Abstract:
One embodiment disclosed pertains to an inspection system for inspecting a specimen. The system includes a plurality of columns for directing a plurality of multi-pixel incident beams onto a plurality of multiple-pixel regions of the specimen. Impingement of said incident beams causes emission of electrons from the regions. The system further includes a plurality of multiple-pixel electron detectors, each said detector configured to detect in parallel electrons emitted from a plurality of pixels in one of the regions, and a plurality of processing sub-systems. Each said sub-system is configured to process data from one of said detectors. Advantageously, throughput for an inspection system in accordance with an embodiment of the invention may be increased by approximately a factor of N, where N is the number of columns in the system.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   The present application claims the benefit of provisional patent application No. 60/453,178, filed Mar. 10, 2003, entitled “Multi-Pixel and Multi-Column Electron Emission Inspector”, by inventor David L. Adler, the disclosure of which is herby incorporated by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to microscopic inspection methods and apparatus. The present invention relates more particularly to automated inspection systems for semiconductor manufacturing. 
   2. Description of the Background Art 
   A variety of methods have been used to examine microscopic surface structures of semiconductors. These have important applications in the field of semiconductor integrated circuit (IC) fabrication, where microscopic defects at a surface layer make the difference between a good or bad IC. For example, holes or vias in an intermediate insulating layer often provide a physical conduit for an electrical connection between two outer conducting layers. If one of these holes or vias becomes clogged, it will be impossible to establish this electrical connection. Automated inspection of the semiconductors is used to ensure a level of quality control in the manufacture of the integrated circuits. 
   An example of an electron beam (e-beam) apparatus for an inspection system is described in U.S. Pat. No. 5,578,821, issued to Meisberger et al (the Meisberger patent). The disclosure of the Meisberger patent is hereby incorporated by reference in its entirety.  FIG. 1  (corresponding to  FIG. 5  in the Meisberger patent) is a simplified schematic representation of the paths of the primary, secondary, back-scatter and transmitted electrons through the electron column and collection system for electron beam inspection. In brief,  FIG. 1  shows a schematic diagram of the various electron beam paths within the column and below substrate  57 . Electrons are emitted radially from field emission cathode  81  and appear to originate from a very small bright point source. Under the combined action of the accelerating field and condenser lens magnetic field, the beam is collimated into a parallel beam. Gun anode aperture  87  masks off electrons emitted at unusable angles, while the remaining beam continues on to beam limiting aperture  99 . An upper deflector (not depicted) is used for stigmation and alignment, ensuring that the final beam is round and that it passes through the center of the objective lens  104  comprising elements  105 ,  106  and  107 . A condenser lens (not depicted) is mechanically centered to the axis defined by cathode  81  and beam limiting aperture  99 . The deflection follows the path shown, so that the scanned, focused probe (beam at point of impact with the substrate) emerges from the objective lens  104 . In High Voltage mode operation, Wien filter deflectors  112  and  113  deflect the secondary electron beam into the secondary electron detector  117 . When partially transparent masks are imaged, the transmitted beam  108  passes through electrode system  123  and  124  that spreads the beam  108  before it hits the detector  129 . In Low Voltage mode operation, the secondary electron beam is directed by stronger Wien filter deflections toward the low-voltage secondary electron detector  160  that may be the same detector used for backscatter imaging at high voltage. Further detail on the system and its operation is described in the Meisberger patent. 
     FIG. 2  is a schematic depiction of a multitude of integrated circuit (IC) dies for manufacture on a single semiconductor wafer. The semiconductor wafer  202  typically comprises a silicon wafer. The wafer  202  may be, for example, 200 mm or 300 mm in diameter. On the surface of the wafer  202 , numerous integrated circuit dies  204  are manufactured thereon. The integrated circuits may comprise, for example, microprocessors, memories, digital logic, analog circuits, and other circuitry. 
     FIG. 3  is a schematic depiction illustrating conventional raster scanning of a conventional e-beam across a semiconductor die. The typical e-beam apparatus, such as the one depicted in  FIG. 1 , raster scans the e-beam across an area of a specimen to generate an image thereof (much like a conventional television raster scans a beam across the screen to generate an image frame). An example path  302  of such raster scanning across an integrated circuit die  204  is illustrated in  FIG. 3 . 
