan line, there is a small but finite probability that peaks in the noise floor can occasionally exceed this level during a complete scan of a wafer. Because there can be on the order of 109samples across the entire surface of a 300 mm wafer of this type, the probability of a noise voltage peak exceeding the height of a voltage peak representative of the PSL should be very low (<1×10−9) to ensure that the background noise pulses can be clearly distinguished from the particle pulses essentially all of the time. As a consequence, the detection threshold is usually set high enough so that the number of “false particles” on the wafer caused by noise peaks is approximately less than 5. In the case ofFIG. 57, the threshold should be set at the voltage corresponding to a 50 nm PSL peak in view of the voltage distribution of the background noise to prevent an excessive number of “false particles” from appearing in the defect map17after the threshold level is applied.

FIG. 59depicts a defect map that was generated from the defect map17ofFIG. 57by inserting a constant value at each pixel that represented a voltage level that exceeded the voltage threshold value corresponding to a 50 nm PSL. As can be readily seen, nearly all of the information that was present inFIG. 57has been discarded to create the defect map25inFIG. 59. The voltage signal of the particle signal shown inFIG. 58is barely above the threshold and so would cause the pixel associated therewith in the defect map ofFIG. 59to be set to its constant value, while several 50 nm particles appearing in the defect map17shown inFIG. 57have associated therewith voltage signals that fall below the threshold and therefore do not appear in the defect map25ofFIG. 59.

It could be expected that, absent the teaching of this aspect of the invention, if system users set the threshold of a prior known system based on the plot23inFIG. 58, they would probably set it considerably lower than the expected voltage level peak of signals associated with 50 nm particles in order to include more of the defects that appear in the defect map17but that do not appear in the defect map25. However, due to the statistics of the background noise, too many noise voltage level peaks would exceed this threshold when the entire wafer is scanned. This has posed problems for users of prior known systems. Since such systems do not recognize a gradation of statistical significance, the statistical significance of the data is misrepresented. If a signal exceeds the preset threshold, the system assumes with 100% confidence that a defect is present at that location (which is not true). If the signal level falls below the preset threshold, the system assumes that there is no defect (which may or may not be true). What is needed is a method for calculating the statistical significance of an event, and properly representing that information to the system user. Because the surface defect data collected is statistical in nature, what is further needed is to provide a processing system for a surface inspection system that operates on surface defect data on a statistical basis. The statistical significance of the surface defect data can be used in the binning recipe calculation to determine whether the wafer has passed or failed inspection. A presently preferred implementation of this process, which will be referred to herein as “Confidence Level Detection Processing Method502,” will now be described.

The defect map17depicted inFIG. 57is a 2-dimensional voltage map that contains representations of both background noise voltage signals and defect voltage signals from a portion of a surface S of a workpiece W. Scatter from the surface structure (measured as haze) appears as a constant background level. Scatter from defects (particles, scratches, epitaxial spikes, COPs, etc.) is added to this micro-roughness background, producing small, localized peaks in the voltage map17. Since the detected power levels in semiconductor wafer inspection applications typically are very low (picoWatt to nanoWatt range), the map17is dominated by shot (quantum-mechanical) noise. Shot noise exhibits a Poisson probability distribution, but can be accurately approximated by a Gaussian distribution if the number of detected photoelectron events within the effective integration time (or bandwidth) of the detection system exceeds ˜30 photoelectrons. For system10as described herein, this condition is normally met after 2-dimensional filtering is performed on the voltage maps17, therefore the underlying background noise distribution ofFIG. 57can be assumed to be Gaussian.

The measured distribution (black points) and underlying Gaussian background noise distribution (X marks) of voltage values associated with the region locations represented by pixels in the defect map ofFIG. 57are shown in the plots542,544,546of, respectively,FIGS. 60,61,62, each of which present a distribution of voltage levels. The black points were calculated by counting the number of voltage values within a ±100 microVolt range around each selected voltage level. The resulting measured voltage count curve504is the measured probability distribution for the defect map ofFIG. 57. The underlying Gaussian background noise probability distribution was calculated by fitting a Gaussian to the lower (left) half of the measured probability distribution where the defect signals are not present; it is represented by the noise probability curve506. As can be seen in the plot542ofFIG. 60, there is significant signal content above the Gaussian background noise probability distribution for voltages greater than about 41 mV.FIG. 61is a plot544that gives an expanded view of a portion of the measured probability distribution and Gaussian probability distribution, as represented by curves504,506of the plot542ofFIG. 60, showing a “hump” near 45-46 mV. This hump is produced by the 50 nm PSLs on the surface S of the workpiece W represented by the defect map17ofFIG. 57. The hump is shown even more clearly on the plot546ofFIG. 62, which depicts an even more expanded scale view of the curves504,506shown in the plot544ofFIG. 61.

In some prior known systems and methods, the threshold level is set at the voltage corresponding to ˜50 nm (6 standard deviations above the background noise mean), or 46 mV, as shown inFIG. 59. This level corresponds to the far right edge of the plot inFIG. 60. Although this threshold level ensures that there are minimal false detected events on the wafer, it is readily apparent inFIGS. 60-62that interesting data between 42 and 46 mV would be discarded. The differences between the black points on the measured voltage count curve504and X marks on the noise probability curve506inFIGS. 60-62indicate that there are thousands of voltage sample values above the underlying background level in this voltage range that are statistically relevant. The presently preferred method implementation provides a means to beneficially utilize this data.

As indicated above, the difference between the measured curve504(black points) and noise curve506(X marks) inFIGS. 60-62represents meaningful signal content that is present in the map17ofFIG. 57. To further quantify this, a Confidence Level Factor (CLF) can be defined as follows:

CLF⁡[V]=H⁡[V]-B⁡[V]H⁡[V](1)
whereCLF[V]=Confidence Level Factor,H[V]=the count of voltage values that are measured within a pre-specified voltage range centered on a selected voltage V, within a selected region of a workpiece surface,B[V]=the count of voltage values in H[V] that are associated or expected to be associated with background noise.

When the CLF is multiplied by 100%, it is referred to as the Confidence Level (CL). If the calculated background noise distribution is very small, the CL will be approximately 100%. As the noise level increases relative to the measured signal content, the CL will decrease.

Note that the CLF is spatially dependent. For example, consider the CLF curve508shown in the plot514ofFIG. 63, which was computed for the sample set of voltages that are represented in the map17ofFIG. 57. This CLF curve508will not necessarily be the same as one produced for the set of voltages associated with a scan at another part of the wafer, where the background and defect-induced voltage distributions may be different from those shown in the defect map17ofFIG. 57. In the case ofFIG. 57, there are numerous 50 nm PSLs present on the region represented by the map17, therefore the CL for the detection of these defects is >99%. The CL would be lower in a wafer region that contains very few 50 nm particles and a higher micro-roughness background. This means that the effective sensitivity (and statistical significance of defects) will vary across the wafer W as the local conditions change during the scan. Instead of using a fixed sensitivity threshold to select and bin, or categorize, defects, the statistical CL can now be used to perform this function.

The CLF curve508shown in the plot514ofFIG. 63shows the Confidence Level Factor as a function of voltage generated by directly applying Equation 1 to the data set represented by the measured voltage count curve504and the noise probability curve506shown inFIGS. 60-62. The CLF curve508inFIG. 63is accurate above 0.04V and below 0.05V. The part of the CLF curve508in the 0.035-0.04V range is normally ignored because non-zero CLFs in the 0.035-0.04V range inFIG. 63represent an expected mismatch between the Gaussian background noise fit and the measured data. The CLFs in the 0.035-0.04V range are therefore artificially set to zero. Similarly, the CLFs above 0.05 V are artificially set to one. The CLF for the data represented by map17increases from zero at 0.04 V to 1 as the voltage increases. Above 0.05V, the CLF for the data represented by map17decreases in an intermittent manner due to the fact that the number of signal events decrease with increasing voltage and there is minimal signal after a certain voltage level. Therefore the CLF drops to zero at numerous voltage levels in this region. In this particular data set (map17), there is minimal signal above 0.05V. If a deposition of larger particles were present, the values in this region would be near 1. Bearing in mind that any voltage value above 0.046V is 6 standard deviations above the background noise mean (the usual threshold used in the single-threshold technique), it is possible to set the region above 0.046V in the plot514ofFIG. 63to 1 without introducing any more false defects than the single-threshold technique would produce.

By setting the lower region of the plot514ofFIG. 63to 0, the upper region to 1, and employing a standard polynomial interpolation method to the region in between, a cleaner version of the CLF curve508is generated, as illustrated by the CLF curve518in the plot516ofFIG. 64. As can be readily seen in the CLF curve518, the CLF is negligible at 41.5 mV (corresponding to a ˜42 nm PSL equivalent peak height) and monotonically increases to 0.99 at 44 mV (˜48 nm PSL equivalent).

The confidence levels so derived may then be used to assign a confidence level to the voltage value that is measured at a location in a region of a surface under investigation, to identify an extent of confidence that the voltage level so measured represents a defect. By mapping each potential voltage level to a confidence level, a CLF curve, such as curves508,518shown inFIG. 63or64, can then be used be utilized as a look-up table (“LUT”) to assign confidence levels to voltage values.

The confidence levels could also be used to provide a visual representation of an extent of confidence that a measured voltage level represents a defect at a selected location. For example, in a defect map17such as the one inFIG. 57, each pixel of the map represents a location in a region of a surface under investigation. A characteristic of each pixel, such as brightness, could be defined to represent the confidence level assigned to the voltage level associated with the pixel. For example, pixels associated with voltage values having higher confidence levels would be brighter, while those associated with voltage values with lower confidence levels would be darker. The brighter the pixel on the map, the higher the statistical probability that the defect so represented is real. A defect map522in which the extent of confidence in an identification of defects is visually represented, known herein as a Confidence Level Map (“CLM”), is shown inFIG. 65.

The Confidence Level Map (CLM)28shown inFIG. 65was achieved by associating a CLF with each pixel in the map17ofFIG. 57, using the mapping of each potential voltage level to a confidence level expressed by the CLF curve518inFIG. 64. Pixels such as pixel524having voltage values for which the CLF is zero are black, just as they would if a simple threshold were applied. Pixels such as pixel526having voltage values for which there is a relatively low confidence level are dim, while those pixels such as pixel528that have voltage values for which there is a relatively high confidence level are bright. Therefore the defect brightness inFIG. 65is closely related to the statistical significance of the defect signal. The variation of CLFs is further demonstrated by the slice plot534inFIG. 66.

Note that there are considerably more defects displayed in the CLM defect map28ofFIG. 65than in the conventional threshold defect map25ofFIG. 59. The conventional threshold scheme used inFIG. 59effectively uses a “unit step” CLF that is zero up to 46 mV, then 1.0 above 46 mV. In contrast, Confidence Level Detection Processing uses a CLF with a gradation of values, thus enabling the use of statistically significant data below 46 mV that would otherwise have been discarded by a “unit step” CLF. The smoothly-varying CLF curve more accurately represents the statistical significance of each voltage level in the map17ofFIG. 57. For the example shown here, Confidence Level Detection Processing effectively extends the defect sensitivity range by several nanometers.

The CLM defect map28inFIG. 65can be used to generate a defect map using standard and known methods of morphological processing. An aggregate defect confidence level for a defect could be assigned from the confidence levels of the set of locations on the workpiece, such as the wafer, that define the defect, in order to indicate the statistical significance of the defect defined by the set of locations. For example, the surface inspection system could consider a defect to be identified at a position on a wafer when a set of locations on the wafer have positive CLFs associated therewith, are connected together, and have an aspect ratio that is within a certain range. Once a defect is so identified at a position, the aggregate defect confidence level can be assigned to the position from the set of confidence levels associated with the set of locations that define the position. The aggregate confidence level could be assigned to be the peak confidence value, comprising the greatest value of the confidence levels of the set of locations that define the position. Alternatively, the aggregate defect confidence level could comprise the average value of the confidence levels of the set of locations, preferably weighted by the expected sample amplitudes, which would be the voltages measured at the locations. The peak confidence value can be noisy due to shot noise, therefore the preferred aggregate defect confidence level, also called a defect's CLF, is the weighted average value.

