Patent Description:
Unfortunately, while highly efficient at removing sample material, samples being processed need to be precisely aligned with special masks that are designed to block portions of the beam from being incident on regions of the sample that users do not desire to be removed. Because this alignment process takes time and requires precise skill, it causes a slowdown in the sample preparation workflow. Additionally, because the higher current broad ion beam removes sample material more rapidly, the rate of redeposition of the removed material onto the broad ion beam source also increases forcing users to more frequently remove the source for cleaning requiring system downtime. Because of these limitations to workflow efficiency, the majority of the current use of BIB polishing systems has been to academic and other non-commercial applications. Therefore, it is desired to have new BIB polishing systems that are able to efficiently and accurately process many samples in shorter periods of time.

<CIT> discloses systems and methods of sample preparation using dual ion beam trenching. An inside of a semiconductor package is non-destructively imaged to determine a region of interest (ROI). A mask is positioned over the semiconductor package, and a mask window is aligned with the ROI. A first ion beam and a second ion beam are swept, simultaneously or sequentially, along an edge of the mask window to trench the semiconductor package and to expose the ROI for analysis.

<CIT> discloses System and method to align a substrate under a shadow mask. A substrate holder has alignment mechanism, such as rollers, that is made to abut against an alignment straight edge. The substrate is then aligned with respect to the straight edge and is chucked to the substrate holder. The substrate holder is then transported into a vacuum processing chamber, wherein it is made to abut against a mask straight edge to which the shadow mask is attached and aligned to. Since the substrate was aligned to an alignment straight edge, and since the mask is aligned to the mask straight edge that is precisely aligned to the alignment straight edge, the substrate is perfectly aligned to the mask.

A method for pre-aligning samples for more efficient processing of multiple samples with a broad ion beam (BIB) system, is disclosed in accordance with claim <NUM>. In accordance with this claim, a method for pre-aligning samples for more efficient processing of multiple samples with a BIB system comprises affixing a sample to an adjustable portion of a sample holder, nesting the sample holder with a first mask having a first mask edge, wherein the first mask is positioned outside of a BIB system, and aligning the sample such that it has a desired geometric relationship to the first mask edge. The method further comprises nesting the sample holder with a second mask having a second mask edge, wherein the second mask is positioned within a BIB system. The first mask and the second mask are geometrically similar such that the geometric relationship between the first mask edge and the sample when the sample holder is nested with the first mask is the same as the geometric relationship between the second mask edge and the sample when the sample holder is nested with the second mask. In this way, the sample holder can be nested within the second mask and processed immediately with a broad ion beam emitted from a BIB source component of the BIB system without the sample needing to be aligned within the BIB system.

In the figures, the left-most digit(s) of a reference number identify the figure in which the reference number first appears. The same reference numbers in different figures indicates similar or identical items.

Generally, in the figures, elements that are likely to be included in a given example are illustrated in solid lines, while elements that are optional to a given example are illustrated in broken lines. However, elements that are illustrated in solid lines are not essential to all examples of the present disclosure, and an element shown in solid lines may be omitted from a particular example without departing from the scope of the present disclosure.

Systems and methods for using broad ion beam (BIB) systems for more efficient processing of multiple samples are disclosed herein. More specifically, the disclosure includes BIB systems that are configured to receive and process one or more samples with an increased throughput and/or uptime over current BIB systems.

<FIG> is an illustration of a cross section <NUM> example BIB system(s) <NUM> according to the present disclosure that are configured to more efficiently process multiple samples <NUM>. The BIB systems <NUM> include a BIB source <NUM> that is configured to emit a broad ion beam <NUM> along a BIB axis <NUM> toward a sample stage area <NUM>. The broad ion beam <NUM> is configured such that, when portions of the broad ion beam <NUM> are incident up on the sample <NUM>, the material of the sample upon which the broad ion beam is incident are milled or otherwise removed from the sample. For example, in some embodiments the BIB source <NUM> may be an Ar ion source configured to emit a beam of Argon ions towards the sample stage <NUM>.

The sample stage area <NUM> may include a mask <NUM> configured to block a portion of the broad ion beam <NUM> such that sample material corresponding to a portion of interest is not milled or otherwise removed from the sample <NUM> by incident ions. For example, <FIG> illustrates a first portion of the cross section of the broad ion beam <NUM>(a) that is incident on the mask <NUM>, and a second portion of the cross section of the broad ion beam <NUM>(a) that is partially incident on a portion of the sample <NUM> whose material will be milled or otherwise removed by the broad ion beam <NUM>. The mask <NUM> is composed of a hard material that is not degraded by the broad ion beam <NUM> allowing it to be used for the processing of multiple samples.

The sample stage area <NUM> may also include a holder interface configured to receive a sample holder <NUM> such that it can be positioned and held in relation to the mask <NUM> during processing of the sample <NUM> such that the mask protects portions of interest in the sample. In some embodiments, the sample stage area <NUM> may include a stage element that is capable of translating, tilting, or rotating the sample <NUM>/sample holder <NUM>. Additionally, in such embodiment the stage element may be further configured to translate, tile, or rotate the sample <NUM>/sample holder <NUM> while the BIB source <NUM> emits the broad ion beam <NUM> toward the sample <NUM>. For example, the stage element may be configured to periodically or continuously rotate the sample <NUM>/sample holder <NUM> through a series of predefined angular positions, and/or rock the sample <NUM>/sample holder <NUM> between two angular positions during milling with the broad ion beam. Such a translation/tilting/rotating can be done at a constant or varied speed. In this way, the stage element may dynamically change the portions of sample <NUM> irradiated by the broad ion beam <NUM> to allow for more efficient or otherwise optimized removal of sample material and/or polishing of a region of interest by the BIB system <NUM>.

The sample holder <NUM> is configured to hold the sample <NUM> during processing as well as during transport of the sample <NUM> into the BIB system <NUM>, out of the BIB system <NUM>, and/or within the BIB system <NUM>. <FIG> further shows the BIB system <NUM> as including one or more additional samples <NUM>(a) held by corresponding additional sample holders <NUM>(a). In some embodiments, the BIB system <NUM> has one or more optional sample storage volumes/areas <NUM> that sample holders can be parked within the BIB system <NUM> when the sample <NUM> that they hold is not currently being processed. <FIG> also shows the BIB system <NUM> as including a storage cassette <NUM> configured to hold a plurality of sample holders <NUM> that is positioned within a cassette storage volume <NUM>. The storage cassette <NUM> is configured to allow many samples <NUM> and their corresponding sample holders <NUM> to be transported to and/or loaded into the BIB system <NUM>.

