`Reg. No. 42,557
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`UNITED STATES PATENT AND TRADEMARK OFFICE
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`BEFORE THE PATENT TRIAL AND APPEAL BOARD
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`INTEL CORPORATION GLOBALFOUNDRIES U.S., INC.
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`AND MICRON TECHNOLOGY, INC,
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`Petitioners
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`V.
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`DANIEL L. FLAMM,
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`Patent Owner
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`CASE lPR2017-00279l
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`US. Patent No. RE40,264 E
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`DECLARATION OF DANIEL L. FLAMM IN
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`SUPPORT OF PATENT OWNER’S RESPONSE
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`Mail Stop: PATENT BOARD
`Patent Trial and Appeal Board
`US. Patent & Trademark Office
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`PO. Box 1450
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`'
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`Alexandria, VA 22313-1450
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`I Samsung Electronics Company, Ltd. Was joined as a party to this proceeding
`1
`Via a Motion for Joinder in IPR2017—01749
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`Exhibit 2001
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`IPR2017—00279
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`Inter Partes Review of US. Patent No. RE40,264
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`IPR2017-00279
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`1, Daniel L. Flamm, Sc.D., hereby declare as follows:
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`1.
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`I worked in academia, research, and industry in various roles for more than 50
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`years. My curriculum vitae, which includes a more detailed summary of my
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`background, experience, and publication, is attached as Appendix A.
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`2.
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`l have been a leading researcher and educator in the fields of semiconductor
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`processing technology, air pollution control, materials science, and other areas of
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`chemical engineering. My research has been funded by NASA, National Science
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`Foundation, Environmental Protection Agency, and AT&T Bell Laboratories.
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`While a Distinguished Member of Technical Staff at Bell Laboratories, I led a
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`semiconductor processing research group comprised of research colleagues,
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`visiting university scientists, post-doctoral associates, and summer students.
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`I
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`have also served as a technical consultant to various semiconductor device and
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`processing equipment manufacturers.
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`3.
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`I have published over one hundred and fifty (150) technical journal articles
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`and books, and dozens of articles in conference proceedings, most of them in
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`highly competitive referred conferences and rigorously reviewed journals.
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`1 am
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`an inventor listed in more than 20 US. patents, a number of which have been
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`licensed through the industry, and most being in the general
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`field of
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`semiconductor processing technology.
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`4.
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`I had experience studying and analyzing patents and patent claims from the
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`1
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`Inter Partes Review of US. Patent No. RE40,264
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`perspective of a personal having ordinary skilled in the art (“PHOSTIA”) starting
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`at least at the time of my employment at AT&T Bell laboratories in 1977. At
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`AT&T Bell Laboratories, I served as a member of the patent licensing review
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`committee where I was responsible for reviewing hundreds of patents for
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`potential utility and licensing potential.
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`I have also served as a technical expert
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`in patent disputes and litigation.
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`5.
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`I was admitted to the patent bar as an Agent in 2003 and have been registered
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`as a Patent Attorney since 2006.
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`I am also a member of the California State Bar.
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`6.
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`I am the inventor of US. Patent No. RE40,264E, in the name of Daniel L
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`Flamm and titled “(“the “264 Patent”).
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`7.
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`I have read the Petitioners Petition for Inter Partes Review in this matter and
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`the various art cited therein, including, among other.,
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`8.
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`Anderson fails to teach that “the thermal mass of the substrate holder is
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`selected.” At best, the term “thermal mass” in Anderson means something
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`completely different
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`from that
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`in the ‘264 patent. Petitioners completely
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`misrepresent facts and the literal reading of Anderson. There is absolutely no
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`mention that the thermal mass of the substrate holder is selected. Anderson’s
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`abstract cited for thermal mass at [Ex. 1111, 25:1-6] teaches nothing about any
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`thermal mass of a substrate holder as required by claim 13. The abstract does no
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`more than mention the use of a hollow cavity to utilize phase change (latent heat
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`of vaporization) to extract heat from a wafer. Latent heat is not thermal mass.
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`The same is true of Anderson col. 2:60-65 that discloses nothing about any
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`thermal mass. The only place Anderson even mentions the term “thermal mass”
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`is in the single sentence concerning a heater that is placed in the chuck, where he
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`states “the preferred embodiment is capable of heating the chuck 11 from room
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`temperature to an operating temperature of 100 to 500 C. in a matter of seconds
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`[before the plasma is switched on], due to the low thermal mass heater employed.”
