Patents by Inventor Souichi Fukaya

Souichi Fukaya has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10747098
    Abstract: A halftone phase shift photomask blank has on a transparent substrate, a first film serving as a halftone phase shift film, a second film serving as a light shielding film, a third film serving as a hard mask film, and a fourth film. The first and third films are formed of silicon-containing materials which are resistant to chlorine base dry etching and removable by fluorine base dry etching. The second and fourth films are formed of silicon-free, chromium-containing materials which are resistant to fluorine base dry etching and removable by chlorine base dry etching.
    Type: Grant
    Filed: February 22, 2018
    Date of Patent: August 18, 2020
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yukio Inazuki, Souichi Fukaya
  • Patent number: 10712654
    Abstract: A photomask blank has on a transparent substrate, an optional first film, a second film, a third film, and a fourth film. The first and third films are formed of silicon-containing materials which are resistant to chlorine base dry etching and removable by fluorine base dry etching. The second and fourth films are formed of chromium-containing materials which are resistant to fluorine base dry etching and removable by chlorine base dry etching. An etching clear time of the fourth film is longer than an etching clear time of the second film, on chlorine base dry etching.
    Type: Grant
    Filed: February 22, 2018
    Date of Patent: July 14, 2020
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Yukio Inazuki
  • Patent number: 10120274
    Abstract: In a chamber (50), a quartz substrate (10) having a main surface on which an optical film (20) is formed is put on a susceptor (30). A flash lamp (60) is housed in a lamp house (90), and the optical film (20) is irradiated with flash light through two quartz plates (70a and 70b). A transmittance adjustment region (80) is formed on a surface of the quartz plate (70b) of the two quartz plates (70a and 70b), and the amount of light with which the optical film (20) is irradiated has in-plane distribution. If the optical film (20) is irradiated with the flash light, optical characteristics of the optical film (20) change depending on the received irradiation energy. Hence, for example, the characteristics of the optical film are not uniform, the optical film is irradiated with flash light having such irradiation energy distribution that cancels the in-plane distribution.
    Type: Grant
    Filed: January 12, 2017
    Date of Patent: November 6, 2018
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Yukio Inazuki
  • Publication number: 20180259842
    Abstract: A halftone phase shift photomask blank has on a transparent substrate, a first film serving as a halftone phase shift film, a second film serving as a light shielding film, a third film serving as a hard mask film, and a fourth film. The first and third films are formed of silicon-containing materials which are resistant to chlorine base dry etching and removable by fluorine base dry etching. The second and fourth films are formed of silicon-free, chromium-containing materials which are resistant to fluorine base dry etching and removable by chlorine base dry etching.
    Type: Application
    Filed: February 22, 2018
    Publication date: September 13, 2018
    Applicant: Shin-Etsu Chemical Co., Ltd.
    Inventors: Yukio INAZUKI, Souichi FUKAYA
  • Publication number: 20180259843
    Abstract: A photomask blank has on a transparent substrate, an optional first film, a second film, a third film, and a fourth film. The first and third films are formed of silicon-containing materials which are resistant to chlorine base dry etching and removable by fluorine base dry etching. The second and fourth films are formed of chromium-containing materials which are resistant to fluorine base dry etching and removable by chlorine base dry etching. An etching clear time of the fourth film is longer than an etching clear time of the second film, on chlorine base dry etching.
    Type: Application
    Filed: February 22, 2018
    Publication date: September 13, 2018
    Applicant: Shin-Etsu Chemical Co., Ltd.
    Inventors: Souichi FUKAYA, Yukio INAZUKI
  • Patent number: 10040220
    Abstract: A hard mask film 2 provided on substrate 1 is formed by tin-containing chromium-containing material. In the chromium-containing material including tin, which forms the hard mask film 2, the etching resistance to fluorine-containing dry etching is equal to or higher than the etching resistance of the tin-free chromium-containing material, and it shows a significantly high etching rate as compared with a chromium-containing material free of tin under conditions for chlorine-containing dry etching. As a result, the time for chlorine-containing dry etching is shortened, and damage to a resist pattern is reduced. Thus, high-precision pattern transfer can be performed. The present invention provides a novel technique for increasing etching process-ability by increasing a dry-etching rate of a hard mask film made of a chromium-containing material while assuring a hard mask function of the hard mask film.
    Type: Grant
    Filed: August 12, 2016
    Date of Patent: August 7, 2018
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Hideo Nakagawa, Kouhei Sasamoto
  • Patent number: 9952501
    Abstract: A photomask blank comprising a transparent substrate (1), an etching stop film (2), a light-shielding film (3), and an etching mask film (4) has on the substrate side a reflectance of up to 35% with respect to exposure light. The etching stop film (2) consists of a first layer (21) which is disposed contiguous to the substrate and functions as an antireflective layer and a second layer (22) functioning as a fluorine-base dry etching-resistant layer, one of the first and second layers is a layer having compressive stress and the other is a layer having tensile stress.
