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Apparatus and method for inspector defects    
United States Patent6400454   
Link to this pagehttp://www.wikipatents.com/6400454.html
Inventor(s)Noguchi; Minori (Mitsukaido, JP); Maeda; Shunji (Yokohama, JP); Shibata; Yukihiro (Fujisawa, JP); Ninomiya; Takanori (Hiratsuka, JP)
AbstractThe present invention provides a defect inspection method and an apparatus adopting the method which comprises the steps of: using a radiation optical system to radiate a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein the Gaussian light beam is shaped to give an illumination-intensity distribution of a Gaussian distribution having a standard deviation about equal to the distance from an optical axis of the area of detection to the periphery of the area of detection; using a detection optical system to form an optical image of the area of detection on the substrate serving as an object of inspection by radiation of the shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to the area of detection and to detect a picture signal corresponding to the area of detection and originating from the detector; and detecting a defect caused by typically an extraneous material existing in the area of detection on the basis of the detected picture signal.



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Drawing from US Patent 6400454
Apparatus and method for inspector defects - US Patent 6400454 Drawing
Apparatus and method for inspector defects
Inventor     Noguchi; Minori (Mitsukaido, JP); Maeda; Shunji (Yokohama, JP); Shibata; Yukihiro (Fujisawa, JP); Ninomiya; Takanori (Hiratsuka, JP)
Owner/Assignee     Hitachi, Ltd. (Tokyo, JP)
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Publication Date     June 4, 2002
Application Number     09/490,844
PAIR File History     Application Data   Transaction History
Image File Wrapper   Patent Term   Fees
Litigation
Filing Date     January 24, 2000
US Classification     356/237.3 356/237.4
Int'l Classification     G01N 021/89
Examiner     Pham; Hoa Q.
Assistant Examiner    
Attorney/Law Firm     Antonelli, Terry, Stout & Kraus, LLP
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Priority Data     Jan 27, 1999[JP]11-019035
USPTO Field of Search     356/237.1 356/237.2 356/237.3 356/237.4 356/237.5 356/237.6 356/394 356/600 250/559.45 250/559.06 250/559.22
Patent Tags     inspector defects
   
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6084671
Holcomb
356/511
Jul,2000

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5774222
Maeda
356/394
Jun,1998

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5739526
Furstenau
250/227.14
Apr,1998

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Hayano
250/559.45
Sep,1997

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Hayano
356/237.2
Dec,1995

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Morioka
356/237.5
Oct,1995

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What is claimed is:

1. A defect inspection method comprising the steps of:

radiating a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon by using a radiation optical system wherein said Gaussian light beam is shaped to give an illumination-intensity distribution of a Gaussian distribution having a standard deviation about equal to a distance from an optical axis of said area of detection to peripheries of said area of detection;

forming an optical image of said area of detection on said substrate serving as an object of inspection by radiating of said shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to said area of detection and detecting a picture signal corresponding to said area of detection and originating from said detector; and

processing so as to judge whether or not a defect exists in said area of detection on the basis of said detected picture signal originating from said detector by a signal processing system.

2. A defect inspection method according to claim 1 wherein said shaped Gaussian light beam has a slit shape; and

said substrate is moved relatively to said Gaussian light beam having said slit shape in a direction crossing a longitudinal direction of said slit shape of the Gaussian light beam.

3. A defect inspection method according to claim 2 wherein said detector is a TDI image sensor.

4. A defect inspection method according to claim 2, wherein said shaped Gaussian light beam is formed by a DUV-light beam and said detector is a TDI image sensor having sensitivity for said DUV-light.

5. A defect inspection method according to claim 4, wherein said TDI image sensor is formed by a back-surface-radiation TDI image sensor which receives an incident light impinging on a rear side of a thin Si substrate.

6. A defect inspection method according to claim 1 wherein said shaped Gaussian light beam is radiated to the area of detection on said substrate from a direction with respect to the optical axis.

7. A defect inspection method according to claim 1, wherein said defect is a defect caused by an extraneous material.

8. A defect inspection method according to claim 1, wherein said shaped Gaussian light beam is formed by a DUV-light beam.