In some embodiments, the sample holder <NUM> may include one or more optional adjustment elements <NUM> that allow the sample <NUM> to be translated, tilted, rotated, or otherwise repositioned in relation to the sample holder <NUM>, the broad ion beam <NUM>, and/or the mask <NUM>. In embodiments with such adjustment elements <NUM>, the BIB system <NUM> may comprise one or more interface elements that allow a user to manipulate the adjustment elements or the sample holder <NUM> itself so that the sample <NUM> has a desired geometric relationship with the mask <NUM> or a feature of the mask (e.g., the mask edge <NUM>(a)). While <FIG> illustrates the adjustment elements <NUM> as being screws, a person having ordinary skill in the art would understand that there are many types of known adjustment elements that are able to translate, tilt, rotate, or otherwise reposition samples in relation to various types of sample holders. <FIG> also shows a sample holder manipulator <NUM> that is configured to reposition the sample holder <NUM> within the BIB system <NUM>. For example, the sample holder manipulator <NUM> may be configured to move a sample holder between a sample holder storage volume <NUM> and the sample stage area <NUM>. Moreover, in some embodiments, the sample holder manipulator <NUM> may be further configured to interface with the adjustment elements <NUM> to cause a translation, tilting, rotation, etc. of the sample <NUM>.

The BIB system <NUM> also includes a housing <NUM> that defines an interior volume <NUM>. In some embodiments, the interior volume may be a sealed volume that doesn't allow the passage of gas with the outside environment. In such embodiments, the interior volume may include a pump system <NUM> that is configured to adjust the pressure of the internal volume and/or change the gaseous makeup of the environment within the internal volume <NUM>. For example, the pump system <NUM> may cause the interior volume <NUM> to be at a lower pressure than the outside the environment and/or be at vacuum. While <FIG> illustrates at least a portion of the pump system <NUM> as being optionally included within the interior volume, persons having skill in the art would understand that some or all of such a pump system <NUM> may be located outside of the interior volume <NUM>. Alternatively, the pump system <NUM> may cause the gaseous makeup of the environment with in the internal volume <NUM> to be composed of inert gases (e.g., gases that do not interact with the broad ion beam <NUM> and/or sample <NUM> material during processing). The BIB system <NUM> is also shown as having a sample holder port <NUM> through which a sample holder <NUM> may be inserted into and/or removed from the BIB system <NUM>. Moreover, <FIG> further illustrates the BIB system <NUM> as having an optional cassette port <NUM> configured to allow a storage cassette <NUM> to be inserted into and/or removed from the BIB system <NUM>.

<FIG> further shows the BIB system <NUM> as including a source housing <NUM> that defines a source volume <NUM> that is configured to contain the BIB source <NUM>. The source housing <NUM> also defines a BIB aperture <NUM> that connects the source volume <NUM> with the interior volume <NUM>, and a BIB source maintenance aperture <NUM> (e.g., flange, door, or other type of sealable component that allows the source housing <NUM> to be switched between a sealed and unsealed state from the outside environment) which allows the BIB source <NUM> to be removed from or reinstalled within the source volume <NUM> (i.e., the source maintenance aperture <NUM> allows the BIB source <NUM> to be removed or accessed via the aperture <NUM> when unsealed). The BIB system <NUM> may further comprise a valve <NUM> configured to switch between an open state where the ions emitted from the BIB source <NUM> are allowed to pass through the BIB aperture <NUM> from the source volume <NUM> to interior volume <NUM>, and a sealed state where the valve <NUM> prevents ions or emissions from the sample <NUM> from passing from the interior volume <NUM> to the source volume <NUM>. A person having skill in the art would understand that valve <NUM> could correspond to any one of a shutter, a valve, a door, or other sealing mechanism that is able to toggle between an open and closed state.

<FIG> shows the valve <NUM> in an open state such that the broad ion beam <NUM> is allowed to pass into the interior volume so as to be incident on the sample <NUM> and mask <NUM>. In some embodiments, when the valve <NUM> is in a closed state, the source volume <NUM> may be opened to the external environment (e.g., via the BIB source maintenance aperture <NUM>) without affecting the pressure within the interior volume. In this way, when the valve <NUM> is in the closed state, the BIB source maintenance aperture <NUM> can be opened to allow the BIB source <NUM> to be cleaned, adjusted, removed, replaced, and/or otherwise maintained without affecting the pressure or gaseous composition of the interior volume <NUM>. In such embodiments, the source volume <NUM> may further include an optional pump system that is able to re-establish the pressure and/or gas composition to match that of the interior volume <NUM>. The BIB source maintenance aperture <NUM> may comprise a port that is configured to switch between an open state in which the first BIB source <NUM> can be removed from or reinstalled within the source volume <NUM>, and a closed state in which the source volume <NUM> is sealed from the external environment.

Unlike a focused ion beam (FIB) system, the BIB system <NUM> does not comprise an optical column that includes optical elements configured to focus the ions emitted by the BIB source <NUM> so that it has a small spot size in and around the sample plane of the sample <NUM>. Because such optical elements are only able to focus, correct, tune, and/or otherwise manipulate ion beams below certain strength thresholds, and since such optical elements are not required to focus the ions emitted by the BIB source <NUM>, the strength of the broad ion beam (i.e. the primary beam current) used ion the BIB system <NUM> can be much greater than in FIB systems. This increase in beam current allows BIB systems <NUM> to remove sample material much faster than FIB systems. Applicant notes that persons having skill in the art will understand that some optical elements may be included to focus the broad ion beam in the BIB system <NUM>, however the inclusion of such elements would impose lesser beam current limitations on the BIB system <NUM> than in FIB systems.

