Patents by Inventor Sean D. Burns

Sean D. Burns 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).

  • Publication number: 20240096627
    Abstract: A method of forming a structure for etch masking that includes forming first dielectric spacers on sidewalls of a plurality of mandrel structures and forming non-mandrel structures in space between adjacent first dielectric spacers. Second dielectric spacers are formed on sidewalls of an etch mask having a window that exposes a connecting portion of a centralized first dielectric spacer. The connecting portion of the centralized first dielectric spacer is removed. The mandrel structures and non-mandrel structures are removed selectively to the first dielectric spacers to provide an etch mask. The connecting portion removed from the centralized first dielectric spacer provides an opening connecting a first trench corresponding to the mandrel structures and a second trench corresponding to the non-mandrel structures.
    Type: Application
    Filed: April 27, 2023
    Publication date: March 21, 2024
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Matthew E. Colburn, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Roger A. Quon, Nicole A. Saulnier
  • Publication number: 20240030036
    Abstract: A method for forming fins includes forming a three-color hardmask fin pattern on a fin base layer. The three-color hardmask fin pattern includes hardmask fins of three mutually selectively etchable compositions. Some of the fins of the first color are etched away with a selective etch that does not remove fins of a second color or a third color and that leaves at least one fin of the first color behind. The fins of the second color are etched away. Fins are etched into the fin base layer by anisotropically etching around remaining fins of the first color and fins of the third color.
    Type: Application
    Filed: February 14, 2023
    Publication date: January 25, 2024
    Inventors: Sean D. Burns, Nelson M. Felix, Chi-Chun Liu, Yann A.M. Mignot, Stuart A. Sieg
  • Patent number: 11670510
    Abstract: A method of forming a structure for etch masking that includes forming first dielectric spacers on sidewalls of a plurality of mandrel structures and forming non-mandrel structures in space between adjacent first dielectric spacers. Second dielectric spacers are formed on sidewalls of an etch mask having a window that exposes a connecting portion of a centralized first dielectric spacer. The connecting portion of the centralized first dielectric spacer is removed. The mandrel structures and non-mandrel structures are removed selectively to the first dielectric spacers to provide an etch mask. The connecting portion removed from the centralized first dielectric spacer provides an opening connecting a first trench corresponding to the mandrel structures and a second trench corresponding to the non-mandrel structures.
    Type: Grant
    Filed: May 24, 2021
    Date of Patent: June 6, 2023
    Assignee: Tessera LLC
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Matthew E. Colburn, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Roger A. Quon, Nicole A. Saulnier
  • Patent number: 11646221
    Abstract: A method of forming a self-aligned pattern of vias in a semiconductor device comprises forming a first layer of mandrels, then forming a second layer of mandrels orthogonal to the first layer of mandrels. The layout of the first and second layers of mandrels defines a pattern that can be used to create vias in a semiconductor material. Other embodiments are also described.
    Type: Grant
    Filed: November 25, 2019
    Date of Patent: May 9, 2023
    Assignee: International Business Machines Corporation
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Nicole Saulnier
  • Patent number: 11610780
    Abstract: A method for forming fins includes forming a three-color hardmask fin pattern on a fin base layer. The three-color hardmask fin pattern includes hardmask fins of three mutually selectively etchable compositions. Some of the fins of the first color are etched away with a selective etch that does not remove fins of a second color or a third color and that leaves at least one fin of the first color behind. The fins of the second color are etched away. Fins are etched into the fin base layer by anisotropically etching around remaining fins of the first color and fins of the third color.
    Type: Grant
    Filed: June 7, 2021
    Date of Patent: March 21, 2023
    Assignee: TESSERA LLC
    Inventors: Sean D. Burns, Nelson M. Felix, Chi-Chun Liu, Yann A. M. Mignot, Stuart A. Sieg
  • Publication number: 20220262636
    Abstract: Selective gas etching for self-aligned pattern transfer uses a first block and a separate second block formed in a sacrificial layer to transfer critical dimensions to a desired final layer using a selective gas etching process. The first block is a first hardmask material that can be plasma etched using a first gas, and the second block is a second hardmask material that can be plasma etched using a second gas separate from the first gas. The first hardmask material is not plasma etched using the second gas, and the second hardmask material is not plasma etched using the first gas.
    Type: Application
    Filed: March 7, 2022
    Publication date: August 18, 2022
    Inventors: John Christopher Arnold, Sean D. Burns, Yann Alain Marcel Mignot, Yongan Xu
  • Patent number: 11302533
    Abstract: Selective gas etching for self-aligned pattern transfer uses a first block and a separate second block formed in a sacrificial layer to transfer critical dimensions to a desired final layer using a selective gas etching process. The first block is a first hardmask material that can be plasma etched using a first gas, and the second block is a second hardmask material that can be plasma etched using a second gas separate from the first gas. The first hardmask material is not plasma etched using the second gas, and the second hardmask material is not plasma etched using the first gas.
    Type: Grant
    Filed: February 22, 2021
    Date of Patent: April 12, 2022
    Assignee: Tessera, Inc.
    Inventors: John Christopher Arnold, Sean D. Burns, Yann Alain Marcel Mignot, Yongan Xu
  • Patent number: 11227793
    Abstract: A method of forming a self-aligned pattern of vias in a semiconductor device comprises forming a first layer of mandrels, then forming a second layer of mandrels orthogonal to the first layer of mandrels. The layout of the first and second layers of mandrels defines a pattern that can be used to create vias in a semiconductor material. Other embodiments are also described.
