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`UNITED STATES PATENT AND TRADEMARK OFFICE
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`UNITED STATES DEPARTMENT OF COMMERCE
`United States Patent and Trademark Office
`Address: COMIVHSSIONER FOR PATENTS
`PO. Box 1450
`Alexandria1 Virginia 22313-1450
`www.uspto.gov
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`15/427,198
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`02/08/2017
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`NORIYUKI MATSUBARA
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`PIPMM—57207
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`2420
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`02’09’2018 —PEARNE&GORDON LLP m
`7590
`52054
`1801 EAST 9TH STREET
`STEVENSON, ANDRE C
`SUITE 1200
`CLEVELAND, OH 441 14-3 108
`
`PAPER NUMBER
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`ART UNIT
`2816
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`NOTIFICATION DATE
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`DELIVERY MODE
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`02/09/2018
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`ELECTRONIC
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`Please find below and/or attached an Office communication concerning this application or proceeding.
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`The time period for reply, if any, is set in the attached communication.
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`Notice of the Office communication was sent electronically on above—indicated "Notification Date" to the
`following e—mail address(es):
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`patdocket @ pearne.c0m
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`PTOL—90A (Rev. 04/07)
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`

`

`
`
`Applicant(s)
`Application No.
` 15/427,198 MATSUBARA ET AL.
`
`Examiner
`Art Unit
`AIA (First Inventorto File)
`Office Action Summary
`
`2816ANDRE‘ c. STEVENSON $233
`
`-- The MAILING DA TE of this communication appears on the cover sheet with the correspondence address --
`Period for Reply
`
`A SHORTENED STATUTORY PERIOD FOR REPLY IS SET TO EXPIRE 3 MONTHS FROM THE MAILING DATE OF
`THIS COMMUNICATION.
`Extensions of time may be available under the provisions of 37 CFR 1.136(a).
`after SIX (6) MONTHS from the mailing date of this communication.
`If NO period for reply is specified above, the maximum statutory period will apply and will expire SIX (6) MONTHS from the mailing date of this communication.
`Failure to reply within the set or extended period for reply will, by statute, cause the application to become ABANDONED (35 U.S.C. § 133).
`Any reply received by the Office later than three months after the mailing date of this communication, even if timely filed, may reduce any
`earned patent term adjustment. See 37 CFR 1.704(b).
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`In no event, however, may a reply be timely filed
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`-
`-
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`Status
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`1)IXI Responsive to communication(s) filed on 11/13/17.
`[I A declaration(s)/affidavit(s) under 37 CFR 1.130(b) was/were filed on
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`2b)|:| This action is non-final.
`2a)IZ| This action is FINAL.
`3)I:I An election was made by the applicant in response to a restriction requirement set forth during the interview on
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`; the restriction requirement and election have been incorporated into this action.
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`4)|:I Since this application is in condition for allowance except for formal matters, prosecution as to the merits is
`closed in accordance with the practice under EX parte Quay/e, 1935 CD. 11, 453 O.G. 213.
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`3) D Interview Summary (PT0_413)
`1) E Notice of References Cited (PTO-892)
`Paper No(s)/Mai| Date.
`.
`.
`—
`4) I:I Other'
`2) D Information Disclosure Statement(s) (PTO/SB/08a and/or PTO/SB/08b)
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`Paper No(s)/Mai| Date .
`US. Patent and Trademark Office
`PTOL-326 (Rev. 11-13)
`
`Office Action Summary
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`Part of Paper No./Mai| Date 20180129
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`Disposition of Claims*
`5)|XI Claim(s) L8is/are pending in the application.
`5a) Of the above claim(s)
`is/are withdrawn from consideration.
`6 III Claim s) _ is/are allowed.
`s L8 is/are rejected.
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`is/are objected to.
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`) )
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`_
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`are subject to restriction and/or election requirement.
`9)|:l Claim(s
`)
`* If any claims have been determined allowable, you may be eligible to benefit from the Patent Prosecution Highway program at a
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`participating intellectual property office for the corresponding application. For more information, please see
`htt
`://www.usoto. ov/ atentS/init events"
`h/index.‘s
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`, or send an inquiry to PF"I-Ifeedback{<‘buspto.qov.
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`Application Papers
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`10)I:I The specification is objected to by the Examiner.
`11)|Z| The drawing(s) filed on 02/08/17 is/are: a)IXI accepted or b)I:I objected to by the Examiner.
`Applicant may not request that any objection to the drawing(s) be held in abeyance. See 37 CFR 1.85(a).
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`Replacement drawing sheet(s) including the correction is required if the drawing(s) is objected to. See 37 CFR 1.121 (d).
