Nanometrics Inc.

Pablo I Rovira

Richard A Yarussi

James Matthew Holden

Jaime Poris

Roger R Lowe-Webb

William A McGahan

John D Heaton

Pedro Vagos

Chunsheng J Huang

Christopher W Blaufus

Claudio L Rampoldi

Jonathan M Madsen

Scott D Penner

Lars Markwort

Guorong Vera Zhuang

A metrology unit includes an integrated reference target with which an automated system check process is performed. The automated system check process includes measuring a feature on the reference target and determining if the measurement is within a desired specification for the metrology unit. When the metrology unit fails the automated system check, or if otherwise warranted, an automated diagnosis process may be performed using the same integrated reference target. The automated system check and automated diagnosis may be optimized based on correlations between parameters of the automated qualification and parameters of the automated diagnosis. Similarly, the measurement of a processed wafer may be optimized based on a correlation between parameters of the metrology of the processed wafer and parameters of the automated system check.

Automated system check for metrology unit

An optical metrology device produces a broadband beam of light that is incident on and reflected by a sample and introduces multiple variations in the polarization state of the beam of light induced by an optical chiral element. Using the detected light, the Muller matrix or partial Mueller matrix for the sample is determined, which is then used to determine a characteristic of the sample. For example, simulated spectra for a Mueller matrix for a model is fit to the measured spectra for the Mueller matrix of the sample by adjusting the parameters of the model until an acceptable fit between the simulated spectra and measured spectra from the Mueller matrices is produced. The varied parameters are then used as the sample parameters of interested, which can be reported, such as by storing in memory or displaying.

Mueller matrix spectroscopy using chiroptic

A normal incidence reflectometer includes a rotatable analyzer/polarizer for measurement of a diffracting structure. Relative rotation of the analyzer/polarizer with respect to the diffracting structure permits analysis of the diffracted radiation at multiple polarity orientations. A spectograph detects the intensity of the spectral components at different polarity orientations. Because the normal incidence reflectometer uses normally incident radiation and an analyzer/polarizer that rotates relative to the diffracting structure, or vice-versa, the orientation of the diffracting structure does not affect the accuracy of the measurement. Thus, the sample holding stage may use X, Y, and Z, as well as r-&#x3b8; type movement and there is no requirement that the polarization orientation of the incident light be aligned with the grating of the diffraction structure. A non-linear multivariate regression process is used to adjust the parameters of an optical model, such as rigorous coupled-wave analysis, to provide a match with the measured data.

Spectrometer measurement of diffracting structures

A metrology instrument includes an eddy current sensor that is mounted to and concentric with a confocal distance sensor. By measuring the precise vertical placement of the eddy current probe with respect to the surface of the sample using the confocal distance sensor, the accuracy and precision of the eddy current measurement is improved. Because the confocal distance sensor and the eddy current sensor are confocal, there is no need to move the relative lateral positions between the sample and instrument, between the distance measurement and the eddy current measurement, thereby reducing error in the measurement as well are maximizing the throughput by minimizing the required stage travel for a single measurement.

Eddy current sensor with concentric confocal distance sensor

A normal incidence reflectometer includes a rotatable analyzer/polarizer, which permits measurement of a diffracting structure. Relative rotation of the analyzer/polarizer with respect to the diffracting structure permits analysis of the diffracted radiation at multiple polarity orientations. A spectograph detects the intensity of the spectral components at different polarity orientations. Because the normal incidence reflectometer uses normally incident radiation and an analyzer/polarizer that rotates relative to the diffracting structure, or vice-versa, the orientation of the diffracting structure does not affect the accuracy of the measurement. Thus, the sample holding stage may use X, Y, and Z, as well as r-&#x3b8; type movement and there is no requirement that the polarization orientation of the incident light be aligned with the grating of the diffraction structure. A non-linear multivariate regression process is used to adjust the parameters of an optical model, such as rigorous coupled-wave analysis, to provide a match with the measured data.

