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
Engineering 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
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
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
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
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
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
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
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
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
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
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
Implementation Method 3
the illumination source includes a pulsed laser... illumination beam includes pulses with temporal pulse widths greater than approximately 1 picometer
Data Source
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.