Once the aggregate defect confidence level for a defect has been assigned, the defect can be binned according to its size attributes and confidence levels of the locations that define the defect. The defect size can be computed using a peak voltage value comprising the voltage value corresponding to the peak confidence level of the locations that define the defect. Other defect sizing techniques that use other values within the defect group may be used as well.

Normally the color of each defect displayed on the display device comprises a color that is associated with a bin into which the defect is categorized. The brightness of the defect displayed on the display device is usually fixed at a specific brightness in the conventional threshold technique, whereas, in a system or method for defect identification incorporating the confidence level detection processing of the present invention, the brightness of the defect so displayed may be modulated by CLF. This enables the user to visualize the statistical significance of each defect.

The counting of defects can also be modified when using Confidence Level Detection Processing. Normally a defect is counted within a certain category (bin) if, when it is detected, it is found to possess the characteristics associated with the bin. Confidence Level Detection Processing can further refine the process of bin counting by weighting the defect count by its CLF. For example, a defect with a CLF of 0.5 will have half the weight of a defect with a CLF of ˜1.0. This means that it will take twice as many defects with a CLF of 0.5 to equal the number of defects with a CLF of 1.0.

By incorporating the CLF into the binning process, the recipes for sorting wafers can utilize the statistical significance of the defect data. Unlike the conventional method of defect identification using threshold processing, defect identification incorporating confidence level processing of the present invention allows rejection of wafers if there are a large number of very small defects. An aggregate bin confidence level can be assigned for a bin from the confidence levels associated with the defects in the bin to indicate the statistical significance of each bin. One such aggregate bin confidence level comprises an average bin CL to indicate the average statistical significance of each bin.

With the present invention, confidence level detection processing as disclosed herein can be used additionally to control the binning and display of data in accordance with the CLF associated with the data. For example, data may be processed using CL cutoff limits in order to limit the identification or display of the number of defects in a region.

FIG. 67depicts a confidence level map29for defect data that has been processed using a CL cutoff limit, specifically a CL cutoff limit of 50%. As in the CLM map28shown inFIG. 65, the thresholded CLM map29inFIG. 67presents the brightness of a pixel according to the CL of the voltage level associated therewith. However,FIG. 67differs fromFIG. 65in that the brightness of a pixel is presented in the defect map29ofFIG. 67only if the CL of the associated voltage level is greater than 50%.

ThusFIG. 67depicts a confidence level map comprising a defect map of a surface of a region under inspection, in which the region comprises a plurality of locations, each of which provided with an assigned confidence level CLA, in which the assigned confidence level CLAis set to zero if the voltage level measured thereat has a CL associated therewith that is lower than 50%, and with the assigned confidence level CLAcomprising the CL associated therewith if the voltage level measured thereat has a CL associated therewith that is greater than or equal to 50%.

Comparing the CLM map28ofFIG. 65with the defect map17ofFIG. 57, it can be seen that confidence level processing results in a significant filtering of the amount of background noise in the defect data. The defect map17depicts voltage values for both background noise and defect signals, without any ability to distinguish between defect and noise, while the CLM map28shows likely defects by their extent of their likelihood. The dimness of display of an unlikely defect indicates the likelihood that it constitutes background noise. Thus, confidence level processing creates a map that focuses on likely defects.

Comparing the thresholded CLM map29ofFIG. 67to the CLM map28ofFIG. 65, it can be seen that the use of cut-limits in confidence level processing results in even greater focus on the likelihood of a position with high voltage level measurements being a defect. It can be seen that several of the small features near the bottom of the CLM map28ofFIG. 65have been eliminated from the thresholded CLM map29ofFIG. 67as a result of CL cutoff limits. For example, position522is displayed in map28(albeit dimly), but is not displayed in map29. A position on the thresholded CLM map29is considered more significant because it is more likely that a defect exists at that position. Thus, thresholded confidence level processing creates a defect map that focuses on defects of greater significance.

Comparing the thresholded CLM map29ofFIG. 67to the thresholded defect map25inFIG. 59, it can be seen that map29depicts more positions as being potential defects, but that it also shows by the dimness of such positions the relative unlikehood of their being defects. By applying a CL cutoff limit to confidence level processing, the conventional defect size threshold process used to create the defect map25inFIG. 59is replaced by a statistical CL threshold in map29. Thus, thresholded confidence level processing exploits the statistical nature of the data to present defects by their significance.

It is also possible to re-map the CL's to another display look-up table (LUT) to accentuate the presence or absence of various defects with certain CL ranges. For example, using the example of the thresholded CLM defect map29ofFIG. 67, in which pixels representing locations having confidence levels lower than 50% are set to zero, the brightness of the pixels representing locations having confidence levels at 50% or greater can be adjusted to accentuate the differences in their CLs. A 50% CL could be remapped to 0%; a 100% CL could remain at 100%; and the CL values in between could be assigned other intermediate values, for greater contrast between the 50% and 100% CL's. Thus, the defects so depicted in the defect map ofFIG. 67could be provided with a wider brightness range.

Confidence Level Detection Processing does not necessarily improve the underlying SNR of the system, but it can enable better utilization of the available data. If the user were interested in studying individual defects, then he or she would set the confidence level cutoff limit very high to ensure that each defect is known to be present with high statistical significance.

It is possible for a few false defects to be presented with a high CL because there is a small but non-zero probability that the noise can reach relatively high voltage levels. This effect can be mitigated by applying a “global” CLF calculation to the entire processed defect wafer map. As described in further detail below, a wafer or a region of a wafer region is often sub-divided into regions, with an image of the entire wafer sub-divided into sub-images that are associated with the sub-divided region, to enable defects to be identified on small, manageable quantities of data and to provide good estimates of local background noise. When a CLF is calculated for each sub-image, defects that are deemed significant in the region local to the sub-image may not be significant on a global basis when all of the sub-images are considered together. A global confidence level image formed by the set of sub-images can be thus be assigned from the set of confidence levels associated with the sub-images in the set to indicate the average global statistical significance of defects in the image.

In order to take the global defect map results into account, a final CL for the entire wafer may be displayed to the user, with the final CL comprising a confidence level that has been modulated by the global confidence level across the wafer, thereby reducing the CL for defect sizes that have counts that are similar to the number of false defects expected across the entire wafer. The background noise distribution for the global CLF can be calculated based on the average haze level for the entire wafer. For example, if, at the end of a wafer scan there are 5 defects in a particular bin category, and the expected number of false defects due to noise across the wafer is 4, the CL's for the defects in this bin category would be averaged with the global CL of 100%*(5−4)/5, or 20%. A final CL comprising a global confidence level and a local confidence level, ensures that the statistical significance of the data is weighted on both a local and global basis.

The example shown above demonstrates how Confidence Level Detection Processing (CLDP) can be used to detect defects in a statistically significant manner using a fixed map of voltage values. This method can be applied to virtually any map of data for which the background noise distribution is known or can be computed, and for which individual discrete events are to be detected and identified. Examples of other applications include laser defect scanners for other types of materials, digital imaging for defect inspection, and motion processing in high speed digital video applications.

CLDP is particularly effective if it is applied to a region of a surface that has a uniform background noise distribution. The entire surface can be scanned and stored as one voltage map, then processed using CLDP. This method has two main limitations, however. First, if the surface is a 300 mm silicon wafer surface, this would involve the storage and processing of over 109sample values per detector module400, placing substantial and perhaps excessive demands on the computational hardware and software required to process this data. Second, if the background level varies substantially across the surface, the global CLFs so generated will be a poor estimate in the regions that have a significantly higher or lower background than the global average background level.

By sub-dividing the surface into sub-images, an example of which is shown inFIG. 68a, the measured distribution and underlying Gaussian background noise distributions can be computed for each sub-image, thereby ensuring that the each distribution is a good estimate of the local background and enabling CLDP to be performed on small, manageable quantities of data.FIG. 68bshows how a silicon wafer could be scanned as a series of cylinders, each of which is divided into multiple sub-images that are processed using CLDP. The sub-image technique can also be applied to a spiral scan pattern, for example, as shown inFIG. 68c.

For each of the scanning geometries shown inFIGS. 68a-68c,the number of scan lines to include within a sub-image is directly limited by the slope of the mean of the background noise, or haze slope. As the maximum expected haze slope increases, the number of scan lines used in the distribution calculation should decrease in order to achieve a good distribution estimate. A distribution and confidence level map can be computed for each sub-image. The background distribution used in the confidence level map can be derived by using a known background distribution based on calibrated PMT signals, or by performing a fit on the lower half of each measured distribution. Morphological processing then may be performed on each confidence level map or sub-image. Some methods of controlling sensitivity banding may be desirable or required.

Many specific hardware and software implementations of Confidence Level Detection Processing can be used. As shown in theFIGS. 86 and 87, which is a block diagram of one Confidence Level Detection Processing method502, the method comprises the following steps:Step851: A region of a workpiece to be evaluated for potential defects is identified.Step852: A potential signal range is identified for signal measurements to be obtained from locations in the selected region. The potential signal range is subdivided into a set of signal intervals comprising selected signal levels and a predefined range around each signal level. In an illustrative but not necessarily preferred embodiment of the current invention, employing the surface inspection system10, the signals comprise voltage signals indicative of photon activity within a collector200, with the photon activity resulting from light scattered from the surface of the region under inspection, and with the extent of the signal measurement being indicative of the extent of such photon activity. In addition, in the illustrative but not necessarily preferred embodiment of the current invention, the potential signal range comprises a potential voltage range, which is subdivided into a set of voltage intervals comprising selected voltage levels V and a predefined range around each voltage level V. For purposes of describing the method502, hereinafter the signals will be described as voltage signals. It should be understood, though, the invention should not be limited to such embodiment. In the embodiment, the voltage levels V could be spaced every 200 microVolts within the potential voltage range, and the predefined range could comprise ±100 microVolts around each voltage level.Step853: Voltage signal measurements are obtained for locations on the selected region in order to obtain a set of voltage measurement values for the region.Step854: The number of voltage measurement values within each selected voltage interval is counted to obtain a voltage measurement value count for each selected voltage level V.Step855: The voltage measurement value counts are sorted into a voltage measurement distribution function H[V] comprising the distribution of voltage measurement values counts in the region, by the selected voltage level V. In a step856, a plot is created having a measured voltage curve504comprising the voltage measurement distribution function, with the curve504presenting the number of voltage signals at each voltage level.Step857: The portion of H[V] that likely comprises underlying background noise is identified by calculating a background noise probability distribution function B[V] comprising probable background noise voltage counts by selected voltage levels V. B[V] is derived by fitting a probability function to a portion of H[V] in which particle and haze variation effects are minimal. In such portion of H[V], voltage values are likely to represent background noise and not workpiece-defects. Preferably, the portion of H[V] used to derive the B[V] comprises the lower tail of H[V]. Also, preferably, a Gaussian or Poisson probability function is used. In a step858, a plot having a noise probability curve506comprising B[V] is created, with the curve506representing the likely number signals that comprise background noise at a voltage level.Step859: A Confidence Level Factor (CLF[V]) is defined for each voltage level V, in order to assign a confidence level to the voltage value that is measured at a location in a region of a surface under investigation, to identify an extent of confidence that the voltage level so measured represents an actual defect. Confidence Level Factor (CLF[V]) is calculated by:

