Multipixel Sensor Arrays for High-Throughput Acoustic Microscopy

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Solution Overview

Problem

Current scanning acoustic microscopy (SAM) systems face challenges in achieving high-throughput inspection without compromising scanning resolution or sensitivity.

Innovation Solution

The development of a scanning acoustic microscope system that includes measurement assemblies with transducers and multipixel sensors, coupled with a stage for scanning samples, and a controller to implement metrology or inspection recipes, enabling simultaneous data generation for multiple locations and efficient scanning configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If inspection speed is increased in SAM devices, then productivity is improved, but measurement precision deteriorates

Engineering Contradiction:
Improveinspection speedVSAvoidscanning resolution
Core Design Contradiction:
ProductivityVSMeasurement precision

Solution Approach 1:

The patent divides the inspection task into multiple measurement assemblies, each with its own transducer and receiver pair. These assemblies operate in parallel to simultaneously inspect different regions of the wafer, enabling high-speed inspection without sacrificing resolution since each assembly maintains its own measurement capabilities.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent transitions from single-point sequential measurement to multi-point parallel measurement by introducing multiple measurement assemblies arranged in arrays. This dimensional expansion from 1D sequential scanning to 2D/3D parallel measurement enables simultaneous data acquisition across multiple locations, achieving high throughput while maintaining measurement precision.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Productivity

If inspection speed is increased in SAM devices, then productivity is improved, but sensitivity deteriorates

Engineering Contradiction:
Improveinspection speedVSAvoidsensitivity
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent segments the inspection system into multiple independent measurement assemblies, each capable of sensitive acoustic measurements. By distributing the inspection task across multiple assemblies rather than accelerating a single assembly, the system achieves high throughput while each individual assembly maintains its sensitivity for detecting subtle acoustic signals.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent combines the outputs from multiple measurement assemblies to achieve both high speed and high sensitivity. The parallel data from multiple sensitive detectors is integrated and processed together, allowing the system to maintain the sensitivity of individual detectors while achieving the throughput of a high-speed system.

Inventive Principle:
Principle #5Merging (Combining)

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 solution allows for increased inspection speed while maintaining high resolution and sensitivity, effectively addressing the limitations of existing SAM systems.

Implementation Method 1

a transducer and a receiver, wherein the receiver of at least one of the one or more measurement assemblies may include a multipixel sensor

Methodology Applied
Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

the receiver of at least one of the one or more measurement assemblies may include a multipixel sensor to simultaneously generate sensor data for multiple locations associated with a sample

Methodology Applied
Scientific EffectAcoustic detection: Acoustic Microscopy

Data Source

PatentUS20250116598A1Enhanced modes for scanning acoustic microscope inspection in semiconductor inspection
Publication Date: 2025.04.10 KLA CORP
  • US20250116598A1 patent drawing
  • US20250116598A1 patent drawing
  • US20250116598A1 patent drawing

AI summary

A scanning acoustic microscope system may include one or more measurement assemblies, wherein a respective one of the measurement assemblies comprises a transducer and a receiver, wherein the receiver of at least one of the one or more measurement assemblies comprises a multipixel sensor to simultaneously generate sensor data for multiple locations associated with a sample. The tool may include a stage configured to scan the sample for measurement by the one or more measurement assemblies. The tool may include a controller communicatively coupled to the one or more measurement assemblies, wherein the controller includes one or more processors configured to execute program instructions causing the processors to implement a metrology recipe by: receiving the sensor data from the one or more measurement assemblies while the sample is scanned by the stage; and generating one or more measurements for the sample based on the sensor data.