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2018-04-10
15/422,454
2017-02-01
US 9,941,094 B1
2018-04-10
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Jason McCormack | Sean Luck
Scheinberg & Associates, P.C. | Michael O. Scheinberg
2037-02-01
Smart Summary: An assembly has been created to produce ion beams using a special method called collision ionization. It consists of two stacked plates with a gap in between, where charged particles can enter and create ions. A gas supply is connected to this gap to help with the ionization process. The assembly includes multiple ion sources that differ in the height of the gap between the plates, allowing for different ion beam production options. A selecting device lets users choose which ion source to use, making it flexible for various applications. đ TL;DR
A source assembly for producing an ion beam and comprising a collision ionization ion source having:
The various sources in said plurality preferably have a scattering quotient QS=d/li with a value in a range 1-500, preferably in a range 1-200, where li is an ionic mean free path length in said ionization space.
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H01J37/08 » CPC main
Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof; Details; Arrangements of electrodes and associated parts for generating or controlling the discharge, e.g. electron-optical arrangement, ion-optical arrangement Ion sources; Ion guns
H01J37/147 » CPC further
Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof; Details; Arrangements of electrodes and associated parts for generating or controlling the discharge, e.g. electron-optical arrangement, ion-optical arrangement Arrangements for directing or deflecting the discharge along a desired path
H01J37/261 » CPC further
Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof; Electron or ion microscopes; Electron or ion diffraction tubes Details
H01J37/26 IPC
Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof Electron or ion microscopes; Electron or ion diffraction tubes
The invention relates to a source assembly for producing an ion beam and comprising a collision ionization ion source having:
The invention further relates to an ion focusing apparatus comprising:
Charged-particle microscopy is a well-known and increasingly important technique for imaging microscopic objects, particularly in the form of electron microscopy. Historically, the basic genus of electron microscope has undergone evolution into a number of well-known apparatus species, such as the Transmission Electron Microscope (TEM), Scanning Electron Microscope (SEM), and Scanning Transmission Electron Microscope (STEM), and also into various sub-species, such as so-called âdual-beamâ tools (e.g. a FIB-SEM), which additionally employ a âmachiningâ Focused Ion Beam (FIB), allowing supportive activities such as ion-beam milling or Ion-Beam-Induced Deposition (IBID), for example. More specifically:
In all cases, a Charged-Particle Microscope (CPM) will comprise at least the following components:
In a lithography imager (e.g. wafer stepper/wafer scanner), an actinic beam of radiation is used to pattern an energy-sensitive later of material (photoresist) that has been provided (e.g. spin-coated) on a surface of a substrate (e.g. semiconductor wafer). Traditionally, the actinic beam has comprised a broad beam of photons (e.g. from a mercury lamp or laser), which pass through a mask/reticle and impart its pattern onto the photosensitive later. However, other types of lithography imager make use of charged particles, such as so-called âdirect writeâ electron beam tools, which trace one or more electron beams over the photosensitive layer according to the desired pattern. Still other lithography imager concepts make use of ion beams. Analogous to the discussion above for a CPM, a lithography imager will also generically comprise a radiation source, illuminator and specimen holder, and will additionally comprise an imaging system in the case of mask-based lithography; moreover, it will generally comprise one or more detectorsâthough these will typically be used for purposes such as dose/uniformity calibration, positioning (overlay/alignment) verification, etc. Some general information on lithography can be found in the following link:
In what follows, the invention mayâby way of exampleâsometimes be set forth in the specific context of charged particle microscopy; however, such simplification is intended solely for clarity/illustrative purposes, and should not be interpreted as limiting.
