Inspection tool for testing and adjusting a projection unit of a lithography system
Claim Score by NHIP
Abstract
An inspection system and method are disclosed. The inspection system is configured to inspect a projection unit having multiple optical subsystems. The optical subsystems are configured to project an image during a lithography step. The inspection system provides self calibration by measuring both a test mask and the aerial image of the test mask with the same detector assembly. The inspection system is also capable of measuring multiple fields simultaneously using multiple detectors and 6 axis interferometry to accurately determine the position of each detector. Additionally, the inspection system is capable of measuring the distance between the test mask and the detector assembly with an indirect path around the projection unit which normally blocks the direct path.

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Projected expiry passed 14 November 2022, 3.9 years ago.
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49 claims: 6 independent, 43 dependent
- 1An inspection system for performing optical tests associated with determining the imaging quality of a plurality of optical subsystems of an optical system, the optical tests being performed with a test mask having a plurality of measurable test patterns formed thereon, the inspection system comprising:a detector assembly capable of measuring the measurable test patterns of the test mask and the aerial image of the measurable test patterns as projected through the optical subsystems so as to determine the optical characteristics of each of the optical subsystems.
- 25Broadest claimClaim Score 86, broad(NHIP)A detector assembly for use in a tool for inspecting optical systems having a plurality of optical subsystems, the detector assembly comprising:a plurality of detector mechanisms, each of the detector mechanisms corresponding to individual ones of the optical subsystems, the detector mechanisms being configured to simultaneously measure the optical characteristics of each of the optical subsystems.
- 31A position location assembly for use in a tool for inspecting optical systems having a plurality of optical subsystems, the assembly comprising:a detection system configured to continuously determine the position of a detector assembly relative to one or more reference points, the detection system including one or more first sensors that measure the distance between a fixed reference frame and the detector assembly, and one or more second sensors that measure the distance between a test mask and the detector assembly.
- 37An inspection system, comprising:a test component configured to help determine the optical characteristics of an optical component;an optical detection component configured to perform optical tests on an optical component, the detector component cooperating with the test component to determine the optical characteristics of the optical component, the optical component being disposed between the test component and the detector component while the tests are being performed;a position detection component configured to measure the distance between the test component and the detector component with an indirect path around the optical component which blocks the direct path.
- 45A method of self calibrating an inspection system, the inspection system being configured to inspect an optical component of a lithography system, the method comprising:providing a test mask having on or more test patterns;measuring the test patterns with the inspection system;measuring the images of the test patterns with the same inspection system, the images being formed by the optical component;and comparing the test patterns with the images.
- 49A method of inspecting optical projection units having multiple fields, the method comprising simulataneously measuring multiple fields with multiple detectors, each of the detectors corresponding to an individual field;moving the multiple detectors to various measurement points within its corresponding individual field;and determining the position of each detector with 6 axis interferometry.
Independent claims6
123 paragraphs in 4 sections, as filed
BACKGROUND OF THE INVENTION
The present invention relates generally to a lithography system. More particularly, the present invention relates to improved techniques for inspecting optical projection units, which are used in lithography systems.
Lithography systems used in the manufacture of integrated circuits and flat panel displays have been around for some time. Such systems have proven extremely effective in the precise manufacturing and formation of very small details in the product. In most lithography systems, a circuit image is written on a substrate by transferring a pattern via a beam (e.g., light beam). As is generally well known, lithography systems typically include an illumination unit for transmitting the beam through patterns resident on the surface of a mask and a projection unit for projecting the transmitted beam onto the surface of the substrate.
The projection unit generally contains an optical subsystem having a plurality of optical components that work together to collect and project the transmitted beam. By way of example, the optical subsystem may include optical components such as lenses, prisms, mirrors and the like. Unfortunately, the optical components, either separately or together, may contain imperfections that cause differences between the pattern on the mask and the projected image of the pattern, i.e., the projected image may not coincide exactly with the pattern on the mask. By way of example, the imperfections may be related to mis-aligned optical components or optical components with defects or variations. As should be appreciated, any differences created between the pattern on the mask and the projected image of the pattern make it difficult to ensure precise manufacturing of the product, i.e., the image differs from what is sought and therefore the printed pattern on the substrate is adversely effected. By way of example, the width of printed lines may be increased or decreased, the position of the lines may be skewed or shifted, subsequently processed patterns in the product may be misaligned and the like.
In general, the optical subsystems are certified in the factory before final shipment to the customer. The certification process generally includes testing and adjusting the optical subsystems until they meet desired specifications. Unfortunately, however, due to the inherent high-precision nature of the optical components, testing and adjustments thereto can be difficult to achieve in a cost effective, accurate and speedy manner.
Conventionally, the projection unit has been installed in the lithography system in order to perform testing on the optical subsystems. In most cases, the optical subsystems are tested by exposing photoresist with a projected image of a test mask and then examining the resultant printed image of the projected image in the photoresist. Unfortunately, photoresist exposure and subsequent measurement is typically very slow, and limited in the type of measurements that may be performed, as well as in the accuracy of the measurements. For example, the determination of focus and therefore the focal plane is typically not very accurate in photoresist. Furthermore, there is generally not enough space to perform the adjustments on the optical subsystems when the projection unit is disposed in the lithography system and therefore the projection unit is typically removed from the lithography system when adjustments on the optical subsystems are needed. In most cases, several iterations of testing and adjustments are needed to meet specifications and thus the process of installing and removing is unfortunately slow and time consuming. Moreover, multiple installations and removals may lead to other imperfections of the optical subsystem, i.e., misalignments may be produced when the projection unit is installed or removed.
Thus, there is a need for improved techniques for testing and adjusting the optical subsystem of a projection unit.
SUMMARY OF THE INVENTION
The invention relates, in one embodiment, to an inspection system for performing optical tests associated with determining the imaging quality of a plurality of optical subsystems of an optical system. The optical tests are performed with a test mask having a plurality of measurable test patterns formed thereon. The inspection system includes a detector assembly capable of measuring the measurable test patterns of the test mask and the aerial image of the measurable test patterns as projected through the optical subsystems so as to determine the optical characteristics of each of the optical subsystems.
The invention relates, in another embodiment, to a detector assembly for use in a tool for inspecting optical systems having a plurality of optical subsystems. The detector assembly includes a plurality of detector mechanisms. Each of the detector mechanisms corresponds to individual ones of the optical subsystems. The detector mechanisms are configured to simultaneously measure the optical characteristics of each of the optical subsystems.
The invention relates, in another embodiment, to a position location assembly for use in a tool for inspecting optical systems having a plurality of optical subsystems. The assembly includes a detection system configured to continuously determine the position of a detector assembly relative to one or more reference points. The detection system includes one or more first sensors that measure the distance between a fixed reference frame and the detector assembly, and one or more second sensors that measure the distance between a test mask and the detector assembly.
The invention relates, in another embodiment, to an inspection system. The inspection system includes a test component configured to help determine the optical characteristics of an optical component. The inspection system also includes an optical detection component configured to perform optical tests on an optical component. The detector component cooperates with the test component to determine the optical characteristics of the optical component. The optical component is disposed between the test component and the detector component while the tests are being performed. The inspection system additionally includes a position detection component configured to measure the distance between the test component and the detector component with an indirect path around the optical component which blocks the direct path.
The invention relates, in another embodiment, to a method of self calibrating an inspection system. The inspection system is configured to inspect an optical component of a lithography system. The method includes providing a test mask having on or more test patterns. The method also includes measuring the test patterns with the inspection system. The method additionally includes measuring the images of the test patterns with the same inspection system. The images are formed by the optical component. The method further includes comparing the test patterns with the images.
The invention relates, in another embodiment, to a method of inspecting optical projection units having multiple fields. The method includes simulataneously measuring multiple fields with multiple detectors. Each of the detectors corresponds to an individual field. The method also includes moving the multiple detectors to various measurement points within its corresponding individual field. The method additionally includes determining the position of each detector with 6 axis interferometry.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
<figref idref="DRAWINGS">FIG. 1</figref> is a simplified diagram of a lithography system <b>10</b>, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 2</figref> is a top view of a light field distribution <b>30</b> produced by an illumination unit, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 3A</figref> is a simplified block diagram of an inspection system <b>100</b> for inspecting a projection unit <b>102</b>, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 3B</figref> is a simplified diagram of test patterns showing deviations between a first test data and a second test data, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 4</figref> is a flow diagram of an inspection method, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 5</figref> is a perspective diagram of an inspection tool and a projection unit, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIGS. 6A</figref> is a perspective diagram of an inspection tool with the projection unit in an adjustment position, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIGS. 6B</figref> is a perspective diagram of an inspection tool with the projection unit in a test position, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 7</figref> is a perspective diagram of a lens calibrating system in a first mode, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 8</figref> is a perspective diagram of a lens calibrating system in a second mode, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIGS. 9A and 9B</figref> are perspective diagrams of a detector box, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 10</figref> is a perspective diagram of a mask holder, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIGS. 11A and 11B</figref> are perspective diagrams of a reference frame, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 12</figref> is a simplified diagram of the reference frame of <figref idref="DRAWINGS">FIG. 11</figref> showing the operation thereof, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 13A</figref> is a simplified diagram of an individual imaging system in a first mode, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 13B</figref> is a simplified diagram of an individual imaging system in a second mode, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 14A</figref> is a simplified diagram of an individual confocal system in a first mode, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 14B</figref> is a simplified diagram of an individual confocal system in a second mode, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 15</figref> is a simplified diagram of a detector unit that includes an imaging system and confocal system, in accordance with one embodiment of the present invention.
<figref idref="DRAWINGS">FIG. 16</figref> is a simplified diagram of a test mask, in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention generally pertains to an inspection system and method for inspecting projection units, which are used in lithography systems. One aspect of the invention relates to an offline inspection tool for testing and adjusting the optical subsystems of projection units. Another aspect of the invention relates to testing multiple optical subsystems of the projection unit with a detector arrangement. Another aspect of the invention relates to comparing a measured pattern of a test mask with a measured image of the pattern projected by the optical subsystem under test. Yet another embodiment of the invention relates to monitoring the position of the detector arrangement to ensure precise and accurate measurements of the pattern and projected image.
These and other aspects of the invention are discussed below with reference to <figref idref="DRAWINGS">FIGS. 1-16</figref>. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments.