9. A defect inspection method comprising the steps of:

radiating a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon by using a radiation optical system wherein said Gaussian light beam is shaped to give an illumination-intensity distribution of a Gaussian distribution having a ratio of illumination-intensities on said peripheries of said area of detection to an illumination-intensity on an optical axis of said area of detection which is in a range of 0.46 to 0.73;

forming an optical image of said:area of detection on said substrate serving as an object of inspection by radiation of said shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to said area of detection and detecting a picture signal corresponding to said area of detection and originating from said detector by using a detection optical system; and

processing so as to judge whether or not a defect exists in said area of detection on the basis of said detected picture signal originating from said detector by a signal processing system.

10. A defect inspecting apparatus comprising:

a radiation optical system for radiating a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein said Gaussian light beam is shaped to give an illuminatio-intensity distribution of a Gaussian distribution having a standard deviation about equal to a distance from an optical axis of said area of detection to peripheries of said area of detection;

a detection optical system for forming an optical image of said area of detection on said substrate by radiation of said shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to said area of detection and for detecting a picture signal corresponding to said area of detection and originating from said detector; and

a signal processing system for forming a judgment as to whether or not a defect exists in said area of detection on the basis of a detected picture signal originating from said detector employed in said detection optical system.

11. A defect inspecting apparatus according to claim 10 wherein said radiation optical system is provided on an optical system which forms said shaped Gaussian beam in a state of a slit shape; and further comprising a stage movement unit for moving relatively a stage mounted said substrate to said Gaussian beam in a direction crossing a longitudinal direction of said slit shape of the Gaussian light beam.

12. A defect inspecting apparatus according to claim 11 wherein said detector is a TDI image sensor.

13. A defect inspecting apparatus according to claim 11, wherein said radiation optical system is provided a DUV-light source for irradiating a DUV-light beam and said detector in said detection optical system is formed by TDI image sensor having sensitivity for said DUV-light.

14. A defect inspecting apparatus according to claim 13, wherein said TDI image sensor is formed by a back-surface-radiation TDI image sensor which receives an incident light impinging on a rear side of a thin Si substrate.

15. A defect inspecting apparatus according to claim 10 wherein said radiation optical system is provided on an optical system for radiating said shaped Gaussian beam to the area of detection on said substrate from a direction with respect to the optical axis.

16. A defect inspecting apparatus according to claim 10, wherein said defect is a defect caused by extraneous material.

17. A defect inspecting apparatus according to claim 10, wherein said radiation optical system is provided a DUV-light source-for irradiating a DUV-light beam.

18. A defect inspecting apparatus comprising:

a radiation optical system for radiating a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein said Gaussian light beam is shaped to give an illumination-intensity distribution of a Gaussian distribution having a ratio of illumination-intensities on said peripheries of said area of detection to an illumination-intensity on an optical axis of said area of detection which is in a range of 0.46 to 0.73;

a detection optical system for forming an optical image of said area of detection on said substrate by radiation of said shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to said area of detection and for detecting a picture signal corresponding to said area of detection and originating from said detector; and

a signal processing system for forming a judgment as to whether or not a defect exists in said area of detection on the basis of a detected picture signal originating from said detector employed in said detection optical system.

19. A defect inspecting apparatus comprising:

a radiation optical system for radiate a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein said Gaussian light beam is shaped by adaptation of the diameter or the longitudinal length of said beam to the distance between peripheries having the optical axis of said area of detection as the center thereof so that the ratio of an illumination intensity on said peripheries of said area of detection to an illumination intensity at the center of said area of detection is in a range of 0.46 to 0.73;

a detection optical system for forming an optical image of said area of detection on said substrate serving as an object of inspection by radiation of said shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to said area of detection and for detecting a picture signal corresponding to said area of detection and originating from said detector; and

a signal processing system for forming a judgment as to whether or not a defect exists in said area of detection on the basis of a detected picture signal originating from said detector employed in said detection optical system.