     FIG. 4  is a schematic depiction illustrating a conventional translation path  402  of a semiconductor wafer  202  under an e-beam column. The translation of the wafer under the raster-scanned e-beam may be performed, for example, in steps such that one portion of a wafer is scanned, then an adjacent portion, and so on, until all the integrated circuits  204  on the wafer have been scanned. Alternatively, if only a fraction of the integrated circuits  204  are to be inspected, the path  402  need cover only those ICs to be inspected. In either case, the translation path fully spans the area to be inspected. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates an example of a conventional singular electron beam (e-beam) column for an inspection or review system. 
       FIG. 2  is a schematic depiction of a multitude of integrated circuit dies for manufacture on a single semiconductor wafer. 
       FIG. 3  is a schematic depiction illustrating conventional raster scanning of a conventional e-beam across a semiconductor die. 
       FIG. 4  is a schematic depiction illustrating a conventional translation path of a semiconductor wafer under an e-beam column. 
       FIG. 5A  schematically illustrates elements of a dual column multi-pixel e-beam apparatus in accordance with an embodiment of the invention. 
       FIG. 5B  schematically illustrates elements of a quad column multi-pixel e-beam apparatus in accordance with an embodiment of the invention. 
       FIG. 6  is a flow chart that depicts a method for e-beam inspection with increased throughput in accordance with an embodiment of the invention. 
       FIG. 7A  depicts a translation path that covers approximately one half of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. 
       FIG. 7B  depicts another translation path that covers approximately one half of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. 
       FIG. 8A  depicts a translation path that covers approximately one fourth of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. 
       FIG. 8B  depicts another translation path that covers approximately one fourth of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. 
   

   SUMMARY 
   One embodiment of the invention pertains to a method for inspecting portion of a substrate to be inspected. The method includes directing N multi-pixel incident beams respectively onto N multi-pixel areas on the substrate. Electrons emitted from the N areas are detected in a parallel manner. Advantageously, the method includes translation of the substrate in a path that only needs to cover approximately 1/N of the portion of the substrate to be inspected. 
   Another embodiment of the invention relates to an inspection system for inspecting a specimen. The system includes a plurality of columns for directing a plurality of multi-pixel incident beams onto a plurality of multiple-pixel regions of the specimen. Impingement of said incident beams causes emission of electrons from the regions. The system further includes a plurality of multiple-pixel electron detectors, each said detector configured to detect in parallel electrons emitted from a plurality of pixels in one of the regions, and a plurality of processing sub-systems. Each said sub-system is configured to process data from one of said detectors. 
   Another embodiment of the invention relates to method for inspecting substrates with increased throughput to detect defects in at least one patterned layer thereon. The method includes directing a plurality of multi-pixel incident beams onto a plurality of multiple-pixel areas on a substrate. Each said beam impinges on a different said area. The method further includes parallel detection of electrons emitted from the plurality of areas, and parallel processing of data collected from the plurality of areas. 
   Another embodiment of the invention pertains to an apparatus having increased throughput for inspecting semiconductor wafers. The apparatus includes a first column for directing a first multi-pixel incident beam onto a first multiple-pixel region of a wafer, and a second column for directing a second multi-pixel incident beam onto a second multiple-pixel region of the wafer. Impingement of said first incident beam causes emission of electrons from the first region, and impingement of said second incident beam causes emission of electrons from the second region. The apparatus further includes a first multiple-pixel electron detector configured to detect in parallel electrons emitted from a plurality of pixels in the first region, and a second multiple-pixel electron detector configured to detect in parallel electrons emitted from a plurality of pixels in the second region. 
   DETAILED DESCRIPTION 
     FIG. 5A  schematically illustrates elements of a dual column multi-pixel e-beam apparatus  500  in accordance with an embodiment of the invention. The apparatus  500  includes two columns (a and b) and forms two multi-pixel e-beam spots ( 502   a  and  502   b ) onto a specimen being examined. In the embodiment illustrated, each column includes at least a source, a beam separator, and an objective lens. 
   The two sources, one for each column, generate two incident multi-pixel beams ( 504   a  and  504   b ). In one embodiment, each of the sources may comprise an electron source. The electron source may be implemented, for example, using a field emission electron gun and a condenser lens system. 
   The two multi-pixel incident beams ( 504   a  and  504   b ) travel through two beam separator devices ( 506   a  and  506   b , respectively). These two beam separators ( 506   a  and  506   b ) separate the two incident beams ( 504   a  and  504   b , respectively) from the two scattered beams ( 510   a  and  510   b , respectively). Each beam separator may comprise, for instance, a magnetic beam separator that bends the incident beam to be directed along the optical axis to the normal of the surface to be inspected. Alternatively, other types of beam separators may be used, for example, those in a prism type configuration. 
