APPARATUS AND METHOD FOR DETECTING ONE OR MORE SCANNING CHARGED PARTICLE BEAMS

Abstract

A method and an apparatus are provided for inspecting a sample. The apparatus includes a sample holder for holding the sample, a charged particle column for generating and focusing one or more charged particle beams at one or more charged particle beam spots onto the sample, a scanning deflector for moving the charged particle beam spot(s) over the sample, a photon detector configured for detecting photons created when the one or more charged particle beams impinge on the sample or when the one or more charged particle beams impinge onto a layer of luminescent material after transmission through the sample, an optical assembly for projecting or imaging at least part of the photons from the charged particle beam spot(s) along an optical beam path onto the photon detector, and a shifting unit for shifting the optical beam path and/or the photon detector with respect to each other.

Claims

1-19. (canceled)

20. An apparatus for inspecting a sample, wherein the apparatus comprises: a sample holder for holding the sample, a charged particle column for generating and directing one or more charged particle beams towards the sample holder, wherein said charged particle column is configured for focusing said one or more charged particle beams at one or more charged particle beam spots onto the sample, a scanning unit for scanning the one or more charged particle beam spots over the sample in a scanning direction, a photon detector for detecting photons created by said one or more focused charged particle beams when said one or more charged particle beams impinge on the sample or when said one or more charged particle beams impinge onto a layer of luminescent material after transmission of said one or more charged particle beams through the sample, an optical assembly for projecting or imaging at least part of said photons from said one or more charged particle beam spots along an optical beam path onto one or more light spots on said photon detector, and a shifting unit for shifting the one or more light spots and/or the photon detector with respect to each other, wherein said shifting unit is configured for at least partially compensating a movement of the one or more charged particle beams on the sample or on the layer of luminescent material due to the scanning of the one or more charged particle beam spots by the scanning unit.

21. The apparatus according to claim 20, wherein the optical assembly comprises an objective lens for collecting at least part of said photons from said one or more charged particle beam spots, wherein the shifting unit comprises an objective lens actuator for moving the objective lens with respect to the sample holder, and wherein the objective lens actuator is configured to move the objective lens in a direction substantially parallel to the scanning direction.

22. The apparatus according to claim 21, wherein the objective lens comprises an optical axis, wherein the objective lens actuator is configured to move the objective lens in a direction substantially perpendicular to the optical axis of the objective lens.

23. The apparatus according to claim 20, wherein the optical assembly comprises a projection lens for projecting said at least part of said photons onto the photon detector, wherein the shifting unit comprises a projection lens actuator for moving the projection lens with respect to the photon detector.

24. The apparatus according to claim 23, wherein the projection lens comprises an optical axis, wherein the projection lens actuator is configured to move the projection lens in a direction substantially perpendicular to the optical axis of the projection lens.

25. The apparatus according to claim 20, wherein the optical assembly comprises a mirror arranged in the optical beam path between the sample holder and the photon detector, wherein the mirror is configured for reflecting the optical beam path at a deflection angle between 0 and 180 degrees, wherein the shifting unit comprises a mirror actuator which is configured for tilting the mirror.

26. The apparatus according to claim 25, wherein the mirror actuator is configured for tilting the mirror around a rotation axis, wherein the rotation axis is arranged substantially perpendicular to the scanning direction.

27. The apparatus according to claim 20, wherein the optical assembly comprises a polygon mirror arranged in the optical beam path between the sample holder and the photon detector, wherein the mirror is configured for reflecting the optical beam path at a deflection angle between 0 and 180 degrees, wherein the shifting unit comprises a rotating actuator which is configured for rotating the polygon mirror.

28. The apparatus according to claim 27, wherein the polygon mirror is configured for rotating the mirror around a rotation axis, wherein the rotation axis is arranged substantially perpendicular to the scanning direction.

29. The apparatus according to claim 20, wherein the optical assembly comprises an optical window arranged in the optical beam path between the sample holder and the photon detector, wherein the optical window is arranged so that the optical beam path traverses said optical window, wherein the shifting unit comprises a tilting actuator which is configured for tilting the optical window.

30. The apparatus according to claim 29, wherein the tilting actuator is configured for tilting the optical window around a rotation axis, wherein the rotation axis is arranged substantially perpendicular to the scanning direction.