Due to the increased beam strength of the broad ion beam <NUM>, material of the sample <NUM> upon which the broad ion beam <NUM> is incident is removed at a faster rate over FIB milling processes. Specifically, because the broad ion beam <NUM> has a higher beam strength and is incident on a large area of the sample, the rate that material is removed from the sample <NUM> is much higher than in FIB systems. Unfortunately, because of this increase in sample material removal, there is a proportional increase in material redeposition as the portions of the sample <NUM> that is removed by the broad ion beam <NUM> redeposits on surfaces within the interior volume <NUM> and/or the source volume <NUM>. In current BIB systems this redeposition imposes a large efficiency reduction, as redeposition on the BIB source <NUM> forces users to frequently remove and/or otherwise access the BIB source <NUM> for cleaning and maintenance. Due to this cleaning and maintenance, current BIB systems have a high rate of downtime where they cannot be used for sample processing.

<FIG> shows the BIB system <NUM> as including an optional additional BIB source <NUM> that is configured to emit an additional broad ion beam along emission axis <NUM>. The additional BIB source <NUM> is illustrate as being positioned within an additional source volume <NUM> defined by an additional source housing <NUM>. The additional source housing <NUM> also defines an additional BIB aperture <NUM> that connects the additional source volume <NUM> with the interior volume <NUM>, and an additional BIB source maintenance aperture <NUM> which allows the additional BIB source <NUM> to be removed from or reinstalled within the additional source volume <NUM>.

The BIB system <NUM> may further comprise an additional valve <NUM> configured to switch between an open state where the ions emitted from the additional BIB source <NUM> are allowed to pass through the additional BIB aperture <NUM> from the additional source volume <NUM> to interior volume <NUM>, and a sealed state where the additional valve <NUM> prevents ions or emissions from the sample <NUM> from passing from the interior volume <NUM> to the additional source volume <NUM>. When the valve <NUM> is in a closed state, the additional source volume <NUM> may be opened to the external environment (e.g., via the additional BIB source maintenance aperture <NUM>) without affecting the pressure within the interior volume <NUM>. Thus, when the valve <NUM> is in the closed state, the BIB source maintenance aperture <NUM> can be removed to allow the additional BIB source <NUM> to be cleaned, adjusted, removed, replaced, and/or otherwise maintained without affecting the pressure or gaseous composition of the interior volume <NUM>.

<FIG> shows the valve <NUM> in a closed state such sample material that is removed from the sample <NUM> via the broad ion beam <NUM> are not allowed to pass into the additional source volume <NUM> and/or redeposit on the additional BIB source <NUM>. Because no redeposition occurs on the additional BIB source <NUM> while the BIB source <NUM> is in use, according to the present invention, the additional BIB source <NUM> will be able to be used to process the sample <NUM> (or additional samples) when the BIB source <NUM> needs to be removed and/or accessed for cleaning and/or maintenance. Thus, because the valve <NUM> can be closed to seal off the source volume <NUM> from the interior volume <NUM>, the valve <NUM> can be opened so that the additional BIB source <NUM> can be used to emit an additional broad ion beam through the additional BIB aperture <NUM> to process samples. Therefore, in some embodiments of the present disclosure, the BIB system <NUM> is able to continuously process samples without downtime greatly increasing its efficiency. Additionally, while not shown in <FIG>, in various embodiments the BIB system <NUM> may comprise only one BIB source or may comprise three or more BIB sources.

<FIG> also shows the BIB system <NUM> as optionally including a laser source <NUM> positioned within a laser volume <NUM> which may be configured to emit an optical beam through a laser aperture <NUM> defined by a laser housing <NUM>. The optical beam emitted by the laser source <NUM> is of a higher beam energy and/or strength that the broad ion beam <NUM>, allowing the optical beam to remove sample material upon which it is incident at a rate that is <NUM>-50x greater that what is possible with a broad ion beam. For example, in less than <NUM> minutes an optical laser can remove as much Nickle or Cobalt as a broad ion beam can remove in <NUM> minutes. Moreover, for harder materials such as graphite, it takes present broad ion beams up to four hours to remove the same amount of material as an optical beam can remove in less than <NUM> minutes.

However, while the removal of the sample material is more rapid with an optical beam, milling and/or processing with the optical beam also causes damage/burning on the remaining sample surface. Therefore, in embodiments of the present invention, the BIB system <NUM> may use the optical beam to rapidly remove initial portions of the sample <NUM>, the final portions of the sample <NUM> which need to be removed are removed using a broad ion beam from a BIB source (e.g., BIB source <NUM>, additional BIB source <NUM>, or another BIB source within the BIB system <NUM>). In this way, the optical beam may be used to remove a bulk portion of the sample <NUM>, followed by a broad ion beam being used to expose a region of interest and/or create a smoother or undamaged surface.

<FIG> further illustrates computing device(s) <NUM> associated with the BIB system <NUM>. <FIG> illustrates computing device(s) <NUM> as being separate from the external devices <NUM>, however in various embodiments one or more of these elements may be combined. That is, applicant notes that the computing device(s) <NUM> may be a component of the BIB system <NUM>, may be a separate device from the BIB system <NUM> in communication via a network communication interface, or a combination thereof.

Those skilled in the art will appreciate that the computing devices <NUM> depicted in <FIG> are merely illustrative and are not intended to limit the scope of the present disclosure. The computing system and devices may include any combination of hardware or software that can perform the indicated functions, including computers, network devices, internet appliances, PDAs, wireless phones, controllers, etc. The computing devices <NUM> may also be connected to other devices that are not illustrated, or instead may operate as a stand-alone system. In addition, the functionality provided by the illustrated components may in some implementations be combined in fewer components or distributed in additional components. Similarly, in some implementations, the functionality of some of the illustrated components may not be provided and/or other additional functionality may be available.

<FIG> further includes a schematic diagram illustrating an example computing architecture <NUM> for the computing device(s) <NUM>. Example computing architecture <NUM> illustrates additional details of hardware and software components that can be used to implement the techniques described in the present disclosure. In the example computing architecture <NUM>, the computing hardware <NUM> of the BIB system <NUM> includes one or more processors <NUM> and memory <NUM> communicatively coupled to the one or more processors <NUM>.

