Process for inspecting objects showing patterns with dimensional tolerances and reject criteria varying with the locations of said patterns and apparatus and circuits for carrying out said process

• US 4,481,664 A
• Filed: 12/11/1981
• Issued: 11/06/1984
• Est. Priority Date: 12/18/1980
• Status: Expired due to Term

• Current Assignee: International Business Machines Corporation
• Original Assignee: International Business Machines Corporation
• Inventors: Locicero, Gisele C., Linger, Claude J. A.
• Primary Examiner(s): Reeves, Robert B.
• Assistant Examiner(s): WACYRA, EDWARD MICHAEL
• Application Number:
  US06/329,892
• Time in Patent Office: 1,061 Days
• Field of Search: 209/576, 209/586, 250/560, 250/563, 356/394, 356/398, 358/101, 358/106, 358/107, 364/489-491, 382/8
• US Class Current: 382/149
• CPC Class Codes: B07C 5/10 measured by light-responsive means sorting according to colour B07C5/342
• CPC Class Codes: G01R 31/308 using non-ionising electromagnetic radiation, e.g. optical radiation investigating or analysing materials by the use of optical means G01N21/00; image analysis G06T7/00
• CPC Class Codes: G03F 7/70616 Monitoring the printed patterns
• CPC Class Codes: G06T 2207/30141 Printed circuit board [PCB]
• CPC Class Codes: G06T 2207/30148 Semiconductor; IC; Wafer
• CPC Class Codes: G06T 7/001 using an image reference approach

Abstract

First of all, this invention relates to a process based on the comparison of the image of a reference object I_ref with the image of an object to be inspected I_exa. Images I_ref and I_exa are picked-up, sampled, discretized and thresheld to produce electronic or binary images I_REF and I_EXA, respectively. These images are cleaned, then centered, I_REF is adjusted to the minimum dimensional tolerances and becomes (I_REF)_min. For each image point (pixel), the adjustment is performed by using a structuring element of variable size, the size of which is controlled by a bus from the data contained in a memory unit which take the location of the pixel on the reference object, into account. (I_REF)_min is compared to I_EXA which ensures the following function:

[(I.sub.REF).sub.min OR I.sub.EXA ]EXCL. OR I.sub.EXA.

The resulting image is the image of the "lack" type defects (which does not appear in I_exa with respect to I_ref). Each defect is studied in a defect analysis unit which computes the dimensions of the defect and compares these dimensions with the maximum allowed size of the defect in this location. For this purpose, this circuit uses the reject criteria for this location, which are contained in a memory unit. The processing operations (adjustment and analysis) and the production of the corresponding data contained in the memory, are synchronized by count and delay circuits. The binary result (accepted/rejected) is available on a line. The defects of the "spreading" type are processed in the same way. The logic level of the line which is connected to a computer, determines the final decision (accepted/rejected). This invention also relates to an apparatus and circuits for carrying out the described process. This invention can be more particularly used in manufacturing semiconductors (masks, modules, chips, . . . ).

Claims

1. A process for inspecting objects showing patterns with dimensional tolerances and reject criteria varying in accordance with the location of said patterns, of the type including the comparision of image I_ref of a reference object with image I_exa of an object to be inspected, the latter being liable to show geometrical defects with respect to the reference object, characterized in that in includes the following steps;

Step 1--elaborating binary electronic images I_REF and I_EXA from images I_ref and I_exa,

Step 2--defining a structuring element B for each image point (pixel) the size of said structuring element being able to vary for each pixel in function of predetermined data and adjusting I_REF to the maximum and minimum dimensional tolerances by expanding and eroding said image by structuring element B, which provides (I_REF)_max and (I_REF)_min,

Step 3--forming images of the "spreading" and "lack" type defects by respectively carrying out the following logical operations;

space="preserve" listing-type="equation">[(I.sub.REF).sub.max OR I.sub.EXA ] EXCL. OR (I.sub.REF).sub.max and

space="preserve" listing-type="equation">[(I.sub.REF).sub.min OR I.sub.EXA ] EXCL. OR I.sub.EXA'"'"' and

Step 4--measuring the size of the defects on the defect images and comparing said defects with respect to reject criteria which define, for each pixel, the dimensions of the defects which can be accepted according to predetermined data.

2. A process as set forth in claim 1 characterized in that the step 1 provided for elaborating images I_REF and I_EXA includes the following operations:

picking-up images I_ref and I_exa of the reference object and of the object to be inspected in analog form, in black and white, with all the grey levels,

sampling images according to a determined frame chosen in the group including the hexagonal frame, the square frame, . . . ,

quantizing the image to retain only a number 2^N of grey levels with 2≦

N≦

6, and

thresholding the images to obtain said electronic binary images.

3. A process as set forth in claim 2 characterized in that the thresholding operation includes the determination of the threshold of images I_ref and I_exa, which is carried out from the frequency curve of the pixel intensities.

4. A process as set forth in claim 3 characterized in that the threshold determination is program controlled.

5. A process as set forth in claim 4 characterized in that it further includes a step for centering electronic images I_REF and I_EXA, said step corresponding to the optical centering of images I_ref and I_exa.

6. A process as set forth in claim 1 characterized in that the step 1 provided for elaborating binary electronic images I_REF and I_EXA includes the following operations:

picking-up image I_exa of the object to be inspected in analog form, in black and white, with all the grey levels,

sampling this image according to a determined frame chosen in the group including;

the hexagonal frame, the square frame, . . . ,

quantizing the image to retain only a number 2^N of grey levels with 2≦

N≦

6,

thresholding the image to obtain I_EXA and

elaborating directly I_REF either from a digital pattern generator or from a data bank.