As regards ion sources, the skilled artisan can choose from various possibilities, including Liquid Metal Ion Sources (LMIS), plasma sources, photoionization sources, etc. Of specific interest in the context of the present invention is the collision ionization ion source (e.g. electron impact ionization source), in which an input beam of charged particles (such as electrons) is used to ionize molecules/atoms of gas in an ionization space. To this end, the gas is introduced into a narrow gap between two oppositely-located retaining plates (sheets, membranes), one of which contains an input zone (such as an aperture, or (locally thinned) lamina/film) to admit said input beam and the other of which contains an oppositely located output aperture to allow emission of a flux of ions produced in said ionization region by interaction of the input beam with the gas. Because at least a portion of the gas in question is converted to said ion flux and/or will leak from said output aperture (and input aperture, if the input zone is configured as such), there needs to be a replenishing supply of gas to said ionization space, in order to realize satisfactory continuous operation of the source. In order to achieve a relatively high source brightness, the ionization region is preferably very small, so as to ensure a relatively high density of input charged particles therein; as a consequence, the whole device tends to be very small, with typical input zone/output aperture diameters of the order of a few microns or a few hundred nanometers, for example. For this reason, such sources can also be alluded to as Nano-Aperture Ionization Sources (NAIS), and they are typically manufactured as integrated devices using MEMS technology (MEMS=Micro Electro Mechanical Systems). For more information on NAIS devices, see, for example:
NAIS devices are advantageous in that they can be relatively easily used to generate a variety of different ion speciesâsimply by changing the gas administered to the ionization region. Moreover, because they are small and relatively cheap, and can be manufactured en masse using MEMS fabrication techniques, they can be easily and cheaply switched out/replaced when they reach end-of-lifetime. However, although they have a relatively straightforward structure, in practice it has proven exceptionally difficult to optimize performance of NAIS sources.
It is an object of the invention to address this issue. More specifically, it is an object of the invention to provide an improved ion beam source assembly that employs collision ionization ion beam generation and in which ion beam properties can be more successfully tuned to the requirements of a given application.
These and other objects are achieved in an ion beam source assembly as set forth in the opening paragraph above, characterized in that the source assembly comprises:
During extensive experimentation and analysis leading to the invention, the inventors investigated why prior-art NAIS devices tended to be unpredictable/inconsistent as regards important parameters such as beam brightness, emission current, beam energy spread, beam opening angle and virtual source size. Ideally, a NAIS source would behave somewhat like a light bulb connected to a dimmer switch: just as the bulb glows predictably brighter when it receives more current from the dimmer, an ideal NAIS should increase ion output in a predictable manner when its gas supply is increased. In reality, such predictable behavior is not observed, and the performance of the NAIS turns out to demonstrate a complicated dependence on a variety of factors. One such factorâthe flow conductance of the gas supply duct in the NAISâreceived particular attention in co-pending patent application U.S. Ser. No. 15/405,139 (filed 12 Jan. 2017; incorporated herein by reference). However, the current inventors surmised that other factors were also playing a significant roleâthough it took significant research effort before such factors could be properly understood. Eventually, the inventors realized that, in addition to fluidic behavior of gas in the supply duct, the fluidic behavior of ions in the ionization space was of key importance. More specifically, the ratio of the (defined) height (d) of the ionization space (i.e. the gap height between the NAIS plates at the ionization space) to the ionic mean free path length (li) turned out to be of critical significance. The inventors dubbed this ratio the âionic scattering quotientâ QS=d/li, because it is indicative of how many scattering events a typical ion will undergo in the ionization space before escaping from the output aperture. As a rule of thumb, the inventors discovered that (relatively low) sub-unity values of QS (e.g. QS=0.2) were generally undesirable, because they allowed insufficient generation of ions to occur in the ionization space, leading (for example) to a relatively low ion current in the emitted ion beam; in contrast, values of QS (substantially) greater than unity (e.g. QS=10) resulted in significant ion scattering, with a tendency toward enlarged energy spread and greater virtual source size as a result. As a consequence of these insights, the inventors realized that, when one adjusts the gap height d of a NAIS designâin order to achieve a higher ion beam current, for exampleâone should concurrently ensure that the value of QS (which is directly influenced by d) remains within an acceptable range. It is thisâpreviously unrecognizedâconcurrency that explains the unpredictable outcome of prior-art NAIS design efforts. At the same time, it is this concurrency that led the inventors to realize that a single NAIS could not, in practice, be satisfactorily operated in disparate âregimesââsuch as âhigh currentâ and âhigh monochromaticityâ. This latter insight led to a source design incorporating a variety of different NAIS sourcesâdesigned to operate in (different parts of) different regimesâin conjunction with a selecting device that allows a given NAISâbest suited to a given applicationâto be selected at will.