<figref idref="DRAWINGS">FIG. 1</figref> is a simplified diagram of a lithography system <b>10</b>, in accordance with one embodiment of the present invention. By way of example, the lithography system may be used to fabricate integrated circuits (IC), flat panel displays, and the like. The lithography system <b>10</b> is generally arranged for writing an image on the surface of a substrate <b>12</b> by transmitting one or more light beams <b>13</b> through a patterned mask <b>14</b>. The light beams may be widely varied. For example, the light beams may be configured to illuminate an area such as a trapezoidal area.
As shown in <figref idref="DRAWINGS">FIG. 1</figref>, the lithography system <b>10</b> generally includes an illumination unit <b>16</b>, a mask stage <b>18</b>, a projection unit <b>20</b> and a substrate stage <b>22</b>. The illumination unit <b>16</b> is configured to generate and direct the light beam(s) <b>13</b> to the surface of the mask <b>14</b>. Although not shown, the illumination unit <b>16</b> generally includes a light source for generating the light beam(s) and associated optics for directing the light beam(s) to the mask <b>14</b>. The projection unit <b>20</b>, on the other hand, is configured to collect the transmitted light <b>13</b>′ that is passed through the mask <b>14</b>, and to direct (e.g., focus) the collected light <b>13</b>″ to the surface of the substrate <b>12</b>. As shown, the projection unit <b>20</b> includes one or more optical subsystems <b>24</b>, each of which contains a variety of optical components such as lenses, prisms, mirrors, and the like. In one embodiment, the optical subsystems may contain 14 to 18 separate lenses for directing the light therethrough. The projection unit <b>20</b>, and more particularly the optical subsystems <b>24</b>, may be arranged to increase, reduce or maintain the size of the images produced by the patterned mask <b>14</b>. In the illustrated embodiment, the projection unit <b>20</b> is arranged to maintain the size of the images produced by the mask <b>14</b> so as to form an image of similar size on the surface of the substrate <b>12</b> (1:1 ratio).
The illumination unit <b>16</b> and projection unit <b>20</b> set-up may be widely varied. For example, the units <b>16</b>, <b>20</b> may be configured to process a single beam or multiple beams. In the illustrated embodiment, the illumination unit <b>16</b> is configured to produce a light field distribution containing a plurality of light beams <b>13</b>. By way of example, the illumination unit may include a plurality of light sources, each of which produces a separate beam or it may include a single light source with a beam splitter that splits the generated beam into a plurality of beams. In addition, the projection unit <b>20</b> is configured to individually collect and direct each of the light beams <b>13</b>′ in the light field distribution to the surface of the substrate <b>12</b> via a plurality of optical subsystems <b>24</b>. In most cases, the number of optical subsystems <b>24</b> corresponds to the number of light beams <b>13</b> produced by the illumination unit <b>16</b>, i.e., there is a distinct optical subsystem for each beam. In the illustrated embodiment, the illumination unit <b>16</b> is configured to direct seven light beams <b>13</b> to the surface of the mask <b>14</b> and therefore the projection unit <b>20</b> includes a seven corresponding optical subsystems <b>24</b>.
As shown in <figref idref="DRAWINGS">FIG. 1</figref>, the mask stage <b>18</b> is positioned between the illumination unit <b>16</b> and the projection unit <b>20</b> and the substrate stage <b>22</b> is positioned below the projection unit <b>20</b>. The mask stage <b>18</b> is generally arranged to hold and move the patterned mask <b>14</b> while the substrate stage <b>22</b> is generally arranged to hold and move the substrate <b>12</b>. The movement of the stages may be widely varied. In the illustrated embodiment, the stages <b>18</b>, <b>22</b> are moved together along a linear scan path so that all or any selected part of the patterned mask <b>14</b> is scanned. Although only a small portion of the mask <b>14</b> is imaged at any one time, the surface of the mask <b>14</b> is sequentially exposed to the fields of the light beams <b>13</b>, thereby allowing a pattern (similar to the pattern on the mask) to be built up on the substrate <b>12</b>. Alternatively, a serpentine path, which moves back and forth in the direction of the X-axis while being incremented in the Y-direction at the end of each traverse, may be used.
<figref idref="DRAWINGS">FIG. 2</figref> is a top view of a light field distribution <b>30</b> produced by an illumination unit, in accordance with one embodiment of the present invention. In this Figure, the light field distribution <b>30</b> is shown incident on a surface <b>32</b> of a mask <b>34</b>. By way of example, the light field distribution <b>30</b> may generally correspond to the light field distribution formed by beams <b>13</b> shown in FIG. <b>1</b>. The light field distribution <b>30</b> generally produces a plurality of distinct light fields <b>36</b> that are scanned in the direction of arrows <b>38</b>. The combination of these fields <b>36</b> forms an overall scanning swath, S.
The field distribution <b>30</b> may be widely varied. In the illustrated embodiment, the fields <b>36</b> are spatially separated relative to one another. That is, each of the fields <b>36</b> are isolated from other fields so that they do not overlap any portion of an adjacent field (in the direction of the incident light). As should be appreciated, it would be difficult to collect each of the individual fields at the projection unit if the fields were not isolated in this manner. Furthermore, the fields <b>36</b> are staggered so that adjacent fields step back in fourth relative to one another (e.g., offset). The staggered fields are generally positioned so that a portion of them covers an edge of an adjacent field in the scanning direction, thus ensuring that the scanning swath, S, is scanned without missing any areas therebetween. That is, although the fields are spatially distinct, they sweep together across the surface of the substrate painting a continuous image. Furthermore, the shape of the fields may be widely varied. For example, they may be square, rectangular, circular, triangular, and the like. In the illustrated embodiment, the fields <b>36</b> are trapezoidally shaped. It should be noted that this particular field distribution is not a limitation and that the field distribution may vary according to the specific needs of each lithography system.
<figref idref="DRAWINGS">FIG. 3</figref> is a simplified block diagram of an inspection system <b>100</b> for inspecting a projection unit <b>102</b>, in accordance with one embodiment of the present invention. The inspection system <b>100</b> is generally configured to perform optical tests for determining the image quality of each of the optical subsystems (not shown in this figure) of the projection unit <b>102</b>. By way of example, the projection unit <b>102</b> may generally correspond to the projection unit shown in FIG. <b>1</b>. The optical tests are generally performed with a test mask <b>106</b> having one or more measurable test patterns formed thereon. The number of test patterns generally corresponds to the number of optical subassemblies of the projection unit <b>102</b>. The test patterns are generally configured to identify imperfections in the optical subsystem that may displace the images produced therethrough. In one embodiment, each of the test patterns may include an array of test marks for helping determine image displacement in the X, Y and Z directions. By way of example, the test marks may be alignment targets (X and Y directions) and/or focus targets (Z direction). As should be appreciated, if the optical subsystems have distortions, the alignment marks may be displaced in the X and Y directions. In addition, if the optical subsystems have aberrations, astigmatisms and the like, the alignment marks may be displaced in the Z direction.
Unfortunately, the test mask <b>106</b>, as well as the inspection system <b>100</b> itself, may have errors in the form of imperfections, defects and deviations that if not otherwise compensated for through calibration would adversely effect the outcome of the tests. For example, the test mask <b>106</b> may be large and thus it cannot be made or measured to the accuracy that is important to making good optics. Therefore, the inspection system <b>100</b> is also configured to test the test mask <b>106</b> before (or after) testing the optical projection unit <b>102</b> so that any errors in the test mask <b>106</b> or inspection system <b>100</b> can be removed (or calibrated) from the test results of the projection unit <b>102</b>. That is, the inspection system <b>100</b> is configured to calibrate by measuring the test mask <b>106</b> directly and then comparing that with the results obtained through the optics <b>102</b>. Errors in the test mask <b>106</b> are removed by the comparison.
To elaborate, the optical tests performed by the inspection system <b>100</b> are generally arranged to produce a first test data associated with the test mask <b>106</b> and inspection system <b>100</b> and a second test data associated with the test mask <b>106</b>, inspection system <b>100</b> and projection unit <b>102</b>. The first test data can be compared with the second test data to determine the image quality of each of the optical subsystems of the projection unit <b>102</b>. The first test data essentially provides a calibration data for helping determine the actual image displacement of the optical subsystems. By way of example, and referring to <figref idref="DRAWINGS">FIG. 3B</figref>, for a given optical subsystem and using x and y coordinates, if the first test data <b>103</b> includes a first mark position at 0,0, and the second set of data <b>105</b> includes the same first mark position at 0,1 (e.g., image of mark), then the inspection system tends to know that the optical subsystem is off with respect to the mask and inspection system in the +Y direction by 1. In addition, if the first test data <b>103</b> includes a second mark position at 2,2, and the second set of data <b>105</b> includes the same second mark position at 1,2 (e.g., image of mark), then the inspection system tends to know that the optical subsystem is off with respect to the mask and inspection system in the −X direction by 1.
Referring back to <figref idref="DRAWINGS">FIG. 3A</figref>, the inspection system <b>100</b> includes a mask assembly <b>104</b>, a detector assembly <b>110</b>, a position locator assembly <b>120</b> and a control assembly <b>130</b>. The mask assembly <b>104</b> is capable of holding and moving the test mask <b>106</b> to multiple test positions. For example, the mask assembly <b>104</b> may be configured to move the test mask <b>106</b> to a calibration position for measuring the test patterns of the test mask <b>106</b> and a measurement position for measuring the image of the test patterns of the test mask <b>106</b> as projected through the projection optics <b>102</b>.
The detector assembly <b>110</b> is capable of measuring the test patterns of the test mask <b>106</b> and the image of the test patterns of the test mask <b>106</b> as projected through the projection optics <b>102</b>. The detector assembly <b>110</b> includes one or more detector mechanisms <b>112</b> for measuring the one or more test patterns of the test mask <b>106</b> (as shown by arrow <b>114</b>) and the one or more projected images <b>109</b> of the test patterns (as shown by arrow <b>116</b>). By way of example, the projected image <b>109</b> may be the aerial image produced by each of the optical subsystems of the projection unit <b>102</b>. The number of detector mechanisms <b>112</b> generally corresponds to the number of optical subsystems of the projection unit <b>102</b>. The detector mechanisms <b>112</b> may be widely varied. For example, the detector mechanisms <b>112</b> may have imaging and/or confocal elements. Imaging elements are generally used to measure distortion characteristics in the X and Y directions while confocal elements are generally used to measure focus characteristics in the Z direction.