20. A defect inspecting apparatus according to claim 19, wherein said defect is a defect caused by extraneous material.
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BACKGROUND OF THE INVENTION

The present invention relates to a defect testing apparatus and a defect testing method for inspecting a state of generation of defects such as foreign particles in a fabrication process such as a semiconductor fabrication process, a liquid-crystal-display fabrication process and a print-board fabrication process wherein a defect such as a foreign particle generated in a process to create a pattern on a substrate to produce an object is detected and analyzed in order to determine a countermeasure.

In the conventional semiconductor fabrication method, a foreign particle existing on a semiconductor substrate also known as a wafer causes a defect such as poor insulation of a wire or a short circuit. Furthermore, in the case of a miniaturized semiconductor device, an infinitesimal foreign particle existing in a semiconductor substrate results in poor insulation of a capacitor or destruction of typically a gate oxide film. These foreign particles are introduced to get mixed with a semiconductor material in a variety of states due to a variety of causes. For example, a foreign particle is generated by a movable part of a transportation apparatus or a human body. A foreign particle can also be generated as a result of a chemical reaction in processing equipment using a process gas or mixed with chemicals or a raw material.

Likewise, if a foreign particle is introduced to get mixed with a pattern, causing some defects in a process to fabricate a liquid-crystal display device, the resulting display device is not usable. The process to fabricate a print board is in the same situation. That is to say, a mixed foreign particle causes a poor connection and a short circuit in a pattern.

Prior arts related to apparatuses and methods for detecting defects such as foreign particles are disclosed in Japanese Patent Laid-open No. Hei 1-250847, Japanese Patent Laid-open No. Hei 6-258239, Japanese Patent Laid-open No. Hei 6-324003, Japanese Patent Laid-open No. Hei 8-210989 and Japanese Patent Laid-open No. Hei 8-271437 and referred to as prior arts 1, 2, 3 ,4 and 5 respectively.

In prior art 1, there is described an inspection apparatus for inspecting surface characteristics of a substrate. The inspection apparatus includes a storage means for storing desired surface characteristics of the substrate, a radiation means for radiating a beam to an area on the surface of the substrate to be inspected all but uniformly, a TDI image sensor means for forming an image of the area on the surface of the substrate to which the beam is radiated by the radiation means, and a comparison means for comparing the image of the area on the surface of the substrate formed by the TDI image sensor means with the desired surface characteristics of the substrate stored in the storage means.

In prior art 2, there is described a defect inspecting apparatus comprising a conveyance means for conveying a substrate having repetitive patterns with different pitches, a radiation means for forming a plane-wave beam into a straight line and radiating the plane-wave beam to the substrate, a space filter, a detector for detecting an optical image formed by an image formation optical system and supplied to the detector through the space filter, elimination means for comparing signals, which are generated to represent the repetitive patterns with large pitches on the substrate and supplied to the elimination means through the space filter for an elimination purpose, with each other, and a defect detection means for detecting a defect caused by typically a very small extraneous material existing on the substrate on the basis of a signal generated by the elimination means.

In prior art 3, there is described a defect inspecting apparatus comprising a detection head, a pitch detection means, an operator processing system, an extraneous-material data memory, a large-extraneous-material data memory, a pattern memory, a software processing system, a parameter transfer means, an extraneous-material memory, a coordinate-data creation means and a microcomputer wherein the detection head includes a radiation means, a detection optical system, a space-filter unit, a detector, an operational amplifier and an A/D converter.

In prior art 4, there is described a very-small-defect detecting apparatus for detecting a-very smell defect caused by typically a very small extraneous material having a size in a range of 0.3.mu.m to 0.8 .mu.m or smaller and existing on a substrate by splitting a laser beam emitted from a semiconductor laser oscillator into a plurality of optical beams not interfering each other so as to make intensities of beams reflected by a thin film created on the substrate smooth or uniform, converging the optical beams and radiating the converged optical beams at effectively the same time to the thin film passing the beams at different incidence angles T1 to Tn, converging lights scattered by a very small defect by using a light converging lens, and detecting the converged lights by using a detector such as a TDI image sensor.