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`The low thermal mass heater of Anderson is not the same as the claimed thermal
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`mass of the substrate holder.
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`1 also note Anderson’s objective is to maintain the
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`operating temperature (not change any temperature) and uses the latent heat of
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`vaporization of the liquid [Ex. 1111 6:28-31] to achieve this objective. Anderson
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`teaches a thermal mass heater can be useful
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`to heat a wafer prior to any
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`processing, but that it is not sufficient to maintain the wafer temperature when
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`processing, never mind changing a wafer temperature during processing as
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`required by the ‘264 patent.
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`the objective of Anderson is to effectuate an extreme
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`temperature change before any processing, not tight control while changing wafer
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`temperature during processing as is required by the ‘264 patent. The purpose of
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`low thermal mass for a heater in Anderson was to effectuate extreme temperature
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`changes very rapidly before processing when tight control is unnecessary.
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`Given the above analysis, it is not well known to select a thermal mass for a
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`substrate holder in the manner claimed, and Anderson does not teach this feature.
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`A PHOSITA would never combine Anderson and Muller to teach claim 13.
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`In
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`particular, a PHOSITA would conclude it would not have been obvious to use a
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`substrate holder with a selected thermal mass of Anderson in the device of Muller.
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`That is, Anderson has nothing to do with etching a substrate at two temperatures
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`during processing, as taught by Muller. On the contrary, the object of Anderson
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`was to rapidly heat or cool before processing, and perform processing at a single
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`constant substrate temperature. (EX. 1111 2:66—3:1-7, 3:30—33, also see 6:19—31)
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`Anderson addresses the problems associated with initially heating or cooling a
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`chuck before beginning a process, and aims to reduce that heating time so that
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`overall
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`throughput
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`is
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`increased.
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`The process itself
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`is performed while
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`maintaining a single temperature.
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`9. Claim 13 also requires that the thermal mass ofthe substrate holder be selected
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`for “a predetermined temperature change with a specific interval oftime during
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`processing.” Anderson fails to teach this element, and even suggests away from
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`this element by only addressing the problems of initially heating or cooling a
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`Chuck before beginning a single constant temperature process, which stands in
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`stark contrast to claim 13. To overcome the failure of Anderson, Petitioners
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`attempt to rely on the remote art of Hinman to disclose this element. They argue
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`that Hinman describes “how to preselect the thermal mass of a material in a
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`chemical analyzer’s ‘temperature control system’ to effectuate predetermined
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`temperature changes within a specific interval.” Pet. 33, 40—41. Hinman,
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`however, is irrelevant.
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`It fails to teach that the “thermal mass of the substrate
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`holder is selected for a predetermined temperature change within a specific
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`interval of time during processing.” It would not have been obvious in view of
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`Anderson and Hinman to select the precise thermal mass of the substrate holder
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`used in Muller,
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`to achieve a predetermined temperature change of a specific
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`interval of time.
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`A PHOSITA would not have had reason to use Hinman’s
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`teachings to calculate the precise thermal mass of the substrate holder taught by
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`Anderson, or
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`to address the goal of throughput
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`in semiconductor wafer
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`processing as respectively done by Muller and Anderson. Not only is Hinman
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`non-analogous art having nothing to do with semiconductor processing, but it is
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`devoid of any relevance. A PHOSITA would find that Hinman has nothing at all
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`in common with the ‘264 patent. Respondent is at a loss to know where even to
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`begin to enumerate the differences and highlight
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`its remoteness. Hinman
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`concerns heating a small cuvette of liquid in a wet-chemical analysis instrument.
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`Hinman mentions (uses the term) “thermal mass” for a preheated (e.g. a
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`temperature reservoir) ring that is used to raise the temperature of liquid in the
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`small cuvette using heat energy already stored in the ring (e.g. the thermal mass
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`is selected for the ring to act as a thermal reservoir). The objective in Hinman is
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`for the ring to be able to heat the cuvette while its own temperature stays
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`sufficiently constant. Hinman accomplishes this by having the thermal mass be
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`about 20 times that of the liquid in the cuvette (stated in another way: bringing
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`about a ldegree temperature change in the liquid only changes the ring
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`temperature by about 1/20 degree). Hinman selects a thermal mass of the ring
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`that can prevent its own temperature from changing significantly, yet be able to
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`change the temperature of the liquid before processing. The thermal mass of the
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`ring is different from the thermal mass of the substrate holder in the ‘264 patent.