The detector assembly <b>110</b> is also capable of moving in the X, Y and/or Z directions during inspection so as to measure the test marks contained within the test patterns of the test mask <b>106</b> (or images <b>109</b> thereof). In most cases, the detector assembly <b>110</b> is moved so that the detector mechanisms <b>112</b> sequentially measure an array of test marks (or images thereof) located within the test pattern (or image thereof). For example, the detector mechanisms <b>112</b> may be moved from a first mark to a second mark and so on within the test pattern or image thereof. For example, referring to <figref idref="DRAWINGS">FIG. 3B</figref>, the detector mechanisms may be moved from the first mark 0,0 to the second mark 0,1 within the first set of data <b>103</b>.
In one embodiment, the detector assembly <b>110</b> includes a plurality of detector mechanisms that are ganged together so as to gather data at the same time as the detector assembly scans. Each individual detector mechanism measures a distinct test pattern at the same time. That is, multiple detector mechanisms are configured to measure multiple test patterns simultaneously. This generally produces fast throughput and minimum drift. For example, it reduces the amount of time needed to scan all of the test patterns, i.e., it may take a long time to scan multiple test patterns with a single detector.
Referring back to <figref idref="DRAWINGS">FIG. 3</figref>, the position locator assembly <b>120</b> is capable of providing positional information associated with the mask and detector assemblies <b>104</b>, <b>110</b>. For example, the position locator assembly <b>120</b> may provide positional information corresponding to the calibration and measurement positions of the mask assembly <b>104</b>. In addition, the position locator assembly <b>120</b> may provide positional information corresponding to the testing positions of the detector assembly <b>110</b>.
The positional locator assembly <b>120</b> is generally configured to measure one or more degrees of freedom of the mask and detector assemblies <b>104</b>, <b>110</b>. For example, the position locator assembly <b>120</b> may be configured to provide positional information in the X, Y and/or Z directions as well as the rotational θ<sub>x</sub>, θ<sub>y</sub>, θ<sub>z </sub>directions. In one embodiment, 6 axis interferometry is used to track the position of the detector assembly. In order to obtain the positional information, the position locator assembly <b>120</b> generally includes one or more positional sensors <b>122</b> for monitoring the positions of the mask and detector assemblies. By way of example, the positional sensors may include interferometers, capacitance sensors and the like. The positional sensors generally include a pair of components A and B that cooperate with one another to determine the position of the assemblies. For example, in the case of interferometers sensors, the interferometers sensors include a laser component and a mirror component. The position of these components may be widely varied. For example, they may be positioned on the mask assembly, detector assembly or some other portion of the inspection system (e.g., a fixed member).
The control assembly <b>130</b> is capable of controlling the various components of the of the inspection system <b>100</b>. For example, the control assembly <b>130</b> may be arranged to act as a master controller of the inspection system <b>100</b>, i.e., commands may be issued to and status may be monitored from the various components so as to facilitate completion of assigned tasks. In the illustrated embodiment, the control assembly <b>130</b> is operatively coupled to the mask assembly <b>104</b>, the detector assembly <b>110</b> and the position locator assembly <b>120</b>. The control assembly <b>130</b> may include capabilities for, but not limited to, retrieving positional information from the position locator assembly <b>120</b>, providing control signals to move the mask and the detector assemblies <b>104</b> and <b>110</b>, retrieving measured data (e.g., first and second data) from the detector assembly <b>110</b>, storing the positional information and measured data, processing the positional information and measured data, and/or the like.
In one embodiment, the control assembly <b>130</b> includes processing steps that calibrate out errors in the test mask and/or inspection system. In essence, the control assembly subtracts the first test data from the second test data to compensate for errors in the mask and inspection system. That is, during processing, distortions in the mask and detectors may be calibrated out of the test results to produce test results that more accurately describe the distortions in the projection unit. In one implementation, the control assembly stores calibration data and measured data, subtracts calibration data from measured data to determine actual data, and outputs this information for further processing.
Although not shown, the inspection system <b>100</b> may also include a computer system for resolving or analyzing information and/or data retrieved by the control assembly so as to determine any adjustments that are needed. The computer system may be a part of the control assembly or it may be a distinct element. The computer system is generally configured to run an algorithm with the first and second data or resultant data therefrom for determining any adjustments that need to be made. For example, the algorithm may determine that a lens needs to be adjusted. Not only does the algorithm take into account the relative positions of each data point, but also the data points relative to one another. The computer system is generally arranged to inform an operator of the desired adjustment. In most cases, its an iterative process, i.e., the operator makes the adjustment and tests it again until the optical subsystems reach a certain limit that is acceptable.
<figref idref="DRAWINGS">FIG. 4</figref> is a flow diagram of an inspection method <b>150</b>, in accordance with one embodiment of the present invention. By way of example, the inspection method may be implemented via the inspection system of FIG. <b>3</b>. The inspection method <b>150</b> is generally configured to help determine the optical characteristics of a projection unit. By way of example, the optical characteristics may include focus plane, astigmatism, distortion, aberrations and the like. In most cases, a test mask is used to perform optical tests associated with determining the optical characteristics on the projection unit. The optical tests are used to provide feedback for making adjustments to the projection unit under test. For example, the optical tests may indicate that a lens in the optical subsystem is not aligned properly.
The inspection method generally begins at block <b>152</b> where a test mask is provided. The test mask generally includes one or more test patterns that are located at various positions on the test mask. The number of test patterns generally corresponds to the number of optical subsystems of the projection unit being inspected. That is, there is generally a test pattern for each field used by the lithography system from which the projection unit is taken. The test pattern is generally configured to be contained within the field of view of the optical subsystems of the projection unit. Each of the test patterns includes one or more test marks that provide measurable information in the X, Y and Z directions. By way of example, test marks associated with measurable information in the X and Y direction may be used to determine distortion and test marks associated with measurable information in the Z direction may be used to determine misfocus. In one implementation, the X and Y test marks are in the form of crosses while the Z test marks are formed by reflective surfaces.
After providing the test mask, the process flow proceeds to block <b>154</b> where the test patterns of the test mask are measured. During measurements, the test mask is generally positioned in a plane that coincides with the image plane of the projection optics under test. The measurements are typically performed using various detector arrangements capable of measuring different optical characteristics. By way of example, the test patterns may be measured with the detector mechanisms of FIG. <b>3</b>. The number of detectors in each of the detector arrangements generally corresponds to the number of optical subsystems of the projection unit under test. For example, if the projection unit includes seven optical subsystems then each of the detector arrangements includes 7 detectors. In one implementation, multiple detectors are used to simultaneously measure multiple test patterns. That is, the individual detectors may be moved together as a group at the same time with each individual detector measuring test marks contained within individual test patterns.
In one embodiment, position measurements are performed. This is generally accomplished by illuminating the test mask and capturing an image of the test marks with measurable information in the X and Y directions. Illumination may be implemented by an illumination unit disposed behind the test mask and capturing may be implemented by imaging detectors disposed in front of the test mask. By way of example, the test marks may be imaged with a CCD. The captured image is typically smaller than the field of view, but larger than the test marks. Standard image processing generally finds the position of each of the test marks within the captured image and a position locator system generally measures the position of the imaging detectors during imaging of the test marks. In one implementation, the relative position of each of the test marks contained within an individual test pattern is sequentially measured by an individual imaging detector.
In another embodiment, focus measurements are performed. This is generally accomplished by a confocal detector arrangement. In one implementation, the confocal detector arrangement includes a light source, an analyzing reticle and a detector. The light source illuminates the analyzing reticle. Thereafter, the light is focused onto the test mask, and more particularly a focus region of the test mask (e.g., a reflecting area-no pattern) with measurable information in the Z direction, and the light reflecting off of the test marks is passed back through the analyzing reticle and onto the confocal detector. By way of example, the focus region may be formed from a reflecting material such as chrome. The analyzing reticle is configured to effect the light incident on the detector in accordance with the focus quality. Similarly to above, a position locator system generally measures the position of the confocal detectors during measurements therewith. In one implementation, the test marks are measured in a sequential manner (e.g., from one mark to another).
After measuring the test mask, the process flow proceeds to block <b>156</b> where the projected image of the test pattern is measured. In most cases, each of the optical subsystems of the projection unit is configured to project an individual test pattern of the test mask. The projected image is generally positioned at the aerial image plane of the projection optics under test. The projected image measurements are typically similar to the test pattern measurements. That is, the same position and focus measurements are performed. In addition, the same detector arrangement is used.
After measuring the test image, the process flow proceeds to block <b>158</b> where the test pattern is compared with the test image. By comparing the test pattern to the test image, imperfections associated with the test mask and inspection system may be calibrated out of the test image so that the actual optical characteristics associated with the optical subsystem under test may be determined. Once the optical characteristics are determined, any needed adjustments based on the actual optical characteristics may be performed on the optical subsystem under test.
<figref idref="DRAWINGS">FIG. 5</figref> is a perspective diagram of an inspection tool <b>200</b>, in accordance with one embodiment of the present invention. The inspection tool <b>200</b> is generally configured to test multiple optical subsystems at the same time so that a projection unit <b>205</b> can be rapidly adjusted and certified in the factory. By way of example, the projection unit <b>205</b> may correspond to the projection unit <b>20</b> shown in FIG. <b>1</b>. In the illustrated embodiment, the projection unit <b>205</b> includes 7 optical subsystems <b>203</b>, each of which is supported within a frame of the projection unit <b>205</b>.
The inspection tool <b>200</b> generally includes a structural chassis <b>202</b>, a support arrangement <b>204</b>, and a lens calibration system <b>206</b>. Broadly, the structural chassis <b>202</b> provides support to the support arrangement <b>204</b> and the lens calibration system <b>206</b>. The support arrangement <b>204</b> provides support to a projection unit <b>205</b>. The lens calibration system <b>206</b> performs optical tests on the projection unit <b>205</b>.
More particularly, the structural chassis <b>202</b> includes a base <b>208</b> for supporting the support arrangement <b>204</b> and lens calibration system <b>206</b> thereon, and a plurality of isolation units <b>210</b> for supporting the base <b>208</b> relative to the ground. In the illustrated embodiment, the base <b>208</b> is isolated from the ground by means of three vibration isolation units <b>210</b>A-C. As should be appreciated, three isolation units are used to avoid the possible structural deformation caused by the typical arrangement of four isolators (in which case two of the isolators are slaved together). The projection unit <b>205</b> is typically very heavy and therefore it is important that the weight of it not distort the base <b>208</b>. This is typically accomplished by using a massive base that tends not to distort under the load of the projection unit <b>205</b>. By way of example, the base <b>208</b> may be formed from a suitable structural material such as cast iron.