In prior art 5, there is described an extraneous-material inspecting apparatus comprising a radiation optical system for radiating a beam generated by a light source to a sample comprising repetitive chips, a detection optical system including a linear image sensor for receiving lights reflected and scattered by the sample and for converting the reflected and scattered lights into a signal, and an interchip comparison means for comparing signals output by the linear image sensor employed in the detection optical system for the repetitive chips in order to detect a comparison mismatch as existence of an extraneous material on the sample, wherein the radiation optical system includes, a shading correction plate having a plurality of curved transmission portions created thereon for an intensity distribution of the beam generated by the light source to correct the beam radiation so as to give an all but equal phase distribution in the straight-line transversal direction and an all but uniform radiation intensity in the straight-line longitudinal direction, and a light converging subsystem for converging the radiated beam and radiating the converged beam to the sample in a slanting direction with respect to the surface of the sample.

In the prior arts described above, however, it is not easy to detect a defect cause by a very small extraneous material with a size of about 0.1 .mu.m or smaller existing on a substrate, on which repetitive patterns coexist with non-repetitive patterns, with a high degree of sensitivity and at a high speed.

This is because, with the prior arts described above, the farther the distance from a location in an inspected area to the optical axis of the detection optical system, the lower the MTF (Modulation Transfer Function) for the location so that the illumination intensity of the radiated light in regions surrounding the inspected area is not sufficient, making it difficult to inspect a defect with a high degree of sensitivity and at a high speed.

SUMMARY OF THE INVENTION

It is thus an object of the present invention addressing the problems described above to provide a defect inspecting apparatus and a defect inspection method that are capable of inspecting an area of inspection also for a defect caused by typically a very small extraneous material having a size of about 0.1 .mu.m or smaller with a high degree of sensitivity and at a high speed by effectively utilizing the light quantity of a Gaussian optical beam emitted by an ordinary low-cost light source.

It is another object of the present invention to provide a defect inspecting apparatus and a defect-inspection method that are capable of inspecting an area of inspection also for a defect caused by typically a very small extraneous material having a size of about 0.1 .mu.m or smaller by employing a TDI image sensor for receiving an optical image based on a DUV (Distant Ultra Violet) laser beam obtained from a substrate being inspected.

It is a further object of the present invention to provide a defect inspecting apparatus and a defect inspection method that are capable of inspecting an area of inspection also for a defect caused by typically a very small extraneous material having a size of about 0.1 .mu.m or smaller with a high degree of sensitivity and at a high speed by effectively utilizing the light quantity of a beam emitted by a lamp serving as a light source and by solving the problem of an insufficient illumination intensity in regions surrounding an area of detection on a substrate serving as an object of inspection with the insufficient illumination intensity caused by the fact that, the farther the distance from a region to the optical axis of the detection optical system, the lower the MTF for the region.

It is a still further object of the present invention to provide a defect inspecting apparatus and a defect inspection method that are capable of inspecting an area of inspection also for a defect caused by typically a very small extraneous material having a size of about 0.1 .mu.m or smaller with a high degree of sensitivity and at a high speed by effectively utilizing the light quantity of a Gaussian optical beam emitted by an ordinary low-cost light source and by solving the problem of an insufficient illumination intensity in regions surrounding an area of detection on a substrate serving as an object of inspection with the insufficient illumination intensity caused by the fact that, the farther the distance from a region to the optical axis of the detection optical system, the lower the MTF for the region.

In order to achieve the objects described above, the present invention is characterized in that, in an area with a minimum illumination intensity in an illumination-intensity distribution within a radiation range, radiation of a beam is implemented to give a maximum illumination intensity and the S/N ratio of a signal representing a detected beam is maximized in order to improve the detection sensitivity and to increase the throughput.

That is to say, the present invention is characterized in that, by radiating a Gaussian optical beam to an area of detection on a substrate serving as an object of inspection with the Gaussian optical beam shaped to provide a maximum illumination intensity on the outermost circumference (or the periphery) of the area of detection, the sensitivity (the S/N ratio) on the outermost circumference in a detector can be increased and a defect caused by typically a very small extraneous material existing in the area of detection can be detected with a high degree of sensitivity and at a high speed. It should be noted that, by a maximum illumination intensity, an illumination intensity of about 60% of the illumination intensity at the center of the area of detection is meant.