The example computing architecture <NUM> can include at least a control module <NUM>, and a sample processing module <NUM> stored in the memory <NUM>. The example computing architecture <NUM> is further illustrated as including sample information <NUM> and processing schedule(s) <NUM> stored on memory <NUM>. The sample information <NUM> may correspond to data that describes characteristics of a sample, identification information for the sample, a history of the sample, a status of the sample, a positioning of the sample on a sample holder, a composition of the sample, a region of interest within the sample, and a surface of interest on in the sample, etc. The processing schedule(s) <NUM> may include one or more methods, settings, or instructions for processing the sample <NUM> with the BIB system <NUM> to achieve desired results (i.e., exposing an polishing a surface of interest within the sample <NUM> so that it may be examined using a charged particle microscope system). For example, a processing schedule <NUM> may include steps of one or more of the methods shown and described in association with <FIG>. A sample processing schedule <NUM> for a sample may include a laser strength, a laser milling time, a portion of the sample to be removed with the laser, a BIB strength, a BIB milling time, a portion of the sample to be removed with BIB, a surface of interest, an processing order, sample identification information, a region of sample to be removed, or a combination thereof. For example, a sample processing schedule <NUM> may be a data structure that identifies a plurality of steps that are to be carried out by components of the BIB system <NUM> in a particular order, where the data structure may also identify various parameters for the components and/or individual steps. In some embodiments, such processing schedules <NUM> may be at least partially presented to a user of the BIB system <NUM> to guide the processing of the sample, may be at least partially used by the computing device(s) <NUM> to automate and/or adjust settings associated with the processing of the sample, or a combination thereof.

In some embodiments, sample information <NUM> and/or individual processing schedule(s) <NUM> may be entered into the computing device <NUM> by a user (e.g., using a keypad, keyboard, mouse, voice command, touchscreen, etc.), received via a hardware connection (e.g., CD/DVD, USB, HDMI, portable memory, etc.), received over a network connection (e.g., Bluetooth, Wi-Fi, the Internet, etc.), received in association with the sample being inserted into the BIB system <NUM> (e.g., accessible memory on the sample holder <NUM>), generated based on sensor information or sample information <NUM>, or a combination thereof. For example, in an example embodiment the BIB system <NUM> may be configured to receive an identifier via an RFID on the sample holder <NUM>, access sample information <NUM> associated with the identifier over a network connection, and then identify or generate a processing schedule <NUM> for the sample <NUM> based on the identifier, the sample information, or both.

As used herein, the term "module" is intended to represent example divisions of executable instructions for purposes of discussion and is not intended to represent any type of requirement or required method, manner, or organization. Accordingly, while various "modules" are described, their functionality and/or similar functionality could be arranged differently (e.g., combined into a fewer number of modules, broken into a larger number of modules, etc.). Further, while certain functions and modules are described herein as being implemented by software and/or firmware executable on a processor, in other instances, any or all of modules can be implemented in whole or in part by hardware (e.g., a specialized processing unit, etc.) to execute the described functions.

The control module <NUM> can be executable by the processors <NUM> to cause a computing device <NUM> and/or BIB system <NUM> to take one or more actions and/or perform a step of a sample processing schedule. In some embodiments, the control module <NUM> may be executable to adjust the settings of individual components of the BIB system <NUM> (e.g., BIB source, laser source, etc.), cause individual components of the BIB system <NUM> to perform particular operations (e.g., move the sample holder within the BIB system <NUM>, open or close valves, emit a broad ion beam, emit an optical beam, align the sample, adjust pressure settings or gases present in a volume <NUM>, <NUM>, and/or <NUM>, etc.), or a combination thereof. For example, the control module <NUM> may be executable to cause the sample holder manipulator <NUM> to engage with a desired sample holder <NUM> stored within the BIB system <NUM> (e.g., stored in a storage cassette <NUM> positioned within a cassette storage volume <NUM>, stored in a sample holder storage volume <NUM>, etc.) and to translate, tilt, and/or rotate the engaged sample holder <NUM> to the sample stage area <NUM> so that it is nested with the mask <NUM> and the sample <NUM> has a desired geometric relationship with the mask <NUM>. In such examples, the control module <NUM> may be further executable to return said sample holder <NUM> to the place it was stored within the BIB system <NUM> once the sample <NUM> has been processed, and then engage with an additional sample holder <NUM>, and then translate the additional sample holder <NUM> to the sample stage area <NUM> so that the additional sample <NUM> can be processed.

Alternatively, or in addition, the control module <NUM> may cause a display <NUM> to present a processing protocol to a user, present information about the sample being processed, etc. For example, the control module <NUM> may present video/image information of the alignment of the sample with the mask <NUM>, a surface of the sample <NUM> being removed/polished/processed, etc. In some embodiments, the control module <NUM> may cause the display <NUM> to present a graphical user interface that includes selectable interfaces that allow a user to input and/or alter data associated with the sample <NUM> and/or select protocol steps or component configurations that are to be used when processing the sample <NUM>.

The sample processing module <NUM> can be executable by the processors <NUM> to at least partially automate the processing of samples <NUM> by the BIB system <NUM>. For example, the sample processing module <NUM> may be executable to reposition sample holder(s) <NUM> in the BIB system <NUM>, access sample information <NUM> for the sample, determine a processing schedule <NUM> for the sample <NUM>, adjust the configuration of components of the BIB system <NUM> drive, and/or cause the components of the BIB system <NUM> to perform the processing of a sample <NUM>. According to the present invention, the sample processing module <NUM> may obtain sample information <NUM> for a sample <NUM> that is to be processed. In various embodiments, the sample processing module <NUM> may obtain the information by receiving it from a user input, over a hardwire or wireless connection. Alternatively, or in addition, the sample processing module <NUM> may obtain the information by determining it based on sensor information.

The sample processing module <NUM> may also be executable to determine desired component configurations for the components of the BIB system <NUM> based on user input, sample information <NUM> for the sample <NUM>, a processing schedule <NUM> associated with the sample <NUM>, or a combination thereof. For example, based on sample information <NUM> indicating the composition of the sample material that is to be removed and the amount of material that is to be removed, the sample processing module <NUM> may determine a desired broad ion beam strength (e.g., BIB current, accelerating voltage, stage rocking, etc.) and time of irradiation with the broad ion beam required to process the sample <NUM>, and may adjust the BIB source <NUM> configurations and/or the associated processing schedule <NUM> accordingly.