Furthermore, the support arrangement <b>204</b> is generally arranged to locate the projection unit <b>205</b> relative to the lens calibration system <b>206</b> and an adjustment window <b>207</b>. The adjustment window <b>207</b> provides space in which the projection unit <b>205</b> can be worked on without removing the projection unit <b>205</b> from the inspection tool <b>200</b>. The projection unit support arrangement <b>204</b> generally includes a pair of pedestal units <b>212</b> and a carriage <b>214</b> that suspends the projection unit <b>205</b> in a vertical direction (e.g., Y-axis). The pedestal units <b>212</b> are structurally attached to the base <b>208</b> and the carriage <b>214</b> is movably attached to the pedestal units <b>212</b>. By way of example, the pedestal units <b>212</b> may be attached to the base <b>208</b> via bolts, and the carriage <b>214</b> may ride on the top of the pedestal units <b>212</b> via air bearings. Similar to the base <b>208</b>, the pedestal units <b>212</b> and carriage <b>214</b> may be formed from a suitable structural material such as cast iron.
The carriage <b>214</b> is generally configured for receiving and holding the projection unit <b>205</b>. In the illustrated embodiment, the carriage <b>214</b> is U-shaped, such that the carriage <b>214</b> includes a base section <b>216</b> and two arms <b>218</b> A and B extending therefrom. An open end <b>220</b> of the carriage is generally configured for allowing the projection unit <b>205</b> to be placed between the extended arms <b>218</b>A&B. Furthermore, a top surface <b>222</b> of the carriage <b>214</b> provides a surface for allowing the projection unit <b>205</b> to be placed thereon. For example, the projection unit <b>205</b> may include support cones <b>224</b> that are configured to rest on the top surface <b>222</b>.
In most cases, the carriage <b>214</b> is configured to precisely position the projection unit <b>205</b> thereon in the X, Y and Z directions. In one implementation, the carriage <b>214</b> and projection unit <b>205</b> may include datum or reference surfaces for placing the projection unit <b>205</b> in a predetermined position relative to the carriage <b>214</b>. For example, the carriage <b>214</b> may include a X-Z planar surface configured for abutting or contacting a X-Z planar surface of the projection unit <b>205</b> thereby precisely holding the projection unit <b>205</b> in the Y direction. Additionally or alternatively, the carriage <b>214</b> may include reference pads that are configured to contact specific location(s) on the projection unit <b>205</b> to place the projection unit <b>205</b> in a predetermined position relative to the carriage <b>214</b>. For example, the reference pads may include cones <b>226</b>, which extend from the top surface <b>222</b> of the carriage <b>214</b>, and which are configured for placement in openings located on the cones <b>224</b> of the projection unit <b>205</b> thereby precisely holding the projection unit <b>205</b> in the X, Y and Z directions. Additionally, the reference pads may be configured to move up and down so as to allow for some adjustment.
Referring to <figref idref="DRAWINGS">FIGS. 6A and B</figref>, the carriage <b>214</b> is configured to slide along the pedestal units <b>212</b> in a linear direction between a test position, placing the projection unit <b>205</b> in a position to be tested (as shown in FIG. <b>6</b>B), and an adjustment position, placing the projection unit <b>205</b> in a position to be adjusted (as shown in FIG. <b>6</b>A). In the illustrated embodiments, the test position places the projection unit <b>205</b> relative to the lens calibrating system <b>206</b>, and the adjustment position places the projection unit <b>205</b> relative to the adjustment window <b>207</b>. The adjustment window <b>207</b> is generally defined by an opening in the pedestal units <b>212</b>. Thus, the window <b>207</b> allows an operator access to various internal components enclosed inside the projection unit <b>205</b>. By way of example, the window <b>207</b> may allow an operator to make adjustments to the plurality of optical subsystems that contain lenses, prisms, mirrors and/or the like. As should be appreciated, the two-position tool allows fast and accurate adjustment of the projection unit <b>205</b>, i.e., the projection unit can be tested and adjusted in the same place thus increasing the speed and accuracy. Although not shown, the carriage <b>214</b> may be driven by an actuator so as to locate the projection unit <b>205</b> in the correct position for testing and adjusting.
Referring to <figref idref="DRAWINGS">FIGS. 7 and 8</figref>, the lens calibrating system <b>206</b> will be described in greater detail. The lens calibrating system <b>206</b> is generally configured for inspecting the projection unit <b>205</b>. By way of example, the lens calibrating system <b>206</b> may correspond to the inspection system <b>100</b> shown in FIG. <b>3</b>. <figref idref="DRAWINGS">FIG. 7</figref> shows the lens calibrating system <b>206</b> in a measurement mode and <figref idref="DRAWINGS">FIG. 8</figref> shows the lens calibrating system <b>206</b> in a calibration mode. The measurement mode generally corresponds to a configuration that allows the projected image of the projection unit to be measured (for ease of discussion the projection unit is not shown). The calibration mode, on the other hand, generally corresponds to a configuration that allows the pattern on a mask to be measured. The measured data can thus be compared to determine the optical characteristics of the projection unit. That is, the data associated with the test mask can be calibrated out of the data associated with the projection unit to produce a resultant set of data that corresponds to the actual optical characteristics of the projection unit. By determining the optical characteristics of the projection unit <b>205</b>, the projection unit can be adjusted (if needed) to remove any possible problems therewith so as to ensure precise manufacturing of a product when the projection unit is used in a lithography system.
The lens calibration system <b>206</b> generally includes a mask assembly <b>252</b>, an illumination assembly <b>254</b>, a detector assembly <b>256</b> and a position locator assembly <b>258</b> that cooperate to help determine the optical characteristics of the projection unit <b>205</b>. The mask assembly <b>252</b> is configured to carry a test mask <b>260</b> for measurements thereof. The mask assembly <b>252</b> includes a mask holder <b>262</b> attached to a mask stage <b>264</b>. The mask holder <b>262</b> is configured to hold the test mask <b>260</b> thereto. The mask holder <b>262</b> may be widely varied. For example, the mask holder <b>262</b> may include a vacuum chuck, a mechanical chuck, an electrostatic chuck and the like, for securing the test mask thereto. The mask stage <b>264</b> is configured to move the mask holder <b>262</b> and thus the test mask <b>260</b> between a measurement position and a calibration position. The measurement position generally corresponds to the measurement mode and thus test mask <b>260</b> is moved back to provide space for placement of the projection unit <b>205</b> between the mask and the detector assembly <b>252</b>, <b>256</b> so that the projection unit <b>205</b> may be inspected (as shown in FIG. <b>7</b>). The calibration position, on the other hand, generally corresponds to the calibration mode and thus the test mask <b>260</b> is moved forwards towards the detector assembly <b>256</b> so as to place the mask in a position to be inspected (as shown in FIG. <b>8</b>).
The mask stage <b>264</b> is generally configured to move relative to the body <b>208</b> in a linear direction. By way of example, the stage <b>264</b> may be capable of moving in the X, Y or Z directions. In the illustrated embodiment, the mask stage <b>264</b> moves back and forth in the Z-direction. In addition, the stage <b>264</b> may be movably coupled to the body <b>208</b> via an anti-friction device (not shown), which allows substantially free movement thereof. By way of example, the anti-friction device may include air bearings, fluid bearings, roller bearings or the like. In one embodiment, the mask stage <b>264</b> is supported on a guide arrangement by three kinematically placed air bearings. By way of example, the guide arrangement may be a V and flat guide arrangement. Furthermore, the mask stage <b>264</b> may be moved via a stage drive unit (not shown) such as a linear servo-motor, a ball screw motor, voice coil motor (VCM), an E-I core actuator, a pneumatic motor, hydraulic motor or the like. In one embodiment, the mask stage <b>264</b> is moved via a rod-less air cylinder having a stroke that is precisely stopped by micrometers. Moreover, the stage drive unit may be coupled to a position controller (not shown), which provides force command signals for driving the stage drive unit. By way of example, the position controller may be included in the control system of the inspection system.
The illumination assembly <b>254</b> is configured to illuminate the test mask <b>260</b> during measurements thereof. The illumination assembly <b>254</b> generally includes an illumination unit <b>268</b> attached to an illumination stage <b>270</b>. The illumination unit <b>268</b> is arranged to both generate and direct a plurality of light beams (fields) through the test mask <b>260</b>. The number of light beams generally corresponds to the number of optical subsystems of the projection unit <b>205</b>. Any suitable illumination unit <b>268</b> may be used. In one embodiment, the illumination unit <b>268</b> is similarly configured to the illumination unit of the lithography system in which the projection unit is used. For example, the illumination unit <b>268</b> may be similar to the illumination unit <b>16</b> used in the lithography system <b>10</b> of <figref idref="DRAWINGS">FIG. 1</figref>, i.e., the illumination unit <b>268</b> closely matches the functionality of the illumination unit <b>16</b>.
The illumination stage <b>270</b> is configured to follow the mask assembly <b>252</b> so as to illuminate the test mask <b>260</b> with the illumination unit <b>268</b> when the mask assembly <b>252</b> is moved between the calibration and measurement positions. Although the illumination stage <b>270</b> moves independent of the mask stage <b>264</b>, the illumination stage <b>270</b> may be similarly configured to the mask stage <b>264</b>. For example, the illumination stage <b>270</b> may be configured to move relative to the body <b>208</b> in a linear direction. The linear direction generally corresponds to the direction of the mask stage <b>264</b>, and thus in the illustrated embodiment the illumination stage <b>270</b> moves back and forth in the Z-direction. In addition, the illumination stage <b>270</b> may be movably coupled to the body <b>208</b> via an anti-friction device, which allows substantially free movement thereof. By way of example, the anti-friction device <b>116</b> may include air bearings, fluid bearings, roller bearings or the like. The illumination stage <b>270</b> may also be moved via a stage drive unit. Alternatively, the illumination unit <b>268</b> may be configured to move with the mask stage <b>264</b> rather than with its own individual stage <b>270</b>.
The detector assembly <b>256</b> is configured to perform optical measurements relating to the test mask <b>260</b> and the projection unit <b>205</b>. That is, the detector assembly <b>256</b> is configured to measure the test pattern on the test mask <b>260</b> and the image of that test pattern projected by the projection unit <b>205</b>. By measuring the patterns and images, the actual optical characteristics of the projection unit can be determined. As shown, the detector assembly <b>256</b> is positioned opposite, but in line with the mask assembly <b>252</b>. The detector assembly <b>256</b> includes a detector box <b>274</b> attached to a detector stage <b>276</b>. The detector box <b>274</b> includes a plurality of detector units <b>278</b>, which are rigidly connected together in the detector box <b>274</b>. The detector units <b>278</b> are configured to scan together and to make simultaneous measurements in all seven fields of the projection unit during movement thereof by the detector stage <b>276</b>.