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`Hinman also fails to teach the objective of changing the temperature of anything
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`during processing. The ‘264 patent teaches to select a thermal mass for the
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`opposite purpose, “the thermal mass of the substrate holder is selected for a
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`predetermined temperature change within a specific interval of time during
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`7
`processing.’ This is completely inconsistent with the Hinman ring that is to
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`indirectly heat and maintain a small amount of liquid sample at a single constant
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`temperature for processing (the reaction temperature). Accordingly, Hinman
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`utterly fails to teach the aforementioned element of claim 13.
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`10. Patent Owner also acknowledges that Hinman was cited in an attempt to
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`overcome the failure of Anderson’s disclosure. Hinman suffers from other
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`shortcomings, as discussed, and further emphasized below. Patent Owner asserts
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`that Anderson does not disclose selecting a thermal mass of a substrate holder,
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`contending that Anderson merely discloses that its heater has a low thermal mass,
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`as discussed. See also, Prelim. Resp. 3—4.
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`It is also not reasonable to conclude, as
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`Petitioners suggest, that heating layer 15 is part of the substrate holder of Anderson
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`such that modifying the thermal mass of the heater substantially affects the overall
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`thermal mass of the substrate holder. As previously noted, and further emphasized
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`again, Petitioners simply misrepresent the facts. Anderson’s abstract cited for
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`thermal mass at [p.25 1-6] teaches nothing about any thermal mass of the substrate
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`holder.
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`It does no more than mention a hollow cavity to in which to use phase
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`change (latent heat of vaporization) to remove heat from a wafer. Latent heat is
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`not thermal mass. Likewise, Anderson col. 2:60—65 discloses nothing about any
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`thermal mass. Only once, in the single sentence concerning a heater that is placed
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`in the chuck, does Anderson mention the term “thermal mass” in stating “the
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`preferred embodiment is capable of heating the chuck 11 from room temperature to
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`an operating temperature of 100 to 500 C. in a matter of seconds [before the
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`plasma is switched on], due to the low thermal mass heater employed.”
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`Furthermore, what Anderson relies on to maintain the operating temperature (not
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`change any temperature) is the latent heat of vaporization of the liquid [Col. 6, 28-
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`31].
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`In other words, Anderson teaches a low thermal mass heater can be useful to
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`bring a wafer to its operating temperature as quickly as possible prior to any
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`processing [Co]. 2, 60—65], but that it is not sufficient to maintain the wafer
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`temperature in controlled manner while processing, never mind changing a wafer
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`temperature during processing as claimed by the ‘264. The objective of
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`Anderson was to effectuate an extreme temperature change before any processing.
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`Anderson discloses nothing about tight control while changing wafer temperature
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`to improve selectively during processing. Furthermore, the purpose of the low
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`thermal mass heater in Anderson was to effectuate extreme temperature changes
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`very rapidly before processing. Anderson teaches to use a liquid spray for
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`controlling heat removal to maintain a single constant processing temperature.
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`Patent Owner also disagrees with the Board that the ’264 patent specification only
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`describes selecting the thermal mass of a portion of the substrate holder, namely
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`the upper surface of the substrate holder. See BX. 1001, 15:40—48 (“the upper
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`surface [of the substrate holder] is made using a low thermal mass, high
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`conductivity material”). To the contrary, the ‘264 patent specifically teaches “the
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`use of a workpiece support which has a low thermal mass in comparison to the heat
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`transfer means” (1d. 2:37-41) and “the selected thermal mass ofthe substrate
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`holder allows for a change for a first temperature to a second temperature within a
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`characteristic time period to process a film.” (Id. 2:51-56) The passage in the “264
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`specification noted by the Board, is a teaching about providing the upper surface of
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`the substrate holder with “desirable heat transfer characteristics.” It discloses a
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`specific embodiment where the upper surface is made using a material having a
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`combination of low thermal mass and high [thermal] conductivity, such a
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`diamond—like or diamond film (overlying a copper or copper like substrate). This
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`teaching does not qualify or negate the selection of a thermal mass of the substrate
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`holder “for a predetermined temperature change
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`during processing,” and the
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`noted embodiment is no evidence to the contrary.