Additionally, sample processing module <NUM> may also be executable to obtain a processing schedule <NUM> associated with a sample <NUM> that is to be processed. Obtaining the processing schedule <NUM> may correspond to accessing a predetermined processing schedule from an accessible data structure, modifying a predetermined processing schedule, generating a processing schedule for the sample, or a combination thereof. For example, after determining an identifier of a sample (e.g., by scanning a barcode on the sample holder <NUM>) the sample processing module <NUM> may use the identifier to access sample information <NUM> and/or a processing schedule <NUM> from a data structure stored on an accessible memory. Alternatively, or in addition, a user may enter an identifier for the sample, sample information <NUM>, a desired result of the process, a type of processing to occur, etc., which the sample processing module <NUM> can use to generate a tailored processing schedule <NUM> that will cause the BIB system <NUM> to perform the desired processing of the sample. For example, based on the specifications of the processing schedule <NUM>, the sample processing module <NUM> may cause the BIB system <NUM> to process one or more samples <NUM> using any of the methods shown in <FIG>. In some embodiments, the sample processing module <NUM> may provide a series of GUI's on the display <NUM> that allow a user to approve and/or give instructions to execute a step of the processing schedule <NUM>. The sample processing module <NUM> may further be executable to perform some or all of the steps of the processing schedule <NUM> independent from user input.

The sample processing module <NUM> can be further executable by the processors <NUM> to automatically move sample holders <NUM> within the BIB system <NUM> so that many samples <NUM> can be processed in succession. For example, based on a user input identifying a plurality of samples that are to be processed, the sample processing module <NUM> may cause the sample holder manipulator <NUM> to sequentially move the associated sample holders <NUM> between storage locations (e.g., a storage cassette <NUM> positioned within a cassette storage volume <NUM>, a sample holder storage volume <NUM>, etc.) and the sample stage area <NUM> so that each of the identified samples can be processed. Because the sample processing module <NUM> is further configured to cause the BIB system <NUM> to perform some or all of the processing steps without user input, the sample processing module <NUM> allows the BIB system <NUM> to automatically process a plurality of samples is quick succession and without user oversight. In this way, the BIB systems <NUM> of the present disclosure allows a single user to monitor the sample processing of many samples across a plurality of BIB systems <NUM>, and/or BIB systems <NUM> to be left without user oversight to process a series of samples over long periods of time.

The computing devices <NUM> include one or more processors configured to execute instructions, applications, or programs stored in a memory(s) accessible to the one or more processors. In some examples, the one or more processors may include hardware processors that include, without limitation, a hardware central processing unit (CPU), a graphics processing unit (GPU), and so on. While in many instances the techniques are described herein as being performed by the one or more processors, in some instances the techniques may be implemented by one or more hardware logic components, such as a field programmable gate array (FPGA), a complex programmable logic device (CPLD), an application specific integrated circuit (ASIC), a system-on-chip (SoC), or a combination thereof.

The memories accessible to the one or more processors are examples of computer-readable media. Computer-readable media may include two types of computer-readable media, namely computer storage media and communication media. Computer storage media may include volatile and non-volatile, removable, and non-removable media implemented in any method or technology for storage of information, such as computer readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, random access memory (RAM), read-only memory (ROM), erasable programmable read only memory (EEPROM), flash memory or other memory technology, compact disc read-only memory (CD-ROM), digital versatile disk (DVD), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other non-transmission medium that may be used to store the desired information and which may be accessed by a computing device. In general, computer storage media may include computer executable instructions that, when executed by one or more processing units, cause various functions and/or operations described herein to be performed. In contrast, communication media embodies computer-readable instructions, data structures, program modules, or other data in a modulated data signal, such as a carrier wave, or other transmission mechanism. As defined herein, computer storage media does not include communication media.

Those skilled in the art will also appreciate that items or portions thereof may be transferred between memory and other storage devices for purposes of memory management and data integrity. Alternatively, in other implementations, some or all of the software components may execute in memory on another device and communicate with the computing devices <NUM>. Some or all of the system components or data structures may also be stored (e.g., as instructions or structured data) on a non-transitory, computer accessible medium or a portable article to be read by an appropriate drive, various examples of which are described above. In some implementations, instructions stored on a computer-accessible medium separate from the computing devices <NUM> may be transmitted to the computing hardware and the computing devices <NUM> via transmission media or signals such as electrical, electromagnetic, or digital signals, conveyed via a communication medium such as a wireless link. Various implementations may further include receiving, sending, or storing instructions and/or data implemented in accordance with the foregoing description upon a computer-accessible medium.

<FIG> is an illustration of an example environment <NUM> where BIB system(s) <NUM> for more efficient processing of multiple samples within a sample preparation workflow. Specifically, <FIG> illustrates the environment <NUM> as including a sample preparation station <NUM>, a sample transportation device <NUM>, a BIB system <NUM>, and a charged particle microscope <NUM>. However, persons having skill in the art will understand how different stations, components, and devices may be used to allow the BIB systems <NUM> according to the present disclosure to efficiently process samples. For example, the example environment <NUM>, or component elements/stations/devices therein, may be used to practice the methods described in <FIG> as well as other processes described herein.

<FIG> illustrates the sample preparation station <NUM> as being a hooded work area having a controlled pressure and atmospheric gas composition. Specifically, <FIG> shows the sample preparation station <NUM> comprising a barrier material <NUM> that defines a working volume <NUM> and one or more optionally sealable apertures <NUM> through which components can be passed between the working volume <NUM> and the outside environment. However, a persona having skill in the art would understand that the sample preparation station <NUM> may correspond to an open environment. Additionally, while the sample preparation station <NUM> is illustrated in <FIG> as being separate from the BIB system <NUM>, a person having skill in the art would understand that in some embodiments the sample preparation station <NUM> may be included within the BIB system <NUM> in a separate chamber form the interior volume such that a sample may be aligned on a sample holder in the sample preparation station <NUM> while a different sample is processed by a BIB source within the interior volume of the BIB system <NUM>.