For the purpose of giving some non-limiting guidance, the inventors have found that, for many applications, a value of QS in the range 5-15 gives very satisfactory all-round results. If one wants to specifically achieve a relatively large beam current, then choice of a larger QS value becomes appropriate, e.g. in a range 25-75. For very large beam currents, QS values of 100 and above become relevant.
The ionization region in a CIIS typically has a relatively low ionization yield, i.e. for each ion therein there will be a much greater number of neutral gas particles present. The ionic mean free path length t can accordingly be regarded as expressing the average distance that such an ion can travel before undergoing a collision with a neutral particle. The inventors have found that, for a neutral particle density n in the ionization space and an electric field E between the retaining plates of the CIIS, li has an approximate functional dependence of the form:
li=1/nf(E/n)
whereby, in practice, the function f(E/n) can (by approximation) be expressed as a natural logarithm (ln):
f(E/n)âa ln(bE/n).
Values of the coefficients a, b can, for example, be calculated and/or derived from calibration runs, and the following table gives some values, for guidance purposes:
| Gas | a (mâ2) | b (Vâ1mâ2) | Fit domain E/n (Vm2) |
| Ar | 2.50 Ă 1017 | 5.56 Ă 1019 | 2.3 Ă 10â19 â 2.0 Ă 10â17 |
| He | 6.93 Ă 1017 | 5.39 Ă 1019 | 3.7 Ă 10â20 â 5.0 Ă 10â18 |
| Xe | 2.22 Ă 1017 | 2.32 Ă 1019 | 3.1 Ă 10â19 â 2.4 Ă 10â17 |
An immediate advantage of the insights set forth above is the realization thatâcontrary to common wisdomâa NAIS source can actually have much larger dimensioning than traditionally has been the case (thereby simplifying its manufacture considerably) and yet concurrently achieve desired operating parameters (such as high brightness/low energy spread); key to this realization is the co-adjustment of other parameters (such as the operating pressure, for example) to ensure that, despite an enlargement of d, the value of QS remains within an acceptable range. This allows innovative NAIS devices with d>1000 nm, for example.
It should be realized that, just because the inventive source assembly comprises a plurality of CIIS modules with a variety of different d-values, this does not mean that all CIIS modules present on the carrier have to have different d-values. There may, for example, be a group of CIIS modules with a given d-value, in which:
There are various ways in which a plurality of different collision ionization ion sources (CIIS) can be incorporated into a source assembly according to the present invention. For example:
As regards the selecting device used in the inventive source assembly, it can also be embodied in various ways. For example, it may comprise one or both of:
The current invention should not be confused with the content of U.S. Pat. No. 9,224,569, (also owned by the present assignee), which only relates to the use of different ion species, and does not disclose/suggest either of:
The invention will now be elucidated in more detail on the basis of exemplary embodiments and the accompanying schematic drawings, in which:
FIG. 1A renders a cross-sectional elevational view of an embodiment of a CIISâin this case a NAISâsuitable for use in an ion source assembly according to the present invention.
FIG. 1B illustrates an embodiment of an ion source assembly according to the present invention, employing a plurality of different CIIS similar to that illustrated in FIG. 1A.
FIG. 2 renders a longitudinal cross-sectional view of an embodiment of a CPM in which the present invention is implemented
In the Figures, where pertinent, corresponding parts are indicated using corresponding reference symbols. It should be noted that, in general, the Figures are not to scale.
FIG. 1A renders a cross-sectional elevational view of an embodiment of a CIIS IsⲠ(in this case a NAIS) suitable for use in an ion source assembly Is according to the present invention (which employs a plurality of different CIIS sources Isâ˛âsee FIG. 1B). As here illustrated, the CIIS IsⲠcomprises:
A structure such as this can, for example, be conveniently manufactured using a chip bonding procedure, whereby the âupper halfâ (plate P1, etc.) and the âlower halfâ (plate P2, etc.) are manufactured on two separate substrates (or substrate portions)âe.g. using etching/ablation techniquesâafter which one half is inverted onto the other, aligned and bonded in position, using appropriate spacers (such as plug P3) to help create the interposed duct/channel Fâ˛. The apertures A1, A2 can be created using etching/ablation, either prior to or after bondingâfor example, a thin actinic (e.g. focused ion) beam can be used to radiatively âdrillâ through the bonded halves from one side, thus realizing perfect mutual alignment of the apertures. Specific examples of chip bonding techniques in the current context include direct bonding, thermocompression bonding, eutectic bonding, anodic bonding, etc.
