Abstract:
A magnetic immersion lens apparatus includes an outer pole piece and an inner pole piece with a gap therebetween proximate a common axis of the first and second pole pieces. The outer pole piece has an opening that permits energetic particles from a target in front of the immersion lens to pass through the outer pole piece to an external detector. The outer or inner pole piece has one or more notches near the gap, including at least one notch that expands cone of acceptance through which the energetic particles can pass from the target to the external detector. This abstract is provided to comply with rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Description:
CLAIM OF PRIORITY 
       [0001]    This application is a nonprovisional of and claims the priority benefit of commonly owned, co-pending U.S. Provisional Patent Application No. 61/881,351, to Christopher M. Sears, filed Sep. 23, 2013, and entitled “NOTCHED RADIAL GAP MAGNETIC LENS FOR IMPROVED SAMPLE ACCESS IN AN SEM” the entire disclosures of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    Embodiments of the present invention relate to electron microscopy, and more particularly, to a modification to a common magnetic immersion lens for electron microscopy. 
       BACKGROUND OF THE INVENTION 
       [0003]    Energy-dispersive X-ray spectroscopy (EDS, EDX, or XEDS), sometimes called energy dispersive X-ray analysis (EDXA) or energy dispersive X-ray microanalysis (EDXMA), is an analytical technique used for the elemental analysis or chemical characterization of a sample. It relies on an interaction of some source of X-ray excitation and a sample. Its characterization capabilities are due in large part to the fundamental principle that each element has a unique atomic structure allowing unique set of peaks on its X-ray spectrum. 
         [0004]    An EDS system generally includes an excitation source (e.g., electron beam or x-ray beam), an X-ray detector, a pulse processor and an analyzer. An X-ray detector is used to convert the collected X-ray energy into voltage signals which are in turn sent to a pulse processor. The pulse processor measures the signals and passes them onto an analyzer for data display and analysis. The most common detector is Si(Li) detector cooled to cryogenic temperatures with liquid nitrogen. Silicon drift detectors (SDD) with Peltier cooling systems are also used. 
         [0005]    Specifically, to stimulate the emission of characteristic X-rays from a sample, a high-energy beam of charged particles such as electrons or protons (e.g. in particle-induced X-ray emission or proton-induced X-ray (PIXE)), or a beam of X-rays, is focused into the sample being studied. At rest, an atom within the sample contains ground state (or unexcited) electrons in discrete energy levels or electron shells bound to the nucleus. The incident beam may excite an electron in an inner shell, ejecting it from the shell while creating an electron hole where the electron was. An electron from an outer, higher-energy shell then fills the hole, and the difference in energy between the higher-energy shell and the lower energy shell may be released in the form of an X-ray. The number and energy of the X-rays emitted from a specimen can be measured by an energy-dispersive spectrometer. As the energy of the X-rays is characteristic of the difference in energy between the two shells, and of the atomic structure of the element from which they were emitted, this allows the elemental composition of the specimen to be measured. 
         [0006]    Scanning electron microscopes (SEM) systems often have a magnetic immersion lens at the front of an electron optical column proximate the sample. The magnetic immersion lens typically has two pole pieces with rotational symmetry about a central axis of the electron optical column A magnetic field is produced in the pole pieces by one or more pairs of current carrying coils. There is a gap between the two pole pieces, which form a magnetic circuit. Fringing fields in the region near the gap focus or deflect electrons from the optical column. X-rays emitted from the target can pass through the gap to the X-ray detector. In SEM systems, it is desirable to increase access to X-rays emitted from the sample. 
         [0007]    Previous methods for increasing access to the sample include moving sample further away from the lens, or increasing the gap between the lens pole pieces. Each of these ways of increasing access to the sample has disadvantages. Moving the sample away increases the electron spot size and thus decreases imaging resolution. Increasing the gap between magnetic pole pieces increases the magnetic reluctance of the circuit, thus requiring more current to achieve the same magnetic field. This in turn increases the heat dissipation within the lens which can have further deleterious effects on system performance. 
         [0008]    It is within this context that aspects of the present disclosure arise. 
       SUMMARY 
       [0009]    Aspects of the present disclosure include a system having a charged particle optical column configured to generate a primary beam of charged particles and focus the primary beam onto a target. A magnetic immersion lens is provided at a front of the column. The immersion lens has an outer pole piece and an inner pole piece with a gap therebetween proximate a common axis of the first and second pole pieces. The outer pole piece has an opening that permits energetic particles from the target to pass through the outer pole piece to an external detector. The inner or outer pole piece has one or more notches proximate the gap, including at least one notch that expands the cone of acceptance through which the energetic particles can pass from the target to the external detector. 