   The two incident beams ( 504   a  and  504   b ) subsequently travel from the two separator devices ( 506   a  and  506   b , respectively) to two objective lenses ( 508   a  and  508   b , respectively). Each objective lens may comprise, for example, a configuration of electromagnetic pole pieces. Alternatively, one or more of the objective lenses may be electrostatic (rather than magnetic). The two objective lenses ( 508   a  and  508   b ) focus the incident beams ( 504   a  and  504   b , respectively) onto the two multiple-pixel areas ( 502   a  and  502   b , respectively) of the specimen. 
   In contrast to a typical scanning electron microscope type apparatus where one single-pixel beam is scanned across an area, the apparatus  500  impinges two multiple-pixel incident beams ( 504   a  and  504   b ) onto the specimen. This is advantageous in that data may be obtained in parallel from the multiple pixels within each beam spot. Moreover, the use of two such multi-pixel beams (instead of just one multi-pixel beam) further increases the efficiency such that the throughput of an inspector may be further improved by approximately a factor of two. 
   Due to impingement of the two incident beams ( 504   a  and  504   b ) onto the multiple-pixel areas ( 502   a  and  502   b ), electrons are emitted from the surface of the areas. In a low energy electron microscopy (LEEM) embodiment, the incident electrons are decelerated between the two objective lenses ( 508   a  and  508   b ) and the specimen to a relatively low energy of one hundred electron volts (eV) or less, prior to impingement onto the specimen. The low-energy electrons interact with and reflect from the surface of the specimen. The reflected electrons are considered to be the scattered electrons. The scattered electrons from the two areas ( 502   a  and  502   b ) are then re-accelerated as they return to the two objective lenses ( 508   a  and  508   b , respectively). 
   Subsequently, the two scattered electron beams ( 510   a  and  510   b ) travel from the two objective lenses ( 508   a  and  508   b , respectively) to the two beam separators ( 506   a  and  506   b , respectively). The two beam separators ( 506   a  and  506   b ) redirect the two scattered electron beams ( 510   a  and  510   b , respectively) to two corresponding multi-pixel detection systems. Each multi-pixel detection system may be implemented, for example, with a charged-coupled device (CCD) array or other type of detector array. 
     FIG. 5B  schematically illustrates elements of a quad column multi-pixel e-beam apparatus  550  in accordance with an embodiment of the invention. The apparatus  550  includes four columns (a, b, c, and d) and forms four multi-pixel e-beam spots ( 502   a ,  502   b ,  502   c  and  502   d ) onto a specimen being examined. In the embodiment illustrated, each column includes at least a source, a beam separator, and an objective lens. 
   The four sources, one for each column, generate four incident multi-pixel beams ( 504   a ,  504   b ,  504   c  and  504   d ). In one embodiment, each of the sources may comprise an electron source. The electron source may be implemented, for example, using a field emission electron gun and a condenser lens system. 
   The four multi-pixel incident beams ( 504   a ,  504   b ,  504   c  and  504   d ) travel through four beam separator devices ( 506   a ,  506   b ,  506   c  and  506   d , respectively). The four beam separators ( 506   a ,  506   b ,  506   c  and  506   d ) separate the four incident beams ( 504   a ,  504   b ,  504   c  and  504   d , respectively) from the four scattered beams ( 510   a ,  510   b ,  510   c  and  510   d , respectively). Each beam separator may comprise, for instance, a magnetic beam separator that bends the incident beam to be directed along the optical axis to the normal of the surface to be inspected. Alternatively, other types of beam separators may be used, for example, those in a prism type configuration. 
   The four incident beams ( 504   a ,  504   b ,  504   c  and  504   d ) continue to travel from the four separator devices ( 506   a ,  506   b ,  506   c  and  506   d , respectively) to four objective lenses ( 508   a ,  508   b ,  508   c  and  508   d , respectively). Each objective lens may comprise, for example, a configuration of electromagnetic pole pieces. Alternatively, one or more of the objective lenses may be electrostatic (rather than magnetic). The four objective lenses ( 508   a ,  508   b ,  508   c  and  508   d ) focus the incident beams ( 504   a ,  504   b ,  504   c  and  504   d , respectively) onto the multiple-pixel areas ( 502   a ,  502   b ,  502   c  and  502   d , respectively) of the specimen. 
