US 7,542,134 B2
System, method and apparatus for in-situ substrate inspection
Aleksander Owczarz, San Jose, Calif. (US); Jaroslaw W. Winniczek, Daly City, Calif. (US); Luai Nasser, Union City, Calif. (US); Alan Schoepp, Ben Lomond, Calif. (US); Fred C. Redeker, Alameda, Calif. (US); and Erik Edelberg, Castro Valley, Calif. (US)
Assigned to Lam Research Corporation, Fremont, Calif. (US)
Filed on Jun. 02, 2008, as Appl. No. 12/131,909.
Application 12/131909 is a division of application No. 11/016022, filed on Dec. 17, 2004, granted, now 7,397,555.
Prior Publication US 2008/0273195 A1, Nov. 06, 2008
Int. Cl. G01N 21/00 (2006.01)
U.S. Cl. 356—237.3  [356/237.4] 9 Claims
OG exemplary drawing
 
1. A method for inspecting a substrate, comprising:
recording a baseline dark field;
directing a light source toward a field of view to be examined;
receiving the field of view in a camera having a centerline, wherein the centerline is oriented toward a field of view, wherein the field of view encompasses at least a first portion of a first surface of the substrate, wherein the light source is directed toward the field of view to be examined at a first angle β relative to the first surface of the substrate, wherein the first angle β orients the light source to emit light impinging the first surface within the field of view, the light source is further oriented at a second angle δ relative to the centerline, the second angle δ being between about 90 degrees and less than about 180 degrees, the centerline intersects the first surface at a third angle α, the third angle α being between about 20 degrees and about 33 degrees, the first angle β is selected to minimize a direct reflection of light from the first portion of the first surface to the camera, wherein the light source and the camera are included in a process chamber for applying a manufacturing process to the substrate, the manufacturing process being in addition to an inspection process, wherein the light source includes a plurality of point light sources, wherein each one of the point light sources has a corresponding selected wavelength of light output and wherein the method further includes:
selecting one of the plurality of light sources having the selected wavelength of light output; and
selecting one of a plurality of intensity levels, wherein the selected wavelength of light output and the selected intensity level corresponds to the manufacturing process applied to the substrate;
comparing the received field of view to the baseline dark field;
detecting at least one of a droplet, a particle or a surface obstruction (DPO) within the received field; and
outputting a test result.