In some embodiments, a user can select the pressure and atmospheric gas composition within the working volume <NUM> so that they are optimal for preparation of a desired sample <NUM> type. The working volume <NUM> is depicted as containing example elements for preparing samples <NUM> for processing in BIB systems <NUM>. For example, the working volume <NUM> is shown as including a plurality of samples <NUM> that have been harvested/generated and prepared for examination, a plurality of empty sample holders <NUM> upon which the samples <NUM> can be positioned, an example aid <NUM> for aligning/positioning the sample on a sample holder, and sample holders <NUM> that contain a sample. While the example aid <NUM> is illustrated as being an optical microscope system, a person having skill in the art will understand that different types of samples <NUM>/preparation workflows may require different types of aids to optimally align/position samples on the sample holder.

In some embodiments of the present invention, the preparation station further includes an additional mask <NUM> for aligning the sample <NUM> on the sample holders <NUM>. The additional mask <NUM> is geometrically configured such that when a sample is aligned and/or positioned to have a certain geometric relationship between the sample and an edge of the additional mask <NUM> when the sample holder is nested with the additional mask <NUM>, then the sample <NUM> will have the same certain geometric relationship between the sample and the edge of the mask <NUM>(a) when the sample holder is nested with the mask <NUM> within the BIB system <NUM>. This geometric similarity between the mask <NUM> and the additional mask <NUM> allows for samples to be aligned on their respective sample holders without taking up potential time in which the BIB system <NUM> can be processing samples with broad ion and/or optical beams. In some embodiments, aligning the sample within the sample preparation station <NUM> may correspond to an optically aligning the sample without the use of the additional mask <NUM>. For example, a sample may be optically aligned with respect to the sample holder by adjusting an adjustable portion of the sample holder such that the sample will be in a desired position with the sample holder is nested with the mask <NUM> within the BIB system <NUM>. Example methods for optically aligning the sample in this way include, but are not limited to adjusting a sample edge to a marked position (e.g., using an optical microscope and/or an image recognition algorithm), using a laser gate sensing to determine desired positioned, etc..

Additionally, <FIG> shows the sample preparation system as including a storage cassette <NUM> that is configured to hold a plurality of sample holders <NUM>. The storage cassette <NUM> is configured to allow many samples <NUM> and their corresponding sample holders <NUM> to be transported to and/or loaded into the BIB system <NUM>. In this way, a user can use the additional mast <NUM> to pre-align each multiple samples <NUM> and then load them within a storage cassette <NUM>.

<FIG> further shows an optional sample transportation device <NUM> that is configured to transport the sample holder <NUM> between the sample preparation station <NUM> and the BIB system <NUM> and/or between the BIB system <NUM> and the charged particle microscope <NUM>. In some embodiments, the sample transportation device <NUM> may maintain a desired pressure and/or gas environment around the sample holder <NUM> during transportation. In such embodiments, the sample transportation device <NUM> allow a sample to be prepared in the sample preparation station <NUM>, processed in the BIB system <NUM>, and investigated in the charged particle microscope <NUM> without being exposed to a pressure or gas other than the desired pressure and/or gas environment. Alternatively, the sample holder <NUM> or the storage cassette <NUM> may be themselves transported between the sample preparation station <NUM> and the BIB system <NUM>. In some embodiments, the storage cassette <NUM> may be able to maintain the plurality of sample holders <NUM> it contains at a desired pressure and/or gas environment.

<FIG> further shows the example environment <NUM> as including example BIB system(s) <NUM> as described in association with <FIG>. The BIB systems <NUM> include a BIB source <NUM> and an optional additional BIB source <NUM> that are configured to emit a broad ion beam along a BIB axis toward a sample stage area <NUM>. The broad ion beam is configured such that, when portions of the broad ion beam incident up on the sample <NUM>, the material of the sample upon which the broad ion beam is incident are milled or otherwise removed from the sample. The sample stage area <NUM> may include a mask <NUM> configured to block a portion of the broad ion beam such that sample material corresponding to a portion of interest is not milled or otherwise removed from the sample <NUM> by incident ions. The sample stage area <NUM> may also include a holder interface configured to receive a sample holder <NUM> such that it can be positioned and held in relation to the mask <NUM> during processing of the sample <NUM> such that the mask protects portions of interest in the sample. BIB system <NUM> is further shown as including an optional laser source <NUM>. The BIB systems <NUM> are configured to process samples as described in the discussion of <FIG> and/or according to the methods described in <FIG> as well as other processes described herein.

Example environment <NUM> is further depicted as including charged particle microscope system(s) <NUM> for inspection of a sample <NUM> that has been processed with a BIB system <NUM> according to the present invention. The example charged particle microscope system(s) <NUM> may include electron microscope (EM) setups or electron lithography setups that are configured to irradiate and/or otherwise impinge the sample <NUM> with a beam of electrically charged particles <NUM> (usually an electron beam or an ion beam). In various embodiments the charged particle microscope system <NUM> may be or include one or more different types of EM and/or charged particle microscopes, such as, but not limited to, a scanning electron microscope (SEM), a scanning transmission electron microscope (STEM), a transmission electron microscope (TEM), a charged particle microscope (CPM), dual beam microscopy system, etc. Additionally, in some embodiments a TEM is capable of operating as a STEM as well. <FIG> shows the example charged particle microscope system(s) <NUM> as being a scanning electron microscope (SEM) <NUM>.

<FIG> depicts a sample process <NUM> for processing samples with a dual BIB system enabling increased system uptime, according to the present invention. The process <NUM> may be implemented with any of the BIB systems <NUM>, in any environment, including any of the example environment(s) <NUM> for more efficient processing of multiple samples within a sample preparation workflow.

At step <NUM>, a sample to be processed is optionally determined. For example, the sample to be processed may be determined based on an input received from a user via an interface on the BIB system, or via an associated computing device. Alternatively, the sample to be processed may be determined by the BIB system or an associated computing device accessing a data structure (i.e., table, schedule, metadata, etc.) and/or execute instructions that result in the determination of the next sample to be processed. For example, a BIB system may be configured such that it sequentially accesses a plurality of sample holders that are stored within it, allowing a user to preload a number of samples into the BIB system to be automatically processed in series. In such an example, the BIB system of associated computing device would keep track of the order the samples are to be processed which sample of the plurality is next to be processed.