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`Again, Anderson teaches nothing about this element. Anderson’s teaching is
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`incompatible with the cited ‘264 passage because copper has a coefficient of
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`thermal expansion (~16.5 um/m-K) which is about 15-16 times greater than that of
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`diamond (~l .1 ttm/m—K), and therefore would be excluded by his requirement that
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`the surface of the chuck 14 match the coefficient of expansion of the heater
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`material (Id. ozl 2—14). Accordingly, Anderson fails to teach that “the thermal mass
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`of the substrate holder is selected...”
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`11. Turning to Hinman, a PHOSHITA in the field of semiconductor
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`processing would not have even considered Hinman. Furthermore, even assuming
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`arguendo that he/she had, Hinman discloses nothing about the “thermal mass of the
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`substrate holder is selected for a predetermined temperature change within a
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`specific interval oftime during processing.” Patent Owner also disagrees with the
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`Board that Hinman provides a more definite example of selecting a specific
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`thermal mass, for example a 1 kg aluminum ring for the reasons already discussed
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`and further emphasized below.
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`As discussed, Hinman concerns heating a small cuvette of liquid in a wet-
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`chemical analysis instrument and mentions “thermal mass” for a preheated ring
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`that is used to raise the temperature of liquid in the small cuvette using heat energy
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`already in the ring. The objective in Hinman is for the ring to be able to heat the
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`cuvette while its own temperature stays sufficiently constant. Hinman
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`accomplishes this by having the thermal mass be about 20 times that of the liquid
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`in the cuvette. Hinman selects a thermal mass of the ring that can prevent its own
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`temperature from changing, yet change the temperature of the liquid prior to any
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`processing. The ring is no substrate holder and thermal mass of the ring is
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`different from the thermal mass of the substrate holder that changes temperature
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`during processing in the ‘264 patent.
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`In fact Hinman is also deficient because it
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`fails to disclose changing the temperature of anything during processing, as
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`required by the ‘264 patent.
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`Patent Owner reiterates that Hinman is not analogous art to the claimed
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`invention of the ’264 patent, because it is neither in the same field of endeavor nor
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`reasonably pertinent to the problem faced by the ’264 patent. Prelim. Resp. 5—10.
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`Patent Owner disagrees with the Board that Hinman is reasonably pertinent to the
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`problem addressed by the ’264 patent. Patent Owner disagrees with the Board that
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`the prior art would recognize a link between the control of substrate holder
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`temperature and the throughput of the etching process. Additionally, a PHOSITA
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`would not perceive any link between the prior art and the ‘264 patent since each of
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`them is directed to solving a totally different problem.
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`That is, the ‘264 patent’s goal does not solely address control of the
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`substrate holder temperature and the throughput of the etching process, as noted by
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`the Board. Rather, the ‘264 patent is concerned with achieving or improving etch
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`selectivity in a high throughput etch process for semiconductor processing, which
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`is a different problem being addressed than any of the cited art. Etch selectivity
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`and throughput for semiconductor processing are important in the ‘264 patent, and
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`not found in either Muller or Hinman, as discussed below.
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`Muller teaches that the change in taper angle of etched trenches correlates
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`with increasing wafer temperature during the trench etching processes. Muller,
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`3:33—66, Figs. 1 and 2. Muller has nothing to do with etch selectivity but is
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`concerned with using two temperatures for profile control in a trench structure
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`drilled from a single material, which would have nothing to do with selectivity.
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`Muller is addressing the distinct and separate problem of profile control in contrast
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`to the ‘264 patent.
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`As noted, Hinman concerns heating a small cuvette of liquid in a wet—
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`chemical analysis instrument. Hinman mentions (uses the term) “thermal mass”
`
`for a preheated (e.g. a temperature reservoir) ring that is used to raise the
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`temperature of liquid in the small cuvette using heat energy already in the ring (e.g.
`
`11
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`the thermal mass is selected for the ring to act as a thermal reservoir). The
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`objective in Hinman is for the ring to be able to heat the cuvette while its own
`
`temperature stays sufficiently constant, that is, Hinman selects a thermal mass of
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`the ring that can prevent its temperature from changing yet change the temperature
`
`of the liquid before processing. The thermal mass for the ring is used to prevent
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`change in temperature of the small cuvette, which is different from changing
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`temperature in the ‘264 patent.
