Grazing-incidence interferometer with dual-side measurement capability using a common image plane
09651358 ยท 2017-05-16
Assignee
Inventors
- Joshua Monroe Cobb (Victor, NY, US)
- THOMAS JAMES DUNN (Penfield, NY, US)
- John Weston Frankovich (Fairport, NY, US)
Cpc classification
G01B9/02021
PHYSICS
G01B9/02041
PHYSICS
International classification
Abstract
A grazing-incidence interferometer includes first and second spaced-apart diffractive optical elements with a generally planar object disposed therebetween. The first diffractive optical element forms sheared first-diffracted-order light beams that reflect from opposite first and second surfaces of the object at grazing-incidence angles, while a zero-diffracted-order light beam goes unreflected. The second diffractive optical element combines the unreflected zero-diffracted-order light beam and the sheared reflected beams to form a collimated, combined beam. A 1 double-telecentric relay system relays the combined beam to a folding optical system that forms first and second interference images on a diffusing screen located at an image plane. Digital images of the first and second interference images are obtained and processed to characterize the thickness variation of the object.
Claims
1. A grazing-incidence interferometer for analyzing opposite surfaces of an object, comprising: a first diffractive optical element (DOE) arranged to receive a substantially coherent light beam and form therefrom a zero-diffracted-order light beam and +1 and 1 first-diffracted-order light beams that respectively reflect from the opposite object surfaces at respective [a] grazing-incidence angles while the zero-diffracted-order light beam is unreflected; a second DOE arranged to receive and combine the unreflected zero-diffracted-order light beam and the reflected +1 and 1 first-diffracted-order light beams to form a combined light beam that is substantially collimated; a 1 double-telecentric relay system having an optical axis co-axial with the combined light beam and an aperture stop sized to transmit or reflect only the combined light beam; a folding optical system that receives the combined light beam from the 1 double-telecentric relay system and forms first and second interference images of the first and second object surfaces at a common image plane; and a diffusing screen arranged at the common image plane and upon which the first and second interference images are formed.
2. The grazing-incidence interferometer according to claim 1, wherein the +1 and 1 first-diffracted-order light beams respectively illuminate substantially the entire opposite surfaces of the object.
3. The grazing-incidence interferometer according to claim 1, wherein the aperture stop includes either a central aperture that passes the combined light beam or a mirror element that reflects the combined light beam.
4. The grazing-incidence interferometer according to claim 1, wherein the folding optical system consists of four fold mirrors.
5. The grazing-incidence interferometer according to claim 1, further comprising: a digital camera having an imaging lens and a digital image sensor, the digital camera being arranged to form on the digital image sensor first and second digital images of the first and second interference images, wherein the digital image sensor forms first and second electrical image signals representative of the first and second digital images; and a processor electrically connected to the image sensor and adapted to receive and process the first and second electrical image signals.
6. The grazing-incidence interferometer according to claim 5, wherein the processor includes instructions embodied in a non-transitory computer-readable medium that cause the processor to determine a variation in the thickness of the object based on the first and second electrical image, signals.
7. The grazing-incidence interferometer according to claim 1, wherein the +1 and 1 diffracted-order light beams respectively illuminate first and second scanned regions of the first and second object surfaces.
8. A grazing-incidence interferometer for analyzing opposite first and second surfaces of a generally planar object having a thickness, comprising: a light source that generates a substantially coherent light beam; first and second spaced-apart diffractive optical elements arranged along an optical axis and downstream of the light source, with the object therebetween, wherein the first and second surfaces defined first and second object planes, and wherein the first diffractive optical element forms 1.sup.st, zero and +1.sup.st diffracted-order light beams, with the 1.sup.st and +1.sup.st diffracted-order light beams respectively reflecting from the first and second surfaces and combining with the zero-diffracted-order light beam in a sheared manner to form a substantially collimated combined light beam; a 1 double-telecentric relay system downstream of the second diffractive optical element and having a transmitting or reflecting aperture stop that transmits or reflects only the collimated combined light beam and that defines first and second image planes at which first and second interference images are respectively formed and which satisfy a Scheimpflug condition with respect to the first and second object planes; a folding optical system downstream of the 1 double-telecentric relay system and that combines the first and second interference images from the first and second image planes at a common image plane; a diffusing screen that resides in the common image plane and upon which the first and second interference images are formed; a digital camera arranged to capture a digital image of the first and second interference images formed on the diffusing screen; and a processor electrically connected to the digital camera and configured to process the digital image of the diffusing screen.
9. The grazing-incidence interferometer according to claim 8, wherein the processor includes instructions embodied in a non-transitory computer-readable medium that cause the processor to determine a variation in the thickness of the object based on the first and second electrical image signals.
10. The grazing-incidence interferometer according to claim 8, wherein the +1 and 1 diffracted-order light beams respectively illuminate first and second scanned regions of the first and second object surfaces.
