Multi-Mode Sample Inspection with Tunable Spectral Filtering

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Solution Overview

Problem

Existing particle detection systems face challenges in achieving high sensitivity and resolution with short wavelengths due to manufacturing difficulties, cost, and sensitivity to environmental factors, particularly with continuous-wave and pulsed laser sources.

Innovation Solution

An inspection system with a tunable spectral filter and adjustable image pixel size, configured for multiple measurement modes, using a high-power pulsed laser and an objective lens with chromatic aberration, to optimize linewidth and power for different noise sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a continuous-wave laser source is used to generate DUV/VUV emission, then laser power and wavelength stability are improved, but device complexity and manufacturing cost increase due to multiple resonator cavities and frequency conversion requirements

Engineering Contradiction:
Improvelaser powerVSAvoidsystem complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The patent replaces expensive, complex continuous-wave laser systems with simpler, more cost-effective pulsed laser sources. While pulsed lasers have broader spectral linewidths, this trade-off is acceptable given the significant reduction in system complexity and cost, especially when combined with spectral filtering techniques to manage chromatic aberration

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the operational parameters of the laser source from continuous-wave to pulsed mode, and adjusts the spectral linewidth through filtering. This parameter change allows the use of simpler laser hardware while managing the resulting chromatic dispersion through optical filtering and detector design

Inventive Principle:
Principle #35Parameter changes

2Ease of manufacture

If a pulsed laser source is used to generate DUV/VUV emission, then manufacturing ease and cost are improved, but spectral linewidth increases causing chromatic dispersion that degrades resolution

Engineering Contradiction:
Improvemanufacturing easeVSAvoidinspection resolution
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces spectral filters as intermediary elements between the pulsed laser source and the sample. These filters selectively transmit certain wavelengths while blocking others, effectively narrowing the spectral linewidth reaching the sample and reducing chromatic dispersion without requiring complex aberration-corrected optics

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies spectral filtering to selectively pass only the necessary wavelength range for inspection, rather than attempting to correct all chromatic aberrations across the entire spectrum. This partial action approach achieves sufficient resolution for particle detection while maintaining system simplicity

Inventive Principle:
Principle #16Partial or excessive action

3Measurement precision

If shorter wavelengths are used for defect inspection, then detection sensitivity is improved, but chromatic aberration effects are enhanced due to larger spectral linewidths

Engineering Contradiction:
Improvedetection sensitivityVSAvoidchromatic aberration
Core Design Contradiction:
Measurement precisionVSManufacturing precision

Solution Approach 1:

The patent converts the harmful effect of broad spectral linewidths into a beneficial feature by using the full spectral bandwidth of pulsed lasers to improve signal strength, while managing chromatic aberration through detector design and processing techniques rather than attempting to eliminate it entirely

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

Solution Approach 2:

The patent employs dynamic spectral filtering where the effective bandwidth and wavelength range are adjusted based on the specific inspection requirements. This allows optimization of the balance between signal strength and chromatic aberration for different particle sizes and inspection conditions

Inventive Principle:
Principle #15Dynamics

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

The system provides cost-effective and robust particle inspection by tailoring measurement configurations for different noise sources, enhancing signal-to-noise ratio and reducing chromatic aberration effects.

Implementation Method 1

an objective lens configured to collect sample light from the sample in response to the illumination beam, where the objective lens exhibits chromatic aberration within a spectrum of the illumination beam

Methodology Applied
Scientific EffectChromatic aberration:

Implementation Method 2

a tunable spectral filter with an adjustable linewidth configured to selectively adjust a spectrum of at least one of the illumination beam or the sample light

Methodology Applied
Scientific EffectSpectral filtering: Filter (optical)

Implementation Method 3

the illumination source includes a pulsed laser... illumination beam includes pulses with temporal pulse widths greater than approximately 1 picometer

Methodology Applied
Scientific EffectLaser emission: Laser

Data Source

PatentUS12535431B2Sample inspection with multiple measurement modes
Publication Date: 2026.01.27 KLA CORP
  • US12535431B2 patent drawing
  • US12535431B2 patent drawing
  • US12535431B2 patent drawing

AI summary

An inspection system may include an illumination source configured to generate an illumination beam with multiple wavelengths, an illumination sub-system including one or more illumination optics to direct the illumination beam to a sample at an off-axis angle, and an imaging sub-system. The system may include an objective lens to collect sample light, where the objective lens exhibits chromatic aberration within a spectrum of the illumination beam. The system may include one or more detectors to image the sample. A size of a point spread function (PSF) of the imaging sub-system relative to a pixel size of at least one of the one or more detectors may be adjustable. The system may include a tunable spectral filter with an adjustable linewidth configured to selectively adjust a spectrum of at least one of the illumination beam or the sample light.