    Type: Grant
    Filed: September 2, 2016
    Date of Patent: April 24, 2018
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Shinichi Igarashi, Takashi Yoshii
  • Patent number: 9880459
    Abstract: In a photomask blank comprising a transparent substrate, a resistance layer, and a conductive layer, the resistivity and thickness of the conductive layer and the resistivity and thickness of the resistance layer are selected so as to meet a specific equation (1). In EB lithography, a ground can be established at a necessary fully low resistance value, and EB writing be carried out at a high accuracy.
    Type: Grant
    Filed: July 11, 2016
    Date of Patent: January 30, 2018
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Kouhei Sasamoto, Souichi Fukaya, Yukio Inazuki
  • Patent number: 9851633
    Abstract: An inorganic material film containing tin within the concentration range of 0.1 atomic percent or higher but no higher than 11.5 atomic percent eliminates the problem in which tin localizes and forms into particles, with the result that these particles turn into defects in an optical film. An inorganic material film for a photomask blank according to the present invention film-formed by sputtering and composed of a chromium-containing material includes a light-shielding layer having electrical conductivity, wherein the light-shielding layer contains 0.1 atomic percent or higher but no higher than 11.5 atomic percent of tin and no higher than 15 atomic percent of oxygen. The lower limit of oxygen concentration is, for example, 3 atomic percent. The inorganic material film has electrical conductivity, which is preferably no higher than 5000 ?/cm2 when evaluated in terms of resistance values.
    Type: Grant
    Filed: June 23, 2016
    Date of Patent: December 26, 2017
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Kouhei Sasamoto, Hideo Nakagawa
  • Patent number: 9798230
    Abstract: A photomask blank includes a chromium-based material film as a hard mask film containing at least one selected from the group consisting of nitrogen, oxygen, carbon and hydrogen, wherein a ratio (A/B) of etching rates per unit film thickness is in a range from 0.7 to 0.9, and the chromium-based material film has a tensile stress or compressive stress corresponding to an amount of warp of up to 70 nm. The present invention provides a photomask blank having a thin film of chromium-based material which is enhanced in etch resistance and lowered in film stress. This enables high-accuracy patterning of a chromium-based material film.
    Type: Grant
    Filed: September 11, 2015
    Date of Patent: October 24, 2017
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Kouhei Sasamoto
  • Patent number: 9798229
    Abstract: A method for designing a photomask blank comprising a transparent substrate and an optical film thereon is provided. The photomask blank is processed into a transmissive photomask having a pattern of optical film such that the film pattern may be transferred when exposure light is transmitted by the photomask. The optical film is selected using a specific reflectance, which is equal to the reflectance divided by the film thickness, as an index.
    Type: Grant
    Filed: July 16, 2015
    Date of Patent: October 24, 2017
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Kouhei Sasamoto, Hideo Kaneko, Yukio Inazuki, Souichi Fukaya
  • Patent number: 9689066
    Abstract: The method for manufacturing a photomask blank according to the present invention, when manufacturing a photomask blank having at least one functional layer on a transparent substrate, in a step of film-formation of such a functional film where the functional film includes a chromium-containing element and an a metallic element that is capable of bringing a mixture of the metallic element and the chromium into a liquid phase at a temperature of 400° C. or lower, a chromium target (target A) and a target (target B) mainly containing at least one kind of the metallic element are simultaneously sputtered (co-sputtered). The present invention provides a technique for manufacturing a functional film having a small variation in its characteristics such as optical density and a low detect, and showing a high etching rate.
    Type: Grant
    Filed: May 13, 2013
    Date of Patent: June 27, 2017
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hiroki Yoshikawa, Souichi Fukaya, Yukio Inazuki, Hideo Nakagawa
  • Publication number: 20170123306
    Abstract: In a chamber (50), a quartz substrate (10) having a main surface on which an optical film (20) is formed is put on a susceptor (30). A flash lamp (60) is housed in a lamp house (90), and the optical film (20) is irradiated with flash light through two quartz plates (70a and 70b). A transmittance adjustment region (80) is formed on a surface of the quartz plate (70b) of the two quartz plates (70a and 70b), and the amount of light with which the optical film (20) is irradiated has in-plane distribution. If the optical film (20) is irradiated with the flash light, optical characteristics of the optical film (20) change depending on the received irradiation energy. Hence, for example, the characteristics of the optical film are not uniform, the optical film is irradiated with flash light having such irradiation energy distribution that cancels the in-plane distribution.
    Type: Application
    Filed: January 12, 2017
    Publication date: May 4, 2017
    Applicant: Shin-Etsu Chemical Co., Ltd.
    Inventors: Souichi FUKAYA, Yukio INAZUKI
  • Patent number: 9618838
    Abstract: A photomask blank includes a chromium-based material film as a light-shielding film, wherein the chromium-based material film has an optical density per unit thickness at a wavelength of 193 nm of at least 0.050/nm, and the chromium-based material film has a tensile stress or compressive stress corresponding to an amount of warp of up to 50 nm. The present invention provides a photomask blank having a thin film of chromium-based material which is lowered in film stress while retaining a high optical density per unit film thickness. This enables high-accuracy patterning of a chromium-based material film.