   In contrast to a typical scanning electron microscope type apparatus where a single-pixel beam is scanned across an area, the apparatus  550  impinges four multiple-pixel incident beams ( 504   a ,  504   b ,  504   c  and  504   d ) onto the specimen. This is advantageous in that data may be obtained from multiple pixels in parallel within each beam spot. Moreover, the use of four such multi-pixel beams (instead of just one multi-pixel beam) further increases the efficiency such that the throughput of an inspector may be further improved by approximately a factor of four. 
   Due to impingement of the four incident beams ( 504   a ,  504   b ,  504   c  and  504   d ) onto the four multiple-pixel areas ( 502   a ,  502   b ,  502   c  and  502   d ), electrons are emitted from the surface of the four areas. In a low energy electron microscopy (LEEM) embodiment, the incident electrons are decelerated between the objective lenses ( 508   a ,  508   b ,  508   c  and  508   d ) and the specimen to a relatively low energy of about one hundred electron volts (eV) or less, prior to impingement onto the specimen. The low-energy electrons interact with and reflect from the surface of the specimen. The reflected electrons are considered to be the scattered electrons. The scattered electrons from the four areas ( 502   a ,  502   b ,  502   c  and  502   d ) are then re-accelerated as they return to the four objective lenses ( 508   a ,  508   b ,  508   c  and  508   d ). 
   Subsequently, the four scattered electron beams ( 510   a ,  510   b ,  510   c  and  510   d ) travel from the four objective lenses ( 508   a ,  508   b ,  508   c  and  508   d ) to the four beam separators ( 506   a ,  506   b ,  506   c  and  506   d ). The four beam separators ( 506   a ,  506   b ,  506   c  and  506   d ) redirect the four scattered electron beams ( 510   a ,  510   b ,  510   c  and  510   d ) to four corresponding multi-pixel detection systems. Each multi-pixel detection system may be implemented, for example, with a charged-coupled device (CCD) array or other type of detector array. 
   While the above two embodiments described in detail include two and four columns, respectively, embodiments of the invention generally include systems with N columns, where N is an integer of at least two. 
   In a preferred embodiment, the N columns of the system are configured so as to avoid interference between the various beams. For example, the columns are separated spatially, and the components of the columns placed to avoid such interference. 
   In alternate embodiments of the invention, one or more photon sources may be used instead of the electron sources discussed above. The photon sources may be implemented, for example, using high-pressure mercury lamps, other types of lamp, or synchrotron radiation. Such photon sources may be configured generate incident multi-pixel photon beams that may be imaged upon multi-pixel areas of the specimen. Of course, the imaging optics for such incident photon beams would be implemented using different elements than those described above in relation to incident electron beams. In such an embodiment, electrons are emitted from the surface of the specimen due to the photoelectric effect. 
     FIG. 6  is a flow chart that depicts a process  600  for e-beam inspection with increased throughput in accordance with an embodiment of the invention. The process  600  includes N sub-processes (a, b, . . . , n) where N is at least two. 
   The N sub-processes (a, b, . . . , n) each begin with a first step ( 602   a ,  602   b , . . . ,  602   n , respectively). In these first steps, N multi-pixel incident beams (e.g.,  504   a ,  504   b , . . . ,  504   n ) are directed onto N areas (e.g.,  502   a ,  502   b , . . . ,  502   n ) of the specimen being inspected. 
   Next, a second step ( 604   a ,  604   b , . . . ,  604   n ) is performed in each of the N sub-processes (a, b, . . . , n). In these second steps, electrons emitted from the N impinged areas (e.g.,  502   a ,  502   b , . . . ,  502   n ) are detected ( 604   a ,  604   b , . . . ,  604   n , respectively). In a preferred embodiment, such detection is advantageously performed in a parallel manner for both the N beam spots and the multiple pixels within each beam spot. 
   Subsequently, a third step ( 606   a ,  606   b , . . . ,  606   n ) is performed in each of the N sub-processes (a, b, . . . , n). In these third steps, data collected from the N areas (e.g.,  502   a ,  502   b , . . . ,  502   n ) are processed. In a preferred embodiment, the processing is advantageously performed in a parallel manner using a separate processor for each of the N beam spots. For example, data from the N columns may be processed in an adaptation of computer systems that are commercially available from Mercury Computer Systems or SKY Computers, both having a place of business in Chelmsford, Mass. Such computer systems include multiple processors that may be configured to work in parallel on different image segments. For example, data from different columns may be sent independently to different sets of processors and handled in a parallel manner. In accordance with an embodiment of the invention, The processing may involve comparison of the collected data from each area with another set of data. For example, data collected from an area may be compared against reference data obtained from a known good die. The comparison between the data may involve, for example, alignment of the two data sets, differencing of the two data sets, filtering of the resultant difference data, and determination and location of apparent defects from the filtered difference data. 