CLF⁡[V]=H⁡[V]-B⁡[V]H⁡[V]In an optional Step860, a Confidence Level (CL[V]) percentage is defined by multiplying CLF[V] by 100.Step862: A Confidence Level Factor function is developed and represented by Confidence Level Factor curve508, for values of confidence level factors (CLF[V]) and the voltage levels V with which they are associated.FIG. 88, which is a block diagram of further detail for step862, shows an optional Step863of using CLF cutoff limits in order to limit the identification of voltage values as potential defects in a region. The cut-off limits may be developed in a step864and step865. Step864involves identifying a minimum potential voltage in the potential voltage range, below which voltage values are expected to represent background noise and not actual defects. The CLF[V] is set to zero for voltage levels at or below the minimum potential voltage. A step865involves identifying a maximum potential voltage in the potential voltage range; above which voltage values are expected to represent actual defects and not background noise. The CLF[V] is set to one for voltage levels at or above the maximum potential voltage.Finally, the step862also comprises an optional Step867, which involves employing a standard polynomial interpolation method to the Confidence Level Factor function to obtain an interpolated Confidence Level Factor function, represented by an interpolated CLF curve518.Step868: A CLF curve508, or the optional interpolated CLF curve518, is used as a look-up table to assign confidence levels to the voltage levels with which the confidence level factor is associated.Step870: A visual display of the region under investigation is created to visually represent voltage signals measured at locations in the region and the extent of confidence that the voltage signals represent actual defects and not background noise. Preferably, a Confidence Level Map (“CLM”), such as map522, is created in which each pixel of the map represents a location in a region of a surface under investigation and a confidence level representative of an extent of confidence that an actual defect exists at the location associated with the pixel.FIG. 89is a block diagram of further detail for step870. It shows a step871, which involves defining a characteristic of each pixel, such as brightness, to represent the confidence level factor CLF[V] assigned to the voltage level V associated with the voltage measurement value obtained at the location that is represented by the pixel.Step870also comprise an optional Step872, which involves adjusting the brightness range of pixels in the visual display to accentuate the presence or absence of a potential defect at the location associated with a pixel and an extent of confidence that the potential defect represents an actual defect.Finally, step870comprises a step873, which involves assigning a zero brightness level to pixels associated with locations having confidence levels lower than a selected minimum confidence level, a maximum brightness level to pixels associated with locations having confidence levels CLF[V] equal to one, and adjust the brightness levels for each pixel associated with a location having a confidence level therebetween to an intermediate pixel brightness level between the zero brightness level and the maximum brightness level, with the intermediate pixel brightness level developed by interpolation from the confidence levels associated with each pixel associated with a location having a confidence level therebetween.Step874: Potential defects are identified in the region under investigation and an extent of statistical significance is associated with each potential defect.FIG. 90is a block diagram of further detail for step874, and shows a step875involving, in one embodiment, identifying a potential defect by identifying a set of contiguous locations in the region under investigation, with the locations having voltage measurement values above a defined voltage level and with the set comprising at least a defined number of contiguous locations.Step874also comprises a step876, which involves computing the potential defect's size. In one embodiment, the step876comprises a step877, which involves computing the potential defect's size using a peak voltage value comprising a voltage measurement value corresponding to the peak confidence level associated with the locations that define the potential defect.The step874further comprises a step880, involving assigning defect confidence level to each potential defect so identified, and a step881, which involves developing an aggregate defect confidence level to the potential defect from the set of confidence levels associated with the set of locations that define the potential defect. The aggregate defect confidence level, and any aggregate confidence level described herein, could be created in any convention manner, for example, using step882A or step882B. Step882A involves defining the aggregate defect confidence level to comprise the peak confidence value, comprising the greatest value of the confidence levels associated with the set of locations that define the potential defect. Alternative Step882B involves defining the aggregate defect confidence level to comprise the average value of the confidence levels associated with the set of locations that define the potential defect, preferably weighted by the voltages measured at the locations.Step883: The potential defects are sorted into bins according to size and confidence levels.Step884: An extent of statistical significance of potential defects is associated with each bin by assigning an aggregate bin confidence level to each bin from the confidence levels associated with the potential defects sorted into the bin. In a step885, an aggregate bin confidence level is assigned to comprise an average value of the confidence levels associated with the potential defects in the bin.Step886: An extent of statistical significance of potential defects is associated with the region under investigation by assigning an aggregate region confidence level to the region from the confidence levels associated with the bins that comprise the region.Step887: An extent of statistical significance of potential defects is associated with a workpiece by assigning a “global” confidence level to the workpiece from the confidence levels associated with the regions that comprise the workpiece.Optional Step890: A region under investigation may be sub-divided into sub-regions and the confidence level detection processing method502performed on the sub-regions in order to identify potential defects using a data set of reduced size and to provide more detailed estimates of local background noise. An extent of statistical significance of potential defects would be associated with a sub-region by assigning an aggregate sub-region confidence level to the sub-region from the confidence levels associated with the potential defects in the sub-region.The step890is particularly helpful in instances in which confidence levels, when calculated separately, would differ significantly across a test surface, such as a workpiece or a region of a workpiece. For example, a portion of a test surface could appear to raise issues that are not present in the rest of the test surface. One area of a workpiece could have scatter patterns that indicate the high likelihood of the presence of a defect, while other areas could have scatter patterns that are more equivocal about the presence of a defect. Confidence levels that are calculated separately for areas with differing scatter characteristics would thus differ significantly. The overall test surface confidence level, being lowered by the lack of confidence in the areas with equivocal scatter signal, would not reflect as strongly as it potentially could the confidence in the existence of the defect in one of its area. Thus, by allowing a test surface to be subdivided, a “global” confidence level may be modulated across the test surface.In a step891, an extent of statistical significance of potential defects could be associated with the region subdivided in step890by assigning an aggregate global region confidence level to the region from the confidence levels associated with the sub-regions.
Method for Combining Collector Output

FIG. 41is a block diagram showing the embodiment of the FTC method814for detecting the presence of defects by collecting scattered portions of the incident beam at a plurality of collectors and identifying defects using signals from selected collectors, comprises the step870of filtering and threshold testing, and then the step860of combining output associated with selected collectors300.

One further embodiment comprises combining thresholded output associated with the entire set of collectors in the surface inspection system. Another further embodiment comprises combining thresholded output from a selected set of collectors.

The individual collector processing method of FTC method814is useful in detecting and classifying asymmetric scatter, e.g. defects on rougher silicon surfaces and “flat” defects. More particularly, it is useful in detecting and classifying defects of various spatial frequencies and geometries that scatter with the symmetry of small particles.

As shown inFIG. 41, a method of using independent or individual processing of collector output to analyze defects, which employs the individual collector processing method or FTC method814, comprises the following steps:Step832: Define a channel600by identifying a selected set of collectors300.Step834: Obtain output associated with each collector300in the selected set of collectors.Step870: Filter the output associated with each collector300to obtain filtered output associated with each collector300. Threshold the filtered output for each detector module400associated with a collector300in the selected set to obtain thresholded filtered output associated with each collector300.Step860: Combine the thresholded filtered output associated with all of the collectors300in the selected set of collectors to obtain combined thresholded filtered output.Step836: Analyze the combined thresholded filtered output.

The step of analyzing the combined thresholded filtered output may be performed using any defect detection method, including those described herein or any known defect detection method, such as those described in U.S. Ser. No. 10/864,962, entitled Method and System for Classifying Defects Occurring at a Surface of a Smooth Substrate Using Graphical Representation of Multi-Collector Data, which is assigned to ADE Corporation of Westwood, Mass. and which is herein incorporated by reference.

In the embodiment shown inFIG. 41, the method of obtaining combined thresholded filtered output comprises obtaining combined channel chords550, which comprise the set of contiguous over-threshold filtered output values in the output of an AOD scan for the set of selected collectors300. More specifically, in the embodiment shown inFIG. 41, the step832of defining a channel600by identifying a selected set of collectors300comprises identifying the dual back collectors340A,340B to form a combined back channel, and obtaining combined channel chords550comprises obtaining combined back channel chords540.

The method of obtaining combined channel chords550when it comprises obtaining combined thresholded filtered output is shown in more detail inFIGS. 42 and 43. It comprises the following:The step834of obtaining output comprises obtaining output for each AOD scan, further comprising obtaining the set of output values from the AOD scan.The output filtering portion of step870further comprises obtaining filtered output for each AOD scan, further comprising obtaining the set of filtered output values for the AOD scan.The output thresholding portion of step870further comprises thresholding the filtered output for each AOD scan, further comprising obtaining the set of thresholded filtered output values for the AOD scan, with thresholding comprising comparing the output values V of the AOD scan elements554in a collector's AOD scan line532against a threshold output value V0and identifying which elements554are over threshold.The step860of combining the thresholded filtered output further comprises identifying channel chords552in the thresholded filtered output, and, from them, forming combined channel chords550.The step836of analyzing the combined thresholded filtered output then further comprises a step838of analyzing the combined channel chords550.

As seen inFIG. 42A, in a selected set of collectors300, each collector300A,300B provides as output a selected number of AOD scan lines532, forming a collector scan534and comprising a selected number of scan elements554. A channel chord552comprises the set of contiguous AOD scan elements554in a collector's AOD scan line532having output values V greater than a threshold output value V0. Output from collectors300A,300B may be used to form a combined channel chord550.

The step838of forming combined channel chords550comprises overlaying the output from an AOD scan532associated with the selected set of collectors300in the following manner: Each AOD scan line532in a collector's scan534has another AOD scan line532associated therewith in the scan534of the other collectors in the selected set, the scan lines532so associated forming a scan line set536such that all scan lines532in a collector's scan534are members of separate scan line sets536. Further, each AOD scan element554in an AOD scan line532has another AOD scan element554associated therewith in each of the AOD scan lines532in the m scan line set536, the scan elements554so associated forming a scan element set538such that all scan elements554in an AOD scan line532are members of separate scan element sets538.

When output from a selected set of collectors300is combined, it is combined on the scan element554level, with all of the scan elements554in a scan element set538forming a combination element556that represents the associated AOD scan elements554in a scan element set538.

A combined channel chord550comprises the set of combination elements556for which at least one of the associated AOD scan elements554that the combination element556represents has an output value V greater than a −threshold output value V0. The magnitude of the combination element556in each combined channel chord550is the magnitude of one of the AOD scan elements554represented thereby, preferably the AOD scan element554having the greatest over-threshold output value V.

An example of the step838of forming combined channel chords550is shown inFIG. 42b,in which the selected set of collectors300comprise back collectors340A,340B. While it is within the spirit of this invention for each collector to have associated therewith several AOD scan lines532, for the sake of this example, let there be only one AOD scan line per collector. For example, the collectors340A,340B provide, respectively, AOD scan lines532A,532B. AOD scan line532A has a plurality of scan elements, e.g. scan elements554AA,554AB. AOD scan line532B also has a plurality of scan elements, as an example554BA,554BB. Scan elements554AA,554AB, would be considered to have associated with them, respectively, scan elements554BA,554BB. Therefore, scan elements554AA,554BA would form a scan element set538, and scan elements554AB,554BB would form a separate scan element set538.

InFIG. 42b,the scan elements554that have an output value V greater than a threshold output value V0are shown as dark, forming a chord552. The set of combination elements556for which at least one of the associated AOD scan elements554that the combination element556represents has an output value V greater than a −threshold output value V0are also shown as dark, forming a combination chord556.

FIG. 43shows channel chords552from a set of five collectors, and the set of combined channel chords550formed therefrom. The formation of combined channel chords550results in the recording of synchronous events therein.

By defining channels600out of selected combinations of collectors300, individual collector filtered output can be consolidated into scatter “fields”, which can then be used to facilitate defect detection of defects such as scratches.

The method of defect detection in which output associated with collectors is independently or individually processed is particularly helpful in identifying asymmetric defects. Further, scratch detection is facilitated by independently or individually processed collector output.

