Patents by Inventor Toshiaki Sudo

Toshiaki Sudo 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: 9653268
    Abstract: A method of manufacturing a vitreous silica crucible includes an inspection method comprising: a measurement step of measuring an infrared absorption spectrum or a Raman shift of a measurement point on an inner surface of the vitreous silica crucible; a determining step of predicting whether a surface defect region is generated or not in the measurement point based on an obtained spectrum to determine a quality of the vitreous silica crucible.
    Type: Grant
    Filed: December 13, 2016
    Date of Patent: May 16, 2017
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Tadahiro Sato, Ken Kitahara, Masami Ohara
  • Patent number: 9637411
    Abstract: A method of manufacturing a vitreous silica crucible includes: a taking-out process of taking out the vitreous silica crucible from the mold, a honing process of removing the unfused silica powder layer on the outer surface of the vitreous silica crucible, and further comprising, after the taking-out process and before the honing process, a marking process of marking an identifier comprised of one or more groove line on the outer surface of the vitreous silica crucible, wherein the groove line after the honing process has a cross-sectional shape of an inverse trapezoid and a depth of 0.2 to 0.5 mm, and a width of 0.8 mm or more at the opening of the groove line. The groove line is formed by repeating shifting a focal point of a laser.
    Type: Grant
    Filed: November 17, 2016
    Date of Patent: May 2, 2017
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Taira Sato, Shuichi Ikehata, Manabu Shonai, Takuji Nishi, Takaya Satou, Shinsuke Yamazaki
  • Patent number: 9637405
    Abstract: An evaluation method of suitable silica powder for forming a bubble-free layer of a vitreous silica crucible for pulling of a silicon single crystal, includes: a process of measuring a porosity between silica particles in the silica powder, a process of melting the silica powder, a process of measuring a bubble content rate of a vitreous silica block obtained by cooling to harden the melted silica powder, and a process of determining whether the silica powder is suitable from the porosity of the silica powder and the bubble content rate of the vitreous silica block.
    Type: Grant
    Filed: June 30, 2013
    Date of Patent: May 2, 2017
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Tadahiro Sato, Ken Kitahara, Makiko Hinooka
  • Publication number: 20170088973
    Abstract: A method of manufacturing a vitreous silica crucible includes an inspection method comprising: a measurement step of measuring an infrared absorption spectrum or a Raman shift of a measurement point on an inner surface of the vitreous silica crucible; a determining step of predicting whether a surface defect region is generated or not in the measurement point based on an obtained spectrum to determine a quality of the vitreous silica crucible.
    Type: Application
    Filed: December 13, 2016
    Publication date: March 30, 2017
    Inventors: Toshiaki SUDO, Tadahiro SATO, Ken KITAHARA, Masami OHARA
  • Publication number: 20170066686
    Abstract: A method of manufacturing a vitreous silica crucible includes: a taking-out process of taking out the vitreous silica crucible from the mold, a honing process of removing the unfused silica powder layer on the outer surface of the vitreous silica crucible, and further comprising, after the taking-out process and before the honing process, a marking process of marking an identifier comprised of one or more groove line on the outer surface of the vitreous silica crucible, wherein the groove line after the honing process has a cross-sectional shape of an inverse trapezoid and a depth of 0.2 to 0.5 mm, and a width of 0.8 mm or more at the opening of the groove line. The groove line is formed by repeating shifting a focal point of a laser.
    Type: Application
    Filed: November 17, 2016
    Publication date: March 9, 2017
    Inventors: Toshiaki SUDO, Taira SATO, Shuichi IKEHATA, Manabu SHONAI, Takuji NISHI, Takaya SATOU, Shinsuke YAMAZAKI
  • Patent number: 9557276
    Abstract: An inspection method of vitreous silica crucibles includes: a measurement step of measuring an infrared absorption spectrum or a Raman shift of a measurement point on an inner surface of the vitreous silica crucible; a determining step of predicting whether or not a surface-defect region occurs at the measurement point based on an obtained spectrum to determine a quality of the vitreous silica crucible.
    Type: Grant
    Filed: June 30, 2013
    Date of Patent: January 31, 2017
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Tadahiro Sato, Ken Kitahara, Masami Ohara
  • Patent number: 9534318
    Abstract: The present invention provides a method of manufacturing a vitreous silica crucible including: a taking-out process of taking out the vitreous silica crucible from the mold, a honing process of removing the unfused silica powder layer on the outer surface of the vitreous silica crucible, and further comprising, after the taking-out process and before the honing process, a marking process of marking an identifier comprised of one or more groove line on the outer surface of the vitreous silica crucible, wherein the groove line after the honing process has a depth of 0.2 to 0.5 mm, and a width of 0.8 mm or more at the opening of the groove line.