31. The apparatus according to claim 20, wherein the optical assembly comprises an optical transparent polygon arranged in the optical beam path between the sample holder and the photon detector, wherein the optical transparent polygon is arranged so that the optical beam path traverses said optical transparent polygon, wherein the shifting unit comprises a rotating actuator which is configured for rotating the optical transparent polygon.

32. The apparatus according to claim 31, wherein the rotating actuator is configured for rotating the optical transparent polygon around a rotation axis, wherein the rotation axis is arranged substantially perpendicular to the scanning direction.

33. The apparatus according to claim 20, wherein the apparatus further comprises a first control unit for controlling the scanning unit, and a second control unit for controlling the shifting unit, wherein the first control unit is configured for sending a scanning information signal to the second control unit, and wherein the second control unit is configured controlling the shifting unit based on the scanning information signal.

34. The apparatus according to claim 20, wherein the shifting unit is a first shifting unit, wherein the apparatus further comprises a second shifting unit, wherein the second shifting unit is configured for shifting the one or more light spots and/or the photon detector with respect to each other in a shifting direction substantially perpendicular to the shifting direction of the first shifting unit.

35. A method for inspecting a sample, wherein the method comprises the steps of: arranging the sample in a sample holder, generating and directing one or more charged particle beams towards the sample using a charged particle column, wherein said charged particle column focuses said one or more charged particle beams at one or more charged particle beam spots onto the sample, wherein photons are created by said one or more focused charged particle beams when said one or more charged particle beams impinge on the sample or when said one or more charged particle beams impinge onto a layer of luminescent material after transmission of said one or more charged particle beams through the sample, projecting or imaging at least part of said photons from said one or more charged particle beam spots along an optical beam path onto one or more light spots on a photon detector using an optical assembly, detecting photons using the photon detector, and scanning the one or more charged particle beam spots over the sample in a scanning direction using a scanning unit, and shifting the one or more light spots and/or the photon detector with respect to each other using a shifting unit, wherein said shifting unit at least partially compensates a movement of the one or more charged particle beams on the sample or on the layer of luminescent material due to the scanning of the one or more charged particle beam spots by the scanning unit.

36. The method according to claim 35, wherein the shifting unit compensates the movement of the one or more charged particle beams so that the one or more light spots substantially remain at the same position on the photon detector during the scanning of the one or more charged particle beams by the scanning unit.

37. The method according to claim 35, wherein the one or more charged particle beams are scanned over a first substantially rectangular area on the sample, subsequently the one or more charged particle beams and the sample are moved with respect to each other over a distance substantially equal to the width of the substantially rectangular area, and then the one or more charged particle beams are scanned over a second substantially rectangular area on the sample.

38. A computer-readable medium having computer-executable instructions adapted to cause an apparatus to perform the method according to claim 35.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The invention will be elucidated on the basis of an exemplary embodiment shown in the attached drawings, in which:

[0048] FIG. 1 schematically shows a first exemplary embodiment of an apparatus as typically improved by the present invention;

[0049] FIG. 2 schematically shows a second exemplary embodiment of an apparatus as typically improved by the present invention;

[0050] FIG. 3 schematically shows an example of a third embodiment of part of the optical assembly as improved by the present invention;

[0051] FIG. 4 schematically shows an example of a fourth embodiment of part of the optical assembly as improved by the present invention;

[0052] FIG. 5 schematically shows an example of a fifth embodiment of part of the optical assembly as improved by the present invention;

[0053] FIGS. 6A and 6B schematically show an example of a sixth embodiment of part of the optical assembly as improved by the present invention; and

[0054] FIG. 7 schematically shows an example of a seventh embodiment of part of the optical assembly as improved by the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0055] FIG. 1 schematically shows a first exemplary embodiment of an apparatus as typically improved by the present invention. The apparatus comprises in combination at least a charged particle microscope 7,8, such as an ion- or electron microscope, an optical assembly, and a detector 3.

[0056] The charged particle microscope 7, 8 comprises a source 7 for emitting one or more primary charged particle beams 9 and directing said one or more primary charged particle beams to a sample 5 supported by a substrate included in a sample holder 10. The apparatus comprises a detector 8 for detection of secondary charged particles 11 backscattered from the sample 10, or emitted, transmitted, or scattered from the sample 10 and produced by the one or more primary charged particle beams 9. The charged particle microscope 7,8 is substantially arranged inside a vacuum chamber 13.