Scratches, also known as line defects, are difficult to identify because their scatter forms a very narrow geodesic on the scatter hemisphere. Since each collector is responsive to scatter in a different region of the scatter hemisphere, data related to a scratch will appear as output in different collectors. In addition, cross-scan filtering attenuates linear defect signatures. When output associated with multiple collectors is combined, the portion of the combined output related to scratches will not produce a sufficient level of output signal to exceed the thresholding value. Therefore, it is preferable to analyze the output associated with each collector for individual detection of line defects. Once the output data are filtered and tested to determine if they exceed a threshold value, the data that exceed the threshold values may be analyzed, alone or in combination with other data, using currently known techniques to identify line defects.

In addition, when output associated with the P-polarized and S-polarized wing collectors is individually processed, channels may be defined for the separation of the wing response for enhanced scratch detection sensitivity and improved detection and classification of additional defect types.

Using the methods described herein, one may define multiple channels600out of a single collector300or a set of collectors300. For example, inFIG. 44, wing collectors310A,310B are shown. The wing collectors310A,310B may be operated in both P and S configurations, and therefore, the output associated with them may be used to form a wing (P) channel610P and wing (S) channel610S

In addition, when combining collectors300to form channels600, the methods described herein may be combined to generate multiple channels600for use in different applications. For example, as shown inFIG. 45, the output associated with the back collector340A and the back collector340B may be filtered and processed in the conventional manner (the FT method813) to form, respectively, the back channel640A and the back channel640B. Alternatively, the output may be processed in accordance with the combined scatter method (the CFT method812; combining collector output, then filtering and then thresholding the output) to form back combined (CFT) channel641, or it may be processed in accordance with the individual collector processing method (the FTC method814; filtering and thresholding the individual collector output, then combining output) to form back combined (FTC) channel642. Finally, the output may be processed in accordance with the dual/CFTC method816(combining the combined scatter method and the individual collector processing method) to form a back combined (dual) channel643.

Returning toFIG. 46, a data reduction module670may be provided for each of the desired combinations of collectors300. In the presently preferred but merely illustrative embodiment described herein, the filtering and thresholding step870would be performed on the data in the data acquisition nodes570and the data reduction nodes670for both the combined scatter method812and the individual collector processing method814. The combining step860for the combined scatter method (CFT method812) would be performed on the data in the data reduction nodes670. For the individual collector processing method (FTC method814), the combining step860would be performed using software in the system controller and processing unit500.

Method for Haze Analysis In A Multi-Collector Surface Inspection System

Defect detection, measurement confidence, and understanding of processes such as wafer production and manufacturing processes are improved when the contribution of surface roughness on a scattering workpiece surface is known and taken into account. A workpiece surface can be said to have an amplitude and a spatial frequency, with the spatial frequency representing the density of the elements on the surface that cause scatter (such as roughness or defects), and the amplitude comprising the height of the elements on a surface. A surface structure comprises the aggregate of the elements (such as roughness or defects) on or in the region of a surface. A surface structure's roughness may be quantified in any conventional manner, one being the average distance of the surface from the mean surface of the wafer. A surface structure's spatial frequency is determined by the density of the elements of which the structure is comprised.FIGS. 91aand91bare illustrations of a workpiece surface structure, showing surface structures S1and S2, each having elements E that cause scatter, structure S1having elements E11, E12, and so on, and structure S2having elements E21, E22, and so on. It can be seen that, while the spatial frequencies of surface structure's S1, S2are essentially identical (the elements E of which they are comprised having essentially the same density), the elements E on structure S2have greater amplitudes than the elements of structure S1, so structure S2can be seen to have a higher roughness value than structure S1.

As an incident beam's photons impinge the elements of a surface, photons from the incident beam scatter off of the elements. The photons, which travel at a frequency that is determined by the incident coherent beam, scatter at a rate that is determined by the roughness of the surface structure. The rougher the surface (the higher the roughness value), the more photons are scattered. The intensity of scatter is determined, for the most part, in a defect free region, by amplitude of the surface frequency. Returning toFIGS. 91a,91b,structure S1, which has a higher amplitude than structure S2, can be seen to scatter more photons than structure S2.

The direction of the photon scatter (the angle at which the photons scatter) is largely determined by the spatial frequency of the surface structure. As the surface structure's spatial frequency increases, the density of the elements of which the structure is comprised increases, and so the angle at which the photons scatter off of the elements becomes more acute relative to the incident beam, shifting back toward the incident beam.

A surface structure's spatial frequency may be divided into components comprising surface structure spatial frequency ranges. For example,FIG. 91ashows a graph of a surface height profile of a model surface structure comprising a region of a surface S of a workpiece W. Using commonly known mathematical techniques such as a Fourier transform, the waveform representative of the model surface structure may be expressed by waveform components. In the example, referring toFIG. 92b,the waveform representative of the model surface structure may be expressed by, specifically, a high surface structure spatial frequency waveform component261having a spatial frequency in a high surface structure spatial frequency range, a medium surface structure spatial frequency waveform component262having a spatial frequency in a medium surface structure spatial frequency range, and a low surface structure spatial frequency waveform component263having a spatial frequency in a low surface structure spatial frequency range. For sake of illustration, the model surface structure was selected so that the waveform defined by its surface height profile could be expressed by waveform components261,262,263with equivalent amplitudes.

As photons scatter from a surface structure, the angles at which they scatter can be modeled using the waveform components of the waveform that is representative of the surface structure. In addition, the extent of scatter that will be present in a region above the surface can be modeled using the waveform components of the waveform that is representative of the surface structure. For example,FIG. 92a-92dare diagrams that show regions representative of the amount of and direction of photons scattered from a surface structure, by waveform component.FIG. 93ashows scatter from the model surface structure ofFIG. 91b,with scatter associated with high surface structure spatial frequency waveform component261scattering into high surface structure spatial frequency surface scatter region HFS, scatter associated with medium surface structure spatial frequency waveform component262scattering into medium surface structure spatial frequency surface scatter region MFS, and scatter associated with low surface structure spatial frequency waveform component263scattering into low surface structure spatial frequency surface scatter region LFS.

As the amplitude of the surface structure changes, the relative contributions of the spatial frequencies to the waveform representative of the surface structure change, and the scatter pattern changes commensurate with the changes in the waveform and its components.FIG. 92bshows an increase in scatter in the low surface structure spatial frequency surface scatter region LFS which would be occur if the low surface structure spatial frequency waveform component of the waveform representative of the surface structure had an increase in amplitude relative to the other waveform components.FIG. 92cshows an increase in scatter in the medium surface structure spatial frequency surface scatter region MFS which would be due to an increase in amplitude in the medium surface structure spatial frequency waveform component relative to the other waveform components.FIG. 92dshows an increase in scatter in the high surface structure spatial frequency surface scatter region HFS due to an increase in amplitude in the high surface structure spatial frequency waveform component relative to the other waveform components.

As noted above, in a multi-collector surface inspection system, such as system10, collectors are positioned at selected positions in the space above a workpiece, with each collector responding to a specific range of surface structure spatial frequencies.FIG. 94is a diagram showing the pattern of surface scatter observable by collectors in a system10in the space above the surface of a workpiece and representative surface structure spatial frequency ranges associated therewith. It can be seen that scatter associated with the low surface structure spatial frequency waveform component263is observable by the front collector330and wing collectors310A,310B, while scatter associated with the medium surface structure spatial frequency waveform component262is observable by the center collector320and wing collectors310A,310B, and scatter associated with the high surface structure spatial frequency waveform component261is observable by the back collector340A,340B. Therefore, it can be seen that surface structure spatial frequency data associated with scatter from a surface structure is obtainable from multi-collector surface inspection system, such as system10.

Determining Surface Roughness of the Workpiece Surface Using the Proportionality of Scatter Power Over a Range of Spatial Frequencies

It is preferable to minimize or eliminate the contribution of surface roughness from discrete defects from surface contamination. Therefore, it is preferable to identify the extent of the contribution of surface roughness in order that the extent of the contribution of surface roughness may be subtracted from the output associated with the collector-detector assembly200.

In accordance with another aspect of this invention, in a surface inspection system having a plurality of collectors, each of which is disposed at a selected collection solid angle, comprising a selected solid angle above a scattering surface, a method for determining an extent of a contribution of surface roughness on the scattering surface comprises determining an extent of a contribution of surface roughness frequencies on the scattering surface. One aspect of the invention further comprises monitoring surface structure spatial frequency contributions to collector signal. In a further aspect, the method comprises monitoring surface structure spatial frequency contributions to the workpiece surface using data from a set of collection solid angles in the space above the workpiece. In another aspect of the invention, the method comprises determining an extent of a contribution of surface roughness frequencies on the scattering surface at a set of collection solid angles that are associated with a selected set of collectors.

In another aspect of the invention, the method comprises collecting “low-surface structure spatial frequency” variations of scatter at one or more selected collection solid angles, whereby the amplitude of the scatter over the selected collection solid angle is proportional to the amplitude of surface variation causing the scatter, over a range of surface structure spatial frequencies detected at the selected collection solid angles.

In a still further aspect of this invention, the contribution/presence of surface roughness frequencies on a scattering surface is determined by displaying a histogram showing the amplitude of scattered photons (in parts per million/billion) for the selected solid angles.

Providing surface amplitude information for specific spatial frequencies so as to determine an extent of a contribution of surface roughness on the scattering surface (conducting haze analysis) allows correlations to be developed between scatter intensity values2and wafer features such as the extent of “grain” or, as referred to in the Stover reference, “surface lay” of the silicon surface or the extent or type of surface structures. Such correlations will then allow insight into the outcome of processing the wafer surface (such as to test the results of chemical mechanical planarization (CMP). In a further aspect of the invention, the step of providing surface amplitude information for specific spatial frequencies further comprises combining output associated with a set of selected collectors to form a haze field, comprising haze associated with combinations of collectors outside of the plane of incidence (e.g. backs and wings). Forming haze fields from output associated with a set of selected collectors is useful in minimizing the effects of incident beam orientation to the “grain” of the silicon surface. By collecting symmetrically above the wafer, a system10is able to reduce the intensity variations caused by the orientation of the incident to the surface “grain”. One such set of selected collectors, the combination of output associated with which has shown to be useful in minimizing the effects of incident beam orientation to the “grain” of the silicon surface, comprises the back collectors.

The idea reflects the proportionality, not absolute determination, of s surface structure spatial frequency and direction of scatter. The method is based on the idea that each collector responds to scattered light associated with a specific range of surface structure spatial frequencies. The theory indicates the “best-case” response range for each collector. Since the response range is constant within a given measurement configuration, e.g. incident beam angle, wavelength, collector dimensions, etc., valid relationships may be drawn between surface structure and the direction of surface roughness scatter.

It should be apparent to those of skill in the art from this illustration that the present invention is not limited to the particular algorithm described herein, and that other approaches and other specific algorithms may be used to process the data obtained from the various detector modules400and to determine defect geometry and classify defects in accordance therewith.

In accordance with the present invention, and as shown inFIG. 75, a method970for determining an extent of a contribution of surface roughness frequencies on the scattering surface comprises the following steps:Step971: Determine the in-scan surface structure spatial frequency response702of a collector300to scatter light, comprising light that has been scattered from a surface S by an incident beam that is applied at a selected angle from normal onto the surface.Step972: Determine a response range comprising the range of the in-scan surface structure spatial frequency response702.Step973: Determine a scatter intensity value representative of the scattered light for the response range in order to determine an extent of a contribution of surface roughness on the scattering surface.

In the presently preferred yet merely illustrative embodiment of the present invention, the incident beam angle comprises about 65 degrees from normal.

The method of the present invention further comprisesStep974: Determine a scatter intensity value for each collector300in a set of selected collectors300, and compare scatter intensity values in order to build an understanding of the haze response by the surface to impingement of an incident beam thereon.

The method of the present invention further comprisesStep975: Determine a scatter intensity value for a collector for a plurality of surfaces, and compare scatter intensity values in order to build an understanding of the haze response by the plurality of surfaces to impingement of a coherent beam thereon.