    Type: Grant
    Filed: September 11, 2015
    Date of Patent: April 11, 2017
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Yukio Inazuki
  • Publication number: 20170082917
    Abstract: A photomask blank comprising a transparent substrate (1), an etching stop film (2), a light-shielding film (3), and an etching mask film (4) has on the substrate side a reflectance of up to 35% with respect to exposure light. The etching stop film (2) consists of a first layer (21) which is disposed contiguous to the substrate and functions as an antireflective layer and a second layer (22) functioning as a fluorine-base dry etching-resistant layer, one of the first and second layers is a layer having compressive stress and the other is a layer having tensile stress.
    Type: Application
    Filed: September 2, 2016
    Publication date: March 23, 2017
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi FUKAYA, Shinichi IGARASHI, Takashi YOSHII
  • Patent number: 9581892
    Abstract: In a chamber (50), a quartz substrate (10) having a main surface on which an optical film (20) is formed is put on a susceptor (30). A flash lamp (60) is housed in a lamp house (90), and the optical film (20) is irradiated with flash light through two quartz plates (70a and 70b). A transmittance adjustment region (80) is formed on a surface of the quartz plate (70b) of the two quartz plates (70a and 70b), and the amount of light with which the optical film (20) is irradiated has in-plane distribution. If the optical film (20) is irradiated with the flash light, optical characteristics of the optical film (20) change depending on the received irradiation energy. Hence, for example, the characteristics of the optical film are not uniform, the optical film is irradiated with flash light having such irradiation energy distribution that cancels the in-plane distribution.
    Type: Grant
    Filed: June 17, 2014
    Date of Patent: February 28, 2017
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Souichi Fukaya, Yukio Inazuki
  • Publication number: 20170031237
    Abstract: In a photomask blank comprising a transparent substrate, a resistance layer, and a conductive layer, the resistivity and thickness of the conductive layer and the resistivity and thickness of the resistance layer are selected so as to meet a specific equation (1). In EB lithography, a ground can be established at a necessary fully low resistance value, and EB writing be carried out at a high accuracy.
    Type: Application
    Filed: July 11, 2016
    Publication date: February 2, 2017
    Applicant: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kouhei SASAMOTO, Souichi FUKAYA, Yukio INAZUKI
  • Patent number: 9541823
    Abstract: A photomask blank comprising a transparent substrate and a chromium-containing film deposited thereon is provided. The chromium-containing film comprises at least one CrC compound layer comprising up to 50 at % of Cr, at least 25 at % of O and/or N, and at least 5 at % of C. From the blank, a photomask having a photomask pattern formed on the substrate is produced, the photomask being used in photolithography of forming a resist pattern with a line width of up to 0.1 ?m, using exposure light having a wavelength of up to 250 nm.
    Type: Grant
    Filed: December 5, 2014
    Date of Patent: January 10, 2017
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Kouhei Sasamoto, Yukio Inazuki, Souichi Fukaya, Hideo Nakagawa, Hideo Kaneko
  • Publication number: 20170003584
    Abstract: An inorganic material film containing tin within the concentration range of 0.1 atomic percent or higher but no higher than 11.5 atomic percent eliminates the problem in which tin localizes and forms into particles, with the result that these particles turn into defects in an optical film. An inorganic material film for a photomask blank according to the present invention film-formed by sputtering and composed of a chromium-containing material includes a light-shielding layer having electrical conductivity, wherein the light-shielding layer contains 0.1 atomic percent or higher but no higher than 11.5 atomic percent of tin and no higher than 15 atomic percent of oxygen. The lower limit of oxygen concentration is, for example, 3 atomic percent. The inorganic material film has electrical conductivity, which is preferably no higher than 5000?/cm2 when evaluated in terms of resistance values.
    Type: Application
    Filed: June 23, 2016
    Publication date: January 5, 2017
    Applicant: Shin-Etsu Chemical Co., Ltd.
    Inventors: Souichi FUKAYA, Kouhei Sasamoto, Hideo Nakagawa
  • Publication number: 20160346960
    Abstract: A hard mask film 2 provided on substrate 1 is formed by tin-containing chromium-containing material. In the chromium-containing material including tin, which forms the hard mask film 2, the etching resistance to fluorine-containing dry etching is equal to or higher than the etching resistance of the tin-free chromium-containing material, and it shows a significantly high etching rate as compared with a chromium-containing material free of tin under conditions for chlorine-containing dry etching. As a result, the time for chlorine-containing dry etching is shortened, and damage to a resist pattern is reduced. Thus, high-precision pattern transfer can be performed. The present invention provides a novel technique for increasing etching process-ability by increasing a dry-etching rate of a hard mask film made of a chromium-containing material while assuring a hard mask function of the hard mask film.
    Type: Application
    Filed: August 12, 2016
    Publication date: December 1, 2016
    Applicant: Shin-Etsu Chemical Co., Ltd.
    Inventors: Souichi FUKAYA, Hideo Nakagawa, Kouhei Sasamoto