Each of the detector units <b>278</b> includes an objective lens <b>280</b> and a confocal and imaging subsystem (not shown in these figures) for measuring the pattern and image. The objective lens <b>280</b> is operatively coupled to both the confocal subsystem and the imaging subsystem. The objective lens magnifies a small part of the aerial image onto detectors. The objective lens <b>280</b> are positioned on the outer shell of the detector box <b>274</b> and the confocal and the imaging subsystems are positioned inside the detector box <b>274</b>. The objective lens <b>280</b> are configured to focus the measuring optics associated therewith on the image plane (e.g., the plane in which the test patterns and test images reside). The confocal subsystem is configured to measure optical characteristics associated with focus (e.g., focal plane and astigmatism) and the imaging subsystem is configured to measure optical characteristics associated with distortion and aberrations (e.g., spherical and coma). The imaging system measures X and Y displacement and the confocal measures Z displacement. The detector units will be described in greater detail below.
The detector stage <b>276</b> is configured to move the detector box <b>274</b> relative to the rigid body <b>208</b> so as to move the detector units <b>278</b> in positions for measuring the test mask <b>260</b> and the projected image of the test mask <b>260</b>. Each detector can measure a limited part of each optical field. The stage <b>276</b> allows the detector array to reach all parts of each field. In the illustrated embodiment, the detector stage <b>276</b> moves in the X, Y and Z-directions so as to allow the detector units <b>278</b> to measure the test mask and projected image in the X, Y and Z directions. That is, during measurement, the detector units <b>278</b> are moved in the X, Y and Z-directions to measure specific targets associated with the test mask <b>260</b> and the projected image therof. By way of example, the specific targets may include alignment targets and focus targets, which are positioned at various locations within test pattern of the test mask. The alignment targets are generally used to determine shifts in the X and Y directions, and the focus targets are used to determine misfocus. By way of example, the alignment targets may be formed as crosses and the focus targets may be formed from reflective surfaces. Each detector needs to be repositioned over all parts of each field. Thus, the stage X and Y motion is generally limited to the size of each field (trapezoid).
In most cases, the test mask <b>260</b> includes a test pattern for each of the optical subsystems of the projection unit <b>205</b>. During the calibration and measurement steps, the detector stage <b>276</b> moves the individual detector units <b>278</b> in a sequenced manner between the specific targets so as to measure the location. For example, there may be a number of sites within each field of the projection unit where the detectors are moved to perform optical measurements (the entire field is not measured in one shot). In most cases, the detectors <b>278</b> are moved in a relative sort of way. For example, during position measurements, the detectors <b>278</b> may be moved approximately to each of the test marks contained in the test pattern, i.e., moved to an X and Y location in close proximity of the particular alignment target that is desired to be measured. Standard image processing may be performed by the control system of the inspection system to find the exact position of each of the test marks if the location of the detector is not centered on the test mark (e.g., there is offset).
Any multi-positional X, Y and Z drive unit may be used in the detector stage <b>276</b>. In one embodiment, the motion of the detector stage is provided by rails with recirculating balls, driven by DC motors through lead screws. By way of example, a drive unit such as this may be provided by the Daedal a division of Parker Hannifin Corporation of Irwin, Pa. The stage drive unit may be coupled to a position controller (not shown), which provides force command signals for driving the stage drive unit. By way of example, the position control may be provided through linear encoders. The range of drive unit may vary according to the specific needs of each lens calibration system.
The position location assembly <b>258</b> is configured for monitoring the positions of the mask and detector assemblies <b>252</b> and <b>256</b> during measurement of the mask <b>260</b> and projection unit <b>205</b>. The position location assembly <b>258</b> includes a plurality of position sensing units <b>284</b>. Some of the position sensing units <b>284</b> are configured to monitor the positions of the detector assembly <b>256</b> as it scans the test mask <b>260</b> and images thereof while others are configured to monitor the position of the mask assembly <b>252</b> when its in the calibration and measurement positions. The position sensing units <b>284</b> may be widely varied. For example, the position sensing units <b>284</b> may be made up of any combination of interferometers, capacitance sensors, encoder sensors, potentiometer sensors, inductive sensors, linear scales and the like.
The position sensing units <b>284</b> are generally arranged to measure the positions of the assemblies relative to a reference point. The reference point may be widely varied. For example, the reference point may be defined by the assemblies themselves, some portion of the frame that supports the system or some component that is external to the system <b>200</b>. In one embodiment, the position location assembly <b>258</b> includes a reference frame <b>286</b> configured to provide a precise reference point relative to the mask assembly <b>252</b> and the detector assembly <b>256</b>. The reference frame <b>286</b> is a separate component of the carriage and support structure and thus the projection optics <b>205</b> will not distort the reference frame <b>286</b>. As shown, the reference frame <b>286</b> is positioned to the side of the mask and detector assemblies <b>252</b>, <b>256</b>. The reference frame <b>286</b> includes an opening defined by upwardly extending arms. The opening provides a space for allowing the projection unit <b>205</b> to be positioned between the mask and detector assemblies <b>252</b>, <b>256</b>. The reference frame <b>286</b> also includes an arm extending underneath the detector assembly <b>256</b>. Each of the arms provides a reference surface for at least a portion of the position sensing units <b>284</b>. Although not shown in <figref idref="DRAWINGS">FIGS. 7 and 8</figref>, the reference frame <b>286</b> may be fixed to the rigid body <b>208</b>. The reference frame <b>286</b> is designed to remain stable during detector assembly scanning.
The position sensing units <b>284</b> are generally arranged to measure the positions of the mask assembly <b>252</b> and detector assembly <b>256</b> relative to the reference frame <b>286</b>, as well as the positions of the mask assembly <b>252</b> and detector assembly <b>256</b> relative to each other. In the illustrated embodiment, the position sensor units <b>284</b> consist of a first sensor arrangement (designated with an A) and a second sensor arrangement (designated with a B).
The first sensor arrangement <b>284</b>A is configured to measure the position of the detector assembly <b>256</b> relative to the reference frame <b>286</b> and relative to the mask assembly <b>252</b> during measurements of the test pattern and image. That is, the first sensor arrangement <b>284</b>A is configured to track the position of the detector assembly <b>256</b>, and more particularly the positions of each of the detector units <b>278</b> during measurement therewith. In one embodiment, the first sensor arrangement <b>284</b>A includes a plurality of interferometers that provide 6 axis interferometry. In particular, the interferometer sensors are set-up to measure the linear positions of the detector assembly <b>256</b> in the in x y z -directions as well as to measure the rotational positions of the detector assembly about the x-axis y-axis and z-axis, i.e., an angle θx, an angle θy and an angle θz, respectively. As should be appreciated, the position of each detector unit <b>278</b> can be accurately determined thus assuring testing accuracy in six dimensions. In one implementation, this type of 6 axis interferometry not only allows the position of the detector assembly <b>256</b> to be measured while scanning each field, but which also continuously measures the detector assembly <b>256</b> during calibration modes.
The interferometer system may be widely varied. In the illustrated embodiment, the interferometer system includes three z direction sensors Z<b>1</b>, Z<b>2</b>, Z<b>3</b> for determining the position of the detector assembly <b>256</b> in the z direction as well as the rotational positions about the x and y axis (to determine the parallelism of the mask and detectors). These may be referred to as Z, roll and pitch interferometers. The Z<b>1</b>-Z<b>3</b> are configured to continuously measure the mask and detector assembly distance. This measurement is continuous as the mask is moved between calibration and measurement positions. The Z<b>1</b> and Z<b>2</b> sensors measure a lower portion of the assemblies and the Z<b>3</b> sensors measure an upper portion of the assemblies. The Lower Z<b>1</b> and Z<b>2</b> interferometers measure directly from detector box to mask stage. The Z<b>3</b> interferometer, on the other hand, measures indirectly from detector box to mask stage. In one embodiment, the Z<b>3</b> interferometer is folded around the space that is occupied by the projection optics through the reference frame <b>286</b>. As should be appreciated, the Z<b>1</b> and Z<b>3</b> measurements provide the rotation about the x axis and the Z<b>1</b> and Z<b>2</b> measurements provides the rotation about the y axis.
The illustrated interferometer system also includes one y direction sensor Y for determining the position of the detector assembly <b>256</b> in the y direction, and two x direction sensors X<b>1</b> and X<b>2</b> for determining the position of the detector assembly <b>256</b> in the x direction as well as the rotational position about the z axis relative to the reference frame. These may be referred to as Y interferometer and X and yaw interferometers. The Y sensor is configured to measure the third arm of the reference frame <b>286</b> and detector box distance while the X<b>1</b> and X<b>2</b> are configured to measure the second arm of the reference frame <b>286</b> and detector box distance. As shown, the X<b>1</b> sensors measures a lower portion while the X<b>2</b> sensor measures an upper portion. As should be appreciated, the X<b>1</b> and X<b>2</b> measurements provide the rotation about the z axis.
The second sensor arrangement <b>284</b>B, on the other hand, is configured to measure the position of the mask assembly <b>252</b> relative to the reference frame <b>286</b> when the mask assembly <b>252</b> is in its two positions. That is, the second sensor arrangement <b>284</b>B is configured to measure the position of the mask assembly <b>252</b> relative to the reference frame <b>286</b> when the mask assembly <b>252</b> is placed in the measurement position (<figref idref="DRAWINGS">FIG. 7</figref>) and the calibration position (FIG. <b>8</b>). During the internal scan of a field, it is important that the mask <b>260</b> not move in the X and Y directions. This movement is minimized by the rigid construction of the base and the mask stage. It is confirmed by the second sensor arrangement <b>284</b>B that measures the static distance between the mask holder <b>262</b> and the reference frame <b>286</b>.
In one embodiment, the second sensor arrangement <b>284</b>B includes a first group of sensors for measuring in measurement position and a second set of sensors for measuring in the calibration position. Each of these groups may be widely varied. In one implementation, each of these groups includes a plurality of capacitance sensors set-up to determine the linear positions of the detector assembly in the in x y directions as well as to determine the rotational position of the detector assembly about the z-axis, i.e., an angle θz. By way of example, the first and second groups may include two x direction sensors for determining the position of the mask assembly in the x direction as well as the rotational positions about the z axis, and one y direction sensor for determining the position of the detector assembly in the y direction. Alternatively, the first and second groups of sensors may include two y direction sensors for determining the position of the mask assembly in the y direction as well as the rotational positions about the z axis i.e., an angle θz, and one x direction sensor for determining the position of the detector assembly in the xdirection. It should be understood, however, that this is not a limitation and that the number of sensors in each direction may vary according to the needs of each inspection tool.