Apparatus and method for the measurement of diffracting structures

A metrology device, such as an ellipsometer, includes a light source that produces a pulsed electromagnetic beam, such as a flash bulb or pulsed laser, and a spatially dependent polarizing element that introduces a spatially dependent retardation in the light beam. The use of a pulsed light source is advantageous over a continuous light source, as a pulsed light source generates less heat, is stronger, lasts longer, and does not need the use of a mechanical shutter. The use of a spatially dependent polarizing element advantageously eliminates the use of temporally dependent moving polarization modulation elements, thereby allowing the use of a pulsed light source. Downstream of the spatially dependent polarizing element are the analyzer and a multi-element detector that may be synchronized with the pulsed electromagnetic beam to detect after one or several pulses of light have been emitted from the pulsed light source.

Pulsed spectroscopy with spatially variable polarization modulation element

An ellipsometer with a variable retarder, which introduces a spatial dependence in the beam, includes a polarizing beam splitter to produce two beams with orthogonal polarization states. The beam splitter may be, e.g., a polarizing displacer or polarizing beam splitter. The intensities of the two beams are measured, e.g., using separate detectors or separate detector elements in an array. The intensity from the two beams may be summed and used as a reference to normalize intensity of the produced beam.

Polarizing beam splitter and dual detector calibration of metrology device having a spatial phase modulation

An interferometer and ellipsometer are combined in a metrology tool to measure the step height of a sample, which may include transparent layers. The metrology tool includes a shared light source that provides a light beam for an interferometer and a light beam for an ellipsometer, interferometer optics which direct the light beam for an interferometer to reflect off of a sample and ellipsometer optics which direct the light beam for an ellipsometer to reflect off a sample, and a detector element for receiving both the reflected light beam for an interferometer and the light beam for an ellipsometer. The light source may produce a single beam that is split into an interferometer and an ellipsometer beam with a beam splitter. In another embodiment, the interferometer and ellipsometer may share at least one of a polarizer, analyzer, or detector element.

Optical metrology system with combined interferometer and ellipsometer

A normal incidence spectroscopic polarimeter is combined with an oblique incidence spectroscopic polarimeter to provide an accurate characterization of complex grating structures, e.g., structures with sloping sidewalls, with notches and with multiple underlying layers. The normal incidence spectroscopic polarimeter includes a polarizing element that is in the path of the normal incidence light beam such that the light beam is transmitted through the polarizing element before reaching the sample and after being reflected off the sample. The two systems may advantageously share a single light source and/or the spectrophotometer.

Combination of normal and oblique incidence polarimetry for the characterization of gratings

A metrology device with a rotatable polarizer is calibrated to align the transmission axis of the polarizer with the axis of orientation of a sample, such as a diffraction grating. The axis of orientation of the diffraction grating can be either the TE or TM axis. The system offset angle between the transmission axis of the polarizer in its home position and an axis of motion of the stage, such as a polar coordinate stage, is determined. Whenever a new substrate is loaded onto the stage, the sample offset angle between the axis of motion of the stage and the axis of orientation of a sample is measured. The polarizer offset angle, which is the angle between transmission axis of the polarizer and the axis of orientation of the sample, is the sum of the system offset angle and the sample offset angle. Thus, by rotating the polarizer by an amount equivalent to the sum of the system offset angle and the sample offset angle, the polarizer offset angle is reduced to zero. If desired, the polarizer may be rotated once to compensate for the system offset angle and then rotated to compensate for the sample offset angle for each newly loaded substrate or the polarizer may be rotated to compensate for both the system offset angle and the sample offset angle for each newly loaded substrate.

Alignment of a rotatable polarizer with a sample

The calibration of a metrology tool with a rotatable polarizer separates the angular dependence of the irradiance from the temporal dependence. The angular dependence of the metrology tool is then modeled, e.g. using a Fourier expansion. The Fourier coefficients are parameterized as a function of wavelength. The actual irradiance, e.g., the reference irradiance and/or back reflection irradiance, is then measured for the metrology tool for one angle of the rotatable polarizer. From the measured irradiance and the modeled angular dependence, the total irradiance of the metrology tool can be determined, which is independent of the angle of the rotatable polarizer. The irradiance, e.g., reference and/or back reflection, can then be determined for any desired angle of the rotatable polarizer using the total irradiance and the angular dependence of the metrology tool.

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San Francisco, CA, United States of America

Pablo I Rovira