[0057] As schematically indicated in FIG. 1, the charged particle microscope is configured for scanning 9′ the one or more primary charged particle beams 9 over the sample 5. Electrostatic and/or magnetic deflectors can be used for scanning 9′ the one or more charged particle beams over the sample 5. Such electrostatic and magnetic deflectors are known in the prior art and are not described in detail in this application.

[0058] The optical assembly comprises a light collecting device 2, usually referred to as an objective lens, to receive in use light 12 from the sample or from a sheet of scintillator material 6, which light 12 is produced by the one or more primary charged particle beams 9 in the sample or after transmission of the one or more primary charged particle beams 9 through the sample 5. The optical assembly is configured to focus the light 12 on a photon detector 4, such as a known per se CCD camera. In the present example the optical assembly and the detector is placed inside the vacuum chamber 13 of the charged particle microscope 7, 8.

[0059] The inspection apparatus 1 comprises a sample holder 10 for holding the sample 5. The sample holder 10 comprises a stage 16 which is configured for positioning and moving the sample 5.

[0060] In addition, the sample holder 10 may comprise a sheet of a scintillator material 6, for example comprising a layer of Yttrium Aluminum Garnet (YAG, Y.sub.3AL.sub.5O.sub.12). The sample holder 10 is configured to position the sample 5 in between the source 7 of the charged particle microscope 7,8 and the sheet of the scintillator material 6. The optical assembly microscope 2, 3, 4 is arranged at a side of the sheet of scintillator material 6 facing away from the sample 5.

[0061] The closed dashed line 14 encircles those parts of the inspection apparatus 1 of the invention that may all or some of them be mounted on a (replaceable) door of the vacuum chamber 13. In particular, the sample holder for the sample 10, the light collecting device 2, and the photon-detector 4, are preferably mounted on said door of the vacuum chamber 13. This particular construction enables an easy retrofit or completion of an existing charged particle microscope in order to convert it into an inspection apparatus according of the integrated type as is subject to the present invention.

[0062] In FIG. 1, a processing unit 15, alternatively denoted controller, is provided and useable as an automation unit, e.g. in the form of a computer, including a personal computer provided with dedicated software, implementing one or more methods of use of the inspection apparatus.

[0063] As schematically indicated in FIG. 1, the sample holder comprises a stage 16 for moving the sample 5 with respect to the optical assembly and/or a charged particle microscope 7,8. Preferably the stage is configured for providing six degrees of freedom for moving the sample 5; thus providing translational movement along the X, Y and Z axis and rotational movement around the X, Y and Z axis.

[0064] Furthermore, the inspection apparatus comprises an objective lens actuator 3 for moving the objective lens 2 and/or a detector actuator 3′ for moving the detector. The objective lens actuator 3 and/or the detector actuator provide a shifting unit for shifting the optical path of the light 12 and/or the photon detector 4 with respect to each other. In particular, the first shifting unit 3 and/or second shifting unit 3′ is configured for at least partially compensating a movement of the one or more charged particle beams 9 on the sample 5 or on the layer of luminescent material 6 due to the scanning of the one or more charged particle beam spots by the scanning unit of the charged particle microscope. As schematically shown in FIG. 1, the objective lens 2 comprise an optical axis OA, wherein the objective lens actuator 3 is configured to move the objective lens 2 in a direction substantially perpendicular to the optical axis OA, in particular in a direction substantially parallel to the scanning direction of the one or more charged particle beams 9. The objective lens actuator 3 preferably comprises a voice coil.

[0065] FIG. 2 schematically shows a second exemplary embodiment of an apparatus as typically improved by the present invention. The apparatus 20 of FIG. 2 comprises a Scanning Electron Microscope (SEM) 27 comprising a vacuum chamber 23 which is connected to a vacuum pump via a connector 35. Inside said vacuum chamber 23, a sample 40 is arranged, which sample 40 can be irradiated with one or more primary electron beams 29. The apparatus 20 comprises a detector 28 for detection of secondary charged particles 31 backscattered from the sample 40, or emitted from the sample 40 as a result of the one or more primary electron beams 29 impinging on the sample 40.

