Patents by Inventor Takuma Yoshioka
Takuma Yoshioka 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).
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Patent number: 11535546Abstract: A silica glass crucible includes a cylindrical side wall portion, a curved bottom portion, and a corner portion that is provided between the side wall portion and the bottom portion and has a higher curvature than a curvature of the bottom portion, in which a first region provided from a crucible inner surface to a middle in a thickness direction, a second region that is provided outside the first region in the thickness direction and has a different strain distribution from the first region, and a third region that is provided outside the second region in the thickness direction and up to the crucible outer surface and has a different strain distribution from the second region, are provided, and internal residual stresses of the first region and the third region are compressive stresses, whereas an internal residual stress of the second region includes a tensile stress.Type: GrantFiled: November 2, 2018Date of Patent: December 27, 2022Assignee: SUMCO CORPORATIONInventors: Ken Kitahara, Masaru Sato, Takuma Yoshioka
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Publication number: 20200392032Abstract: A silica glass crucible includes a cylindrical side wall portion, a curved bottom portion, and a corner portion that is provided between the side wall portion and the bottom portion and has a higher curvature than a curvature of the bottom portion, in which a first region provided from a crucible inner surface to a middle in a thickness direction, a second region that is provided outside the first region in the thickness direction and has a different strain distribution from the first region, and a third region that is provided outside the second region in the thickness direction and up to the crucible outer surface and has a different strain distribution from the second region, are provided, and internal residual stresses of the first region and the third region are compressive stresses, whereas an internal residual stress of the second region includes a tensile stress.Type: ApplicationFiled: November 2, 2018Publication date: December 17, 2020Inventors: Ken KITAHARA, Masaru SATO, Takuma YOSHIOKA
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Publication number: 20200123676Abstract: In an exemplary embodiment, a quartz glass crucible 1 includes: a straight body portion 1a having a cylindrical shape; a bottom portion 1b; and a corner portion 1c, in which a bubble content of an inner surface layer portion ranging from an inner surface to a depth 0.5 mm in an upper portion 1a1 of the straight body portion 1a is 0.2% to 2%, the bubble content of the inner surface layer portion in a lower portion 1a2 of the straight body portion 1a is more than 0.1% and not more than 1.3 times a lower limit of the bubble content of the upper portion 1a1, the bubble content of the inner surface layer portion in the corner portion 1c is more than 0.1% and 0.5% or less, and the bubble content of the inner surface layer portion in the bottom portion 1b is 0.1% or less.Type: ApplicationFiled: June 11, 2018Publication date: April 23, 2020Inventors: Takuma YOSHIOKA, Masami OHARA
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Patent number: 9758900Abstract: Buckling of a vitreous silica crucible 12 or inward fall of a sidewall 15 is effectively suppressed. The vitreous silica crucible 12 includes the cylindrical sidewall 15 having an upward-opening rim, a mortar-shaped bottom 16 including a curve, and a round portion 17 connecting the sidewall 15 and the bottom 16. In the vitreous silica crucible 12 the per-unit area thermal resistance in the thickness direction of the sidewall 15 is higher than that of the round portion 17.Type: GrantFiled: October 31, 2012Date of Patent: September 12, 2017Assignee: SUMCO CORPORATIONInventors: Toshiaki Sudo, Tadahiro Sato, Ken Kitahara, Takuma Yoshioka, Hiroshi Kishi
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Patent number: 9527763Abstract: A method of manufacturing a composite crucible includes: supplying mullite material powder to an upper region of a mold, and supplying second silica powder to a lower region provided below the upper region while rotating the mold; supplying third silica powder on an inner surface side of a layer made of the mullite material powder and the second silica powder; heating and fusing the mullite material powder, the second silica powder, and the third silica powder to form an opaque vitreous silica layer provided on the outer surface of the crucible, a transparent vitreous silica layer provided on an inner surface side of the crucible, and a mullite reinforcement layer provided on the outer surface side of an upper end portion of the crucible.Type: GrantFiled: December 27, 2015Date of Patent: December 27, 2016Assignee: SUMCO CORPORATIONInventors: Toshiaki Sudo, Ken Kitahara, Takuma Yoshioka