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`Priority under 35 U.S.C. § 119
`12)I:I Acknowledgment is made of a claim for foreign priority under 35 U.S.C. §119(a)-(d) or (f).
`Certified copies:
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`b)I:I Some” c)I:I None of the:
`a)I:I All
`1.I:I Certified copies of the priority documents have been received.
`2.I:I Certified copies of the priority documents have been received in Application No.
`3.I:I Copies of the certified copies of the priority documents have been received in this National Stage
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`application from the International Bureau (PCT Rule 17.2(a)).
`** See the attached detailed Office action for a list of the certified copies not received.
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`Attachment(s)
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`

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`Application/Control Number: 15/427,198
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`Art Unit: 2816
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`Page 2
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`The present application, filed on or after March 16, 2013, is being examined under the first
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`inventor to file provisions of the AIA.
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`Response to Arguments
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`Applicant's arguments filed 11/17/17 have been fully considered but they are not persuasive. The
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`Applicant argues that neither Arita nor Lei, alone on in combination, disclose teaches or render obvious
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`that the attaching process being performed in an atmospheric pressure.
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`The Examiner has considered the argument of the Applicant that neither Arita et al. nor Lei et al.
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`teaches the presently presented amendment to the claimed method. The Examiner agrees that neither
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`Arita nor Lei teaches explicitly wherein the attaching process of the resin layer is performed in a
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`pressurized atmospheric condition. However, further searching has shown that lkeda et al. teaches
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`attaching a resin layer under reduced atmospheric pressure to reduce the air trapped between the resin
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`and the die structure; as will be shown in the rejection below.
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`Claim Rejections - 35 USC § 103
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`The following is a quotation of 35 U.S.C. 103 which forms the basis for all obviousness rejections
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`set forth in this Office action:
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`A patent for a claimed invention may not be obtained, notwithstanding that the claimed
`invention is not identically disclosed as set forth in section 102, if the differences between the
`claimed invention and the prior art are such that the claimed invention as a whole would have
`been obvious before the effective filing date of the claimed invention to a person having
`ordinary skill in the art to which the claimed invention pertains. Patentability shall not be
`negated by the manner in which the invention was made.
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`The factual inquiries set forth in Graham v. John Deere Co., 383 U.S. 1, 148 USPQ 459 (1966),
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`that are applied for establishing a background for determining obviousness under 35 U.S.C. 103 are
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`summarized as follows:
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`1. Determining the scope and contents of the prior art.
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`Application/Control Number: 15/427,198
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`Art Unit: 2816
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`Page 3
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`2. Ascertaining the differences between the prior art and the claims at issue.
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`3. Resolving the level of ordinary skill in the pertinent art.
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`4. Considering objective evidence present in the application indicating obviousness or
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`nonobviousness.
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`Claim #1-4 and 6-8 is/are rejected under 35 U.S.C. 103 as being unpatentable over Arita et al.,
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`(U.S. Pub. No. 2012/0021608 A1), hereinafter referred to as “Arita” as modified by Lei et al., (U.S. Pub.
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`No. 2015/0214109 A1), hereinafter referred to as “Lei” and in further view of lkeda et al., (U.S. Pub. No.
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`2002/0125588 A1), hereinafter referred to as “lkeda”.
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`Arita shows, with respect to claim #1, a plasma processing method comprising: an attaching process of
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`attaching a resin film (fig. #23, item 3) to a first main surface (fig. #23, item 13) of a substrate (fig. #23, item 1)
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`which is provided with the first main surface and a second main (fig. #2, item 1b) surface on an opposite side of the
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`first main surface mask (paragraph 0046, 0054, 0055); a patterning process of forming a, which includes an
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`opening exposing a region to be processed of the substrate, by patterning the resin film (paragraph 0046, 0056); a
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`second plasma process (after first plasma process, paragraph 0047) of generating second plasma from second
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`gas in atmosphere including the second gas, exposing, to the second plasma, the region to be processed exposed
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`from the opening, and etching the region to be processed (paragraph 0053).
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`Arita substantially shows the claimed invention as shown in the rejection above.
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`Arita fails to show, with respect to claim #1 a plasma process of generating first plasma of first gas in a
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`depressurized atmosphere including the first gas, exposing the mask to the first plasma, and reducing a void between
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`the mask and the first main surface.
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`Lei teaches, in similar method of wafer dicing, with respect to claim #1 a plasma process of generating first
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`plasma of first gas in a depressurized atmosphere including the first gas, exposing the mask (fig. #63, item 602) to
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`the first plasma, and reducing a void between the mask and the first main surface (surfaces between item 602 and
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`606, fig. 63) (paragraph 0051).
