Defect Inspection Device Using Dual Spatial Filters
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Solution Overview
Problem
Existing defect inspection methods for semiconductor wafers and liquid-crystal substrates often overlook defects due to spatial filters blocking both repetitive pattern diffracted light and defect scattered light, leading to a decrease in defect signal levels.
Innovation Solution
The use of spatial filters with minimum light-blocking areas to block diffracted light from repetitive circuit patterns, combined with image processing to remove noise components caused by diffracted-light leakage, by integrating two frames of image data from different spatial filters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If spatial filters are used to block diffracted light from repetitive patterns, then defect detection sensitivity is improved, but defect signal level decreases causing defects to be overlooked
Solution Approach 1:
The patent divides the light-blocking function into multiple spatial filters with different light-blocking patterns. Instead of using a single spatial filter that blocks all diffracted light (including defect signals), the system segments the filtering function across multiple filters, each blocking specific diffraction orders while preserving defect signals. This segmentation allows selective rejection of pattern diffraction while maintaining defect detection capability.
Solution Approach 2:
The patent applies different light-blocking patterns to different spatial filters, creating local quality variations in the filtering characteristics. Each spatial filter has a specific light-blocking pattern optimized for blocking certain diffraction orders, while the combination of all filters ensures comprehensive pattern rejection without sacrificing defect signals. This local differentiation of filtering properties resolves the contradiction between pattern suppression and defect signal preservation.
2Object-generated harmful factors
If spatial filters block diffracted light, then noise from repetitive patterns is reduced, but defect scattered light is also blocked reducing detection capability
Solution Approach 1:
The patent segments the noise reduction function across multiple spatial filters, each targeting specific diffraction orders that constitute pattern noise. By dividing the noise rejection task among multiple filters with specialized light-blocking patterns, the system reduces pattern noise effectively while preserving defect scattered light that appears in different spatial frequencies, thereby maintaining detection reliability.
Solution Approach 2:
The patent converts the harmful effect of diffracted light from repetitive patterns into a beneficial filtering mechanism. By analyzing the diffraction pattern characteristics and designing spatial filters with complementary light-blocking patterns, the system transforms the problematic diffracted light into useful information for distinguishing defects from pattern noise, improving both noise reduction and detection reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances defect detection sensitivity by maintaining the defect signal level while reducing noise components, thereby improving the ability to detect defects that might be overlooked in previous methods.
Implementation Method 1
light collecting unit that collects light reflected, diffracted, and scattered from the object
Implementation Method 2
light collecting unit that collects light reflected, diffracted, and scattered from the object
Implementation Method 3
light collecting unit that collects light reflected, diffracted, and scattered from the object
Implementation Method 4
first spatial filter fitted with a first light blocking pattern to block specific reflected, diffracted, and scattered light
Data Source
AI summary
To prevent overlooking of a defect due to reduction in a defect signal, a defect inspection device is configured such that: light is irradiated onto an object to be inspected on which a pattern is formed; reflected, diffracted, and scattered light generated from the object by the irradiation of the light is collected, such that a first optical image resulting from the light passed through a first spatial filter having a first shading pattern is received by a first detector, whereby a first image is obtained; the reflected, diffracted, and scattered light generated from the object is collected, such that a second optical image resulting from the light passed through a second spatial filter having a second shading pattern is received by a second detector, whereby a second image is obtained; and the first and second images thus obtained are processed integrally to detect a defect candidate(s).