11. A method of performing grazing-incidence interferometry of an object having first and second opposite surfaces, comprising: forming from a substantially coherent wavefront a zero-diffracted-order light beam and +1 and 1 first-diffracted-order light beams; respectively reflecting the +1 and 1 first-diffracted-order light beams from the object first and second surfaces of the object while leaving the zero-diffracted-order light beam unreflected; combining the reflected +1 and 1 first-diffracted-order light beams with the unreflected zero-diffracted-order light beam in a sheared manner to form a combined light beam that is substantially collimated; relaying the collimated combined light beam through a 1 double-telecentric relay having an aperture stop that passes or reflects substantially only the combined light beam to form first and second interference images at first and second image planes which respectively satisfy a Scheimpflug condition with respect to the first and second opposite surfaces of the object; using a folding optical system, combining the first and second interference images formed at the first and second image planes onto a common image plane; disposing a diffusing screen at the common image plane to form the first and second interference images on the diffusing screen; and capturing a digital image of the first and second interference images as formed on the diffusing screen.
12. The method according to claim 11, further comprising moving the object in a manner that changes a phase of the reflected +1 and 1 first-diffracted-order light beams.
13. The method according to claim 11, further including processing the digital image of the first and second interference images to determine a thickness variation of the object.
14. The method according to claim 11, wherein the +1 and 1 diffracted-order light beams are respectively scanned over the first and second object surfaces.
15. The method according to claim 11, further comprising subtracting a perfect reference from the first and second interference images to at least partially compensate for a wavefront error.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings are included to provide a further understanding and are incorporated into and constitute a part of this specification. The drawings illustrate one or more embodiment(s) and together with the Detailed Description serve to explain principles and operation of the various embodiments. As such, the disclosure will become more fully understood from the following Detailed Description, taken in conjunction with the accompanying Figures, in which:
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DETAILED DESCRIPTION
(12) Reference is now made in detail to various embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same or like reference numbers and symbols are used throughout the drawings to refer to the same or like parts. The drawings are not necessarily to scale, and one skilled in the art will recognize where the drawings have been simplified to illustrate the key aspects of the disclosure.
(13) The claims as set forth below are incorporated into and constitute a part of this Detailed Description.
(14) Cartesian coordinates are shown in some of the Figures for the sake of reference and are not intended to be limiting as to direction or orientation.
(15) In the description below, the term first order or first diffracted order refers to either the 1 or +1 diffracted order, while the term first orders or first diffracted orders refers to both the 1 and +1 diffracted orders. Also, while the term zero diffracted order or zero order refers to the straight-through undiffracted portion of the light, this portion of the light is nevertheless referred to as a diffracted order to follow its common use in the art and to maintain consistency of terminology.
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(17) The interferometer 10 also includes a first diffractive optical element (DOE) 50A arranged along optical axis A1 to receive collimated light beam 22 and form therefrom light beams 23, 24 and 25 associated, respectively, with the 1, 0 and +1 diffracted orders, along with higher diffracted orders (dashed-line arrows) collectively denoted HO. A generally planar object 60 to be measured resides in the X-Z plane along optical axis A1 adjacent and downstream of DOE 50A.
(18) The object 60 has an upper surface (i.e., an upper side) 62 and an opposite lower surface (i.e., a lower side) 64. The object 60 can be any type of generally planar object in need of characterization, such as a transparent window, a semiconductor wafer, an opaque plate, etc. In an example, object 60 has a nominal thickness TH and also has an unknown thickness variation TH(x,z) that needs to be determined.
(19) In an example, object 60 is supported in a manner that allows for both its upper and lower surfaces 62 and 64 to be illuminated, as described below. Thus, in one example, object 60 is supported at its edges, while in another example the object is supported at lower surface 62 by thin support members 66 (see
(20) The 1.sup.st and +1.sup.st diffracted-order light beams 23 and 25 are incident upon and reflect from upper surface 62 and lower surface 64, respectively, at a grazing-incidence angle measured relative to a line PL perpendicular to the upper and lower surfaces (see close-up inset of
(21) The interferometer 10 also includes a second DOE 50B arranged adjacent and downstream of object 60. The second DOE 50B is arranged to receive the reflected 1.sup.st and +1.sup.st diffracted-order light beams 23 and 25, as well as the non-reflected zero-diffracted-order light beam 24. The second DOE 50B also receives the reflected higher-diffracted-order light beams HO.
(22) Exemplary DOEs for use as DOE 50A and 50B include a phase grating, which can be in the form of a holographic optical element; a binary optic; a computer-generated hologram; a surface-relief diffracted lens; etc. The DOEs 50A and 50B are shown as transmissive elements, but one or both of these elements may be made reflective elements by employing a suitably folded configuration for interferometer 10.
(23) In an alternate embodiment of interferometer 10, only zero-diffracted-order light beam 24 and one of the first-diffracted-order light beams 23 or 25, which respectively reflect from either lower surface 64 or upper surface 62, are employed.