[0066] As schematically shown, the sample 40 is arranged on top of as sheet of scintillating material 30 which acts as a holder for holding the sample 40. The sheet of scintillator material 30, for example comprising a thin slab of Yttrium Aluminum Garnet (YAG, Y.sub.3AL.sub.5O.sub.12).

[0067] The sample holder comprises a stage 41 which is configured for positioning and moving the sample 40 and the sheet of scintillating material 30. The sample holder comprises a stage for moving the sample 40 for providing six degrees of freedom in movement of the sample 40; thus providing translational movement along the X, Y and Z axis and rotational movement around the X, Y and Z axis. The sample holder is configured to position the sample 40 in between the SEM 27 and the sheet of the scintillator material 30.

[0068] Below the sheet of scintillator material 30 a microscope objective 22 is arranged inside the vacuum chamber 23, which is part of the optical assembly for detecting luminescent light from the scintillator material 30. In this particular example, the other major parts of the optical assembly are arranged outside the vacuum chamber 23 in an illumination and detection box 24.

[0069] The illumination and detection box 24 may comprise a light source 21, for example a LED of a Laser. The emitted light 36 from het light source 21 is directed out of the illumination and detection box 24 via a half transparent mirror or dichroic 25 and is directed into the vacuum chamber 23 via a window 32. This light 37, 38 is coupled into the microscope objective 22 via a mirror 26, for illuminating the sample 40. Although the illumination arrangement can be used for illuminating the sample with light and to study the sample under illumination by light, the illumination arrangement is not necessary to obtain an image using the transmitted electrons through the sample 40 which are converted into light by the sheet of scintillating material 30.

[0070] Light 37, 38 from the sample 40 and/or the sheet of scintillator material 30 is collected by the microscope objective 22 and is directed via the mirror 26 and the window 32 towards the illumination and detection box 24, and is imaged 39 onto a camera 33, for example a CCD detector.

[0071] As shown in FIG. 2, the light beams for illuminating and/or imaging the sample 40 enter into and passed from the vacuum chamber 23 via a window 32 which in this example is arranged in a door 34 of said vacuum chamber 23. The illumination and detection box 24 of the light optical microscope system is arranged outside vacuum chamber 23 and may be attached to the outside of the door 34. However, the illumination and detection part of the light optical assembly may as well be included fully inside, e.g. attached to a bottom part, of the vacuum chamber 23.

[0072] In this exemplary embodiment, it is advantageous to select a sheet of scintillator material 30 which is at least substantially transparent, preferably wherein the sheet of scintillator material is substantially transparent for light in a wavelength range in the visual spectrum. Accordingly, the sample 40 can be observed by means of the light optical microscope through the sheet of scintillator material 30.

[0073] As schematically indicated in FIG. 2, the mirror 26 is provided with an actuator 42 for moving the mirror 26 in a reciprocal linear movement in a direction towards and away from the microscope objective 22. Accordingly, the mirror 26 and the microscope objective 22 provides a shifting unit for shifting the optical beam path with respect to the camera 33. In addition, the inspection apparatus comprises a first control unit 44 for controlling the SEM and in particular the scanning unit inside the SEM, and a second control unit 43 for controlling the actuator 42 of the shifting unit. The first control unit 44 is configured for sending a scanning information signal to the second control unit 43, and the second control unit 43 is configured controlling the actuator based on the scanning information signal in order to synchronize the shifting of the optical beam path by the shifting unit with the scanning of the one or more electron beams by the SEM 27, in particular for at least partially compensating the movement of the one or more electron beams 29 on the sample 40 or on the layer of luminescent material 30 due to the scanning of the one or more electron beam spots by the scanning unit inside the SEM 27. Preferably said actuator 42 comprises a voice coil.

[0074] FIG. 3 schematically shows a third exemplary embodiment of an optical assembly 50 for use in the inspection apparatus as typically improved by the present invention. The optical assembly 50 comprises an objective lens 51, a folding mirror 52 and a projection lens 53 for projecting said at least part of said photons onto the photon detector 54. The projection lens 53 is connected to a projection lens actuator 55 for moving the projection lens 53 with respect to the photon detector 54. The projection lens 53 with the projection lens actuator 55 provides a shifting unit. The projection lens 53 comprise an optical axis OA and the projection lens actuator 55 is configured to move the projection lens 53 in a direction 56 substantially perpendicular to the optical axis OA of the projection lens 53. When the projection lens actuator 55 moves the projection lens 53 in the direction 56, the light projected by the projection lens 53 moves in the direction 57 over the detector 54. When applied in the inspection apparatus of the present invention, this movement is used to at least partially compensate the scanning movement of the one or more charged particle beams. Preferably the projection lens actuator 55 comprises a voice coil.