In a further aspect of the present invention, the scatter intensity value comprises a value that is an amplitude of the scattered light. In the presently preferred yet merely illustrative embodiment of the present invention, the scatter value comprises a value representative of a maximum amplitude of the scatter light. Alternatively, the scatter value comprises a value representative of a minimum amplitude, a value representative of the difference between a minimum and maximum value, or a value derived from any desired function of the scatter light.

In the presently preferred yet merely illustrative embodiment of the present invention, the step971of determining the in-scan surface structure spatial frequency response of each collector further comprises creating a surface structure spatial frequency plot705in which the cross-scan surface structure spatial frequency704for each collector is mapped against in-scan surface structure spatial frequency702, forming the spatial frequency response region700for each collector300in the multi-collector surface inspection system10. One such surface structure spatial frequency plot is shown inFIG. 52, which presents the surface structure spatial frequency response defined by the cross-scan surface structure spatial frequency response704and the in-scan surface structure spatial frequency response702for a set of collectors300comprising the front collector330, center collector320, dual wing collectors310A,310B, and back collectors340A,340B of the presently preferred yet merely illustrative embodiment of the present invention. The mapping results in a visual representation of a spatial frequency response region700for each collector300, such as front collector spatial frequency response region730, a center collector spatial frequency response region720, dual wing collectors spatial frequency response regions710A,710B, and back collector spatial frequency response regions740A,740B.

As seen inFIG. 52, each collector300responds over a specific range of wafer surface structure spatial frequencies. The response range is constant within a given measurement configuration, e.g. incident beam angle, wavelength, collector dimensions, etc. Mapping surface structure spatial frequency response in terms of cross-scan surface structure spatial frequency response704and the in-scan surface structure spatial frequency response702produces a means of monitoring the various surface structure spatial frequency contributions to surface roughness scatter.

It can also be seen that the origin in the spatial frequency plot705is offset to reflect the offset of the incident beam angle from surface normal of the sample. The step of determining response ranges further comprises using the surface structure spatial frequency plot to identify ideal response ranges760for each collector300.

In the presently preferred yet merely illustrative embodiment of the present invention, the step974of comparing the scatter intensity values further comprises a step976of displaying the scatter intensity values for each response in a visual representation. The displaying step976may comprise forming a chart706, as shown inFIG. 54, identifying the scatter intensity values. Alternatively, as shown inFIG. 53, the displaying step976may comprise a step977of mapping the ideal response ranges760into a histogram780illustrating the scatter value.

The histogram780ofFIG. 53has an element782associated with each ideal response range760, with the height of an element782comprising a power value representative of the power scattered at each collector300within the response range760. In a presently preferred yet merely illustrative embodiment of the present invention, the power value comprises a value representative of an amount of scatter measured (for example, in parts per million, or nanowatt per steradian, or ppm per steradian).

In a still further embodiment, the step977of mapping the ideal response ranges760into a histogram780further comprises having the histogram780illustrate the breadth of the ideal response range760associated with each collector300. As shown inFIG. 53, each element782on the histogram780is provided with a width that is representative of the ideal response range760associated therewith.

In a still further embodiment, as shown inFIG. 53, the histogram780illustrates the surface structure spatial frequency values of the in-scan spatial frequency responses702associated with the scattered light by placing the elements at locations on the histograms780that represent the range of the in-scan spatial frequency responses702. For example, the back collector spatial frequency response regions740A demonstrates a range of responses between in-scan spatial frequency740A1and in-scan spatial frequency740A2. The difference between the frequencies740A1,740A2determines the breadth of the histogram element782A associated with the back collector spatial frequency response regions740A. Referring toFIG. 53, it can be seen that certain of the surface structure spatial frequency responses overlap. For example, the histogram element820associated with the center collector surface structure spatial frequency response region720overlaps with the histogram element840A (associated with the back collector surface structure spatial frequency response region740A), the histogram element810A (associated with the wing collector surface structure spatial frequency response region71A), and the histogram element830(associated with the front collector surface structure spatial frequency response region730. Therefore, when a histogram780is created for the surface structure spatial frequency responses760, as seen inFIG. 53, the elements782associated with the overlapping surface structure spatial frequency response760also overlap on the histogram780.

Overlapping data may be displayed in any conventional manner, such as color changes, hash marks, or using overlapping transparencies. In addition, a decision could be made to ignore data having certain characteristics or associated with certain collectors. For example, data associated with the wing collectors operating in the P configuration may be excluded from the analysis in order to reduce the extent of overlap. Such exclusion would provide minimal impact on the analysis, since most surface scatter would be filtered from the wing data due to polarization.

The histogram780fromFIG. 53may also be flipped horizontally to present the histogram784inFIG. 55, in which the x-axis is oriented in a more common manner, showing low to high frequency.

As noted above, the method of the present invention further comprises determining a scatter intensity value for a collector for a plurality of surfaces by impinging an incident beam on the plurality of surfaces, and comparing scatter intensity values in order to build an understanding of the haze response by the plurality of surfaces. Scatter intensity values and surface structure spatial frequency response ranges for a plurality of surfaces may thus be used to identify and highlight differences in surface roughness that are due to differences in processing, such as pressure polish time, slurry type, chemical concentrations. The chart ofFIG. 54identifies scatter intensity values for three different wafer processes. Levels of surface structure spatial frequencies (such as low, medium and high) may be assigned different colors so that the significant differences in the haze in wafer created using the different processes are readily shown.

The scatter intensity values associated with surface roughness3may be normalized for each collection area represented in a histogram such as histogram784in order to produce a low-resolution power spectral density (PSD)-type chart. The power spectral density (PSD) of a quasi-stationary random process is the Fourier Transform of the autocovariance function. Specifically, the spectral density Φ(ω) of a signal f(t) is the square of the magnitude of the continuous Fourier transform of the signal.

where ω is the angular frequency (2π times the cyclic frequency) and F(ω) is the continuous Fourier transform of f(t).

Power spectral density is usually expressed in units squared per frequency. For two-dimensional roughness, this would be um2/(cycles/um)2—equivalent to um4. The contribution of surface roughness on a scattering surface to scattered light may be calculated from amount of scattered light observed in the solid angle associated with each selected collector.FIG. 76is a diagram illustrating the solid angle of collection of scatter signal from a surface S at a collector300.FIG. 76shows an incident beam Aiwith an incident power Piand λ=532 m, impinging on a surface S, producing a reflected beam Arhaving a reflected power PrPsfor the solid angle defined by an angle θcthat is disposed at a scattering angle θSω is: 2π times the cyclic frequency). Therefore, ω may be determined to be:
Ω=2π(1−cos θc),

where θsis the scattering angle.

The Bidirectional Reflectance Distribution Function BRDF is the differential ratio of the sample radiance normalized by its irradiance. Therefore, once the ω is determined, one can then determine

When all scattered light is being collected across the area of the hemisphere, and the total power measured at each collector is summed, the RMS roughness σrmsmay then be determined by

It is preferable to minimize or eliminate the contribution to scatter signal of surface roughness so that discrete defects can be distinguished from surface contamination. Therefore, it is preferable to identify the extent of the contribution of surface roughness in order that it may be subtracted from the output associated with the collector-detector assembly200. Further, it is preferable to track haze for each of the collectors in order to understand the confidence in the measurement. The composition of all collectors is used to provide surface roughness information. RMS Roughness is derived from summing all of the scatter intensity values for each collector. Further detail on RMS roughness-based haze analysis is found below.

It is further preferable to identify the extent of the contribution of surface roughness to collector output in order to analyze collector response to light scattered from surface structural conditions.

Visualization of Spatial Frequency Distributions Occurring in a Workpiece Surface Structure

Typically, surface inspection tools that measure RMS roughness have a normal incident beam. The surface inspection system10differs from surface inspection tools that measure RMS roughness in that it has an oblique incident beam and it collects scatter from collectors disposed at selected angles. The present invention involves an improvement in haze analysis comprising analyzing the spatial frequency distributions in surface scatter. As noted above, haze analysis, or analysis of the diminished atmospheric visibility that results, in the case of a surface inspection tool, from light scattered from a surface, is typically performed in order to analyze collector response to light scattered from surface structural conditions. Examples of systems and methods that provide haze analysis include those of the '701 patent, as well as U.S. Pat. No. 6,118,525 and U.S. Pat. No. 6,292,259, all of which are assigned to ADE Optical Systems Corporation and all of which are herein incorporated by reference.

In a multi-collector surface inspection system such as system10described above, the summation of haze from each of the plurality of surface collectors300is approximately the haze observed by a total integrated scatter tool, such as is described in the Stover reference. The placement of the plurality of collectors (front, center, backs, and wings) in the surface inspection system10described above, at their respective locations allows for the collection of angular information on light scattered from a surface, which, as noted above, can facilitate separation of scattered light into the spatial frequency ranges of surface structures, which then in turn can be used to provide detail about the kind of structures causing the surface roughness.

In addition, scattered light having selected light characteristics, such as a selected polarization, may be used to identify the source of the scatter on or in a workpiece surface. For example, scattered light of a selected polarization may be used to distinguish between surface roughness and a surface defect. When a P-polarized incident coherent beam hits a workpiece surface, it is rotated 90 degrees, and scatter from surface roughness becomes S-polarized at the wing locations. However, scatter caused by a P-polarized incident coherent beam hitting a particle on a workpiece surface remains P-polarized at some ratio, especially in scatter observable in the solid angles occupied by the wing collectors. Therefore, polarization-may be used to distinguish between particles and surface roughness, especially in the wing collectors that were located, as described above, in a location in which P-contribution from scatter associated with surface roughness is at a minimum. In addition, power measured at each collector can be summed with all other collectors to produce total (measured) scatter power (TIS).

Therefore, it is an object of the present invention to use knowledge of the characteristics of light scattered from surface structural conditions in order to improve the analysis of collector response to light scattered from surface structural conditions.

It is a further object of the present invention to use characteristics of the light scattered from surface structural conditions, such as intensity of the scattered light and surface structure spatial frequency range associated with the scattered light, to identify characteristics of the surface structural conditions, such as average surface roughness over a selected range of wafer surface structure spatial frequencies.

It is a further object of the present invention to monitor workpiece production processes using characteristics of scattered light from workpiece surfaces, comprising intensity of the scattered light and surface structure spatial frequency range of the scattered light.

With the present invention, there is provided a method and a system for inspection of surface structural conditions of a workpiece, over a range of surface structure spatial frequencies determined by system geometry, by analyzing surface scatter, comprising light scattered from a surface and comprising surface roughness over a determinable surface structure spatial frequency range, involving analyzing relationships between portions of the scattered light associated with defined surface structure spatial frequency ranges. In one aspect of the invention, analyzing surface scatter involves treating the power measured in the collectors from the surface scatter, over a determinable range of surface structure spatial frequency responses, as a variable in the analysis.

In one embodiment of the invention, the method comprises separating surface roughness scatter into surface structure spatial frequency ranges, where direction of surface roughness scatter is predominately determined by incident beam properties and the idealized spatial frequency of the structure scattering the light, and analyzing at least a first scatter portion comprising a portion of the surface roughness scatter within a first surface structure spatial frequency range. In a further aspect, the method comprises analyzing the first scatter portion alone or in combination with a second scatter portion comprising a portion of the surface roughness scatter within a second surface structure spatial frequency range. In a still further embodiment, the method comprises analyzing a plurality of scatter portions of surface scatter, each scatter portion comprising a portion of the surface roughness scatter having surface structure spatial frequencies within a selected spatial frequency range defined by the architecture of the surface inspection system.

The method comprises observing the presence of surface roughness scatter within an area above the surface, with the area being selected for the power range of the power measured over the measurable spatial frequency within the area, in order to observe surface roughness scatter by spatial frequency over the selected frequency range, and to analyze surface roughness scatter by power measured over a known area.