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`Accordingly, Patent Owner would not conclude that a PHOSITA would
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`have found Hinman pertinent to the problem addressed by the ‘264 patent. Patent
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`Owner has restated its position on non—analogous art, and respectfully requests the
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`Board to reconsider its arguments.
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`12. Still further, from the discussion presented, Hinman taught use of a ring
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`having a large thermal mass to store energy to maintain the small cuvette at a
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`constant temperature, in contrast to Anderson that taught modifying the low thermal
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`mass of a heater for rapidly increasing temperature in a matter of seconds before
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`processing. A PHOSITA would not combine Hinman and Anderson since such
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`combination would be inoperative because the large thermal mass taught by Hinman
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`is in consistent with the low thermal mass of Anderson, and the combination would
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`be in operable. Anderson and Hinman still lack the teaching of“the thermal mass
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`of the substrate holder is selected for a predetermined temperature change within a
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`9
`specific interval of time during processing.’ Anderson, at best, taught changing
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`temperature before processing, and Hinman, which does not even mention any
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`etching process, uses its ring for maintaining the temperature of the cuvette for
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`chemical analysis,
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`rather
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`than the thermal mass of
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`the substrate holder
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`is
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`selected. . .within a specific time interval during processing as required by claim 13.
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`13. Patent Owner asserts that claims 19 and 20 are not obvious over the combined
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`disclosures of Muller, Matsumura, Anderson, Hinman, and Wright. Pet. 45—47.
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`Claim 19 depends from claim 13 and further requires that the etching temperatures
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`correspond to substrate holder temperatures, and that the etching temperatures are
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`in a “known relationship” to the substrate holder temperatures. xx Claim 20
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`depends from claim 19, and further requires that the etching temperatures are
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`within 1°C of the substrate holder temperatures.
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`Wright fails to teach the elements of claims 19 and 20. Wright fails to teach
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`any “known relationship to the substrate holder temperatures. Wright also fails to
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`teach that the etching temperatures are within 1 Degree C of the substrate holder
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`temperatures. That is, Wright has great difficulty in controlling even one wafer
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`temperature within 1 Degree C (or within 1 Degree C of the chuck temperature
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`after 20 seconds, let alone changing temperature from one predetermined value to
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`another while maintaining a correspondence within 1 Degree C. as required by
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`claim 20). Ex1008 Figures 4, 5, and 6, and accompanying text.
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`13
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`Petitioner conflates different temperatures and processes in Wright. Figures
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`4 and 6 show data for the cryogenic polycold polysilicon etch. Figure 5 has data
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`for a different process: an oxide etch in a different chamber of the machine
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`(chamber 2) performed at 30 C (by cooling with a circulating methanol chiller).
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`Wright’s data show large temperature excursions between the wafer holder
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`temperature and the wafer after plasma is ignited and etching occurs. The
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`maximum temperature difference is about 3 °C or more in Figure 2, and more than
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`25 Degrees C in Figure 5. Figure 4 shows a wafer temperature fluctuating between
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`about ——102C and —105C. with a chuck temperature of about —105.5°C. Figure 5
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`shows a chuck temperature drifting from about -32.5°C to —30°C while wafer
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`temperature fluctuates from about —30°C to —5°C, each of which is a much wider
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`variation than the claimed 1 degree C.
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`On page 325, 2nd full paragraph, Wright explains, “At this scale the
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`exponential behaviors of both the heating and cooling ofthe wafer are apparent.”
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`In other words, Wright shows his wafer temperatures can fall within 1 Degrees C
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`of the substrate temperatures about 20 seconds after the plasma is extinguished.
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`When the plasma is active there is a large temperature difference outside of the
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`claimed 1 degree range.
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`Additionally, a PHOSITA would not combine Wright with any of the other
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`cited art. That is, Wright is directed to controlling a cryogenic coolant temperature
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`that always removes heat from the substrate holder. Wright’s substrate holders
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`never heat a substrate (e.g. it only cools the substrate). Accordingly, Wright
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`addresses a problem that is different than the object of the ‘264, and also different
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`from the respective objectives of Muller, Matsumura, Anderson, and Hinman.