If desired, the âuniform-heightâ supply duct FⲠin FIG. 1A can, for example, be replaced by a âmulti-heightâ supply duct as set forth in the aforementioned U.S. Ser. No. 15/405,139.
Turning now to FIG. 1B, this shows a plan view of an embodiment of an ion source assembly Is according to the present invention. The depicted source assembly Is comprises a carrier Câsuch as a metallic plate or frame, for exampleâprovided with a plurality of different CIIS modules Isâ˛, e.g. arranged along an edge of the carrier C. Each CIIS IsⲠis of a type as depicted in FIG. 1A, for example, but at least some of them are mutually different in respect of their inter-plate gap height d (see FIG. 1A). Also depicted is a selecting device S, which allows a given one of said CIIS modules IsⲠto be individually selected for production of an output ion beam (Bâ˛) from an input charged-particle beam (e.g. electron beam) B. A footprint of this input beam B (which propagates along the depicted Z axis) is schematically illustrated as a black dot, matched in size to the respective input zones (schematically illustrated as white dots) of the CIIS modules Isâ˛. As here embodied, the selecting device S comprises a mechanical actuator mechanism Sâ˛, which can be used to move the carrier C (attached to an actuation arm Câ˛) relative to the input beam B, thereby allowing a selected CIIS IsⲠto be aligned with a propagation axis of beam B. The depicted actuator mechanism SⲠcan, for example, have a relatively large movement stroke in Y (e.g. of the order of tens of millimeters), but need only have a relatively small (correctional) movement stroke in X (e.g. of the order of a few hundred microns).
Also depicted are gas supply lines (tubes/pipes) Fâł, which serve to supply gas to the various CIIS modules Isâ˛. These supply lines Fâł can, for example, be connected to individual gas reservoirs (tanks), or to a valve assembly (switching unit) that allows a selectable one of them to be connected through to a common gas reservoir. Each supply line Fâł will generally comprise a throttle valve somewhere along its course, to allow the gas supply pressure to be adjusted (thereby also adjusting the ionic mean free path li). Such throttle valves can be controlled manually, or by a pre-programmed controller device such as a microprocessor.
It should be noted that, as an alternative to the ârectilinearâ (translatory) architecture depicted in FIG. 1B, one could instead opt for a circular (rotational) architecture, whereby (for example):
It should also be noted that, instead of moving the carrier C relative to the beam B, one could alternatively/supplementally opt to move the beam B relative to the carrier C, e.g. using a deflector assembly (not depicted) to cause selectable deflections of the beam B from its nominal course parallel to Z.
FIG. 2 is a highly schematic depiction of an embodiment of a charged-particle focusing apparatusâin this case a Charged Particle Microscope Mâin which the present invention is implemented; more specifically, it shows an embodiment of a FIB-SEM, though, in the context of the current invention, it could just as validly be a purely ion-based microscope, for example. The microscope M comprises a particle-optical column 1, which produces a beam 3 of charged particles (in this case, an electron beam) that propagates along a particle-optical axis 3â˛. The column 1 is mounted on a vacuum chamber 5, which comprises a specimen holder 7 and associated actuator(s) 7Ⲡfor holding/positioning a specimen 51. The vacuum chamber 5 is evacuated using vacuum pumps (not depicted). With the aid of voltage supply 17, the specimen holder 7, or at least the specimen 51, may, if desired, be biased (floated) to an electrical potential with respect to ground. Also depicted is a vacuum port 5â˛, which may be opened so as to introduce/remove items (components, specimens) to/from the interior of vacuum chamber 5. A microscope M may comprise a plurality of such ports 5â˛, if desired.