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Patent number: 9469560Abstract: The present invention provides a method of manufacturing a vitreous silica crucible having a transparent layer by use of waste vitreous silica. According to the present invention, there is provided a method of manufacturing a vitreous silica crucible for manufacturing a monocrystalline or polycrystalline silicon ingot, including a process of vitrifying a silica powder sintered body having a crucible shape in the whole or part of the thickness direction by arc fusing the silica powder sintered body from the inner surface side, wherein the method further includes at least one means of (1) depressurizing the silica powder sintered body from the outer surface side during the arc fusing, and (2) forming a synthetic vitreous silica layer on the inner surface by spraying synthetic silica powder onto the inner surface of the silica powder sintered body during the arc fusing.Type: GrantFiled: November 30, 2011Date of Patent: October 18, 2016Assignee: JAPAN SUPER QUARTZ CORPORATIONInventors: Toshiaki Sudo, Takuma Yoshioka, Koichi Suzuki, Shinsuke Yamazaki
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Publication number: 20160115625Abstract: A method of manufacturing a composite crucible includes: supplying mullite material powder to an upper region of a mold, and supplying second silica powder to a lower region provided below the upper region while rotating the mold; supplying third silica powder on an inner surface side of a layer made of the mullite material powder and the second silica powder; heating and fusing the mullite material powder, the second silica powder, and the third silica powder to form an opaque vitreous silica layer provided on the outer surface of the crucible, a transparent vitreous silica layer provided on an inner surface side of the crucible, and a mullite reinforcement layer provided on the outer surface side of an upper end portion of the crucible.Type: ApplicationFiled: December 27, 2015Publication date: April 28, 2016Inventors: Toshiaki SUDO, Ken KITAHARA, Takuma YOSHIOKA
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Patent number: 9284207Abstract: The present invention provides a method of manufacturing a vitreous silica crucible having a transparent layer by use of waste vitreous silica, and silica powder suitable for the manufacturing. According to the present invention, there is provided a method of manufacturing granulated silica powder comprising a process for pulverizing waste vitreous silica generated in the manufacturing process of a crucible to form silica fine powder having an average particle diameter of 100 ?m or less, and a process for granulating the silica fine powder to obtain granulated silica powder having an average particle diameter of 50 ?m or more under helium atmosphere.Type: GrantFiled: November 30, 2011Date of Patent: March 15, 2016Assignee: SUMCO CORPORATIONInventors: Toshiaki Sudo, Takuma Yoshioka, Koichi Suzuki, Shinsuke Yamazaki
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Patent number: 9266763Abstract: The purpose of the present invention is to provide a crucible which has high viscosity at high temperature, can be used for a long time, and can be manufactured at low cost, and a method of manufacturing the crucible. The present invention provides a composite crucible including a vitreous silica crucible body having a sidewall portion and a bottom portion, and a reinforcement layer provided on an outer surface side of an upper end portion of the vitreous silica crucible body, wherein the reinforcement layer is made of mullite material whose main component is alumina and silica.Type: GrantFiled: December 22, 2011Date of Patent: February 23, 2016Assignee: SUMCO CORPORATIONInventors: Toshiaki Sudo, Ken Kitahara, Takuma Yoshioka
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Publication number: 20150337456Abstract: A composite crucible 10 is characterized in the use of mullite (3Al2O3.2SiO2) as the basic material of the crucible. The composite crucible 10 has a crucible body 11 made of mullite material whose main component is alumina and silica, and a transparent vitreous silica layer 12 formed on the inner surface of the crucible body 11. The thickness of the transparent vitreous silica layer 12 is smaller than that of the crucible body 11. The crucible body 11 is formed by the slip casting method, and the transparent vitreous silica layer 12 is formed by the thermal spraying method.Type: ApplicationFiled: August 4, 2015Publication date: November 26, 2015Inventors: Toshiaki SUDO, Takuma YOSHIOKA, Hiroshi KISHI, Takeshi FUJITA, Minoru KANDA, Koichi SUZUKI, Ken KITAHARA