In addition, the present invention also provides a defect inspection method and an apparatus adopting the method comprising the steps of:

using a radiation optical system including a radiation light source to radiate a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein the Gaussian light beam is shaped to give an illumination-intensity distribution of a Gaussian distribution having a standard deviation about equal to the distance from the optical axis of the area of detection to the periphery of the area of detection;

using a detection optical system to form an optical image of the area of detection on the substrate serving as an object of inspection by radiation of the shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to the area of detection;

detecting a picture signal corresponding to the area of detection and originating from the detector; and

detecting a defect caused by typically an extraneous material existing in the area of detection on the basis of the detected picture signal.

Furthermore, the present invention also provides a defect inspection method and an apparatus adopting the method comprising the steps of:

using a radiation optical system to radiate a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein the Gaussian light beam is shaped by adaptation of the diameter or the longitudinal length of the beam to the distance between peripheries having the optical axis of the area of detection as the center thereof so that the ratio of the illumination intensity on the peripheries of the area of detection to the illumination intensity at the center of the area of detection is in a range of about 0.46 to about 0.73 or, ideally, in a range of about 0.54 to about 0.67;

using a detection optical system to form an optical image of the area of detection on the substrate serving as an object of inspection by radiation of the shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to the area of detection;

detecting a picture signal corresponding to the area of detection and originating from the detector; and

detecting a defect caused by typically an extraneous material existing in the area of detection on the basis of the detected picture signal.

Moreover, in the defect inspection method and the apparatus adopting the method provided by the present invention, the Gaussian light beam has a slit shape and the substrate serving as an object of inspection is moved relatively to the Gaussian light beam with a slit shape in a direction crossing the longitudinal direction of the Gaussian light beam.

Further, in the defect inspection method and the apparatus adopting the method provided by the present invention, the detector is a TDI image sensor.

In addition, in the defect inspection method and the apparatus adopting the method provided by the present invention, the shaped Gaussian light beam is radiated to the area of radiation on the substrate serving as an object of inspection in a slanting direction with respect to the surface of the area.

Furthermore, the present invention also provides a defect inspection method and an apparatus adopting the method comprising the steps of:

using a radiation optical system to radiate a Gaussian light beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein the Gaussian light beam is shaped wherein the Gaussian light beam is shaped by adaptation of the diameter or the longitudinal length of the beam to the distance between peripheries having the optical axis of the area of detection as the center thereof so that the ratio of the illumination intensity on the peripheries of the area of detection to the illumination intensity at the center of the area of detection is in a range of about 0.46 to about 0.73 or, ideally, in a range of about 0.54 to about 0.67;

using a detection optical system to form an optical image of the area of detection on the substrate serving as an object of inspection by radiation of the shaped Gaussian light beam to a photo-sensitive surface of a detector corresponding to the area of detection;

detecting a picture signal corresponding to the area of detection and originating from the detector; and

detecting a defect caused by typically an extraneous material existing in the area of detection on the basis of the detected picture signal.

Moreover, the present invention also provides a defect inspection method and an apparatus adopting the method comprising the steps of:

using a radiation optical system to radiate a DUV beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon;

using a detection optical system to form an optical image of the area of detection on the substrate serving as an object of inspection by radiation of the shaped DUV beam on a DUV-light-sensitive surface of a TDI image sensor corresponding to the area of detection;

detecting a picture signal corresponding to the area of detection and originating from the TDI image sensor; and

detecting a defect caused by typically an extraneous material existing in the area of detection on the basis of the detected picture signal.

Further, the present invention also provides a defect inspection method and an apparatus adopting the method comprising the steps of:

using a radiation optical system to radiate a DUV beam to an area of detection on a substrate serving as an object of inspection and having a circuit pattern created thereon wherein the DUV beam is shaped to give an illumination-intensity distribution of a Gaussian distribution having a standard deviation about equal to the distance from the optical axis of the area of detection to the periphery of the area of detection;

using a detection optical system to form an optical image of the area of detection on the substrate serving as an object of inspection by radiation of the shaped DUV beam on a DUV-light-sensitive surface of a TDI image sensor corresponding to the area of detection;

detecting a picture signal corresponding to the area of detection and originating from the TDI image sensor; and

detecting a defect caused by typically an extraneous material existing in the area of detection on the basis of the detected picture signal.