At step <NUM>, a processing schedule for the sample is determined. A processing schedule for the sample corresponds to the BIB system configurations and workflow settings that are to be followed to achieve a desired processing result for the sample (e.g., a BIB strength, a BIB milling time, a portion of the sample to be removed with BIB, a surface of interest, or a combination thereof). In some embodiments, the processing schedule may be input by a user by selecting a processing schedule from a list of premade processing schedules, inputting/generating a new processing schedule, inputting individual step or configuration instructions, or a combination thereof. For example, an associated computer may present a graphical user interface that includes selectable interfaces that allow a user to input and/or alter data associated with the sample and/or select protocol steps or component configurations that are to be used when processing the sample. In another example, in cases where a BIB system is frequently used to process a particular type of sample to prepare it for a certain examination modality, the BIB system or associated computer may have stored an associated processing schedule that a user can select (either manually or via metadata associated with the sample, sample holder, etc.) to initiate the frequently used processing configuration/workflow.

In some embodiments, the processing schedule may be received with sample information associated with the sample to be processed. Sample information includes one or more of a sample identification information, sample composition, a region of interest, a surface of interest, associated processing schedules, etc. Alternatively, or in addition, the BIB system or associated computing system may use predefined rules/instructions to determine the processing schedule for the sample based on the sample information. For example, a user may enter an identifier for the sample which the BIB system may use to access a data structure that specifies the relevant sample information, which the BIB system then uses predefined rules to create a tailored processing schedule that will cause the BIB system to perform the desired processing of the sample. As an example, the BIB system may set the beam strength of the broad ion beam based on the material composition that is to be removed, and/or adjust the milling time based on the amount of the material that is to be removed.

At step <NUM>, the sample is prepared for processing. Preparing the sample for processing may include harvesting the sample from a larger specimen or otherwise generating the sample (e.g., growing or depositing portions of the sample), loading the sample onto a sample holder, aligning the sample, transporting the sample to the BIB system, transporting the sample holder to a sample stage area within the BIB system, etc. For example, the BIB system may cause a component sample holder transporting element to retrieve a sample holder associated with the sample to be processed from a storage area, and translate, tilt, and/or rotate the sample holder so that the geometric relationship between the sample and a protective mask is such that the mask will protect desired portions of the sample during irradiation/milling.

At step <NUM>, a BIB source is caused to emit a broad ion beam toward the sample. <FIG> further shows step <NUM> as being performable while the broad ion beam is being emitted toward the sample. At step <NUM> an additional BIB source is accessed. According to the present invention, the additional BIB source is positioned within a volume that can be selectable sealed from the interior of the BIB system via a valve. In this way, when the valve is closed, milled material from the sample cannot pass into the volume containing the additional BIB source. Additionally, in some embodiments the pressure and/or gaseous makeup is not affected when the additional BIB source is accessed. In various embodiments, accessing the additional BIB source at <NUM> may include one or more of removing the additional BIB source <NUM> from the BIB system (e.g., for cleaning, adjustment, repair, etc.), performing maintenance on the additional BIB system <NUM> (e.g., cleaning, aligning, etc.), replacing the additional BIB source <NUM> (e.g., reinstalling the BIB source after cleaning/maintenance), and/or installing a new BIB source <NUM> in the BIB system.

At step <NUM>, portions of the sample are removed with the broad ion beam. According to the present invention, step <NUM> may include milling with a source different from the broad ion beam, such as the dual optical and ion milling process described in <FIG>. In step <NUM> portions of the sample that are not shielded by the protective mask are removed from the sample. In this way, a region of interest and/or portion of the sample that will be subject to additional processing may be rapidly exposed.

At step <NUM>, it is determined whether another sample is to be milled. If the answer at <NUM> is yes, then the process returns to step <NUM> and the sample that is to be processed is determined. In this way, numerous samples can be processed while the additional BIB system is being accessed. If the answer at <NUM> is no, then the process <NUM> may end.

<FIG> depicts a sample process <NUM> for processing samples with a dual mode, optical and BIB milling system for more efficient sample processing, according to the present invention. The process <NUM> may be implemented with any of the BIB systems <NUM>, in any environment, including any of the example environment(s) <NUM> for more efficient processing of multiple samples within a sample preparation workflow.

At step <NUM>, a sample to be processed is optionally determined. For example, the sample to be processed may be determined based on an input received from a user via an interface on the BIB system, or via an associated computing device. Alternatively, the sample to be processed may be determined by the BIB system or an associated computing device accessing a data structure (i.e., table, schedule, metadata, etc.) and/or execute instructions that result in the determination of the next sample to be processed.

At step <NUM>, a processing schedule for the sample is determined. A processing schedule for the sample corresponds to the BIB system configurations and workflow settings that are to be followed to achieve a desired processing result for the sample (e.g., a BIB strength, a BIB milling time, a portion of the sample to be removed with BIB, a surface of interest, or a combination thereof). In various embodiments, the processing schedule may be input by a user, received with sample information associated with the sample to be processed, or determined by the BIB system (e.g., based on the sample information).

At step <NUM>, a laser source is caused to emit an optical beam (e.g., laser) toward the sample. The optical beam emitted by the laser source is of a higher beam energy and/or strength than a broad ion beam. At step <NUM>, a first portion of the sample are removed with the optical beam. Because of the increased strength of the optical beam, it can remove sample material upon which it is incident at a rate that is <NUM>-50x greater that what is possible with a broad ion beam. However, while the removal of the sample material is more rapid with an optical beam, milling and/or processing with the optical beam also causes damage/burning on the remaining sample surface.

At step <NUM>. a BIB source is caused to emit a broad ion beam toward the sample, and at step <NUM>, a second portion of the sample are removed with the broad ion beam. Because the broad ion beam is able to remove sample material without damaging the sample surface, the broad ion beam is able to remove final portions of the sample (i.e., damaged portions of the sample) without causing further damage to the sample. In this way, once a large portion of material is rapidly removed with the optical beam, the broad ion beam can be used to remove final portions of the sample to expose a region of interest.

<FIG> depicts a sample process <NUM> for a processing multiple samples within a dual BIB system with reduced downtime, according to the present invention. The process <NUM> may be implemented with any of the BIB systems <NUM>, in any environment, including any of the example environment(s) <NUM> for more efficient processing of multiple samples within a sample preparation workflow.