    Type: Grant
    Filed: December 22, 2011
    Date of Patent: January 3, 2017
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Taira Sato, Shuichi Ikehata, Manabu Shonai, Takuji Nishi, Takaya Satou, Shinsuke Yamazaki
  • Patent number: 9527763
    Abstract: 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: Grant
    Filed: December 27, 2015
    Date of Patent: December 27, 2016
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Ken Kitahara, Takuma Yoshioka
  • Publication number: 20160313234
    Abstract: In an embodiment, a distortion-measuring apparatus for measuring a distortion distribution of an entire vitreous silica crucible in a non-destructive way includes: a light source 11; a first polarizer 12 and a first quarter-wave plate 13 disposed between the light source 11 and an outer surface of a vitreous silica crucible wall; a camera 14 disposed inside of a vitreous silica crucible 1; a camera control mechanism 15 configured to control a photographing direction of the camera 14; a second polarizer 16 and a second quarter-wave plate 17 disposed between the camera 14 and an inner surface of the vitreous silica crucible wall. An optical axis of the second quarter-wave plate 17 inclines 90 degrees with respect to the first quarter-wave plate 13.
    Type: Application
    Filed: December 25, 2014
    Publication date: October 27, 2016
    Applicant: SUMCO CORPORATION
    Inventors: Toshiaki SUDO, Tadahiro SATO, Ken KITAHARA, Eriko KITAHARA
  • Patent number: 9469560
    Abstract: 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: Grant
    Filed: November 30, 2011
    Date of Patent: October 18, 2016
    Assignee: JAPAN SUPER QUARTZ CORPORATION
    Inventors: Toshiaki Sudo, Takuma Yoshioka, Koichi Suzuki, Shinsuke Yamazaki
  • Publication number: 20160289862
    Abstract: In an embodiment, a vitreous silica crucible 1 includes a cylindrical straight body portion 10a, a corner portion 10c formed at lower end of the straight body portion 10a, and a bottom portion 10b connected with the straight body portion 10a via the corner portion 10c. Moreover, the vitreous silica crucible 1 includes a bubble-containing opaque layer 11 constituting an outer layer, and a bubble-free transparent layer 12 constituting an inner layer. A boundary surface, between the opaque layer 11 and the transparent layer 12 in at least the straight body portion 10a, forms a periodic wave surface in a vertical direction. The vitreous silica crucible can suppress deformation under high temperature.
    Type: Application
    Filed: December 25, 2014
    Publication date: October 6, 2016
    Applicant: SUMCO CORPORATION
    Inventors: Toshiaki SUDO, Tadahiro SATO, Ken KITAHARA, Eriko KITAHARA
  • Patent number: 9416463
    Abstract: Provided is a vitreous silica crucible having a reference point, which is capable of accurately detecting the location of a defect in the vitreous silica crucible used for pulling silicon single crystal, determining a defect generating site of silicon single crystal, and investigating the cause of the defect. The reference point used for specifying the position relationship with respect to a particular part is formed in at least one site of an end portion, an inner wall and an outer wall of the crucible.
    Type: Grant
    Filed: December 13, 2010
    Date of Patent: August 16, 2016
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Hiroshi Kishi
  • Publication number: 20160200617
    Abstract: An evaluation method of suitable silica powder for forming a bubble-free layer of a vitreous silica crucible for pulling of a silicon single crystal, includes: a process of measuring a porosity between silica particles in the silica powder, a process of melting the silica powder, a process of measuring a bubble content rate of a vitreous silica block obtained by cooling to harden the melted silica powder, and a process of determining whether the silica powder is suitable from the porosity of the silica powder and the bubble content rate of the vitreous silica block.
    Type: Application
    Filed: June 30, 2013
    Publication date: July 14, 2016
    Inventors: Toshiaki SUDO, Tadahiro SATO, Ken KITAHARA, Makiko HINOOKA
  • Publication number: 20160202192
    Abstract: An inspection method of vitreous silica crucibles includes: a measurement step of measuring an infrared absorption spectrum or a Raman shift of a measurement point on an inner surface of the vitreous silica crucible; a determining step of predicting whether or not a surface-defect region occurs at the measurement point based on an obtained spectrum to determine a quality of the vitreous silica crucible.