Although not shown in detail in this Figure, capacitance gauges generally consist of two sensor elements that have a small gap. These sensor elements are mounted to the mask holder <b>262</b> and the reference frame <b>286</b> to measure motion between the mask holder <b>262</b> and the reference frame <b>286</b>. The capacitance gauge measures the distance between two sensor elements.
Referring to <figref idref="DRAWINGS">FIGS. 9A and 9B</figref> the detector box <b>274</b> will be described in greater detail. <figref idref="DRAWINGS">FIG. 9A</figref> is a perspective diagram showing the detector box <b>274</b> from a first side, and <figref idref="DRAWINGS">FIG. 9B</figref> is a perspective diagram showing the detector box <b>274</b> from a second side (which is opposite the first side). The detector box <b>274</b> includes a housing <b>300</b> for supporting the detector units <b>278</b>. The detector housing <b>300</b> may be formed any suitable material. By way of example, the detector housing <b>300</b> may be formed from invar for position stability. Invar is a steel nickel alloy with a low thermal coefficient. The detector housing <b>300</b> is configured to carry the plurality of detector units <b>278</b> for measurement of the mask <b>260</b> and projection unit <b>205</b>. Each of the detector units <b>278</b> includes a microscope objective <b>280</b>, which is attached to a front side of the housing <b>300</b>. The microscope objectives <b>280</b> are configured for focusing the detector units <b>278</b> on the image plane to which the test mask <b>260</b> is positioned or to which the images thereof are projected. In one embodiment, the objectives <b>280</b> have a working distance of 3.7 mm. Even this small distance provides a clearance between the image plane of the projection lens and the detector array.
Each of the detector units <b>278</b> also includes an imaging system and a confocal system, which are contained inside the housing <b>300</b>. For illustration purposes, walls of the housing <b>300</b> have been removed to show the imaging system and a confocal system contained therein. As shown, the imaging system includes plurality of CCD cameras <b>308</b> and confocal system includes a plurality of confocal detectors <b>310</b>. Although not shown, each of the microscope objectives <b>280</b> is optically coupled to an individual CCD camera <b>308</b> and confocal detector <b>310</b>.
The number of detector units <b>278</b> may be widely varied. In one embodiment, the number of detector units <b>278</b> corresponds to the number of optical subsystems of the projection unit <b>205</b>. That is, for each optical subsystem there is a corresponding microscope objective <b>304</b>, CCD camera <b>308</b> and confocal detector <b>310</b>. In the illustrated embodiment, the detector assembly <b>256</b> includes seven detector units <b>278</b>, of which three are positioned on the right side and four on the left side in the front of the housing <b>300</b>. They are generally positioned in a similar configuration as the light fields produced by the illumination system and thus the optical subsystems of the projection optics, i.e., they are offset and staggered relative to one another.
The detector assembly <b>256</b> also includes a plurality of interferometers for helping to determine the position of the detector assembly <b>256</b>, and thus each of the detector units <b>278</b>, during measurements of the mask <b>260</b> and projection units <b>205</b>. In this embodiment, the plurality of interferometers includes a pair of X interferometers (designated X<b>1</b> and X<b>2</b>), a pair of Z interferometers (designated Z<b>1</b> and Z<b>2</b>) and a Y interferometer. As shown, the Z interferometers, the Y interferometer and the X<b>1</b> interferometers are positioned on the bottom of the detector box <b>274</b>. The X<b>2</b> interferometer is positioned on an upper portion of the second side of the detector box <b>274</b>. The X interferometers are spaced apart along a similar axis and positioned on the side of the detector assembly <b>256</b> adjacent the reference frame <b>286</b>. The Z interferometers are spaced apart along a similar axis and positioned on the front of the detector assembly <b>256</b> towards the mask assembly <b>252</b>. Each of these interferometers has a corresponding mirror. For example, the X and Y interferometers have corresponding mirrors that are attached to the reference frame <b>286</b>, and the Z interferometers have corresponding mirrors attached to the mask stage <b>264</b>. The detector assembly <b>256</b> also includes a mirror <b>312</b> for receiving a signal from another Z interferometer (designated Z<b>3</b>). The mirror <b>312</b> is position on an arm <b>314</b> that extends away from an upper portion of the second side of the detector box <b>274</b>.
In one embodiment, the CCD cameras have remote electronics so as minimize heat within the detector box.
Referring to <figref idref="DRAWINGS">FIG. 10</figref> the mask holder <b>262</b> of the mask assembly <b>252</b> will be described in greater detail. The mask holder <b>262</b> is generally mounted on top of the mask stage <b>264</b>, which is not shown in this Figure. The mask holder <b>262</b> generally includes a frame <b>318</b> that may be formed from any suitable material. By way of example, the frame <b>318</b> may be formed from invar. The mask holder <b>262</b> is shown holding the test mask <b>260</b> thereon. This is generally accomplished with vacuum, i.e., the mask holder <b>262</b> includes a chucking surface that includes one or more holes that apply a suction force to the back of the test mask <b>260</b>.
The mask holder <b>262</b> may include one or more locating pins <b>320</b>. The locating pins provide reference points for positioning the mask <b>260</b> on the mask holder <b>262</b>. The arrangement of locating pins <b>320</b> generally corresponds to the number of available patterns on the mask <b>260</b>. For example, the mask <b>260</b> may include one or more adjacent test patterns, each of which can be used to provide a different set of data points. In the illustrated embodiment, the mask <b>260</b> includes 3 adjacent patterns.
The locating pins <b>320</b> may be widely varied. In the illustrated embodiment, the mask holder <b>262</b> includes a pair of spaced apart locating pins <b>320</b> on a first side and second side of the mask holder <b>262</b>, and a single locating pin <b>320</b> at a bottom of the mask holder <b>262</b>. The locating pins <b>320</b> on the first side provide a first mask position, and the locating pins on the second side provide a second mask position. A third mask position may be provided between the first and second pair of locating pins <b>320</b>. The mask <b>260</b> may placed at these various positions by sliding it between positions. By way of example, the first mask position may correspond to a first adjacent pattern, the second mask position may correspond to a second adjacent pattern, and the third mask position may correspond to a third adjacent pattern.
The mask holder <b>262</b> may also include one or more safety catches <b>322</b>, which prevent the mask from falling off of the mask holder <b>262</b> during loss of vacuum. The safety catches <b>322</b> may be widely varied. In the illustrated embodiment, the mask holder <b>262</b> includes a pair of spaced apart catches <b>322</b> at the bottom of the mask holder <b>262</b> and a single catch at the top of the mask holder <b>262</b>.
The mask holder <b>262</b> may also include one or more linear variable differential transformers <b>324</b> (LVDTs) configured to measure the distance from the mask holder <b>262</b> to the projection unit <b>205</b> when the projection unit is placed in the inspection tool <b>200</b>. The LVDTs <b>324</b> may be widely varied. In the illustrated embodiment, the mask holder <b>262</b> includes three LVDTs <b>324</b>. Two of the LVDTs <b>324</b> are positioned on the first side of the mask holder <b>262</b> in a spaced apart relationship, and a single LVDT <b>324</b> is positioned on a second side of the mask holder <b>262</b>. The LVDT's <b>324</b> generally extend to reference pads located on the projection optics <b>205</b> to make sure the optics are properly located. The projection unit <b>205</b> banks against a micrometer the LVDT <b>324</b> simply verifies that its in the right place. As should be appreciated, the system needs to ensure the projection optics are in the right place relative to the detector box, mask holder, etc., in order to provide accurate test results.
The mask holder <b>262</b> may also include one or more capacitance sensors <b>326</b> or mirrors <b>328</b> attached thereto. Each of these sensors has a corresponding capacitance sensor mounted on the reference frame (see FIG. <b>10</b>B). A first group of capacitance sensors is used to ensure that the mask assembly <b>252</b> is in the measurement position (pulled back), and a second group of capacitance sensors is used to ensure that the mask assembly <b>252</b> is in the calibration position (pushed forward). Furthermore, each of the mirrors has a corresponding Z interferometer. In the illustrated embodiment, the mask holder includes a mirror attached to an upper extension arm of the mask holder. The mirror is configured to receive a beam coming from the backside of the mask holder.
Referring to <figref idref="DRAWINGS">FIGS. 11A and 11B</figref>, the reference frame <b>286</b> will be described in greater detail. The reference frame <b>286</b> is the main measurement reference structure in the inspection system <b>200</b>. The reference frame <b>286</b> may be formed from any suitable material that provides static, dynamic and temperature stability. By way of example, the reference frame <b>286</b> may be formed from invar. The reference frame is U-shaped, so as to include a base section <b>340</b> and two arms <b>342</b>A and B extending therefrom. As shown, the arms <b>342</b> extend upward in the Y direction. The two arms <b>342</b>A and B are spaced apart so as to define an open end <b>220</b> for allowing the projection unit <b>205</b> to be placed therebetween. The reference frame <b>286</b> also includes a third arm <b>344</b> extending in the X direction. The third arm <b>344</b> is positioned below the detector assembly (not shown). The reference frame <b>286</b> also includes a mounting foot <b>346</b> for attachment to the base <b>208</b>. In one implementation, the mounting foot <b>346</b> is arranged isolate the reference frame <b>286</b> from distortions of the base <b>208</b>.
The reference frame <b>286</b> provides the reference position for the interferometric position measurements of the detector assembly <b>256</b> and the capacitance measurements of the mask assembly <b>252</b>. The X position and the Yaw θ<sub>y </sub>position of the detector box <b>274</b> are referenced to the reference frame <b>286</b> with two mirrors <b>348</b> located on the second arm <b>342</b>B of the reference frame <b>286</b>. The two mirrors <b>348</b> are spaced apart in the Y direction so as to engage laser inputs <b>349</b> from the X interferometers (X<b>1</b> and X<b>2</b>) located on the detector box <b>274</b>. The Y position of the detector box <b>274</b> is referenced to the reference frame <b>286</b> via a mirror <b>350</b> located on the third arm <b>344</b> of the reference frame <b>286</b>. The mirror <b>350</b> is positioned under the detector assembly <b>256</b> so as to engage a laser input <b>351</b> from the Y interferometer (Y) located on the detector box <b>274</b>.
