Apparatus for Providing Surface Images and Method for Making the Apparatus

This invention relates, in general, to surface imaging probes, and more particularly, to probes that provide atomic force microscopy images and methods for forming such probes.

To investigate the failure modes of semiconductor devices, it is very advantageous to be able to generate images of the surface of the semiconductor device. Such images have been traditionally formed using atomic force microscopy (AFM). A probe tip is dragged across the surface of the semiconductor device and the topography of the surface is measured by an optical signal which is reflected off of a mirror affixed to the probe. Movement of the probe will result is a corresponding motion in the mirror. To mount the mirror, an insulating epoxy or an insulating layer is used to electrically isolate the mirror from the AFM probe. Due to the thermal conditions of operation, this insulation can breakdown with time and cause the probe to fail. An additional problem with the mirror is that they are typically mounted to the probe at a significant distance away from the probe tip. As a result, the motion of the mirror does not necessarily replicate the motion of the probe, and there is a loss of accuracy in the measuring of the topography of the surface.

In addition to the AFM, a thermal image of the device's surface is very valuable in identifying hot spots. To produce a thermal image, a previously known method forms the AFM probe from a thermocouple which measures the temperature of the surface as the probe is moved. However a disadvantage is that the thermal energy of the semiconductor device is transferred to the reflective mirror which can create noise in both the topographical image and the thermal profile of the semiconductor device.

By now, it should be appreciated that it would be advantageous to provide an improved method for forming an AFM/thermal image probe that does not require the use of a mirror mounted to the probe. It would of further advantage if the probe were easier to manufacture and more reliable than previously known imaging probes.

FIG. 1 is an enlarged isometric view showing a probe according to the present invention; and

FIG. 2 is an enlarged isometric view of a probe according to an alternate embodiment of the present invention.

FIG. 1 is a enlarged isometric view showing an Atomic Force Microscope (AFM) probe or probe 10, capable of providing a surface image, according to the present invention. Probe 10 can be used in conjunction with an atomic force microscope such as a Digital Instruments Nanoscope III to generate both a thermal and topographical image of the surface of a semiconductor device. The Nanoscope III instrument is manufactured by Digital Instruments Inc., of Santa Barbara, Calif. and method for its use with a probe is described in U.S. Pat. No. 5,388,323, which issued to Hopson et al. on Feb. 14, 1995 and is hereby incorporated by reference. The present invention offers an improvement in that the thermal and topographical image can be provided without the use of a mounted mirror as taught in some previously known probes.

Probe 10 comprises a thermocouple formed from a first ribbon of material 11 and a second ribbon of material 12. First ribbon of material 11 and second ribbon of material 12 can be formed from a variety of materials such as nickel-chrome alloy, nickel-rhodium alloy, platinum-rhodium alloy, platinum, iron, copper, copper-nickel alloy, and tungsten-rhenium alloy. For example, first ribbon of material 11 and second ribbon of material 12 can be formed from "Chromel" and "Alumel," which are trademarks of Hoskins Manufacturing Co. of Detroit, Mich. "Chromel" is an alloy having approximately 90% nickel and 10% chromium. "Alumel" is an alloy of approximately 95% nickel, 2.5% manganese, and 2.5% aluminum. Preferably, first ribbon of material 11 and second ribbon of material 12 are formed to have a width of 25 microns to 500 microns and a thickness of about 25 microns to about 500 microns.

To form thermocouple junction 13, a portion of first ribbon of material 11 and second ribbon of material 12 are placed in contact with each other and welded together. In order to form thermocouple junction 13, first ribbon of material 11 and second ribbon of material 12 are materials with different composition. One method for forming thermocouple junction 13, for example, is by applying electric current through the overlapping portions of first ribbon of material 11 and second ribbon of material 12. A probe tip 15 is then attached to probe 10 using an epoxy 14. Probe tip 15 is formed from an electrically insulating and thermally conductive material such as diamond, carbon, or silicon nitride. Probe tip 15 is attached to probe 10 such that at least a portion of probe tip 15 is in contact with thermocouple junction 13. This allows probe tip 15 to provide data on both the surface temperature and surface topography of a semiconductor device.

A significant advantage of the present invention is that probe 10 is formed with thin ribbons of material 11 and 12, rather than circular wires as shown in some previously known probes. Since first ribbon of material 11, second ribbon of material 12, and the top of thermocouple junction 13 have a reflective planar surface, the need for an additional reflective mirror is obviated. In order to detect the motion of probe 10, the present invention uses a light emitter 30 to direct a light source 31 directly onto either first ribbon of material 11, second ribbon of material 12, or thermocouple junction 13. As probe tip 15 follows the surface topography of a semiconductor device, the motion is detected by a light detector 32 which monitors the optical signal 33 coming off the reflective surface of either first ribbon of material 11, second ribbon of material 12, or thermocouple junction 13. It should be understood that only a portion of first ribbon of material 11 and second ribbon of material 12 need to have a flat and reflective surface. It is also possible that first ribbon of material 11 and second ribbon of material 12 are formed from round or oddly shaped wires that have a flat surface to reflect light from a light emitter.

Since probe 10 does not require the use of a mirror, there is no risk of shorting first ribbon of material 11 to second ribbon of material 12. The motion of probe tip 15 can be measured directly above or in close proximity to probe tip 15 which will improve the accuracy of the image relative to a system that measures the motion from a mirror which is placed away from the probe tip. The removal of the mirror will also reduce noise and further improve the accuracy of the image generated. Further, since a mirror is no longer required, the total manufacturing cost is reduced and the manufacturing procedure is simplified.

An alternate embodiment of the present invention will now be provided. FIG. 2 is an enlarged isometric view of a probe 20 according to this alternate embodiment. Instead of mounting a probe tip 15 onto probe 10, a portion of thermocouple junction 13 is bent to form a point region 17. Point region 17 is coated with a thermally conductive material such as diamond, carbon, or silicon nitride to form a coated region 18. Coated region 18 is used to provide topographical measurements of the surface of a semiconductor device. Since coated region 18 is thermally conductive, it can also be used to provide a thermal path to thermocouple junction 13, allowing thermal measurement of the surface of a semiconductor device.

As described above, point region 17 is formed by bending only a portion of thermocouple junction 13. It should also be understood, that point region 17 can also be formed by bending a portion of first ribbon of material 11 and second ribbon of material 12 as well as thermocouple junction 13. The flat surfaces of first ribbon of material 11, second ribbon of material 12, or thermocouple junction 13 can be used to reflect an optical signal from an laser emitter to an optical detector to determine the surface profile of a semiconductor device. In this alternate embodiment, coated region 18 has less mass than probe tip 15 of the previous embodiment. As a result, probe 20 will have an improved thermal response to changes in the surface temperature of the semiconductor device.

By now it should be appreciated that the present invention provides improved methods for forming a probe capable of generating a thermal and topographical image of the surface of a semiconductor device. Since flat ribbons of themocoupling material are used, the need for an additional mirror is obviated. The probes of the present invention are easier to fabricate and require fewer elements, which will reduce the final manufacturing cost. Since a mirror, and the complications associated with attaching a mirror to the probe, are eliminated, the present invention has improved accuracy in its topographical sensitivity and improved operational reliability.