The column 1 (in the present case) comprises an electron source 9 (such as a Schottky gun, for example) and an illuminator 2. This illuminator 2 comprises (inter alia) lenses 11, 13 to focus the electron beam 3 onto the specimen 51, and a deflection unit 15 (to perform beam steering/scanning of the beam 3). The microscope M further comprises a controller/computer processing apparatus 25 for controlling inter alia the deflection unit 15, lenses 11, 13 and detectors 19, 21, and displaying information gathered from the detectors 19, 21 on a display unit 27.
The detectors 19, 21 are chosen from a variety of possible detector types that can be used to examine different types of âstimulatedâ radiation emanating from the specimen 51 in response to irradiation by the (impinging) beam 3. In the apparatus depicted here, the following (non-limiting) detector choices have been made:
By scanning the beam 3 over the specimen 51, stimulated radiationâcomprising, for example, X-rays, infrared/visible/ultraviolet light, secondary electrons (SEs) and/or backscattered electrons (BSEs)âemanates from the specimen 51. Since such stimulated radiation is position-sensitive (due to said scanning motion), the information obtained from the detectors 19, 21 will also be position-dependent. This fact allows (for instance) the signal from detector 21 to be used to produce a BSE image of (part of) the specimen 51, which image is basically a map of said signal as a function of scan-path position on the specimen 51.
The signals from the detectors 19, 21 pass along control lines (buses) 25â˛, are processed by the controller 25, and displayed on display unit 27. Such processing may include operations such as combining, integrating, subtracting, false colouring, edge enhancing, and other processing known to the skilled artisan. In addition, automated recognition processes (e.g. as used for particle analysis) may be included in such processing.
In addition to the electron column 1 described above, the microscope M also comprises an ion-optical column 31. This comprises an ion source assembly Is according to the present invention (e.g. such as that illustrated in FIG. 1B) and an illuminator 32, and these produce/direct an ion beam 33 along an ion-optical axis 33â˛. To facilitate easy access to specimen 51 on holder 7, the ion axis 33Ⲡis canted relative to the electron axis 3â˛. As hereabove described, such an ion (FIB) column 31 can, for example, be used to perform processing/machining operations on the specimen 51, such as incising, milling, etching, depositing, etc. Alternatively, the ion column 31 can be used to produce imagery of the specimen 51.
As here depicted, the CPM M makes use of a manipulator arm 41, which can be actuated in various degrees of freedom by actuator system 41â˛, and can (if desired) be used to assist in transferring specimens to/from the specimen holder 7, e.g. as in the case of a so-called TEM lamella excised from the specimen 51 using ion beam 33.
Also illustrated is a Gas Injection System (GIS) 43, which can be used to effect localized injection of gases, such as etching or precursor gases, etc., for the purposes of performing gas-assisted etching or deposition. Such gases can be stored/buffered in a reservoir 43â˛, and can be administered through a narrow nozzle 43âł, so as to emerge in the vicinity of the intersection of axes 3Ⲡand 33â˛, for example.
It should be noted that many refinements and alternatives of such a set-up will be known to the skilled artisan, such as the use of a controlled environment at the specimen 51, e.g. maintaining a pressure of several mbar (as used in an Environmental SEM or low-pressure SEM).
1. A source assembly for producing an ion beam comprising:
a collision ionization ion source comprising:
a pair of stacked plates, sandwiched about an intervening gap;
an ionization space between said plates, connected to a gas supply duct;
an input zone, provided in a first of said plates, to admit an input beam of charged particles to said ionization space; and
an output aperture, located opposite said input zone and provided in the second of said plates, to allow emission of a flux of ions produced in said ionization space by said input beam,
a carrier provided with a plurality of different collision ionization ion sources that mutually differ in respect of a gap height d between said plates; and
a selecting device, which allows a given one of said ion sources to be individually selected for production of said ion beam.
2. A source assembly according to claim 1, wherein said plurality of collision ionization sources are provided as integrated devices on a single chip structure mounted on said carrier.
3. A source assembly according to claim 1, wherein each of said plurality of collision ionization sources is provided as an integrated device on a separate chip structure, and these separate chip structures are mounted on different positions on said carrier.