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Patent number: 9133063Abstract: The purpose of the present invention is to provide a crucible which has high viscosity at high temperature, and can be used for a long time, and can be manufactured at low cost, and a method of manufacturing the same. The composite crucible 10 is characterized in the use of mullite (3Al2O3.2SiO2) as the basic material of the crucible. The composite crucible 10 has the crucible body 11 made of mullite material whose main component is alumina and silica, and a transparent vitreous silica layer 12 formed on the inner surface of the crucible body 11. The thickness of the transparent vitreous silica layer 12 is smaller than that of the crucible body 11. The crucible body 11 can be formed by the slip casting method, and the transparent vitreous silica layer 12 can be formed by the thermal spraying method.Type: GrantFiled: August 20, 2010Date of Patent: September 15, 2015Assignee: SUMCO CORPORATIONInventors: Toshiaki Sudo, Takuma Yoshioka, Hiroshi Kishi, Takeshi Fujita, Minoru Kanda, Koichi Suzuki, Ken Kitahara
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Publication number: 20150027364Abstract: Buckling of a vitreous silica crucible 12 or inward fall of a sidewall 15 is effectively suppressed. The vitreous silica crucible 12 includes the cylindrical sidewall 15 having an upward-opening rim, a mortar-shaped bottom 16 including a curve, and a round portion 17 connecting the sidewall 15 and the bottom 16. In the vitreous silica crucible 12, the per-unit area thermal resistance in the thickness direction of the sidewall 15 is higher than that of the round portion 17.Type: ApplicationFiled: October 31, 2012Publication date: January 29, 2015Inventors: Toshiaki Sudo, Tadahiro Sato, Ken Kitahara, Takuma Yoshioka, Hiroshi Kishi
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Patent number: 8671716Abstract: There is provided a method of manufacturing a vitreous silica crucible having non-bubbles on the inner surface without necessitating new apparatuses for grinding and polishing and without damaging the productivity. According to the present invention, there is provided a method of manufacturing a vitreous silica crucible including the processes of: gathering a vitreous silica layer containing residual bubbles existing in a near-surface region of the transparent layer of the vitreous silica crucible by controlling the number of rotations applied to the vitreous silica crucible in a state that an inner surface side of the vitreous silica crucible is fused by arc heating; and moving a portion of a non-bubble layer in the surface of the transparent layer exposed by movement of the residual bubble-containing layer to cover a region in which bubbles have gathered with the non-bubble layer.Type: GrantFiled: November 30, 2011Date of Patent: March 18, 2014Assignee: Japan Super Quartz CorporationInventors: Toshiaki Sudo, Takuma Yoshioka
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Publication number: 20120160158Abstract: The purpose of the present invention is to provide a crucible which has high viscosity at high temperature, can be used for a long time, and can be manufactured at low cost, and a method of manufacturing the crucible. The present invention provides a composite crucible including a vitreous silica crucible body having a sidewall portion and a bottom portion, and a reinforcement layer provided on an outer surface side of an upper end portion of the vitreous silica crucible body, wherein the reinforcement layer is made of mullite material whose main component is alumina and silica.Type: ApplicationFiled: December 22, 2011Publication date: June 28, 2012Applicant: JAPAN SUPER QUARTZ CORPORATIONInventors: Toshiaki SUDO, Ken KITAHARA, Takuma YOSHIOKA
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Publication number: 20120160155Abstract: The purpose of the present invention is to provide a crucible which has high viscosity at high temperature, and can be used for a long time, and can be manufactured at low cost, and a method of manufacturing the same. The composite crucible 10 is characterized in the use of mullite (3Al2O3.2SiO2) as the basic material of the crucible. The composite crucible 10 has the crucible body 11 made of mullite material whose main component is alumina and silica, and a transparent vitreous silica layer 12 formed on the inner surface of the crucible body 11. The thickness of the transparent vitreous silica layer 12 is smaller than that of the crucible body 11. The crucible body 11 can be formed by the slip casting method, and the transparent vitreous silica layer 12 can be formed by the thermal spraying method.Type: ApplicationFiled: August 20, 2010Publication date: June 28, 2012Applicant: JAPAN SUPER QUARTZ CORPORATIONInventors: Toshiaki Sudo, Takuma Yoshioka, Hiroshi Kishi, Takeshi Fujita, Minoru Kanda, Koichi Suzuki, Ken Kitahara