7. A process as set forth in claim 1 characterized in that it further includes a step for cleaning images I_REF and I_EXA (noise suppression) carried out prior to the dimensional tolerance adjustment step and consisting either in an opening operation, or in a closing operation, or in a combination of both, the size of the erosion being lower than the size of the smallest defect to be detected.

8. A process as set forth in claim 1 characterized in that the structuring element of step 2 has the approximate shape of a circle with a variable diameter.

9. A process as set forth in claim 8 characterized in that the structuring element of step 2 is comprised of a plurality of concentric rings which are developed from the central pixel which is the pixel under analysis, these rings being separated one from the others by an interval equal to the interval separating two pixels.

10. A process as set forth in claim 1 characterized in that the size of each defect in step 4 is determined by computing the horizontal and vertical projections along at least, a pair of axes perpendicular along directions θ

and θ

+90°

.

11. A process as set forth in claim 10 characterized in that direction θ

corresponds to the direction of the pattern which contains the defect.

12. A process as set forth in claim 11 characterized in that reject criteria are deduced from the dimensions and direction of the pattern and appear as terms which can be compared with said projections.

13. A process as set forth in claim 12 characterized in that the reject criteria, the dimensional tolerance and direction θ

are common to all the pixels of a same region.

14. A process as set forth in claim 13 characterized in that the reject criteria, the dimensional tolerance and direction θ

are automatically generated for each region by a computer after scanning of I_REF along the possible directions of the configuration patterns through the use of a program.

15. A process as set forth in claim 1 characterized in that said predetermined data of step 4 are provided in two data tables No. 1 and No. 2, respectively;

for the defects of the "lack" type and of the "spreading" type.

16. A process as set forth in claim 15 characterized in that, for each pixel, the corresponding data include dimensional tolerances N, pattern direction θ

and the reject criteria which define one or several analysis windows.

17. An apparatus for inspecting objects showing patterns with dimensional tolerances and reject criteria varying with the location of said patterns, of the type comparing image I_ref of a reference object with image I_exa of an object to be inspected liable to show geometrical defects with respect to the reference object, characterized in that it includes:

means for picking-up at least I_exa,

means for elaborating binary electronic images I_REF and I_EXA,

processing means including means for adjusting I_REF by expanding and eroding it to the maximum and minimum tolerances, by a structuring element B the size of which can vary for each pixel, in function of predetermined data, compare means for forming images of the defects of the "spreading" and "lack" types by respectively carrying out the following logic operations;

space="preserve" listing-type="equation">[(I.sub.REF).sub.max OR I.sub.EXA ] EXCL. OR (I.sub.REF).sub.max and

space="preserve" listing-type="equation">[(I.sub.REF).sub.min OR I.sub.EXA ] EXCL. OR I.sub.EXA, and

means for analysing defects, including means for measuring the size of the defects and means for comparing said defects with reject criteria defining for each pixel, the defect dimensions which can be accepted, in accordance with predetermined data.

18. An apparatus as set forth in claim 17 further characterized in that it includes:

synchronizing and addressing means which, for each pixel which is analysed, fetch said predetermined data out of a memory into which they have been previously charged.

19. An apparatus as set forth in claim 18 characterized in that the picking-up means are chosen from the group including the electron microscopes, the TV cameras, the photodiodes arrays and the coupled charge devices.

20. An apparatus as set forth in claim 18 characterized in that said means for elaborating electronic images I_REF and I_EXA include a unit for detecting a threshold and for thresholding at least I_EXA.

21. An apparatus as set forth in claim 18 characterized in that I_REF is stored in a buffer memory.

22. An apparatus as set forth in claim 18 characterized in that it further includes computing means for recentering electronic images I_REF and I_EXA.

23. A circuit for adjusting an electronic reference signal I_REF to minimum dimensional tolerances by using a structural element of circular shape and variable size, formed of a plurality of concentric rings characterized in that it includes:

means for storing all the pixels of I_REF constituting said structuring element, into memory cells,

a plurality of AND gates respectively forming each of said rings, the inputs of each AND gate being constituted by the contents of the cells corresponding to the constitutive pixels of the ring under consideration,

decoding means for selecting the number and rank of the rings to be considered, and

an AND gate for integrating said selected rings so that signal (I_REF)_min is obtained at the output of said gate.

24. A circuit as set forth in claim 23, characterized in that:

said storing means include on the one hand, n shift registers, the cell number of which corresponds to the pixel number of each line of I_REF, and n corresponds to the line number of the structuring element, and on the other hand, n shift registers comprised of cells with parallel outputs, the number of cells corresponding to the number of columns of the structuring element.

25. A circuit for adjusting an electronic reference signal I_REF to maximum dimensional tolerances by using a structuring element of circular shape and variable size, comprised of a plurality of concentric rings, characterized in that it includes:

means for storing all the pixels of (I_REF) constituting said structuring element into memory cells,

a plurality of AND gates respectively constituting each of said rings, the inputs of each AND gate constituted by the contents of the cells corresponding to the constitutive pixels of the ring under consideration,

decoding means for selecting the number and rank of the rings to be considered, and

an AND gate (69) followed by an invert circuit (71) for integrating said selected rings so that signal (I_REF)_max is obtained at the output of this gate.