   The above-described parallel detection and parallel processing of the data across the N beam spots is particularly advantageous in that the efficiency of the inspection technique may be increased by approximately a factor of N. 
   In the embodiment illustrated in  FIG. 6 , the process  600  also includes translation  608  of the specimen so as to effectively move the N areas being impinged by the N incident beams in different swaths across the specimen being examined. Example paths for such translation  608  are described below. 
     FIG. 7A  depicts a translation path  702  that covers approximately one half of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. Depicted as an example specimen is a semiconductor wafer  202  with numerous integrated circuit dies  204  being manufactured thereon. In this case, two multi-pixel beam spots ( 502   a  and  502   b ) are being impinged by two columns onto separate areas of the wafer  202 . Translation  608  of the wafer  202  may occur, for example, on the path  702  depicted in  FIG. 7A . In one embodiment, the translation  608  along the path  702  may be performed in a step-wise manner to move the two beam spots ( 502   a  and  502   b ) across the desired areas of the substrate  202 . Alternatively, the translation  608  may be continuous, in which case the data detection ( 604   a  and  604   b ) and/or the data processing ( 606   a  and  606   b ) would have to be configured to take into account the continuous movement. Advantageously, the example translation path  702  covers only about half the wafer  202 , while the data is being collected from the entire wafer  202 . This provides for an increased throughput by approximately a factor of two in comparison with a single column system. 
     FIG. 7B  depicts another translation path  704  that covers approximately one half of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. Similarly, this translation path  704  covers only about half the wafer  202 , while the data is being collected from the entire wafer  202 . Again, this provides for an increased throughput by approximately a factor of two in comparison with a single column system. 
     FIG. 8A  depicts a translation path  802  that covers approximately one fourth of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. In this case, four multi-pixel beam spots ( 502   a ,  502   b ,  502   c  and  502   d ) are being impinged by four columns onto separate areas of the wafer  202 . Translation  608  of the wafer  202  may occur, for example, on the path  802  depicted in  FIG. 8A . In one embodiment, the translation  608  along the path  802  may be performed in a step-wise manner to move the four beam spots ( 502   a ,  502   b ,  502   c  and  502   d ) across the desired areas of the substrate  202 . Alternatively, the translation  608  may be continuous, in which case the data detection ( 604   a ,  604   b ,  604   c  and  604   d ) and/or the data processing ( 606   a ,  606   b ,  606   c  and  606   d ) would have to be configured to take into account the continuous movement. Advantageously, the example translation path  802  covers only about a quarter of the wafer  202 , while the data is being collected from the entire wafer  202 . This provides for an increased throughput by approximately a factor of four in comparison with a single column system. 
     FIG. 8B  depicts another translation path  804  that covers approximately one fourth of a specimen during an inspection of the entire specimen in accordance with an embodiment of the invention. Similarly, this translation path  804  covers only about a quarter of the wafer  202 , while the data is being collected from the entire wafer  202 . Again, this provides for an increased throughput by approximately a factor of four in comparison with a single column system. 
   Note that in the above illustrations ( FIGS. 7A ,  7 B,  8 A and  8 B), the beam spots are depicted as spanning approximately half of a dimension of a circuit die. The beam spots, of course, need not be of that size. The beam spot size would depend on the particular implementation of the columns. Implemented beam spot sizes may range from a small fraction of a die or may even be greater in size than a die. The above-described translation paths would be adjusted accordingly in dependence on the particular beam spot size. 
   The above-described diagrams are not necessarily to scale and are intended be illustrative and not limiting to a particular implementation. The above-described invention may be used in an automatic inspection or review system and applied to the inspection or review of wafers, X-ray masks and similar substrates in a production environment. While it is expected that the predominant use of the invention will be for the inspection or review of wafers, optical masks, X-ray masks, electron-beam-proximity masks and stencil masks, the techniques disclosed here may be applicable to the high speed electron beam imaging of other samples. 
   In the above description, numerous specific details are given to provide a thorough understanding of embodiments of the invention. However, the above description of illustrated embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise forms disclosed. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific details, or with other methods, components, etc. In other instances, well-known structures or operations are not shown or described in detail to avoid obscuring aspects of the invention. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. 
   These modifications can be made to the invention in light of the above detailed description. The terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims. Rather, the scope of the invention is to be determined by the following claims, which are to be construed in accordance with established doctrines of claim interpretation.