According to a configuration described above, a problem of an insufficient illumination intensity on the periphery of an area of detection on a substrate serving as an object of inspection caused by the fact that, the farther the distance from a region to the optical axis of the detection optical system, the lower the MTF (Modulation Transfer Function) for the region, is solved by effectively utilizing the light quantity of a Gaussian light beam emitted by an ordinary low-cost light source, making it possible to detect also a defect caused by typically a very small extraneous material with a size in a range of about 0.1 .mu.m s to about 0.5 .mu.m or even a defect caused by typically a very small extraneous material with a size smaller than 0.1 .mu.m with a high degree of sensitivity and at a high speed.

In addition, according to configuration described above, an optical image based on a DUV (Distant Ultra Violet) laser beam such as an excima laser obtained from a substrate serving as an object of inspection can be received by a TDI image sensor, making it possible to detect also a defect caused by typically a very small extraneous material with a size in a range of about 0.1 .mu.m to about 0.5 .mu.m or even a defect caused by typically a very small extraneous material with a size smaller than 0.1 .mu.m.

Furthermore, according to a configuration described above, a problem of an insufficient illumination intensity on the periphery of an area of detection on a substrate serving as an object of inspection caused by the fact that, the farther the distance from a region to the optical axis of the detection optical system, the lower the MTF for the region, is solved by effectively utilizing the light quantity of a beam emitted by a lamp serving as a light source, making it possible to detect also a defect caused by typically a very small extraneous material with a size of about 0.1 .mu.m or smaller in the area of detection with a high degree of sensitivity and at a high speed. It should be noted that the detection is moved from one area to another over the substrate serving as an object of inspection.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing the configuration of a fourth embodiment implementing a defect inspecting apparatus provided by the present invention in a simple and plain manner;

FIG. 2(a) is a diagram showing an embodiment implementing an illumination optical system employed in the fourth embodiment implementing a defect inspecting apparatus of FIG. 1 in concrete terms as seen from a position on the y axis; and FIG. 2(b) is a diagram showing the same in concrete terms as seen from a position on the x axis;

FIG. 3 is an explanatory diagram used for describing a basic concept of shaping a slit-shaped Gaussian beam by means of an illumination optical system to increase the illumination efficiency;

FIGS. 4(a) and 4(b) are explanatory diagrams used for describing an image-pickup method to receive a light representing an optical image in an area of detection on a substrate being inspected by using a TDI image sensor as a detector;

FIG. 5 is a diagram showing variations in illumination f(x.sub.0) at a periphery (x.sub.0 =1) of a detection area with changes in standard deviation .sigma. (corresponding to the width of illumination) of a Gaussian Beam;

FIG. 6 is a diagram showing variations in illumination f(x.sub.0) with changes in distance x.sub.0 from the optical axis of a detection area for a radiated Gaussian beam at standard deviations .sigma. of 0.5, 1 and 2;

FIG. 7 is a diagram showing the configuration of the second embodiment implementing a defect inspecting apparatus provided by the present invention in a simple and plain manner.

FIGS. 8(a) and 8(b) are explanatory diagrams used for describing an embodiment implementing a TDI image sensor capable of receiving a DUV light;

FIG. 9 is a diagram showing the configuration of an embodiment implementing a signal processing system capable of inspecting an object by detection of a signal generated by a defect caused by typically a very small extraneous material with a size of about 0.1 .mu.m or smaller by discrimination of a false-information signal;

FIG. 10 is a diagram showing the configuration of another embodiment implementing the radiation optical system employed in the first embodiment implementing the defect inspecting apparatus shown in FIG. 1;

FIG. 11 is an explanatory diagram showing a case in which the illumination intensity on the periphery of an area of detection is increased by using the radiation optical system shown in FIG. 10 to effectively utilize the light quantity of a beam emitted by a lamp serving as a light source and make use of the orientability of the beam emitted by the lamp serving as a light source; and

FIG. 12 is a diagram showing an illumination distribution over an area of detection obtained by using the radiation optical system shown in FIGS. 10 and 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Some preferred embodiments implementing a defect inspecting apparatus and method provided by the present invention, are explained by referring to diagrams as follows.