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Publication number: 20120141704Abstract: The present invention provides a method of manufacturing a vitreous silica crucible having a transparent layer by use of waste vitreous silica. According to the present invention, there is provided a method of manufacturing a vitreous silica crucible for manufacturing a monocrystalline or polycrystalline silicon ingot, including a process of vitrifying a silica powder sintered body having a crucible shape in the whole or part of the thickness direction by arc fusing the silica powder sintered body from the inner surface side, wherein the method further includes at least one means of (1) depressurizing the silica powder sintered body from the outer surface side during the arc fusing, and (2) forming a synthetic vitreous silica layer on the inner surface by spraying synthetic silica powder onto the inner surface of the silica powder sintered body during the arc fusing.Type: ApplicationFiled: November 30, 2011Publication date: June 7, 2012Applicant: JAPAN SUPER QUARTZ CORPORATIONInventors: Toshiaki SUDO, Takuma YOSHIOKA, Koichi SUZUKI, Shinsuke YAMAZAKI
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Publication number: 20120137732Abstract: The present invention provides a method of manufacturing a vitreous silica crucible having a transparent layer by use of waste vitreous silica, and silica powder suitable for the manufacturing. According to the present invention, there is provided a method of manufacturing granulated silica powder comprising a process for pulverizing waste vitreous silica generated in the manufacturing process of a crucible to form silica fine powder having an average particle diameter of 100 ?m or less, and a process for granulating the silica fine powder to obtain granulated silica powder having an average particle diameter of 50 ?m or more under helium atmosphere.Type: ApplicationFiled: November 30, 2011Publication date: June 7, 2012Applicant: JAPAN SUPER QUARTZ CORPORATIONInventors: Toshiaki Sudo, Takuma Yoshioka, Koichi Suzuki, Shinsuke Yamazaki
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Publication number: 20120137735Abstract: There is provided a method of manufacturing a vitreous silica crucible having non-bubbles on the inner surface without necessitating new apparatuses for grinding and polishing and without damaging the productivity. According to the present invention, there is provided a method of manufacturing a vitreous silica crucible including the processes of: gathering a vitreous silica layer containing residual bubbles existing in a near-surface region of the transparent layer of the vitreous silica crucible by controlling the number of rotations applied to the vitreous silica crucible in a state that an inner surface side of the vitreous silica crucible is fused by arc heating; and moving a portion of a non-bubble layer in the surface of the transparent layer exposed by movement of the residual bubble-containing layer to cover a region in which bubbles have gathered with the non-bubble layer.Type: ApplicationFiled: November 30, 2011Publication date: June 7, 2012Applicant: JAPAN SUPER QUARTZ CORPORATIONInventors: Toshiaki SUDO, Takuma YOSHIOKA
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Patent number: 8128055Abstract: A mold for the production of a silica crucible by heat-fusing silica or quartz powder attached onto an inner wall of a rotating mold, wherein a ring-shaped heat insulating barrier material having a specified inner diameter is disposed on an inner peripheral wall of an upper opening portion of the mold corresponding to an upper region of the silica crucible.Type: GrantFiled: October 22, 2009Date of Patent: March 6, 2012Assignee: Japan Super Quartz CorporationInventors: Takuma Yoshioka, Masaki Morikawa
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Patent number: 8105514Abstract: In a mold for use in the production of a silica crucible, a mold cover corresponding to a small-diameter thinned portion of an upper part of the silica crucible is detachably disposed on a mold substrate corresponding to a main body of the silica crucible, and the mold cover has a barrier function against arc heating, and an inner diameter of the mold cover is smaller than that of the mold substrate but larger than that of the silica crucible.Type: GrantFiled: January 15, 2010Date of Patent: January 31, 2012Assignee: Japan Super Quartz CorporationInventors: Takuma Yoshioka, Masaki Morikawa