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`Application/Control Number: 15/427,198
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`Art Unit: 2816
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`Page 4
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`It would have been obvious to one having ordinary skill in the art at the time the invention was made, with
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`respect to claim #1 a plasma process of generating first plasma of first gas in a depressurized atmosphere including
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`the first gas, exposing the mask to the first plasma, and reducing a void between the mask and the first main surface,
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`into the method of Arita, with the motivation that this is used to effect strong physical bombardment to "hammer"
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`the exposed mask surface, and thus realize improvement of mask etch resistance. The improvement of mask etch
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`resistance under physical bombardment may be due to different mechanisms depending on specific mask materials,
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`as taught by Lei.
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`Arita as modified by Lei substantially shows the claimed invention as shown in the rejection above.
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`Arita as modified by Lei fails to show, with respect to claim #1 a method wherein the preparing of the resin
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`film, having an adhesiveness, for an attaching process is done in an atmospheric pressure.
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`Ikeda teaches, in similar method of supplying resin film, with respect to claim #1 a method wherein the
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`attaching process of the resin film (fig. #14a, item #4, paragraph 0067) with adhesiveness (paragraph 0141) is
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`done in a lowered pressurized atmospheric environment (paragraph 0022, 0023).
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`It would have been obvious to one having ordinary skill in the art at the time the invention was made, with
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`respect to claim #1 a method wherein the preparing of the resin film, having an adhesiveness, for an attaching
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`process is done in an atmospheric pressure, into the method of Arita as modified by Lei, with the motivation that this
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`creates an atmospheric conditions that reduces the air trapped between the die and the resin film, as taught by Ikeda.
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`Arita fails to show with respect to claim #2, a plasma process wherein in the first plasma process, the mask
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`is heated with the first plasma, and at least a part of the mask is softened.
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`Lei teaches, in similar method of wafer dicing, with respect to claim #2 a plasma process wherein a mask
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`plasma treatment operation (fig. #5, item504) is carried out on the mask (fig. #6a, item 602) at high energy
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`Application/Control Number: 15/427,198
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`Art Unit: 2816
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`Page 5
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`(paragraph 0051). The Examiner notes that Lei does not state specifically that the process causes a softening of the
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`mask. However, the Examiner notes that Lei states, in the sited section above, that high energy levels of the plasma
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`range are just short of etching and that low energy ranges causes a hardening of the mask. Furthermore, the
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`Examiner notes that the claim language fails to show any temperature range or specific processes of the plasma
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`operation that teach away from Lei‘s treatment step.
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`It would have been obvious to one having ordinary skill in the art at the time the invention was made, with
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`respect to claim #2, a plasma process wherein in the first plasma process, the mask is heated with the first plasma,
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`and at least a part of the mask is softened, into the method of Arita, with the motivation that this is used to effect
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`strong physical bombardment to "hammer" the exposed mask surface, and thus realize improvement of mask etch
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`resistance. The improvement of mask etch resistance under physical bombardment may be due to different
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`mechanisms depending on specific mask materials, as taught by Lei.
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`Arita fails to show, with respect to claim #3, a plasma process wherein the first gas includes a least one
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`selected form a group of argon, oxygen, nitrogen and helium.
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`Lei teaches, in similar method of wafer dicing, with respect to claim #3 a plasma process wherein the first
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`gas consist of argon, nitrogen or a combination (paragraph 0051).
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`It would have been obvious to one having ordinary skill in the art at the time the invention was made, with
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`respect to claim #3, a plasma process wherein the first gas includes a least one selected form a group of argon,
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`oxygen, nitrogen and helium, into the method of Arita, with the motivation that this is used to effect strong physical
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`bombardment to "hammer" the exposed mask surface, and thus realize improvement of mask etch resistance. The
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`improvement of mask etch resistance under physical bombardment may be due to different mechanisms depending
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`on specific mask materials, as taught by Lei.
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`Application/Control Number: 15/427,198
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`Art Unit: 2816
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`Page 6
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`Arita fails to show, with respect to claim #4, a plasma process wherein pressure of the depressurized
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`atmosphere including the first gas is 0.1 Pa to 100 Pa.
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`Lei teaches, in similar method of wafer dicing, with respect to claim #4, a plasma process wherein pressure
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`of the depressurized atmosphere including the first gas is 100 mTorr to 250 mTorr (13.33 to 33.3 Pa) (paragraph
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`0051).
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`It would have been obvious to one having ordinary skill in the art at the time the invention was made, with
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`respect to claim #4, a plasma process wherein pressure of the depressurized atmosphere including the first gas is 0.1
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`Pa to 100 Pa, into the method of Arita, with the motivation that this is used to effect strong physical bombardment to
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`"hammer" the exposed mask surface, and thus realize improvement of mask etch resistance. The improvement of
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`mask etch resistance under physical bombardment may be due to different mechanisms depending on specific mask
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`materials, as taught by Lei.