By the way, with semiconductor devices miniaturized more and more, a further increase in yield is also required. To put it in detail, a circuit pattern created on a semiconductor substrate such as a semiconductor wafer for making such semiconductor devices is subjected to super miniaturization with a design rule of 0.3 to 0.2 .mu.m or even smaller. For this reason, a foreign particle existing on the semiconductor substrate causes a semiconductor device created on the substrate to operate abnormally even if the foreign particle is an infinitesimal molecule with a size of about 0.1 .mu.m or smaller or a particle with a size close to that at an atomic level.

In such a state of the art to fabricate a semiconductor device, the defect inspecting apparatus provided by the present invention for detecting a defect such as a foreign particle is required to have a capability of inspecting a defect such as an infinitesimal foreign particle existing on a semiconductor substrate such as a semiconductor wafer, on which a circuit pattern undergoing a super-miniaturization by a design rule of 0.3 to 0.2 .mu.m or even smaller exists, with a high degree of sensitivity at a high speed.

FIG. 1 is a diagram showing the first embodiment implementing a defect inspecting apparatus provided by the present invention for detecting a defect such as a foreign particle in a simple and plain manner. FIG. 2 is a diagram showing an embodiment implementing an illumination optical system employed in the defect inspecting apparatus.

As shown in FIG. 1, the defect inspecting apparatus for detecting a defect such as a foreign particle comprises: stage 201 for mounting an inspection object 1 such as a semiconductor device or a semiconductor wafer on which a super-miniaturized circuit pattern with a defect thereof to be detected has been created; an illumination-light source 101 implemented by a laser-beam source such as a semiconductor laser, an argon laser, a YAG-SHG laser or an excima laser; an illumination optical system 102 for radiating a high-luminance light emitted by the illumination-light source (laser source) 101 to an illumination area 2 on the inspection object 1 from a slanting direction as a slit-shaped Gaussian beam 107 having a illumination distribution close to the Gaussian distribution as shown in FIG. 3; a detection optical system 301 comprising an image formation lens includes an objective lens which are used for forming an image from reflection lights, or diffraction lights or scattered lights obtained by a detection area 3; detector 302 each implemented typically by a TDI image sensor or a CCD image sensor having a photo-sensitive surface corresponding to the detection area 3; and an image-signal processing unit 401 for detecting a defect such as a foreign particle from an image signal output by the detector 302.

It should be noted that the defect inspecting apparatus also has an automatic focus control system for controlling formation of an image of the surface of the inspection object 1 on the photo-sensitive surface of the detector 302.

The detection optical system 301 may be formed of a spatial filter unit for shielding diffraction light coming from repetitive patterns having a small pitch formed on a substrate to be inspected, and Fourier transform lens as described in Japanese Patent Laid-open Nos. Hei 6-258239 and Hei 6-324003.

The actual configuration of the illumination-light optical source 101 and the illumination optical system 102 is shown in FIG. 2. In the figure, reference numeral 103 denotes a concave or convex lens for enlarging the diameter of a laser beam 106 emitted by the illumination-light source 101. Reference numeral 104 denotes a collimate lens for converting a laser beam output by the concave or convex lens 103 with an expanding diameter into substantially parallel beams. Reference numeral 105 denotes a cylindrical lens with a conical surface for converging the substantially parallel beams obtained as a result of the conversion in the collimate lens 104 in the direction of the y axis and for radiating the converged beams to an illumination area 2 on the inspection object 1 as a slit-shaped Gaussian beam 107 having an illumination distribution close to the Gaussian distribution as shown in FIG. 3. The cylindrical lens 105 serves as an optical system having a converging function in the direction of the y axis.