         [0010]    In some implementations, the one or more notches may include two or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column. 
         [0011]    In some implementations, the one or more notches include three or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column. 
         [0012]    In some implementations, the one or more notches include four or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column. 
         [0013]    In some implementations, the notches may be made large enough to provide a desired access for the detector device to the target without increasing power needed to drive the immersion lens by more than 1%. 
         [0014]    In some implementations, the outer pole piece may have a number of notches proximate the gap. In other implementations, the inner pole piece may have a number of notches proximate the gap. In still other implementations, both the inner pole piece and the outer pole piece have a number of notches proximate the gap. 
         [0015]    In some implementations, the gap may be a radial gap. In other implementations, the gap may be an axial gap. 
         [0016]    The system may optionally further comprise the external detector. In some such implementations, the external detector may be an X-ray detector. In certain particular implementations, the charged particle optical column may configured to generate a primary beam of electrons and focus the primary beam of electrons onto the target. 
         [0017]    According to other aspects of the present disclosure a magnetic immersion lens apparatus may include an outer pole piece and an inner pole piece with a gap there between proximate a common axis of the pole pieces. The outer pole piece has an opening that permits energetic particles from a target in front of the immersion lens to pass through the outer pole piece to an external detector. The outer or inner pole piece has one or more notches proximate the gap, including at least one notch that expands cone of acceptance through which the energetic particles can pass from the target to the external detector. 
         [0018]    In some implementations, the one or more notches include two or four or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column. 
         [0019]    In some implementations, the notches may be large enough to provide a desired access for the detector device to the target without increasing power needed to drive the immersion lens by more than 1%. 
         [0020]    In some implementations, the outer pole piece has a number of notches proximate the gap. In other implementations, the inner pole piece has a number of notches proximate the gap. In still other implementations both the inner pole piece and the outer pole piece have a number of notches proximate the gap. 
         [0021]    In some implementations, the gap is a radial gap. In other implementations, the gap is an axial gap. 
         [0022]    According to other aspects, an outer pole piece for a magnetic immersion lens has an opening that permits energetic particles from a target in front of the immersion lens to pass through the outer pole piece to an external detector. The outer pole piece has one or more notches proximate a central aperture, including at least one notch that expands cone of acceptance through which the energetic particles can pass from the target to the external detector. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    Objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which: 
           [0024]      FIGS. 1A-1B  illustrate an example of a charged particle beam system according to an aspect of the present disclosure in the form of an Energy Dispersive X-ray (EDX) system. 
           [0025]      FIG. 2  illustrates a close-up view of a portion of a magnetic immersion lens for a charged particle beam system in accordance with an aspect of the present disclosure. 
           [0026]      FIG. 3A  is a bottom-up view of a portion of a magnetic immersion lens in accordance with an aspect of the present disclosure. 
           [0027]      FIG. 3B  is a side view of a portion of a magnetic immersion lens in accordance with an aspect of the present disclosure. 
           [0028]      FIG. 4A  is a three-dimensional ¼ cutaway view of an interior portion of a magnetic immersion lens in accordance with an aspect of the present disclosure. 
           [0029]      FIG. 4B  is a bottom-up view of the magnetic immersion lens of  FIG. 4A . 
           [0030]      FIGS. 5A-5B  are three-dimensional views along an opening in a magnetic immersion lens in accordance with an aspect of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. The drawings show illustrations in accordance with examples of embodiments, which are also referred to herein as “examples”. The drawings are described in enough detail to enable those skilled in the art to practice the present subject matter. The embodiments can be combined, other embodiments can be utilized, or structural, logical, and electrical changes can be made without departing from the scope of what is claimed. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. 
         [0032]    In this document, the terms “a” and “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. 
         [0033]    As used herein, the term “light” generally refers to electromagnetic radiation characterized by a frequency somewhere in a range of frequencies miming from the infrared through the ultraviolet, roughly corresponding to a range of vacuum wavelengths from about 1 nanometer (10 −9  meters) to about 100 microns. 