[0075] FIG. 4 schematically shows a fourth exemplary embodiment of an optical assembly 60 for use in the inspection apparatus as typically improved by the present invention. The optical assembly 60 comprises an objective lens 61, a folding mirror 62 and a projection lens 63 for projecting said at least part of said photons onto the photon detector 64. The mirror 62 is configured for reflecting the optical beam path at a deflection angle between 0 and 180 degrees, in this example at a deflection angle of substantially 90 degrees. The mirror 62 is connected to a mirror actuator 65 for tilting the mirror 62 with respect to the photon detector 64. The mirror 62 with the mirror actuator 65 provides a shifting unit. The mirror actuator 65 is configured for tilting the mirror 62 around a rotation axis 68, wherein the rotation axis 68 is arranged substantially perpendicular to the plane of the drawing. When the mirror actuator 65 moves the mirror 62 in the direction 66, the light projected onto the detector moves in the direction 67 over the detector 64. When applied in the inspection apparatus of the present invention, this movement is used to at least partially compensate the scanning movement of the one or more charged particle beams. Preferably the mirror actuator 65 comprises a galvanometer or a piezo-motor.

[0076] FIG. 5 schematically shows a fifth exemplary embodiment of an optical assembly 70 for use in the inspection apparatus as typically improved by the present invention. The optical assembly 70 comprises an objective lens 71, a polygon mirror 72, and a projection lens 73 for projecting said at least part of said photons onto the photon detector 74. The polygon mirror 72 is configured for reflecting the optical beam path at a deflection angle toward the detector 74. The polygon mirror 72 is connected to a rotation actuator (not shown) for rotating the polygon mirror 72 around a rotation axis 78, wherein the rotation axis 78 is arranged substantially perpendicular to the plane of the drawing. The outward facing facets 75, 75′, 75″ . . . of the polygon mirror each comprises a mirror surface for reflecting the light coming from the objective lens 71. When the rotation actuator rotates the polygon mirror 72, the facets 75, 75′, 75″ . . . are arranged successively in the light beam and successively reflect the light from the objective lens 71 towards the detector 74. The polygon mirror 72 with the rotation actuator provides a shifting unit. Due to the rotation, the angle of the reflecting mirror facet 75 with respect to the optical axis OA is constantly changed. When the rotation actuator rotates the polygon mirror 72 in the direction 76, the light projected onto the detector moves in the direction 77 over the detector 74. When applied in the inspection apparatus of the present invention, this movement is used to at least partially compensate the scanning movement of the one or more charged particle beams.

[0077] FIG. 6A schematically shows a sixth exemplary embodiment of an optical assembly 80 for use in the inspection apparatus as typically improved by the present invention. The optical assembly 80 comprises an objective lens 81, a folding mirror 82, and a projection lens 83 for projecting said at least part of said photons onto the photon detector 84. The optical assembly 80 further comprises an optical window 85 arranged in the optical beam path between the sample holder and the photon detector 84. In this particular example, the optical window 85 is arranged between the projection lens 83 and the detector 84. The optical assembly further comprises a tilting actuator 86 which is configured for tilting the optical window 85 in a tilting direction 87 as schematically indicated in FIG. 6A and FIG. 6B. The optical window 85 with the tilting actuator 86 provides a shifting unit. When the optical window 85 is arranged in a tilted position as shown in FIG. 6B, the optical beam path between the optical window 85 and the detector 84 is shifted in a direction 87′ in the plane of the drawing. In the specific position shown in FIG. 6B, the focus point of the light is shifted from a first position 88 when the optical window is not tilted, to a second position 89 when the optical window is tilted as shown. When applied in the inspection apparatus of the present invention, this movement is used to at least partially compensate the scanning movement of the one or more charged particle beams.