It should be noted that the concave or convex lens 103 and the collimate lens 104 constitute a beam expander for enlarging the diameter of the laser beam 106. Thus, the illumination optical system 102 can be regarded as a system comprising the beam expander, the cylindrical lens 105 and a mirror as described in Japanese Patent Laid-open Nos. Hei 6-258239 and Hei 6-324003. The beam expander typically comprises a collimate lens, a concave lens and a receiver lens. As described above, the cylindrical lens 105 is used for converging the substantially parallel beams obtained as a result of the conversion in the beam expander in the direction of the y axis and for radiating the converged beams to an illumination area 2 on the inspection object 1 as a slit-shaped Gaussian beam 107 having an illumination distribution close to the Gaussian distribution as shown in FIG. 3. The mirror reflects the slit-shaped Gaussian beam 107 output by the cylindrical lens 105 and radiates the beam 107 to the inspection object 1 in a slanting direction.

By the way, by changing the distance b between the concave or convex lens 103 and the collimate lens 104 or the distance between the concave lens and the receiver lens in the configuration described above, the x-direction width of the luminance beam having an illumination distribution substantially resembling the Gaussian distribution can be altered. That is to say, by adjusting the beam expander, the x-direction length Lx of the illumination area 2 (or the slit-shaped beam 107) having an illumination distribution substantially resembling the Gaussian distribution can be changed. In addition, by varying the distance between the conical lens 104 and the inspection object 1, the y-direction length Ly of the illumination area 2 (or the slit-shaped beam 107) having an illumination distribution substantially resembling the Gaussian distribution can also be changed.

A detection area 3 shown in FIG. 3 is an area on the inspection object 1 to be inspected by using a TDI image sensor or a CCD image sensor. In the case of a TDI image sensor, for example, the dimensions of each pixel are typically 27 .mu.m.times.27 .mu.m. The TDI image sensor is typically a 64.times.4,096 CCD image-pickup sensor which comprises 64 rows in the TDI (Time Delay Integration) direction and 4,096 columns in the MUX direction, and operates in a TDI mode. That is to say, the TDI image sensors 302a has a configuration comprising n stages of line sensors as shown in FIG. 4 where n is typically 64. A line rate rt is the amount of information output by the sensor which is the line sensors in this case. At a line rate rt, accumulated charge is transferred through lines 1, 2 and so on, from one line to another. By synchronizing the movement speed of the y-axis stage 201 for moving the inspection object 1 in the direction of the y axis with the line rate rt, an image 6 based on a scattered light and a diffraction light generated by typically an infinitesimal foreign particle 5 is accumulated for a long time it takes to transfer the charge to the line n so that a defect such as an infinitesimal foreign particle can be detected with a high degree of sensitivity. In this image sensor, the image of a defect such as an infinitesimal foreign particle is detected as a sum of intensities of a scattered light and a diffraction light traveling from the line 1 to the line n. However, a scattered light or a diffraction light coming from the same point on the object of inspection and reaching the lines is timewise entirely incoherent.

As described above, a beam emitted by the illumination-light source 101 is converted by the illumination optical system (or the radiation optical system) 102 into a slit-shaped Gaussian beam 107 which is radiated to the surface of the inspected substrate 1 on the stage 201 typically in a slanting direction to form an illumination area 2 on the surface. While the inspected substrate 1 is being moved in the direction of the y axis by moving the stage 201 in the direction of the y axis, the detector 302a implemented typically by a TDI image sensor transfers electric charge accumulated in each pixel from one line to another at a line rate rt synchronized with the movement speed of the stage 201. In this way, while an optical image of the detection area 3 on the inspected substrate 1 formed by the detection optical system 301 is being picked up, each pixel (or each device) along the width H of the detection area 3 is scanned to generate a detection signal which is then supplied to the image-signal processing unit 401. By processing the detection signal in the image-signal processing unit 401, it is possible to detect a defect such as an infinitesimal foreign particle existing in the detection area 3 with a high degree of sensitivity and at a high speed.

By using the TDI image sensor 302a as described above, it is possible to compute a total of illumination values of a scattered light or a diffraction light generated by a defect such as an infinitesimal foreign particle where (quantity of light=illumination value.times.time) and, hence, to increase the sensitivity. In addition, once the slit-shaped beam