         [0034]      FIG. 1A  and  FIG. 1B  illustrate an example of a charged particle beam system  100  that incorporates certain aspects of the present disclosure. In this non-limiting example, the system  100  is configured as a scanning electron microscope (SEM) having charged particle optical column  102  with an electron source  115 , beam optics elements  135 , and an immersion lens  104  having an outer pole piece  104 A and an inner pole piece  104 B. The optical column  102  may be controlled by electronics  136 , referred to herein as a beam driver. The beam driver  136  may control the electron source  115 , beam optics elements  135  and immersion lens  104 . In this example, the beam optics  135  include two or more electrically conductive cylinders maintained at voltages that produce electric fields to extract electrons from the source  115  and form them into a primary beam  103  that travels in the direction of a target  101 . The immersion lens  104  focuses the primary beam into a narrow spot at the surface of the target. 
         [0035]    Electrons from the electron beam column  102  are focused onto a surface of the target  101 , which may be an integrated circuit wafer or a test wafer. The target  101  is supported by a stage  118 . The electrons may be scanned across the surface of the target  101 , e.g., by magnet deflecting fields provided by one or more electrostatic deflector plates  106 . Voltages are provided to the deflector plates  106  via a beam scanner driver  108 . In some implementations, the beam scanner driver  108  may apply currents to magnetic coils to scan the electron beam across the target  101 . Alternatively, the stage  118  may include a stage scanning mechanism  111  and stage scanner driver  119  configured to move the target along X-Y plane parallel to the surface of the target  101  in one or more directions relative to the optical column  102 . In some implementations the stage scanning mechanism  111  and stage scanner driver  119  may move the stage in one direction (e.g., the X direction) as the beam scanner driver  108  scans the beam in a different direction (e.g., the Y direction). Alternatively, the stage scanner driver  119  may drive the stage in both the X and Y directions relative to the optical column  102  to scan the beam across the target while the beam remains fixed relative to the optical column. 
         [0036]    Electrons striking the target  101  are either backscattered or initiate secondary emission. The electron beam column collects a portion of such backscattered or secondary electrons  117  (or other secondary particles) that emerge from the surface of the target  101 . Some of the secondary particles  117  may travel back up through the electron beam column and impinge on an internal secondary particle detector  110 , which generates a secondary signal that is proportional to the amount of backscattering or secondary emission. 
         [0037]    Other types of secondary particles  117  are also emitted from the target  101  and may be collected by an external detector  140 . For example, characteristic X-rays when the electron beam removes an inner shell electron from the target, causing a higher-energy electron to fill the shell and release energy. A portion of these characteristic X-rays that are within an acceptance cone  142  of the external detector  140  are collected by the external detector, which converts the collected particle energy into voltage signals. The signals may be amplified by an amplifier  112  and analyzed by analyzer  116  for composition identification and measurement of the abundance of elements in the target  101 . The landing energy of the electrons of the primary beam  103  at the target  101  may be between about 3000 electron volts (3 keV) and about 30,000 electron volts (30 keV) depending on the desired characteristic X-ray lines of the elements of the target that are to be excited by the primary beam. 
         [0038]    The outer pole piece  104 A and inner pole piece  104 B are substantially symmetric with respect to a common axis, which in the example shown in  FIG. 1A  is also an axis of symmetry z of the optical column  102 . Some variation from axial symmetry is within the scope of the present disclosure. Specifically, during some stage of the machining of the pole pieces, they may be turned on a lathe, resulting in pieces which can be considered symmetric with respect to the axis of the lathe within some degree of tolerance. In addition, subsequent machining may result in one or both of the pole pieces being somewhat non symmetric with respect to this axis in a mathematical sense. For example, according to aspects of the present disclosure, the outer pole piece  104 A may include an opening to allow secondary particles  117  in the cone of acceptance  142  to pass through the outer pole piece to the external detector  140 . The formation of such an opening on only one side of the outer pole piece  104 A does not change the common axis of symmetry of the pole pieces, however. 
         [0039]    In alternative implementations, sources of energetic particles other than electrons (e.g., ions, neutrons, ultraviolet radiation, or X-rays) may be used as alternatives to the electron source  115 , depending on the nature of the system. By way of example and not by way of limitation, electron beam excitation is used in electron microscopes, scanning electron microscopes (SEM) and scanning transmission electron microscopes (STEM), and X-ray beam excitation is used in X-ray fluorescence (XRF) spectrometers. 