In a further aspect, the method comprises collecting the surface scatter in a plurality of areas above the surface, with each area being selected for its association with a selected spatial frequency range in the frequency of surface roughness in a surface structure, order to analyze the surface roughness of the surface structure by the selected spatial frequency ranges and to analyze relationships between surface scatter associated with different ones of the spatial frequency ranges.

In one embodiment, collecting the surface roughness scatter at a plurality of areas comprises positioning a plurality of scattered light collectors at selected positions above the surface, with each position selected so that the scattered light collector, at the position, is able to observe power of a surface roughness scatter associated with a determinable surface structure spatial frequency range. The method further comprises observing surface roughness scatter at the scattered light collectors and analyzing the surface roughness scatter by scattered light collector. In a further embodiment, the step of observing surface roughness scatter comprises identifying the presence of surface scatter at the scattered light collectors and measuring an extent of the surface roughness scatter.

In another embodiment, the method further comprises using a plurality of collectors disposed at positions above the surface, identifying a surface structure spatial frequency range to be associated with scattered light observable by each of the collectors, and analyzing the surface roughness scatter by scattered light collector.

In another aspect of the invention, analyzing surface scatter involves developing visual representations of haze produced by the surface roughness scatter, with haze comprising an atmospheric condition above the surface of diminished visibility that results from conditions such as background noise or surface roughness, the visual representations showing the presence of haze arising from surface scatter, comprising scattered light from an incident beam impinging on selected locations on the surface, according to the spatial frequency range of the surface roughness scatter. In a further embodiment, developing visual representations further comprises presenting an extent of the haze.

In a still further embodiment, developing visual representations further comprises presenting haze associated with surface roughness scatter associated with a plurality of spatial frequency ranges, with the haze displayed according to the spatial frequency range with which its associated surface roughness scatter is associated. In further embodiments, presenting haze associated with surface roughness scatter associated with a plurality of spatial frequency ranges further comprises identifying an extent of haze for each spatial frequency range.

In another embodiment, developing visual representations of haze comprises developing composite haze maps, in which map positions are associated with locations on the region under investigation, and which shows multiple representations of haze associated with surface roughness scatter arising from an incident beam reflected from each of said locations, with each representation of haze associated with surface roughness scatter associated with a different spatial frequency range.

According to another aspect of the present invention, there is provided a method for inspection of surface structural conditions of a workpiece by analyzing collector response to light scattered from surface structural conditions, with the system and method involving analyzing a portion of the light associated the a selected surface structure spatial frequency range.

In a further aspect of this invention, a method and a system for inspection of surface structural conditions of a workpiece involves observing scattered light with a plurality of scattered light collectors, each collector disposed to observe scattered light over a determinable surface structure spatial frequency range, said scattered light having intensity representative of surface roughness scatter having a determinable surface structure spatial frequency range, combining output associated with at least two of the selected scattered light collectors to form combined surface roughness scatter output, and analyzing the spatial frequency contributions of the combined surface roughness scatter output.

In an even further aspect of the invention, analyzing the spatial frequency distributions further comprises forming visual displays of surface roughness scatter output. In a further embodiment, forming visual displays comprises developing displays in which spatial frequency distributions are represented by a display element, with each spatial frequency to be presented in the display being associated with a display element. Preferably, the display element comprises a display color. In a further embodiment, forming visual displays comprises developing displays showing an extent of the surface roughness scatter output of a selected spatial frequency, in order to identify the relative contribution of light associated with the selected spatial frequency in the light of the surface roughness scatter output.

In addition, forming visual displays comprises constructing composite haze maps, further comprising developing workpiece surface maps in which map regions are associated with surface structures on the workpiece, and in which a characteristic of the display, such as graphical elements or color, in a map region identifies the relative contribution of roughness having a selected spatial frequency in the surface structure associated with the map region. A further embodiment comprises defining channels in a surface inspection system, and constructing composite haze maps further comprises representing surface roughness scatter output associated with selected defined channels in a haze map.

In an even further aspect of the invention, analyzing the spatial frequency distributions further comprises forming graphical representations of the spatial frequency distributions. In a further embodiment, developing graphical displays further comprises developing bar charts of the measured power by the spatial frequency response range.

When light is scattered from surface structural conditions and observed by a collector positioned above the surface, the intensity of the portion of the light that is present in the space defined by the solid angle of the collector, coupled with the identification of the spatial frequency range of the surface structure from which the portion is scattered, allows analysis of the portion by frequency range. Determining an extent of a contribution of surface roughness on the scattering surface allows correlations to be developed between scatter intensity values and wafer features such as the extent of “grain” of the silicon surface or the extent or type of surface structures.

One aspect of the invention further comprises monitoring spatial frequency contributions to surface roughness scatter. In a further aspect, the method comprises monitoring spatial frequency contributions to surface roughness scatter at a set of collection solid angles that is associated with a selected set of collectors.

Since the response range is constant within a given measurement configuration, e.g. incident beam angle, wavelength, collector dimensions, etc., valid relationships may be drawn between surface structure and the direction of surface roughness scatter. Scatter intensity values may be compared in order to build an understanding of the surface response by haze levels.

In a surface inspection system such as system10, in which a plurality of collectors are disposed above a surface, the identification of scattered light's intensity and frequency range allows sorting of light that is scattered from surface structural conditions by surface structure spatial frequency range and the use of surface structure spatial frequency range as a variable in the analysis of scattered light. Haze associated with a selected surface structure spatial frequency range may then be analyzed alone or in combination with haze associated with other selected surface structure spatial frequency ranges.

Collectors such as the collectors300in the surface inspection system10may be used to measure the intensity of light scattered from surface structural conditions, and positioning the collector in the space above the workpiece relative to the angle of the incident beam impinging on the surface may be used to associate the collector output with a selected surface structure spatial frequency range. It is within the scope of the present invention to place collectors at selected positions in the space above a surface under investigation, with the positions so selected to optimize the presence of haze associated with surface scatter propagating from a surface having a specific surface structure spatial frequency.

It should be noted that the output obtained by a collector such as collector300in a collection and detection assembly200does not identify the presence of scatter having a particular frequency. A collector's output indicates the presence of light in the space that is defined by the solid angle of the collector. When the light results from incidence of a coherent beam from a workpiece surface, it is the position of the collector in the space above the surface that defines to a large extent the observable scattered light for the collector. The observable scattered light will be that portion of the scattered light that is associated with the range of spatial frequency of the surface structure impinged upon by the incident beam. t. Therefore, it is the knowledge of the spatial frequency range of surface structure that is associated with the scattered light that is observable by a collector (obtained from knowledge of the position of the collector relative to the surface) that allows the observation of surface scatter associated with a particular spatial frequency.

In addition, it should be noted that the output obtained by a collector such as collector300in a collection and detection assembly200indicates the amplitude of the roughness of the structures in and on the workpiece surface by identifying the intensity of light scattered from the workpiece surface when a coherent beam is incident from the surface. Output from collector300comprises voltage signals that are indicative of photon activity within a collector, with the photon activity resulting from light scattered from the surface of the region under inspection, and with the extent of the voltage signal being indicative of the extent of the intensity of such photon activity. In addition, the extent of the intensity of such photon activity at the collector indicates the amplitude of the roughness of the structures in and on the workpiece surface.

The intensity of the light scatter indicates the amplitude of the roughness of surface structures because, first, the scatter's intensity at the collector is proportional to the amplitude of the light waves comprising the scatter, and, second, the amplitude of the scattered light waves is proportional to the amplitude of the roughness of the structures in and on the workpiece surface. The higher the roughness of surface structures, the higher the number of photons scattered from the surface, and, in turn, the higher the number of photons collected, for example in parts per million (ppm), by the collector. The output of a collector, being a voltage value representative of the number of photons observed in the space above a workpiece surface within a solid angle about the collector, thus identifies the amplitude of structures in and on the workpiece surface.

Providing surface amplitude information for specific spatial frequencies further comprises combining output associated with a set of selected collectors to form a haze field. Forming haze fields from output associated with a set of selected collectors is useful in minimizing the effects of incident beam orientation to the “grain” of the silicon surface.

It is known that scatter patterns, also known as haze patterns, differ given the location above the workpiece surface at which the haze is observed. For example, collectors located in the front quartersphere FQ (referring toFIG. 6, FQ being the region lying above the workpiece surface, between the base plane B and the normal plane NP, through which passes the incident beam before it reaches the base plane B) receive scatter having more lower frequency components than do collectors located in the back quartersphere BQ or than do collectors in regions along or containing the normal plane NP. Therefore, front collectors will register increased levels of lower spatial frequencies.

It is also known that scatter patterns differ given characteristics of the wafer under examination. For example, wafers that have been processed with treatments (such as annealing or epitaxial processes) that result in smoother surfaces, tend to produce scatter with more lower frequency components than do wafers with polished surfaces. Given that front collectors will register scatter levels of lower spatial frequencies more than will collectors in other locations above the surface, light from the surfaces of annealed or epitaxial wafers will scatter more to front collectors than to collectors in other locations.

The following is an illustrative but not necessarily preferred method for analyzing surface scatter using a multi-collector surface inspection system such as system10to inspect workpieces such as wafers: The method, shown inFIG. 98, comprises a step264in which output representative of surface scatter is separated by surface structure spatial frequency associated with the surface scatter, and a step268in which the surface scatter is then analyzed by its associated surface structure spatial frequency range.

The step264of separating the output representative of surface scatter by the spatial frequency of the surface structures further comprises the following steps:In a step265, a set of expected spatial frequency ranges is selected for the surface structure to be observed. For example, the selected frequency ranges could comprise a high surface structure spatial frequency range, a medium surface structure spatial frequency range and a low surface structure spatial frequency range.Step266: Recognizing that collector placement above a test surface determines the surface structure spatial frequency range associated with the scattered light observable by the collector, the collectors in a multi-collector surface inspection system10that will provide output associated with the selected surface structure spatial frequency ranges are identified. For example, a front collector330would be selected as the low surface structure spatial frequency range collector for its ability to observe scatter associated with surface structure having a spatial frequency within a low surface structure spatial frequency range, a center collector320would be selected as the medium surface structure spatial frequency range collector for its ability to observe scatter associated with surface structure having a spatial frequency within a medium surface structure spatial frequency range, and a back collector340A,340B, alone or in combination as a channel640, would be selected as the high surface structure spatial frequency range collector for its ability to observe scatter associated with surface structure having a spatial frequency within a high surface structure spatial frequency range.Step267: Surface scatter output is obtained for each of the selected collectors in order to obtain output to be associated with each selected surface structure spatial frequency range. If desired, output of selected collectors is combined to create output to be associated with a channel. For, example, in order to obtain scatter surface output to be associated with a high surface structure spatial frequency range, output from the back collectors340A,340B could be combined using the methods described above to obtain output associated with back combined (CFT) channel641, back combined (FTC) channel642, back combined (dual) channel643, or another desired channel.

In one embodiment, as shown inFIG. 99, the step268in which the surface scatter is then analyzed by its associated surface structure spatial frequency range may comprise the step269of analyzing the output associated with a portion of surface scatter alone or in combination with output associated with other portions of surface scatter, with each scatter portion comprising a portion of the scatter from surface structure having a spatial frequency within a selected surface structure spatial frequency range. In one embodiment, the output analyzing step269comprises analyzing output associated with surface scatter by scattered light collector.