    Type: Application
    Filed: June 30, 2013
    Publication date: July 14, 2016
    Inventors: Toshiaki SUDO, Tadahiro SATO, Ken KITAHARA, Masami OHARA
  • Publication number: 20160201216
    Abstract: A vitreous silica crucible includes: a substantially cylindrical straight body portion having an opening on a top end and extending in a vertical direction; a curved bottom portion; and a corner portion connecting the straight body portion with the bottom portion and a curvature of which is greater than that of the bottom portion, wherein an inner surface of the crucible has a concavo-convex structure in which groove-shaped valleys are interposed between ridges, and an average interval of the ridges is 5-100 ?m.
    Type: Application
    Filed: June 30, 2013
    Publication date: July 14, 2016
    Inventors: Toshiaki SUDO, Tadahiro SATO, Ken KITAHARA, Eriko KITAHARA
  • Publication number: 20160153116
    Abstract: A method for pulling silicon single crystal includes a process of placing a molded body between a susceptor's inner surface and a crucible's outer surface. The molded body is formed based on three-dimensional data of the inner surface shape of the susceptor which can hold the vitreous silica crucible and three-dimensional data of the crucible so as to make the susceptor's central axis and the crucible's central axis substantially aligned when it is placed between the susceptor's inner surface and the crucible's outer surface.
    Type: Application
    Filed: June 29, 2013
    Publication date: June 2, 2016
    Inventors: Toshiaki SUDO, Tadahiro SATO, Ken KITAHARA, Eriko KITAHARA
  • Patent number: 9347148
    Abstract: Provided is a vitreous silica crucible, which is resistant to deformation and corrosion even when heated at high temperature for a long time. There is provided a vitreous silica crucible of the present invention including a substantially cylindrical straight body portion, a curved bottom portion, and a corner portion smoothly connecting the straight body portion and the bottom portion, wherein a wall of the vitreous silica crucible includes, from an inner surface side, a transparent layer and a bubble-containing layer, and a ratio of a thickness of the bubble-containing layer with respect to a thickness of the transparent layer at an intermediate position between an upper end and a lower end of the straight body portion is 0.7 to 1.4.
    Type: Grant
    Filed: November 30, 2011
    Date of Patent: May 24, 2016
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Ken Kitahara, Koichi Suzuki, Shinsuke Yamazaki
  • Patent number: 9328009
    Abstract: Provided is a vitreous silica crucible for pulling a silicon single crystal, which stably suppresses surface vibration of a silicon melted solution filled therein and has a long life, and a method for manufacturing the same. The vitreous silica crucible for pulling a silicon single crystal includes a peripheral wall portion, a curved portion, and a bottom portion, wherein a plurality of minute concave portions are formed on a certain area of an inner surface of the peripheral wall portion, and a plurality of bubbles are formed on a lower position of the minute concave portions.
    Type: Grant
    Filed: May 13, 2011
    Date of Patent: May 3, 2016
    Assignee: SUMCO CORPORATION
    Inventors: Toshiaki Sudo, Hiroshi Kishi, Eriko Suzuki
  • Publication number: 20160115625
    Abstract: 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: Application
    Filed: December 27, 2015
    Publication date: April 28, 2016
    Inventors: Toshiaki SUDO, Ken KITAHARA, Takuma YOSHIOKA
  • Publication number: 20160108550
    Abstract: The present invention provides a vitreous silica crucible which inhibits a deformation even when used under a high temperature condition for a long time, and a method for manufacturing the same. The vitreous silica crucible comprises: a substantially cylindrical straight body portion having an opening on the top end and extending in a vertical direction, a curved bottom portion, and a corner portion connecting the straight body portion with the bottom portion and a curvature of which is greater than that of the bottom portion, wherein, the vitreous silica crucible comprises a transparent layer on the inside and a bubble layer on the outside thereof, a compressive stress layer in which compressive stress remains in the inner surface side of the transparent layer, and a tensile stress layer in which tensile stress remains and is adjacent to the compressive stress layer at a gradual rate of change of stress.
    Type: Application
    Filed: May 31, 2013
    Publication date: April 21, 2016
    Inventors: Toshiaki SUDO, Ken KITAHARA, Akihiro AIBA, Kazushi OUSYUYA, Fumie YOSHIDA, Makiko HINOOKA, Eriko KITAHARA, Tadahiro SATO