         [0040]    As shown in the block diagram of  FIG. 1B , the analyzer  116  may be part of a controller  120 . The controller  120  may be a self-contained microcontroller. Alternatively, the controller  120  may be a general purpose computer configured to include a central processor unit (CPU)  122 , memory  124  (e.g., RAM, DRAM, ROM, and the like) and well-known support circuits  128  such as power supplies  121 , input/output (I/O) functions  123 , clock  126 , cache  134 , and the like, coupled to a control system bus  130 . The memory  124  may contain instructions that the CPU  122  executes to facilitate the performance of the system  100 . The instructions in the memory  124  may be in the form of the program code  125 . The code  125  may control, e.g., the electron beam voltage and current produced by the source  115 , the focusing of the beam with the beam optics  135  and the immersion lens  104 , the scanning of the electron beam by the coils  106 , the scanning of the stage  118  by the stage scanner  111  and the formation of images with the signal from the detector  110  in a conventional fashion. The code  125  may also implement analysis of the images. 
         [0041]    The code  125  may conform to any one of a number of different programming languages such as Assembly, C++, JAVA or a number of other languages. The controller  120  may also include an optional mass storage device,  132 , e.g., CD-ROM hard disk and/or removable storage, flash memory, and the like, which may be coupled to the control system bus  130 . The controller  120  may optionally include a user interface  127 , such as a keyboard, mouse, or light pen, coupled to the CPU  122  to provide for the receipt of inputs from an operator (not shown). The controller  120  may also optionally include a display unit  129  to provide information to the operator in the form of graphical displays and/or alphanumeric characters under control of the processor unit  122 . The display unit  129  may be, e.g., a cathode ray tube (CRT) or flat screen monitor. 
         [0042]    The controller  120  may exchange signals with the imaging device scanner driver  108 , the e-beam driver  135 , the secondary detector  110 , the X-day detector  140  or amplifier  112  through the I/O functions  123  in response to data and program code instructions stored and retrieved by the memory  124 . Depending on the configuration or selection of controller  120 , the scanner driver  108 , detector  110 , and/or amplifier  112 , may interface with the I/O functions  123  via conditioning circuits. The conditioning circuits may be implemented in hardware or software form, e.g., within code  125 . 
         [0043]      FIG. 2  illustrates a close-up view of a portion of an immersion lens  104  of  FIG. 1A  in accordance with an aspect of the present disclosure. The immersion lens  104  is provided in front of an electron optical column  102  (not shown in  FIG. 2 ) proximate to the target  101 . The immersion lens  104  has two magnetically permeable axially-symmetric pole pieces, an outer pole piece  104 A and an inner pole piece  104 B. As used, herein, the term “outer pole piece” refers to the pole piece closest to the target  101  and the term “inner pole piece” refers to the other pole piece. The terms “front pole piece” and “back pole piece” are sometimes used to refer to the outer and inner pole pieces, respectively. By way of example and not by way of limitation, the pole pieces  104 A and  104 B are made of soft iron. The immersion lens  104  also include a pair of current carrying coils  150  (e.g., coils of copper wires) inside the pole pieces to produce magnetic field in the pole pieces  104 A and  104 B respectively. An axially symmetric fringing magnetic field is produced near the target  101  as a result of flux leakage due to a gap g between the inner and outer pole pieces. The gap g may be either a radial gap (as shown in  FIGS. 4A-4B  and  FIGS. 5A-5B ) or an axial gap as shown in  FIG. 1A  or some combination of a radial and axial gap, e.g., as shown in  FIG. 2  and  FIGS. 3A-3B . The magnetic field focuses charged particles in the primary beam  103  onto the target  101 . The gap g between the two pole pieces also allows for X-rays or other secondary particles  117  emitted from the target to pass through toward the external detector  140 . 
         [0044]    The outer pole piece  140 A includes an opening  144  that permits secondary particles  117  from the target  101  to pass through the outer pole piece  104 A and into the external detector  140 . According to an aspect of the present disclosure, the outer pole piece  104 A additionally has a number of notches  302  proximate the gap g, as seen in  FIG. 3A . The notches  302  increase the acceptance cone  142  to allow better viewing of the target by the external detector  140  and reduce clipping.  FIG. 3A  is a bottom-up view of a portion of the immersion lens  104  of  FIG. 2 , and  FIG. 3B  is the side view. In the example shown in  FIG. 3A , the outer pole piece  104 A has four notches  302  near the axis of symmetry of the pole pieces. Portions of the magnetic material in the outer pole piece are cut as a cone projected from focus to form a notch. By way of example and not by way of limitation, notches  302  may be formed by electro discharge machines (EDM) and/or CNC machine. In other embodiments, notches  302  can be cut in the inner pole piece  104 B or both the inner and outer pole pieces  104 A and  104 B. In some implementation, notches  302  are in a cone shape. 
