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

VSEngineering 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

Engineering Contradiction:
Improvedefect detection sensitivityVSAvoiddefect signal level
Core Design Contradiction:
Measurement precisionVSLoss of information

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.

Inventive Principle:
Principle #1Segmentation

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.

Inventive Principle:
Principle #3Local quality

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

Engineering Contradiction:
Improvenoise from repetitive patternsVSAvoiddefect detection reliability
Core Design Contradiction:
Object-generated harmful factorsVSReliability

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.

Inventive Principle:
Principle #1Segmentation

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.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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

Methodology Applied
Scientific EffectReflection: Reflection

Implementation Method 2

light collecting unit that collects light reflected, diffracted, and scattered from the object

Methodology Applied
Scientific EffectDiffraction: Diffraction

Implementation Method 3

light collecting unit that collects light reflected, diffracted, and scattered from the object

Methodology Applied
Scientific EffectScattering: Scattering

Implementation Method 4

first spatial filter fitted with a first light blocking pattern to block specific reflected, diffracted, and scattered light

Methodology Applied
Scientific EffectOptical filtering: Filter (optical)

Data Source

PatentUS9019492B2Defect inspection device and defect inspection method
Publication Date: 2015.04.28 HITACHI HIGH TECH CORP
  • US9019492B2 patent drawing
  • US9019492B2 patent drawing
  • US9019492B2 patent drawing

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).