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`Arita shows, with respect to claim #6, a plasma processing method wherein, in the mask which is made of
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`resin, (fig. #2a, item 4) is removed by wet mask removal method (paragraph 0080).
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`Arita fails to show, with respect to claim #7 a plasma processing method wherein, in the patterning
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`process, by scribing using laser, a part, corresponding to the opening, of the resin film is removed.
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`Lei teaches, with respect to claim #7, a plasma processing method wherein, in the patterning process, by
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`scribing using laser, a part, corresponding to the opening (fig. #4b, item 410), of the resin film (fig. #4b, item 408)
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`is removed (paragraph 0037).
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`It would have been obvious to one having ordinary skill in the art at the time the invention was made, with
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`respect to claim #7, a plasma processing method wherein, in the patterning process, by scribing using laser, a part,
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`corresponding to the opening, of the resin film is removed, into the method of Arita, with the motivation that
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`Application/Control Number: 15/427,198
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`Art Unit: 2816
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`Page 7
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`provides benefits and advantages such as providing sufficiently high laser intensity to achieve ionization of
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`inorganic dielectrics (e. g., silicon dioxide) and to minimize delamination and chipping caused by underlayer damage
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`prior to direct ablation of inorganic dielectrics, as taught by Lei.
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`Arita shows, with respect to claim #8, a plasma processing method wherein, in the second plasma process,
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`the region to be processed (fig. #2b, item 4) is etched from the first main surface (fig. #2a, item 4, top) to the
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`second main surface (fig. #2e, item 1b) (paragraph 0053), and the substrate is divided into individual pieces
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`(paragraph 0079).
`
`//
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`Claim #5 is/are rejected under 35 U.S.C. 103 as being unpatentable over Arita et al., (U.S. Pub.
`
`No. 2012/0021608 A1), hereinafter referred to as “Arita” as modified by Lei et al., (U.S. Pub. No.
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`2015/0214109 A1), hereinafter referred to as “Lei” and Ikeda et al., (U.S. Pub. No. 2002/0125588 A1),
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`hereinafter referred to as “Ikeda” as applied to claim #1 above, and further in view of KUO et al., (U.S.
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`Pub. No. 2014/0038419 A1 ), hereinafter referred to as " KUO
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`Arita as modified by Lei and Ikeda substantially shows the claim invention as shown in the rejection below.
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`Arita as modified by Lei and Ikeda fails to show, with respect to claim #5, a method wherein the first
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`plasma process and the second plasma process are continuously performed in the same space.
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`KUO teaches, with respect to claim #5, a method wherein both plasma process are carried out in the same
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`chamber (paragraph 0043).
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`

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`Application/Control Number: 15/427,198
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`Art Unit: 2816
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`Page 8
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`It would have been obvious to one having ordinary skill in the art at the time the invention was made, with
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`respect to claim #5, a method wherein the first plasma process and the second plasma process are continuously
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`performed in the same space, into the method of Arita as modified by Lei and lkeda, with the motivation that
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`performing both plasma process in the same chamber decreases the possibility of contamination and also reduces
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`cost and time of to complete design, as taught by KUO.
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`Conclusion
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`THIS ACTION IS MADE FINAL. Applicant is reminded of the extension of time policy as set forth
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`in 37 CFR1.136(a).
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`A shortened statutory period for reply to this final action is set to expire THREE MONTHS from
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`the mailing date of this action.
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`In the event a first reply is filed within TWO MONTHS of the mailing date
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`of this final action and the advisory action is not mailed until after the end of the THREE-MONTH
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`shortened statutory period, then the shortened statutory period will expire on the date the advisory action
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`is mailed, and any extension fee pursuant to 37 CFR 1.136(a) will be calculated from the mailing date of
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`the advisory action.
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`In no event, however, will the statutory period for reply expire later than SIX
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`MONTHS from the mailing date of this final action.
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`Any inquiry concerning this communication or earlier communications from the examiner should be
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`directed to Andre’ Stevenson whose telephone number is (571) 272 1683. The examiner can normally be reached
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`on Monday through Friday from 7:30 am to 4:30 pm. If attempts to reach the examiner by telephone are
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`unsuccessful, the examiner’s supervisor, Zandra Smith can be reached on 571-272 2429. The fax phone number for
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`the organization where this application or proceeding is assigned is 571-273-8300. Information regarding the status
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`of an application may be obtained from the Patent Application Information Retrieval (PAIR) system. Status
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`information for published applications may be obtained from either Private PAIR or Public PAIR. Status
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`information for unpublished applications is available through Private PAIR only. For more information about the
`
`