4. A source assembly according to claim 1, wherein said selecting device consists of at least one of:
a mechanical actuator mechanism, for moving said carrier relative to said input beam, so as to position a selected collision ionization ion source in a path of that beam; and
a beam deflector mechanism, for deflecting said input beam relative to said carrier, so as to direct that beam into a selected collision ionization ion source.
5. A source assembly according to claim 1, wherein at least some of the collision ionization ion sources on said carrier differ as regards their output aperture diameter.
6. A source assembly according to claim 1, wherein a given pair of collision ionization ion sources in said source structure are configured to be mutually different in respect of at least one of:
ion beam brightness;
ion beam energy spread;
ion beam emission current;
ion beam opening angle; and
ion beam virtual source size.
7. A source assembly according to claim 1, further comprising a controller that is configured to adjust at least one of the following parameters:
a gas pressure in said ionization space; and
an electrical potential applied between said plates,
so that an ionic scattering quotient QS=d/li maintains a value in a range of 1-500, where li is an ionic mean free path length in said ionization space.
8. A source assembly according to claim 7, wherein QS lies in the range of from 5 to 15.
9. A method of producing an ion beam using a collision ionization ion source comprising:
a pair of stacked plates, sandwiched about an intervening gap;
an ionization space between said plates, connected to a gas supply duct;
an input zone, provided in a first of said plates, to admit an input beam of charged particles to said ionization space; and
an output aperture, located opposite said input zone and provided in the second of said plates, to allow emission of a flux of ions produced in said ionization space by said input beam,
the method comprising:
providing a source assembly comprising a carrier provided with a plurality of different collision ionization ion sources that mutually differ in respect of a gap height d between said plates;
using a selecting device to select a given one of said ion sources for production of said ion beam; and
adjusting at least one of the following parameters:
a gas pressure in said ionization space; and
an electrical potential applied between said plates,
so that an ionic scattering quotient QS=d/li maintains a value in a range of from 1 to 500 , where li is an ionic mean free path length in said ionization space.
10. A method according to claim 9, comprising the following steps:
using said selecting device to select a first collision ionization ion source from said plurality, so as to produce a first ion beam for a first purpose; and thereafter:
using said selecting device to select a second, different collision ionization ion source from said plurality, so as to produce a second, different ion beam for a second, different purpose.
11. An ion focusing apparatus comprising:
a source assembly, for producing an ion beam;
a specimen holder, for holding a specimen in an irradiation position; and
an optical column, for directing said beam so as to irradiate said specimen, which source assembly is as claimed in claim 1.
12. An ion focusing apparatus according to claim 11, which apparatus is selected from the group consisting of:
a charged particle microscope; and
a lithography imager.
13. A source assembly according to claim 2, wherein said selecting device comprises consists of at least one of:
a mechanical actuator mechanism, for moving said carrier relative to said input beam, so as to position a selected collision ionization ion source in a path of that beam; and
a beam deflector mechanism, for deflecting said input beam relative to said carrier, so as to direct that beam into a selected collision ionization ion source.
14. A source assembly according to claim 2, wherein at least some of the collision ionization ion sources on said carrier differ as regards their output aperture diameter.
15. A source assembly according to claim 2, wherein a given pair of collision ionization ion sources in said source structure are configured to be mutually different in respect of at least one of:
ion beam brightness;
ion beam energy spread;
ion beam emission current;
ion beam opening angle; and
ion beam virtual source size.
16. A source assembly according to claim 1, further comprising a controller that is configured to adjust at least one of the following parameters:
a gas pressure in said ionization space; and
an electrical potential applied between said plates,
so that an ionic scattering quotient Os=d/li maintains a value in a range of 1-200, where li is an ionic mean free path length in said ionization space.
17. An ion focusing apparatus comprising:
a source assembly, for producing an ion beam;
a specimen holder, for holding a specimen in an irradiation position; and
an optical column, for directing said beam so as to irradiate said specimen, which source assembly is as claimed in claim 2.
18. The method of claim 9, wherein the value of the ionic scattering quotient Qs=d/li is in a range of from 1 to 200.