         [0045]    These notches  302  allow for a greater viewing cone  142  of the target by the external detector  140 . In some embodiments the notches are sized to be large enough to provide the desired access but not so large to increase power needed to drive the lens by more than about 1%. 
         [0046]    By way of example and not by way of limitation, the size of a cone-shaped notch  302  may be about 20 mm deep (as shown in  FIG. 3A ) and about 6 mm in width at the front of the outer pole piece  104 A. The radius of the original (i.e., un-notched) aperture ( 304  of  FIG. 3A ) in the middle of the outer pole piece  104 A is about 8 mm. 
         [0047]    The conventional practice is to maintain strictly rotational symmetry of the pole pieces for magnetic immersion lenses proximate the exit aperture. The presence of notches in the inner or outer pole piece proximate the aperture  304  breaks the rotational symmetry in a way that is contrary to accepted practice by those skilled in the art. However, contrary to this conventional wisdom, it turns out to be advantageous to put the notches in the pole pieces if the notches induce relatively weak or easily correctable perturbations to the beam. One notch  302  would introduce a dipole term that would shift the beam. This may be corrected using the deflector plates  106  if the beam shift is not too large. Two notches  302  would introduce a quadrupole perturbation term that would cause astigmatism. However, astigmatism may be corrected by suitably configured beam optics  135  if the quadrupole perturbation is not too large. Three notches would introduce a hexapole perturbation which would make the primary beam spot look like a three leaf clover at the target. As more notches added, the higher order perturbation terms become weaker and thus tend to become obscured by other aberrations. In some implementations, a minimum of four notches may be added to the outer pole piece  104 A to eliminate any need for correction. 
         [0048]    The three dimensional diagrams shown in  FIGS. 4A-5B  illustrate the relative configuration of the notches  302  and the opening  144  in the outer pole piece  104 A. In  FIG. 4A  four cone shaped notches formed in the outer pole piece  104 A of a magnetic immersion lens  104  in accordance with an aspect of the present disclosure. In this example, the immersion lens  104  was modified from a commercially available electron beam wafer defect review and classification system.  FIG. 4B  is a bottom up view of  FIG. 4A . In the example illustrated in 
         [0049]      FIGS. 4A-4B , an X-ray detector may be provided with a working distance about 3 mm and 5° half angle from the wafer plane. Portions of the outer pole piece near the axis of the lens are cut out to form 4 notches in a pattern similar to a four leaf clover. Elliptical holes are formed in the side walls as shown in  FIG. 4A . No significant increase in the magnetic reluctance of the lens in octopole terms was observed. 
         [0050]      FIGS. 5A-5B  are three-dimensional views through an opening  144  in an immersion lens in accordance with an aspect of the present disclosure. In some embodiments the immersion lens is modified from a commercially available electron beam wafer defect review and classification system. The view depicted in  FIG. 5A  roughly corresponds to a view along the upper dashed line of the acceptance cone  142  in  FIG. 3B . The view depicted in  FIG. 5B  roughly corresponds to a view along the lower dashed line of the acceptance cone  142  in  FIG. 3B . The spheres are located at the intersection of the target  101  and the primary beam optical axis at two different working distances z=−2.3 mm and −3.4 mm. The working distance z is measured along the axis between the front of the outer pole piece and the target. Both spheres may be seen in  FIG. 5A  and  FIG. 5B , which indicates that the external detector  140  can detect particles originating at the intersection of the beam axis and the target for both working distances. 
         [0051]    In application, such immersion lens with notches added to the pole piece near the axis of rotation could be used for optical camera imaging access to a target or to provide illumination, e.g., laser illumination to a target. 
         [0052]    It should be noted that in addition to SEM systems, many other charged particle systems may employ the above described immersion lens. Examples of systems may include systems configured to implement focused ion beam (FIB), ultraviolet photoelectron spectroscopy (UPS), X-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES), Helium Ion Microscopy (HIM), and Secondary Ion Mass Spectroscopy (SIMS). 
         [0053]    The appended claims are not to be interpreted as including means-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase “means for.” Any element in a claim that does not explicitly state “means for” performing a specified function, is not to be interpreted as a “means” or “step” clause as specified in 35 USC §112(f). In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of 35 USC §112(f).