In one embodiment, one of the three interferometers (Z<b>3</b>) used for measuring in the Z direction includes a path through the reference frame <b>286</b> to go around the projection unit under test <b>205</b> thereby allowing an upper Z measurement, i.e., the projection unit would otherwise block a direct path. The upper Z measurement is generally needed to measure rotation about the X axis (θ<sub>x</sub>). As shown, a beam <b>354</b> is directed through the first and second arms <b>342</b> as well as the base section <b>340</b> of the reference frame <b>286</b>. This is generally accomplished using the Z<b>3</b> interferometer and a plurality of bending mirrors <b>356</b> rigidly attached to and located within the reference frame <b>286</b>. In particular, the Z<b>3</b> interferometer is disposed inside the base section <b>340</b> and the bending mirrors <b>356</b> are disposed inside the first and second arms <b>342</b>. In the illustrated embodiment, four bending mirrors <b>356</b> pass the beams <b>354</b> around the projection optics <b>205</b>. With regards to the interferomic position of the mask holder <b>262</b>, a first beam <b>354</b>A is directed out of the top of the first arm <b>342</b>A so as to engage the mirror <b>328</b> on the mask holder <b>262</b>. With regards to the interferomic position of the detector box <b>274</b>, a second beam <b>354</b>B is directed out of the top of the second arm <b>342</b>B so as to engage the mirror <b>312</b> on the detector box <b>274</b>. The other Z positions of are referenced to each other with the use of mirrors located on the mask holder <b>262</b> and the Z<b>1</b> and Z<b>2</b> on the detector box <b>274</b>.
The reference frame <b>286</b> also includes a plurality of capacitance sensors <b>360</b> attached thereto. Each of these sensors <b>360</b> has a corresponding capacitance sensor mounted on the mask assembly (see FIG. <b>9</b>). A first group of capacitance sensors <b>360</b> (designated with an m) is used to ensure that the mask assembly <b>252</b> is in the measurement position (pulled back), and a second group of capacitance sensors <b>360</b> (designated with a c) is used to ensure that the mask assembly <b>252</b> is in the calibration position (pushed forward).
Each of these groups of capacitance sensors are used to measure the X position, Y position and rotation about Z (θ<sub>z</sub>) of the mask assembly <b>252</b> relative to the reference frame <b>286</b>. In the illustrated embodiment, the first group of sensors <b>360</b>-m includes a pair of spaced apart X sensors and a single Y sensor. The X sensors measure the X position of the mask assembly <b>252</b> relative to the reference frame <b>286</b>, as well as the rotation position (tilt) about the Z axis (θ<sub>z</sub>). The Y sensor measures the Y position of the mask assembly <b>252</b> relative to the reference frame <b>286</b>. As shown, the X sensors are position in line in the Y direction with the first X sensor being positioned on the first arm <b>342</b>A of the reference assembly <b>286</b>, and the second X sensor being positioned on the base section <b>340</b> of the reference assembly <b>286</b>. The Y sensor is positioned on the base section <b>340</b>. In addition, the second group of sensors <b>360</b>-c includes a pair of spaced apart Y sensors and a single X sensor. The Y sensors measure the Y position of the mask assembly <b>252</b> relative to the reference frame <b>286</b>, as well as the rotation position (tilt) about the Z axis (θ<sub>z</sub>). The X sensor measures the X position of the mask assembly <b>252</b> relative to the reference frame <b>286</b>. As shown, the Y sensors are positioned on the third arm <b>344</b> of the reference assembly <b>286</b> in line in the X direction, and the second X sensor is positioned on the base section <b>340</b> of the reference assembly <b>286</b>. It should be noted that this arrangement of sensors is not a limitation and may vary according to the specific needs of each system.
Referring to <figref idref="DRAWINGS">FIG. 12</figref>, the operation of the Z axis interferometers will be described in greater detail. As shown, the projection unit under test <b>205</b> does not block the beams of the Z<b>1</b> and Z<b>2</b> interferometers and mirrors <b>370</b> that are mounted on the bottom of the detector box <b>274</b> and mask holder <b>262</b>, respectively. The Z<b>1</b> and Z<b>2</b> interferometers allow measurement in the Z direction as well as measurement of rotation about the Y axis (θ<sub>y</sub>). As shown, the beams of Z<b>1</b> and Z<b>2</b> follow a direct path between the interferometers and corresponding mirrors.
The projection unit under test <b>205</b> also does not block the beams of the Z<b>3</b> because of their path through the reference frame. The Z<b>3</b> interferometer allows measurement in the Z direction as well as measurement of rotation about the X axis (θ<sub>x</sub>). As shown, the beams of Z<b>3</b> follow an indirect path through the reference frame. In particular, the reference and measurement beams of the Z<b>3</b> interferometer are sent up separate arms of the reference frame. The reference beam <b>354</b>A is sent up though the first arm and the measurement beam <b>354</b>B is sent up through the second arm. The distance the beams travel from the interferometer and through the arms is generally designated L<b>1</b> and L<b>2</b>. In order to ensure measurement accuracy, the paths L<b>1</b> and L<b>2</b> should be kept proportional in length, as for example, through temperature change and any outside forces. In one implementation, the arms of the frame are configured to expand the same. For example, the frame may be made symmetrical to encourage uniform expansion.
Furthermore, the reference beam <b>354</b>A is directed out of the first arm and onto the mirror <b>328</b> mounted on the mask holder and the measurement beam is directed out of the second arm and onto the mirror <b>312</b> mounted on the detector box. This is generally accomplished via the top bending mirrors <b>356</b>. There are two short paths P<b>1</b> and P<b>2</b> provided by the two beams between the top bending mirrors and the mirrors mounted on the mask holder and the detector box. The interferometer measures the difference between P<b>1</b> and P<b>2</b>. As should be appreciated, a differential change in these paths P<b>1</b>, P<b>2</b> indicates a change in distance between the mask and the detectors. There is no measured difference if both paths change the same.
<figref idref="DRAWINGS">FIGS. 13A and 13B</figref> are simplified diagrams of an individual imaging system <b>396</b> in the calibration and measurement modes, respectively, in accordance with one embodiment of the present invention. By way of example, the individual imaging system may be one of the imaging systems used in the detector units of FIG. <b>9</b>. As shown in <figref idref="DRAWINGS">FIG. 13A</figref>, the projection unit is removed and a test mask <b>398</b> is moved to the plane that coincides with the aerial image of the projected image of the projection optics. During imaging, the illumination <b>400</b> comes from behind the mask <b>398</b> and the test pattern is imaged on a CCD array <b>402</b> through an objective lens <b>403</b>. The CCD array thus captures the image of the test pattern, and more particularly an alignment mark <b>404</b> (e.g., cross) within its field of view. Standard image processing finds the position of the alignment mark <b>404</b> within the field of view. In practice an array of alignment marks is located on the test mask <b>398</b> and the relative position of each is sequentially measured. Also during imaging, an interferometer system measures the position of the CCD array <b>402</b>. The actual position of the alignment mark is thereby determined via standard image processing and the interferometer measurements.
As shown in <figref idref="DRAWINGS">FIG. 13B</figref>, the projection unit <b>394</b> is inserted and the projection unit projects an image of the test mask in the aerial image plane. During imaging, the illumination <b>400</b> comes from behind the mask <b>398</b> and the projected image of the test pattern is imaged on the CCD array. The CCD array thus captures the projected image of the test pattern, and more particularly a projected image of an alignment mark <b>408</b> (e.g., cross) within its field of view. Standard image processing finds the position of the projected image of the alignment mark within the field of view. In practice an array of alignment marks is located on the test mask and thus an array of projected images is created. The relative position of each is sequentially measured. Also during imaging, the interferometer system measures the position of the CCD array. The actual position of the projected image of the alignment mark is thereby determined via standard image processing and the interferometer measurements.
The measured positions of the alignment marks <b>408</b> can then be compared with the calibrated positions of the alignment marks <b>404</b> to determine distortions of the optical subsystem under test. As should be appreciated, distortion in the optical components (e.g., lens) of the optical subsystems may displace the projected image of the alignment mark and thus the projected image may be displaced on the surface of the CCD array <b>402</b> relative to the location of the alignment mark on the surface of the CCD array.
<figref idref="DRAWINGS">FIGS. 14A and 14B</figref> are simplified diagrams of an individual confocal system <b>409</b> in the calibration and measurement modes, respectively, in accordance with one embodiment of the present invention. By way of example, the individual confocal system may be one of the confocal systems used in the detector units of FIG. <b>9</b>. As shown in <figref idref="DRAWINGS">FIG. 14A</figref>, the projection unit is removed and a test mask <b>411</b> is moved to the plane that coincides with the aerial image of the projected image of the projection optics. During confocal measurements, illumination <b>410</b> comes from a light source <b>412</b> inside the confocal system. The light illuminates an analyzing reticle <b>413</b>. The analyzing reticle <b>413</b> can be opaque chrome with clear slits. The analyzing reticle <b>413</b> has slits in four orientations. Light from each slit is focussed by an objective lens <b>414</b> onto the test mask <b>411</b>, and more particularly a focus mark that provides a reflective surface. If the reflective surface is at the focus point (in focus), all light will be reflected back through the same slit and will be fully detected on a quad detector <b>416</b>. If the reflective surface is not at the focus point (out of focus), not all the light will return through the slits and the detected signal will decrease. Thus, the detected signal will peak at best focus as the detector unit is moved along the focus axis (Z). All focus marks on the test mask <b>411</b> that correspond to a useful field are measured in sequence. In this way, the detector system and the mask are calibrated.
As shown in <figref idref="DRAWINGS">FIG. 14B</figref>, the projection unit <b>418</b> is inserted and the projection unit projects an image of the test mask <b>411</b> at the aerial image plane. During confocal measurements, illumination <b>410</b> comes from the light source <b>412</b> inside the confocal system. The light <b>412</b> illuminates the analyzing reticle <b>413</b>. Light from each slit is focussed by the objective lens <b>414</b> onto the test mask, and more particularly a focus mark that provides a reflective surface. If the reflective surface is at the focus point (in focus), all light will be reflected back through the same slit and will be fully detected on a quad detector <b>416</b>. If the reflective surface is not at the focus point (out of focus), not all the light will return through the slits and the detected signal will decrease. Thus, the detected signal will peak at best focus as the detector is moved along the focus axis (Z). All focus marks on the test mask that correspond to a useful field are measured in sequence. In this way, the detector system and the mask are calibrated.
Imperfections in the lens will cause the focus to vary at different parts of the field. Moreover astigmatism will cause the four orientations of slits to focus at different points along the focus axis. A comparison of the calibration and measurement data then shows the focal plane and the astigmatism of the lens under test.