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`14. Patent Owner asserts that claim 17 is not obvious over the combined disclosures
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`of Muller, Matsumura, Anderson, Hinman, and Kikuchi. Claim 17 depends from
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`claim 13 and further requires that the etching of at least one of the portions of the
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`film comprises radiation. Kikuchi teaches away Muller’s process by using its
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`infrared lamps to heat a wafer [Pet 48 (citing EX. 1004, 725—31)] for an etching
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`process.
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`In particular, Kikuchi relates to an “etching process,” as opposed to a deep
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`trench silicon etching process of Muller. Ex. 1002 Abstract. Additionally, Kikuchi
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`teaches “a plurality of supports, which may be movably disposed within a vacuum
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`treatment chamber for moving the substrate away from a source of heat and for
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`moving the substrate into contact with the heating source.” Ex.1002 Abstract.
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`Kikuchi takes affirmative measures to teach away from Muller’s source of heat,
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`which is its chuck, would not be combined with Kikuchi’s infrared lamps since it
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`would defeat the purpose of either Kikuchi or Muller according to a PHOSITA.
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`Based upon the earlier arguments associated with claim 13, the combination of the
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`cited art including Kikuchi still fails to teach claim 17.
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`15. Patent Owner asserts that claims 24—26 are not obvious over the combined
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`disclosures of Muller, Matsumura, Anderson, Hinman, and Moslehi. These claims
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`are directed to certain aspects of the substrate holder, such as fluid passages or
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`heating elements. Based upon the earlier arguments associated with claim 13, the
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`combination of the cited art including Moslehi fails to teach claims 24—26.
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`16. Patent Owner asserts that claims 14—16, 18—23, 64, and 65 are non-obvious
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`over the combined disclosures of Kadomura, Matsumura, Anderson, and Hinman.
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`Petition’s contentions are similar to those provided in its grounds involving Muller,
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`Matsumura, Anderson, and Hinman, except that in place ofMuller’s etch chamber
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`Petitioners rely on the etch chamber of Kadomura. Given this and based upon the
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`earlier arguments associated with claim 13, the combination of the cited art
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`including replacing Muller with Kadomura fails to teach claims 14-16, 18-23, 64,
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`and 65.
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`17. Patent Owner asserts that claim 17 is non-obvious over the combined
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`disclosures of Kadomura, Matsumura, Anderson, Hinman, and Kikuchi. For the
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`same reasons that Kikuchi fails to teach claim 17 with Muller, Kikuchi has the
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`same problems with Kadomura. That is Kikuchi relates to an “etching process,” as
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`opposed to a deep trench silicon etching process of Muller. Ex. 1002 Abstract.
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`Additionally, Kikuchi takes affirmative measures to teach away from M uller’s
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`source of heat, which is its chuck, would not be combined with Kikuchi’s infrared
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`lamps since it would defeat the purpose of either Kikuchi or Muller according to a
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`PHOSITA. Based upon the earlier arguments associated with claim 13, the
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`combination of the cited art including Kikuchi still fails to teach claim 17.
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`18. Patent Owner asserts that claims 24—26 are not obvious over the
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`combined disclosures of Kadomura, Matsumura, Anderson, Hinman, and Moslehi.
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`Based upon the earlier arguments associated with claim 13, the combination of the
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`cited art including Moslehi and replacement of Muller by Kadomura fails to teach
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`claims 24—26.
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`19. Patent Owner asserts that claim 15 is not obvious over the combined
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`disclosures of Kadomura, Matsumura, Anderson, Hinman, and Muller. Claim 15
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`depends from claim 13, and further requires that the change from the first substrate
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`holder temperature to the second substrate holder temperature is an in—situ process
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`during the first portion etching and second portion etching.
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`A PHOSITA would not combine Kadomura, which teaches exhausting the
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`etching gas between etching steps, and changing the temperature during the time
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`used to exhaust the gas, with the continuous process of Muller. Muller relates to a
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`deep trench etching process, which would be compromised and not work, if
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`combined with the multi—step process of Kadomura.
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`Additionally, based upon the earlier arguments associated with claim 13, the
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`combination of the cited art including Muller now (for teaching in-situ) and
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`replacement of Muller by Kadomura fails to teach claim 15.
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`20. I declare under penalty of perjury under the laws of the United States of
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`America that the foregoing is true and correct.
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`Executed on this 20th day of September, 2017
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`/'
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`7 W
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`K
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`Daniel L. Flamm
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