[0078] FIG. 7 schematically shows a seventh exemplary embodiment of an optical assembly 90 for use in the inspection apparatus as typically improved by the present invention. The optical assembly 90 comprises an objective lens 91, a folding mirror 92, and a projection lens 93 for projecting said at least part of said photons onto the photon detector 94. The optical assembly 90 further comprises an optical transparent polygon 95 arranged in the optical beam path towards the photon detector. In this example, the optical transparent polygon 95 is arranged between the projection lens 93 and the detector 94. The optical transparent polygon 95 is arranged so that the optical beam path traverses said optical transparent polygon 95 via two opposite side facets 96, 96′. The optical transparent polygon 95 preferably comprises an even number of side facets 96, 96′, preferably 4, 6 or 8 side facets. The optical transparent polygon 95 is coupled to a rotation actuator (not shown) which is configured for rotating the optical transparent polygon 95 around a rotation axis 97. The optical transparent polygon 95 and the rotation actuator provides a shifting unit. When the optical transparent polygon 95 is rotated in a direction 98, the two opposite side facets 96, 96′ move into a tilted position, in the same way as the optical window shown in FIG. 6B. Accordingly, the optical beam path between the optical transparent polygon 95 and the detector 94 is shifted in a direction 98′ in the plane of the drawing. When the rotation continues, the two opposite side facets 96, 96′ are tilted further and further, and the optical beam path is shifted further and further, until the next adjacent opposite side facets 99, 99′ are arranged in the optical beam path and the shifting of the optical beam path starts a-new. When applied in the inspection apparatus of the present invention, this movement is used to at least partially compensate the scanning movement of the one or more charged particle beams.

[0079] It is noted that in the above exemplary embodiments the described movements of the shifting unit are a translation or rotation in the plane of the drawing. However, the movements of the various examples of the shifting unit may also be a translation or rotation in an other direction, in particular in a direction perpendicular to the plane of the drawing for compensating a scanning direction of the one or more charged particle beams in the direction perpendicular to the plane of the drawing.

[0080] In addition, when the scanning deflector is arranged for moving the one or more charged particle beam in more than one direction, in particularly in two orthogonal directions, the inspection apparatus may comprise a first and a second shifting unit. The second shifting unit is preferably configured for shifting the one or more light spots and/or the photon detector with respect to each other in a shifting direction substantially perpendicular to the shifting direction of the first shifting unit. Each of the above described embodiments may be used for one, or for both of the first and second shifting units.

[0081] In summary, the invention relates to an apparatus for inspecting a sample. The apparatus comprises: [0082] a sample holder for holding the sample, [0083] a charged particle column for generating and focusing one or more charged particle beams at one or more charged particle beam spots onto the sample, [0084] a scanning deflector for moving said charged particle beam spot(s) over the sample, [0085] a photon detector configured for detecting photons created when said one or more charged particle beams impinge on the sample or when said one or more charged particle beams impinge onto a layer of luminescent material after transmission through the sample, [0086] an optical assembly for projecting or imaging at least part of said photons from said charged particle beam spot(s) along an optical beam path onto said photon detector, and [0087] a shifting unit for shifting the optical beam path with respect to the photon detector or vice versa.

[0088] [74] In a particular embodiment, a transmission detector for a multi-beam SEM wherein an array of electron beams hit a luminescent plate after traversing through a thin sample, is provided. A light microscope images the bottom of the luminescent plate onto a light detector. In addition, a unit is arranged in the light path between the luminescent plate and the light detector, which unit can independently move the light spots on the light detector. Without this unit the light emitting spots generated in the luminescent plate move when the electron beams are scanned over the sample. Thus the light spots imaged on the light detector also move over the surface of the light detector. It is however preferred to keep the signal from particular electron beam substantially on the same spot on the light detector. Accordingly, the unit arranged in the light path can compensate the movement of the light emitting spots on the luminescent plate so that the light spots on the light detector do not move. In addition, the detector of the present invention also allows to move the array of electron beams over a larger distance, which allows to record several (for instance 3×3) scan field before moving the sample stage. This saves the overhead time related to the stage settling.

[0089] It is to be understood that the above description is included to illustrate the operation of the preferred embodiments and is not meant to limit the scope of the invention. From the above discussion, many variations will be apparent to one skilled in the art that would yet be encompassed by the scope of the present invention.