The output analyzing step269is facilitated by a step274of establishing a visual representation to be associated with the output associated with each surface structure spatial frequency range in the analysis. Establishing a visual representation further comprises the following steps:Step275: A characteristic of the visual representation is assigned to represent an identification of the presence of surface scatter in the output. In one embodiment, the visual representations are haze maps, with haze comprising an atmospheric condition above the surface of diminished visibility that results from conditions such as background noise or surface roughness. Haze maps comprise maps of the surface of a wafer, in which the positions on the map represent locations on a surface that caused an observation of haze by a collector during the reflection of an incident beam from the surface at the location. The haze map has a characteristic assigned thereto to represent the observation of surface scatter at a position on the haze map that represents the location on the wafer surface at which haze was observed.FIG. 78a,FIG. 78b, andFIG. 78care examples of haze maps for displaying haze associated with a set of frequency ranges.FIGS. 78A,78B, and78C show wafer haze maps271,272,273for output associated with haze from scatter from surface structures having a surface structure spatial frequency within, respectively, the high surface structure spatial frequency range, the medium surface structure spatial frequency range, and the low surface structure spatial frequency range. InFIG. 78A,78B, and78C, the characteristic of the visual representation that represents the observation of surface scatter (i.e., identifying the presence of haze) is a graphical element, with a different graphical element associated with each selected surface structure spatial frequency range.InFIG. 78A, the graphical element for identifying haze associated with high surface structure spatial frequency range comprises dots. InFIG. 78B, the graphical element for identifying haze associated with a medium surface structure spatial frequency range comprises parallel lines in a first direction. InFIG. 78C, the graphical element for identifying haze associated with a low surface structure spatial frequency range comprises parallel stripes of a second direction.In another embodiment of the present invention, the graphical representation could be color. For convenience, the haze map colors may be chosen to be consistent with the human visual spectrum, with blue representing high surface structure spatial frequency ranges, green representing medium surface structure spatial frequency ranges, and red representing low surface structure spatial frequency ranges. For purposes of illustrating this embodiment of the present invention employing color, the dots ofFIG. 78acould represent blue, the parallel lines in a first direction ofFIG. 78bcould represent green, and the parallel lines in a second direction ofFIG. 78ccould represent red.Step276: An extent of surface scatter observed by each collector is represented by variation in the visual representation. In a further embodiment, the step276of representing extent of surface scatter further comprises presenting an extent of the haze. For example, presenting an extent of the haze could comprise modifying the characteristic to represent an extent of surface scatter.InFIGS. 78A,78B, and78C, variation in the amount of haze is shown by variation in the graphical element. InFIG. 78A, variation in a high structure spatial frequency range is shown by variation in dot density. InFIG. 78B, variation in the amount of haze of a medium surface structure spatial frequency range is shown by variation in density of the parallel lines in a first direction. InFIG. 78C, variation in the amount of haze in a low surface structure spatial frequency range is shown by variation in density of the parallel stripes in a second direction.In the embodiment in which color represents surface structure spatial frequency range, the variation in the visual representation could be shown by variation in the intensity of the color associated with the surface structure spatial frequency range, with no scatter represented by no color, a low amount of scatter represented by color of low intensity, and the maximum amount of scatter represented by the most intense color. For purposes of illustrating this embodiment of the present invention employing color, the density of the dots ofFIG. 78Acould represent the intensity of blue, the density of the parallel lines in a first direction ofFIG. 78Bcould represent the intensity of green, and the density of the parallel lines in a second direction ofFIG. 78Ccould represent the intensity of red.The step276of representing an extent of surface scatter by variation in the visual representation could comprise a step277, in which the values representative of the extent of haze are mapped into values for the extent of variation in the visual representation. In the embodiment in which graphical elements are modified to represent scatter intensity, for each graphical element, each scatter intensity value could be mapped into a value representative of the amount of density of the graphical element. In the embodiment in which color intensity is used to represent scatter intensity, for each color, each scatter intensity value could be mapped into a pixel color value. For example, if the display system provides 256 levels of a color, each scatter intensity value could be mapped into a pixel color value ranging from 0 to 255. The manner in which the values representative of the extent of haze is assigned to values for the extent of variation in the visual representation is described in more detail below.Step280: For a set of surface scatter output associated with a defined surface structure spatial frequency, the visual representations are constructed, using the assigned characteristic of the visual representation to represent an identification of the presence of surface scatter in the output, the assigned variation in the visual representation to represent an extent of the surface scatter, and values for the extent of variation in the visual representation to represent the values representative of the extent of haze.In the embodiments described above, the resultant visual representations will comprise haze maps, in which each pixel in the display is associated with a location on the surface under investigation, and in which each pixel displays a variation in visual representation representative of an amount of haze observed by a collector during the incidence of a coherent beam on the surface at the location associated with the pixel.The step280of constructing visual representations could comprise a step284aof constructing one haze map for each selected surface spatial frequency range, or it could comprise a step284b,comprising constructing a composite haze map by combining maps for at least two selected surface spatial frequency ranges into a single map.FIG. 79shows an example of a composite haze map306, created by superimposing the haze maps271,272,273shown inFIGS. 78A,78B, and78C.

The step277, in which the values representative of the extent of haze are mapped into values for the extent of variation in the visual representation, could be performed using any conventional mapping process. For example, the values of surface scatter or haze could be assigned into values for extent of variation using any known technique, such as interpolation, or they could be assigned using a step278with reference to distributions of the scatter intensity values:

Referring toFIG. 95, there is shown a plot279of the distribution of scatter intensity values on a wafer, by the percentage of a wafer's area at which a scatter intensity value was measured, for the output associated with three collectors. The plot279can be developed for a single wafer or for a set of wafers: preferably over a set of wafers representing a process or related processes. The scatter intensity values for the output associated with three collectors are measured in photons observed in parts per million (ppm). The plot279specifically displays the scatter distributions associated with a a low surface structure spatial frequency range283(in the embedment described above, from the output associated with the front collector330), for a medium surface structure spatial frequency range282(from the output associated with the center collector320), and for a high surface structure spatial frequency range281(from the output associated with a back collector340A,340B, alone or in combination).

The plot279shows minimum and maximum scatter intensity values for the low surface structure spatial frequency range283, medium surface structure spatial frequency range282, and high surface structure spatial frequency range281, and it identifies the scatter value associated with the greatest percentage of locations on the wafer or set of wafers, respectively, the most frequent low surface structure spatial frequency scatter intensity value943, the most frequent medium surface structure spatial frequency scatter intensity value, and the most frequent high surface structure spatial frequency scatter intensity value941. The most frequent surface structure spatial frequency scatter intensity values941,942,943are assigned the median value for the extent of variation in the visual representation, respectively median low surface structure spatial frequency variation value303, median medium surface structure spatial frequency variation value302, and median high surface structure spatial frequency variation value301. In the embodiment in which color is used to represent surface structure spatial frequency range, the most frequent surface structure spatial frequency scatter intensity values941,942,943are assigned the median pixel color value for the display. In a display system which provides256levels of a color, the most frequent surface structure spatial frequency scatter intensity values941,942,943are assigned the median pixel color value 256/2, which is 128. The surface structure spatial frequency scatter intensity values above and below the most frequent surface structure spatial frequency scatter intensity values941,942,943but within the respective surface structure spatial frequency ranges281,282,283are then assigned to the values for the extent of variation in the visual representation using any known technique, such as interpolation.

Assigning of surface structure spatial frequency scatter values into values for extent of variation with reference to distributions of the surface structure spatial frequency scatter intensity values could be performed using the surface structure spatial frequency scatter intensity values distribution from the wafer under investigation, or it could be performed using surface structure spatial frequency scatter intensity values from a plurality of wafers, for example, from a production run of wafers having the same characteristics as the wafer under investigation. Using a plurality of wafers, nominal surface structure spatial frequency ranges for surface scatter may be identified and applied to the ranges of the extent of variation in the visual representation.

As noted above, surface structure spatial frequency distributions may be analyzing by forming graphical displays of the surface structure spatial frequency distributions. Accordingly, the step268, in which the surface scatter is analyzed by its associated surface structure spatial frequency range, further comprises a step930of forming graphical displays to present scatter intensity associated with surface structure having a spatial frequency within a selected surface structure spatial frequency range and the intensity's statistical characteristics at the displayed spatial frequency ranges, such as median or mean. In a multi-collector surface inspection system such as system10, the graphical displays would comprise graphical displays of the outputs of selected collector. They could comprise charts or, preferably, histograms or bar charts in which the width of the bars represents the extent of the range of the surface structure spatial frequency response for the output of the collector.

The step930of forming graphical displays could further comprise a forming a composite graphical display in which the output of the selected collector or collector and the output's statistical characteristics is displayed at at least two surface structure spatial frequency ranges. The composite graphical display could comprise a combined view histogram or bar chart, with each bar on the histogram representative of a surface structure spatial frequency level. Histogram bars may be placed on the graph by increasing or decreasing frequency level, and overlaps in collector response ranges in surface structure spatial frequency levels could be shown by overlaps in bars.

An example of a combined view histogram is shown inFIG. 80, which presents a graphical display of the output data that formed the frequency level haze maps ofFIGS. 78A,78B, and78C. InFIG. 80, the surface structure spatial frequency ranges defining high and medium surface structure spatial frequency levels overlap. The combined view histogram ofFIG. 80comprises a form of power spectral density (PSD) plot, in which power (represented by scatter intensity measured in ppm) is plotted in terms of surface structure spatial frequency.

As noted above, collectors are placed such that they receive light scattered by surface structures having a spatial frequency within a certain surface structure spatial frequency range. In general, the relative proportionality of surface structure spatial frequencies for each collector may be derived for wafer surfaces having defined characteristics. When nominal responses by a collector or set of collectors are established for surfaces having defined characteristics, any deviation from the nominal response of a collector response for a test surface having the defined characteristic indicates a possible abnormality in the surface. For example, it could indicate a surface defect in or on a surface structure, due to a change in the production run in which the workpiece was produced.

Since changes in surface structure spatial frequency contributions from a workpiece surface may identify changes in workpiece production, deviations from nominal collector responses may be used to monitor workpiece production. Baseline or norms comprising acceptable ranges of scatter intensity measurement values for a collector in a defined-position in the space above a surface could be developed for-a representative set of workpieces having specified characteristics.

For example, for a collector in a multiple collector surface inspection system such as system10and in a defined position above the workpiece surface, nominal responses may be developed from data obtained by operating the collector to observe scatter from the surfaces of several workpieces, for example, workpieces produced using the same production process. Minimum and maximum values could be determined in the ranges of acceptable scatter intensity measurement values for each selected collector. In addition, baseline or norms comprising ranges of acceptable scatter intensity measurement values could be developed for a set of collectors in defined positions in the space above a surface for workpieces sharing specified characteristics.

The baseline or norms could be associated with an acceptable level of surface roughness on a workpiece of a specified characteristic. The baseline or norms could then be used to define norm value ranges for the scatter intensity measurement values in the output of the selected collector or collectors for workpieces sharing specified characteristics, such as wafers in a production run. In a subsequent production run, deviations from the norm value ranges in the output of the selected collector or collectors could then be used to indicate problems in the production run.

Nominal ranges could be developed using the following method, shown inFIG. 100:Step931: Distinguishing characteristics (such as wafer type, production type, polishing process, wafer annealing, epitaxial processing, grain size) ) are identified for the wafers to be analyzed.In a step932, a set of surface structure spatial frequency ranges is selected for the surface structures to be observed.Step933: The collectors in a multi-collector surface inspection system such as system10, which will provide output representative of surface scatter sort-able by surface structure spatial frequency range associated with the surface structures to be observed, are selected to provide output associated with the selected surface structure spatial frequency ranges.Step934: Output comprising scatter intensity values is obtained for each of the selected collectors from a plurality of wafers, for example, from a production run of wafers having the same characteristics as the wafer under investigation. As described above, output of selected collectors may be combined to create output to be associated with a channel.Step935: Nominal scatter intensity values, for example in PPM units, are developed for wafers sharing the distinguishing characteristic for each selected collector (and thus each selected surface structure spatial frequency range), and are used to develop nominal scatter intensity ranges.