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(25) Continuing with
(26) This same reasoning applies to the +1.sup.st and zero-diffracted-order light beams 25 and 24 relative to lower surface 64 of object 60. Thus, the interfering portions of the reference and the measurement diffracted orders (i.e., reference and measurement wavefronts 0W, 1W and +1W associated with the zero and 1.sup.st and +1.sup.st diffracted orders) do not generally originate from substantially the same portions of the initial illumination wavefront 22F.
(27) Because the wavefronts 0W, 1W and +1W are sheared, there will be in the interference pattern an error induced by wavefront aberration as the beam exits DOE 50A. This residual system error can be removed from the interference pattern by measuring a perfect reference flat and then removing the part of the interference pattern that deviates from the perfect reference.
(28) With reference again to
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(30) With reference again to
(31) The relay optical system 80 relays images for both upper and lower surfaces 62 and 64 of object 60 (or portions thereof, as explained below). In
(32) Satisfying the Scheimpflug condition for a 1 double-telecentric configuration provides for an in-focus, distortion-free and coma-free image. The image planes IP.sub.U and IP.sub.L have tilt angles that are the same as the grazing-incidence angle of the 1.sup.st and +1.sup.st diffracted-order light beams 23 and 25 relative to upper and lower surfaces 62 and 64 of object 60 (i.e., =).
(33) The effective tilts of upper and lower surfaces 62 and 64 are of the opposite sign so that image planes IP.sub.U and IP.sub.L are tilted in opposite directions. This presents a difficulty in forming images of upper and lower surfaces 62 and 64 in a common image plane IP.sub.C (see
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(35) A processor 130 is electrically connected to digital image sensor 124 and is configured to receive and process electrical image signals S.sub.L and S.sub.U. In an example, processor 130 is provided with instructions embodied in a computer-readable medium that causes the processor to calculate respective upper and lower surface topographies h.sub.U(x,z) and h.sub.L(x,z) for upper and lower surfaces 62 and 64 of object 60 and to further calculate the thickness variation TH(x,z)=h.sub.U(x,z)h.sub.L(x,z) of the object based on the upper and lower surface topographies.
(36) A common method of increasing the resolution of an interferometer is to incorporate the process of phase-shifting interferometry (also called phase-modulation interferometry). Phase-shifting interferometry described in detail in the book Optical Shop Testing, Daniel Malacara, ed., John Wiley and Sons, (2007) Chapter 14, pp. 547-665. A static interferogram has the disadvantage of requiring the data analysis to find the center of a fringe. The resolution of this method is limited because the fringe pattern has a limited number of pixels.
(37) With phase-shifting interferometry, the phase of the reference or object beam is modulated. This modulation not only gives the polarity of the wavefront but also allows for much higher resolution. It is therefore advantageous to incorporate some method for employing phase-shifting interferometry in this grazing-incidence diffraction grating interferometer. One way to do this is to translate object 60 orthogonally to the axis of the diffraction grating, as indicated by the arrows AR in
(38) Referring again to
(39) It is advantageous that upper and lower image planes IP.sub.U and IP.sub.L be made to coincide on common image plane IP.sub.C.
(40) The first fold mirrors 92A and 92B reside in a plane orthogonal to upper and lower surfaces 62 and 64 of object 60 (i.e., orthogonal to the X-Z plane). This configuration serves to reflect respective upper and lower light beams U and L in the +X and X directions. Second fold mirrors 96A and 96B are arranged to respectively receive upper and lower light beams U and L and fold them so that they travel in the Y-direction. The diffusing screen 110 can then be tilted substantially at the grazing-incidence angle so that both upper and lower interference images IM.sub.U and IM.sub.L appear side-by-side on the screen. Thus, folding optical system 90 can be said to map the upper and lower image planes IP.sub.U and IP.sub.L onto common image plane IP.sub.C. In one example, folding optical system 90 consists of four fold mirrors 92A, 92B, 96A and 96B as shown in
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(43) It will be desirable in some cases to illuminate and thus image substantially the entire upper and lower surfaces 62 and 64 of object 60. This may be accomplished by configuring interferometer 10 so that first and second DOEs 50A and 50B and collimated light beam 22 are sized to illuminate substantially the entire upper and lower surfaces 62 and 64 of object 60.
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(47) An advantage of interferometer 10 is that thickness variation TH(x,z) of object 60 can be determined by simultaneously measuring both upper and lower surfaces 62 and 64 of the object. This provides a more accurate measurement of thickness variation TH(x,z) than is possible by mounting object 60 to a chuck to measure upper surface 62 and then flipping the object over and re-mounting the object to the chuck to measure lower surface 64. This is because the act of mounting object 60 to a chuck causes measurable changes in the surface topography of the object, and such changes translate into thickness variations that are not inherent in the object.
(48) It will be apparent to those skilled in the art that various modifications to the preferred embodiments of the disclosure as described herein can be made without departing from the spirit or scope of the disclosure as defined in the appended claims. Thus, the disclosure covers the modifications and variations provided they come within the scope of the appended claims and the equivalents thereto.