At step <NUM>, a sample holder associated with the sample to be processed is removed from a storage location within the BIB system. For example, the BIB system may cause a component sample holder transporting element (e.g., sample holder manipulator) to retrieve a sample holder associated with the sample to be processed from a storage area within the BIB system and/or from within a sample storage/transport device (e.g., a storage cassette).

At step <NUM>, the sample holder is positioned in a sample stage area. Specifically, the sample holder may be translated, tilted, and/or rotated by a sample holder transporting element such that a geometric relationship between the sample and a protective mask is such that the mask will protect desired portions of the sample during irradiation/milling. In some embodiments, the sample may also be aligned with the mask based on user and/or sensor input. Alternatively, or in addition, the sample may have been realigned using a workflow such as the one described in <FIG>.

At step <NUM>, the sample is processed. Specifically, a BIB source is caused to emit a broad ion beam toward the sample. First portions of the sample upon which the broad ion beam is incident are milled away, while second portion of the sample that the protective mask of the BIB source blocks is not milled away. Alternatively, or in addition, the sample may be processed in the BIB system using other sample preparation workflows, including but not limited to, the processes described herein.

At step <NUM>, the sample holder is removed from the sample stage area. That is, the sample holder is translated, tilted, and/or rotated by the sample holder transporting element so that the sample holder is either stored in a storage location, a sample transport device, or transported through a port out of the BIB system.

At step <NUM>, it is determined whether another sample is to be processed. If the answer at <NUM> is yes, then the process returns to step <NUM> and the sample that is to be processed is determined. If the answer at <NUM> is no, then the process <NUM> may end.

<FIG> depicts a sample process <NUM> for processing samples with a BIB system enabling increased system uptime, according to the present invention. The process <NUM> may be implemented with any of the BIB systems <NUM>, in any environment, including any of the example environment(s) <NUM> for more efficient processing of multiple samples within a sample preparation workflow.

At step <NUM>, a sample is obtained. Specifically, the sample may be obtained by harvesting the sample from a larger specimen, growing or depositing portions of the sample, milling away portions of a larger sample, or a combination thereof.

At step <NUM>, the sample is affixed to a sample holder, and at step <NUM>, nesting the sample holder with a first mask. The first mask is geometrically similar to a second protective mask within a BIB system such that a sample that is in a desired alignment with relation to the first mask will also be in the desired alignment with the second sample. That is, when the sample is aligned to a desired position on the sample holder with the first mask, it does not need to be further aligned when the sample holder is subsequently nested in the second mask in the BIB system.

At step <NUM>, aligning the sample with the first mask. For example, a user may use an optical microscope, sensors, or eyesight to manipulate sample alignment elements on the sample holder so that the sample is translated, tilted, or rotated until it is in a desired alignment position. Once the sample is aligned, the sample holder can be translated to a sample storage area within the BIB system and/or from within a sample storage/transport device (e.g., a storage cassette). For example, after a sample is pre-aligned in this way, the sample holder may be transported to a storage location in the BIB system in which the sample is to be processed. In some embodiments, the BIB system may have a separate sample alignment chamber in which some or all of steps <NUM>-<NUM> may be performed, and a sample manipulation element may transport the sample holder containing the aligned sample into a storage location within the BIB system. In this way, as a user is aligning samples with the first mask, the BIB system can be processing pre-aligned samples using the second mask.

In an alternative example, once the sample is aligned with the first mask, the sample may be loaded onto a sample transport device that protect the sample during transportation/loading into the BIB system in which they will be processed. Such a transport device may be configured to transport a single sample holder or many sample holders. In some embodiments, the transport devices may preserve a pressure or gaseous environment around the sample during transport. In this way, a sample can be prepared in a sample preparation area having a controlled pressure and/or gaseous composition, and then transported to the BIB system without exposing the sample to a new pressure/gaseous composition.

At step <NUM>, it is determined whether another sample is to be aligned. If the answer at <NUM> is yes, then the process returns to step <NUM> and another sample is obtained. In this way, multiple samples can be pre-aligned and loaded into a sample storage area within the BIB system and/or from within a sample storage/transport device. Because a user can align many samples in a continuous manner, the throughput of the sample preparation across a plurality of samples using this method can be greatly streamlined.

If the answer at <NUM> is no, then the process <NUM> continues at step <NUM> where the sample holder is nested with a second mask within a BIB system. Because the sample was pre-aligned with the first mask, when the sample holder is nested with the second mask it does not need further alignment. This greatly increases the speed at which samples can be processed within the system.

At step <NUM>, the sample is processed with the BIB system. For example, portion of the sample can be removed with an optical or broad ion beam according to any of the processes described herein. Additionally, since much of the user input that is presently needed by current BIB systems is related to the alignment process, by pre-aligning the samples using this process, the required user input can be performed all at once during the alignment of multiple samples, and the remaining processing steps can be at least partially automated such that a BIB system according to the present invention is able to process multiple pre-aligned samples with little or no user input/oversight.

At step <NUM>, it is determined whether another sample is to be processed. If the answer at <NUM> is yes, then the process returns to step <NUM> and another sample holder is nested with the second mask. If the answer at <NUM> is no, then the process <NUM> may end.

Claim 1:
A method for pre-aligning samples (<NUM>) for more efficient processing of multiple samples with a broad ion beam (BIB) system (<NUM>), the method comprising the steps of:
affixing (<NUM>) a sample (<NUM>, <NUM>) to an adjustable portion of a sample holder (<NUM>);
nesting (<NUM>) the sample holder (<NUM>) with a first mask (<NUM>) having a first mask edge, wherein the first mask (<NUM>) is positioned outside of a broad ion beam (BIB) system (<NUM>);
aligning (<NUM>) the sample (<NUM>, <NUM>) such that it has a desired geometric relationship to the first mask edge; and
nesting (<NUM>) the sample holder (<NUM>) with a second mask (<NUM>) having a second mask edge, wherein the second mask (<NUM>) is positioned within a BIB system (<NUM>), and wherein the first mask (<NUM>) and the second mask (<NUM>) are geometrically similar such that the geometric relationship between the first mask edge and the sample (<NUM>, <NUM>) when the sample holder (<NUM>) is nested with the first mask (<NUM>) is the same as the geometric relationship between the second mask edge and the sample (<NUM>, <NUM>) when the sample holder (<NUM>) is nested with the second mask (<NUM>).