Once nominal scatter intensity ranges are developed for the set of selected surface structure spatial frequency ranges for the set of distinguishing characteristics of wafers to be analyzed, multiple surface structure spatial frequency haze analysis may be performed on a workpiece. As shown inFIG. 101, one embodiment of a surface structure spatial frequency-based haze analysis method follows:Step936: A test wafer is selected for analysis. The wafer's distinguishing characteristics are identified, and the nominal scatter intensity ranges associated with wafer of the distinguishing characteristics are identified.Step937: A surface inspection system such as system10is used to obtain surface scatter patterns for the wafer from the selected collectors. The system10scans the wafer using the methods described above to identify surface scatter patterns.Step938: The surface scatter associated with the wafer is then analyzed by its associated surface structure spatial frequency range in the manner described above.

As noted above, the architecture of the multi-collector surface inspection system10supports providing a visual presentation of data in haze maps from multiple collectors based on surface structure spatial frequency content. One haze map could be used to show the entire distribution of surface structure spatial frequency content (SFC) for the system10, with high SFC from the back collectors340A,340B, mid SFC from the center collector320, low SFC from the front collector, mid to low SFC from the wing collectors310A,310B, and very low SFC from the light channel650. Given a measurement system in a state of control, analysis of haze response over multiple scatter fields facilitates wafer quality control that can cater to the substrate's end use and/or required channel sensitivities.

Analysis of haze response in which the surface structure spatial frequency content associated with the haze is a variable encompasses qualitative and/or quantitative approaches. As an example of a qualitative approach, if a wafer produces a preponderance of haze associated with lower surface structure spatial frequency in one region and a preponderance of haze associated with medium surface structure spatial frequency haze in another region, the lack of uniformity of haze associated with different spatial frequency ranges might indicate that polishing uniformity is not ideal.

Lack of uniformity of haze between different surface structure spatial frequency ranges would be more easily observable in the embodiment of a composite haze map in which scatter variation is shown by color. In the example, one color would be present in one region and another color would be present in another region. If the haze readings were within nominal (standard) ranges, the surface of the wafer would be uniformly colored. For example, if the haze responses shown in a composite haze map were within nominal (standard) ranges, the uniform red/green/blue colors would blend together to present a wafer of a uniform gray color.

As another example, scratches, that could be caused by a number of problems, such as poor polishing, would be more apparent in composite haze maps in which haze is separated by surface structure spatial frequency than in haze maps showing haze associated with only one surface structure spatial frequency range (i.e., a haze map showing haze response for only one collector) or haze maps showing haze not separated by surface structure spatial frequencies. Scratches appear in haze maps as lines; the deeper the scratch, the stronger the line in the map. Certain scratches may be apparent in the haze associated with only one surface structure spatial frequency range or in only a limited number of surface structure spatial frequency ranges, and they may not be apparent at all in the haze associated with another surface structure spatial frequency range. Therefore, a scratch that is apparent in the haze associated with one surface structure spatial frequency range will not be displayable in a haze map for haze associated with other surface structure spatial frequency ranges. In addition, in output of haze not separated by surface structure spatial frequencies, signal associated with a scratch that is apparent in haze of a limited number of surface structure spatial frequency ranges is attenuated by the signals of haze associated with the other surface structure spatial frequencies in which the scratch is not apparent. The aggregation of signals in the display of haze that is not separated by surface structure spatial frequency will result in a signal in which the scratch is dim or not apparent at all. On the other hand, in a composite haze map in which haze is separated by surface structure spatial frequency, the scratch could be presented using a plurality of representations, for example in a plurality of colors, and the scratch will therefore will stand out in the physical representative of the surface structure spatial frequency ranges of haze in which the scratch is apparent (for example, a light green line will show up in a field of soft red and green haze).

In one embodiment, analysis of haze response in which the surface structure spatial frequency content of haze is a variable comprises disabling selected portions of the surface scatter intensity ranges in output associated with an individual contributing collectors. Disabling portions of a surface scatter intensity range essentially comprises subdividing data associated with a surface structure spatial frequency range with which a collector is associated into scatter intensity sub-ranges so that haze may be analyzed in even smaller sets of data. After scatter intensity range sub-division, the data associated with the scatter intensity sub ranges may be used as the data associated with the surface structure spatial frequency distributions in haze analysis.

With sub-divided scatter intensity frequency ranges, a haze map may be constructed that shows how scatter magnitudes (in ppm units) are distributed throughout the individual scatter intensity ranges in relationship to the other surface structure spatial frequency response ranges. By disabling a certain range of scattered power over a selected surface structure frequency response collector, can generate a map showing the absence of the eliminated scatter intensity ranges in a map. While scatter from surface structure is more readily differentiated when it is analyzed by selected surface structure spatial frequency ranges, signals associated with the scatter is still integrated within the selected surface structure spatial frequency range. Subdividing the selected surface structure spatial frequency range into sub-ranges associated with the scatter intensity within the range provides smaller integration and facilitates differentiation, even within a surface structure frequency range. With subdivided scatter intensity ranges, it is possible to remove a range of scatter intensities from a haze map to show only some the presence of only some intensity values within a surface structure spatial frequency range.

An example of the utility of subdividing selected surface structure spatial frequency ranges is shown inFIGS. 96 and 97. Referring toFIG. 96, a medium surface structure spatial frequency range haze map939, comprising a haze map associated with the medium surface structure spatial frequency range, could show scatter of no discernible pattern. However, when the medium surface structure spatial frequency range is subdivided and a modified medium surface structure spatial frequency range haze map941, such as inFIG. 97, is constructed, haze associated with all scatter intensity values in the medium surface structure spatial frequency range except the higher scatter intensity values could be displayed. It can be seen that map941shows a cluster of haze events in the center of the map. Such a haze pattern could indicate that locations in the center of the wafer are producing more haze than are locations elsewhere on the wafer.

Haze produced by the center of a wafer could result from increased amplitude of surface structures in the center of the wafer, which could arise from over-polishing on the outside of the wafer and incomplete polishing in the center of the wafer, which, in turn, could arise from a deformation of the wafer while it is being polished. It is known that bowing in the center of a wafer during polishing could arise from uneven pressures on the wafer platen. In response to seeing increased haze events in the center of a wafer map, a production manager could tune pressures on the platen in order to eliminate the deformation. Thus surface structure spatial frequency range-based haze analysis could be used to facilitate monitoring of wafer production.

Subdividing other surface structure spatial frequency ranges, creating modified surface structure spatial frequency range haze maps, and combining the modified surface structure spatial frequency range haze maps into modified composite haze maps could highlight with even greater specificity haze events that could be used to diagnose structural conditions and processing problems.

Surface structure spatial frequency range-based haze analysis can be particularly useful in conducting production problem troubleshooting. In the example described above, in which pressures on a platen caused wafer deformations that resulted in non-uniform polishing, confirmation of the existence of a similar but aberrant scatter pattern in another frequency range indicated the presence of a global problem with the surface structure irrespective of the surface structure spatial frequency range. On the other hand, a composite haze map or haze maps of different surface structure spatial frequency ranges that show that all but one of the response collectors is observing uniform haze could indicate a different problem, such as polishing being uniform within some surface structure spatial frequency ranges but not all surface structure spatial frequency ranges. A production manager, using the haze maps to identify de-correlated data or data with low correlation, could then concentrate on other production issues, such as deficiency in the size of a polishing slurry or a chemical reaction.

If the production manager using surface structure spatial frequency-based haze analysis identified a scatter pattern in the middle to high surface structure spatial frequency response ranges (in data from the center or back collectors) but not from the low surface structure spatial frequency range, (in data from the front collector, he or she could suspect certain issues such as problems with the slurry, which are more likely to introduce scatter associated with middle or high surface structure spatial frequencies. On the other hand, if the production manager identified a scatter pattern only in the low surface structure spatial frequency response range, he or she could eliminate slurry issues and focus on problems that are more correlated with low surface structure spatial frequency scatter, such as problems with holding the wafer (i.e. a defective gripper).

A multi-collector surface inspection system such as system10is particularly advantageous in that it is capable of being used to analyze surface structure scatter.FIG. 77is a block diagram showing methods of analyzing surface structure scatter analysis according to the present invention, in which the optical collection and detection subsystem7provides output associated with each collector detection module200. The output may then be used to perform angle-resolved scatter haze analysis or total integrated scatter haze analysis.

As described above, each collector detector module200is positioned above a surface workpiece in order to respond to scatter associated with a particular spatial frequency range for a surface structure. Because the response range is constant within a given measurement configuration, e.g. incident beam angle, wavelength, collector dimensions, etc, the output from the module200may be used to perform angle-resolved scatter haze analysis, with the back collector modules340A,340B observing scatter associated with the high surface structure spatial frequency range281, the center collector module320observing scatter associated with the medium surface structure spatial frequency range282, and the front collector modules330observing scatter associated with the low surface structure spatial frequency range283. Since the scatter is thus observable according to the surface structure spatial frequency associated with it, angle-resolved scatter haze analysis produces a means of monitoring the various spatial frequency contributions to surface roughness scatter. Collectors may be combined into haze fields to minimize the effects of incident beam orientation to the silicon surface, e.g. combined back collectors and combined wing collectors. Visual representations such as composite haze maps may be developed to assist in analysis.

The output from the module200may also be used to perform total integrated scatter haze analysis, with the output form all of the collectors summed, the reflected power measured and RMS roughness values produced as described above. Visual representations such as single RMS maps may then be developed to assist in haze analysis. Single RMS maps would look very similar to haze maps, with map positions being associated with locations on the region under investigation, and with each map position having a graphical element representing an extent of the single RMS roughness associated with the location on the wafer associated with the map position.

As noted above, typically, surface inspection tools that measure RMS roughness have a normal incident beam and obtain RMS roughness measurements by obtaining measurements of the Total Integrated Scatter (TIS) from the wafer. When such tools comprise multi-collector tools, they obtain RMS roughness measurements from the haze observed across all of the collection optics, by summing the scatter output associated with all of their available collectors.

The system10differs from other surface inspection tools that measure RMS roughness in that it has an oblique incident beam and it collects scatter from collectors disposed at selected angles. The oblique incident beam and the angular positioning of its collectors introduce a surface structure spatial frequency component to the surface scatter output that provides improved haze analysis. However, system10could also be operated as a total integrated scatter tool, obtaining TIS measurements by summing the scatter output associated with collectors300.

It should be noted, though, that aspects of the architecture of the system10cause RMS roughness measurements developed by the system10to not match the RMS roughness measurements developed by typical RMS roughness surface inspection tools using normal incident beams. The surface structure spatial frequency response ranges of certain of the collectors300to overlap, thus causing some “double counting” of scatter when the output of the collectors is simply summed. Therefore, because of double-counting, the RMS roughness measurements developed by the system10will not match the RMS roughness measurements developed by typical RMS roughness tools. However, RMS roughness measurements developed by the system10will strongly correlate RMS roughness measurements developed by typical RMS roughness tools.

While, as noted above, it is not necessary in angle-resolved haze analysis to include data from all collectors300, in order for system10to obtain strong correlation of roughness measurements with those of typical RMS roughness tools, the output associated with all collectors should be summed.

For example, as noted above, data associated with the wing collectors operating in the P configuration may be excluded from angle-resolved haze analysis in order to reduce extent of overlap. Such a practice is acceptable in angle resolved haze analysis because most surface scatter would be filtered from wing data due to polarization. However, in order to obtain strong correlation of roughness measurements with typical RMS roughness tools, it is useful to include scatter associated with wing collectors operating in P configuration.

The above invention has been described in terms of it use in the analysis of unpatterned wafers. However, it is to be understood that the invention is not limited to use in the analysis of wafers. The invention could be applied to the analysis of any suitable workpiece, such as glass and polished metallic surfaces and film wafers.

CONCLUSION

Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative devices and methods, and illustrative examples shown and described. Departures may be made from such without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.