The imaging and confocal systems may be separate systems or they may be combined. <figref idref="DRAWINGS">FIG. 15</figref> illustrates a detector unit that includes an imaging system and confocal system that are combined, in accordance with one embodiment of the present invention. In this embodiment, the imaging and confocal systems share a microscope objective <b>432</b> and a beam splitter cube <b>434</b>. The microscope objective <b>432</b> is generally focussed on the aerial image plane. The beam splitter cube <b>434</b> is arranged to provide shared optical path <b>438</b> that is split from an imaging path <b>440</b> and a confocal path <b>442</b>, i.e., the beam splitter separates the beams used by the imaging and confocal systems.
With regards to the imaging system, an illumination unit directs a light field through a test pattern of the test mask. The detector moves to an alignment mark contained within the test pattern and the microscope objective <b>436</b> picks up the image of the alignment mark (and if needed magnifies it). The image of the alignment mark is then directed along the optical path <b>438</b> until it reaches the splitter <b>434</b>. The splitter <b>434</b> then directs a portion of the light to form an image along imaging path <b>440</b>. The light continues along the imaging path <b>440</b> until it is received by a relay lens <b>444</b>, which forms an image onto a CCD camera <b>446</b>. In most cases, the microscope objective <b>432</b> and relay lens <b>444</b> are balanced to match the resolution of the aerial image to the resolution of the CCD camera <b>446</b>. In one embodiment, the microscope objective <b>432</b> magnifies the image about 10× and the relay lens <b>444</b> magnifies the image about 6×. As such, the aerial image is magnified by 60× onto the CCD camera <b>446</b>. This magnification matches the resolution of the aerial image to the resolution of the CCD camera <b>446</b>. It also results in a reduced field size. This generally requires that the detector unit <b>430</b> be translated in the x and y directions to measure all parts of the projection unit optical field. The image captured by the CCD camera <b>446</b> is processed to find the position of the alignment target on the CCD camera <b>446</b>. This data is combined with the interferometer data associated with the detector unit position to produce a resultant set of data associated with the position of the alignment target. If both measurements have been performed, the resultant data of the projection unit may then be compared with the resultant data of the test mask. This comparison removes the need to know offsets and origins. Unlike the imaging system, the confocal system includes its own illuminator <b>448</b>. By way of example, the illuminator <b>448</b> may be a mercury lamp. In one embodiment, a single mercury lamp is used, and each detector <b>430</b> includes a fiber conduit <b>450</b> that transfers light therefrom. The light emitted from the fiber conduit <b>450</b> is collected by a lens <b>452</b> and focused onto the pupil of the microscope objective <b>432</b>. In so doing, the light beam travels along the confocal path <b>442</b> and the optical path <b>438</b>. While on the confocal path <b>442</b>, the light beam intersects a splitter <b>454</b> that distributes a first light portion to an analyzing reticle <b>456</b> along the confocal path <b>442</b> and a second light portion to a reference detector <b>458</b>. The reference detector <b>458</b> is arranged to measure the intensity of the light for signal normalization. In most cases, a small percentage of the light is distributed to the reference detector <b>458</b> along path <b>460</b>. Reference detectors are generally well known in the art and for the sake of brevity will not be discussed in detail.
The light that continues on the confocal path <b>442</b> illuminates the analyzing reticle <b>456</b>. In one embodiment, the analyzing reticle <b>456</b> includes a plurality of slits for allowing the light to pass therethrough. By way of example, the slits may have a width of about 30um and a period of about 120 um. In one embodiment, the analyzing reticle <b>456</b> includes four orientations A-D for measuring astigmatism (e.g., horizontal, vertical, 45 degrees). After passing through the analyzing reticle <b>456</b> the light intersects the splitter <b>434</b> where it is transferred to the optical path <b>438</b>. The light continues along the optical path <b>438</b> until it is received by the microscope objective <b>432</b>, which directs the light onto the aerial image plane <b>436</b>. In one embodiment, the light is demagnified by 10× onto the aerial image plane and thus the slits are only 3 um wide at the aerial image plane. This width is about the same as the resolution of the optics under test. It should be noted that this is not a limitation and that the demagnification may be modified to coincide with the resolution of the optics under test (if something other than 3 um).
When using the confocal system, the detector <b>430</b> moves to a focus mark contained within the test pattern. Because the focus target is reflective, the image of the reticle is reflected back through the microscope objective <b>432</b> and along the optical path <b>438</b> until it reaches the splitter <b>434</b>. In the measurement mode, the light makes a double pass through the optics under test. The splitter <b>434</b> then directs the image along the confocal path <b>442</b> where it intersects the analyzing reticle <b>456</b>. If in focus, most of the light passes back through the slits in the analyzing reticle <b>456</b>. If out of focus, a smaller portion of the light passes through slits of the analyzing reticle <b>456</b>. After passing through the analyzing reticle <b>456</b>, the light then continues along the confocal path <b>442</b> until it reaches the splitter <b>454</b>. The splitter <b>454</b> distributes the light along a detector path <b>458</b> where it intersects a lens <b>460</b> that re-images the analyzing reticle <b>456</b> onto a quadrant detector <b>462</b>. The image position is adjusted so that each type of slit (e.g., orientation) is detected by only one segment of the quad detector <b>462</b>. Thus, the quadrant detector <b>462</b> is used as four separate detectors mounted conveniently close together.
As the detector is moved in the focus axis, the confocal signal on each quadrant varies. The peak signals generally occur at best focus. Because of astigmatism, the best focus may be at different positions for each quadrant. When the aerial image plane is filled by the optics under test, the focus peaks may be shifted by imperfections of the projection unit optics. Again, the desired result is obtained by comparing the data by subtraction. The offsets and origins are therefore eliminated mathematically.
It should be noted that beam splitter <b>434</b> may be designed to reflect about 90% of the incident light while transmitting 10% of the incident light. This ratio is typically selected to optimize the confocal signal. The confocal signal (amount of light) is preferably raised since light reflects from the splitter <b>434</b> twice, and therefore having a higher reflectivity splitter improves the signal. The imaging light turns out to be relatively plentiful and the 90% loss of light by passing once through the beam splitter is not a detriment to quality performance.
<figref idref="DRAWINGS">FIG. 16</figref> is a simplified diagram of a test mask <b>480</b>, in accordance with one embodiment of the present invention. The test mask <b>480</b> includes a plurality of test patterns <b>482</b>. The number of test patterns <b>482</b> generally corresponds to the number of subsystems to be tested. In the illustrated embodiment, there are seven test patterns <b>482</b>. Each of the test patterns <b>482</b> includes a plurality of inspection targets <b>484</b>. The inspection targets <b>484</b> are used to determine displacement in the X, Y and Z directions. The inspection targets <b>484</b> may include alignment marks <b>486</b> for determining shifts in the X and Y directions and/or focus marks <b>488</b> for determining offset in the Z direction. The alignment marks <b>486</b> may be formed as a cross in the X and Y directions and the focus mark <b>488</b> may be formed from a planar reflective surface in the X and Y directions. During imaging, each of the detectors provides a field of view in which the alignment marks <b>486</b> are imaged. The alignment marks <b>486</b> may or may not be centered in the field of view. Standard image processing as is well known in the art can determine the position of the alignment marks <b>486</b> within the field of view. In one embodiment, individual detectors simultaneously image an alignment mark <b>486</b> in an individual test pattern <b>482</b>. For example, as shown, a first detector may image an alignment mark in a first test pattern, a second detector may image an alignment mark in a second test pattern, and the like. Furthermore, the individual detectors may follow a specific sequence so as to measure the plurality of alignment marks contained within an individual test pattern. For example, as shown, each detector may move to a first alignment mark <b>486</b>A, a second alignment mark <b>486</b>B and so on through <b>486</b>E.
While this invention has been described in terms of several preferred embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. For example, although the mask holder is shown and described as moving via a stage, it should be noted that in some cases the mask holder may be fixed or stationary, i.e., without a stage. In cases such as these, the detector assembly may be configured to move between the measurement position and the calibration position. Furthermore, the interferometry system may include large mirrors for helping detect the position of the detector assembly when moved to these two positions, i.e., the mirrors may be continuous such that they span the measurement position and the calibration position.
In one particular implementation, the interferometry system may include a y interferometer, a pair of x interferometers, and three z interferometers. The y interferometer is attached to the detector assembly and is configured to interact with a continuous and calibrated fixed mirror to measure detector positions in the y direction. The x interferometers are also attached to the detector assembly and are configured to interact with a continuous and calibrated fixed mirror. Both the x and y mirrors are configured to span the z direction. The z interferometers are attached to a fixed portion of the inspection system and are configured to interact with small mirrors located on the detector assembly. As should be appreciated, the x interferometers detect x and yaw positions of the detector assembly, the y interferometer detects y positions of the detector assembly, the z interferometers detect z, roll and pitch positions of the detector assembly.
It should also be noted that the detector assembly may be varied. For example, each of the detectors of the detector assembly may include a different arrangement of elements. In one particular implementation, each detector of the detector assembly may include an objective, an analyzing reticle, a lens and a quadrant detector. The objective is used to re-image the test mask image onto the analyzing reticle. That is, each objective focuses an enlarged image of the aerial image (typically 10×) onto the analyzing reticles. Each of the analyzing reticles has a slit or cross shaped opening. The reticles can be opaque chrome with a cross of clear slits. The lens is used to re-image the pupil onto the quadrant detector. The entire detector (in unison with the other detectors) is scanned in the x and y direction and the quadrants are summed in pairs to find the focus in the x and y directions. That is, when scanned in x and y, the detectors record that part of the aerial image that passes through the slits. The complete scan signal indicates the profile of the aerial image.
It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. For example, the multiple detectors of the detector assembly may cooperate to measure one large field rather than their own individual field. That is, each detector measures a particular region of the field rather than the entire field. In addition, a wafer exposure function may be added to provide an independent means of checking the aerial image measurement.
It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.
Contents4
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Priority claims2
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| 29828602 | United States of America | A | |
| US20020298286 | – | – | – |
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Numbers
- Publication
- H0002114
- Publication, DOCDB
- H2114
- Publication, EPODOC
- USH2114H
- Application
- 298286
- Application, DOCDB
- 29828602
- Application, EPODOC
- US20020298286
Titles
- English
- Inspection tool for testing and adjusting a projection unit of a lithography system
Classification
- CPC, 5
- G01N21/95607
- G03F7/70258
- G03F7/70591
- G03F7/70666
- G03F1/44
- IPC, 3
- G01B9 00
- G01N21 956
- G03F7 20