    Type: Grant
    Filed: May 1, 2018
    Date of Patent: January 18, 2022
    Assignee: INTERNATIONAL BUSINESS MACHINES CORPORATION
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Nicole Saulnier
  • Publication number: 20210335619
    Abstract: A method for forming fins includes forming a three-color hardmask fin pattern on a fin base layer. The three-color hardmask fin pattern includes hardmask fins of three mutually selectively etchable compositions. Some of the fins of the first color are etched away with a selective etch that does not remove fins of a second color or a third color and that leaves at least one fin of the first color behind. The fins of the second color are etched away. Fins are etched into the fin base layer by anisotropically etching around remaining fins of the first color and fins of the third color.
    Type: Application
    Filed: June 7, 2021
    Publication date: October 28, 2021
    Inventors: Sean D. Burns, Nelson M. Felix, Chi-Chun Liu, Yann A.M. Mignot, Stuart A. Sieg
  • Publication number: 20210280422
    Abstract: A method of forming a structure for etch masking that includes forming first dielectric spacers on sidewalls of a plurality of mandrel structures and forming non-mandrel structures in space between adjacent first dielectric spacers. Second dielectric spacers are formed on sidewalls of an etch mask having a window that exposes a connecting portion of a centralized first dielectric spacer. The connecting portion of the centralized first dielectric spacer is removed. The mandrel structures and non-mandrel structures are removed selectively to the first dielectric spacers to provide an etch mask. The connecting portion removed from the centralized first dielectric spacer provides an opening connecting a first trench corresponding to the mandrel structures and a second trench corresponding to the non-mandrel structures.
    Type: Application
    Filed: May 24, 2021
    Publication date: September 9, 2021
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Matthew E. Colburn, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Roger A. Quon, Nicole A. Saulnier
  • Publication number: 20210183653
    Abstract: Selective gas etching for self-aligned pattern transfer uses a first block and a separate second block formed in a sacrificial layer to transfer critical dimensions to a desired final layer using a selective gas etching process. The first block is a first hardmask material that can be plasma etched using a first gas, and the second block is a second hardmask material that can be plasma etched using a second gas separate from the first gas. The first hardmask material is not plasma etched using the second gas, and the second hardmask material is not plasma etched using the first gas.
    Type: Application
    Filed: February 22, 2021
    Publication date: June 17, 2021
    Inventors: John Christopher Arnold, Sean D. Burns, Yann Alain Marcel Mignot, Yongan Xu
  • Patent number: 11031248
    Abstract: A method for forming fins includes forming a three-color hardmask fin pattern on a fin base layer. The three-color hardmask fin pattern includes hardmask fins of three mutually selectively etchable compositions. Some of the fins of the first color are etched away with a selective etch that does not remove fins of a second color or a third color and that leaves at least one fin of the first color behind. The fins of the second color are etched away. Fins are etched into the fin base layer by anisotropically etching around remaining fins of the first color and fins of the third color.
    Type: Grant
    Filed: July 11, 2019
    Date of Patent: June 8, 2021
    Assignee: Tessera, Inc.
    Inventors: Sean D. Burns, Nelson M. Felix, Chi-Chun Liu, Yann A. M. Mignot, Stuart A. Sieg
  • Patent number: 11018007
    Abstract: A method of forming a structure for etch masking that includes forming first dielectric spacers on sidewalls of a plurality of mandrel structures and forming non-mandrel structures in space between adjacent first dielectric spacers. Second dielectric spacers are formed on sidewalls of an etch mask having a window that exposes a connecting portion of a centralized first dielectric spacer. The connecting portion of the centralized first dielectric spacer is removed. The mandrel structures and non-mandrel structures are removed selectively to the first dielectric spacers to provide an etch mask. The connecting portion removed from the centralized first dielectric spacer provides an opening connecting a first trench corresponding to the mandrel structures and a second trench corresponding to the non-mandrel structures.
    Type: Grant
    Filed: November 6, 2019
    Date of Patent: May 25, 2021
    Assignee: Tessera, Inc.
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Matthew E. Colburn, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Roger A. Quon, Nicole A. Saulnier
  • Patent number: 10957583
    Abstract: An interconnect structure having a pitch of less than 40 nanometers and a self-aligned quadruple patterning process for forming the interconnect structure includes three types of lines: a ? line defined by a patterned bottom mandrel formed in the self-aligned quadruple patterning process; a ? line defined by location underneath a top mandrel formed in the self-aligned quadruple patterning process; and an ? line defined by elimination located underneath neither the top mandrel or the bottom mandrel formed in the self-aligned quadruple patterning process. The interconnect structure further includes multi-track jogs selected from a group consisting of a ??? jog; a ??? jog; an ??? jog; a ??? jog, and combinations thereof. The first and third positions refer to the uncut line and the second position refers to the cut line in the self-aligned quadruple patterning process.
    Type: Grant
    Filed: August 28, 2019
    Date of Patent: March 23, 2021
    Assignee: INTERNATIONAL BUSINESS MACHINES CORPORATION
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Matthew E. Colburn, Sivananda K. Kanakasabapathy, Yann A. M. Mignot, Christopher J. Penny, Roger A. Quon, Nicole A. Saulnier
  • Patent number: 10930504
    Abstract: Selective gas etching for self-aligned pattern transfer uses a first block and a separate second block formed in a sacrificial layer to transfer critical dimensions to a desired final layer using a selective gas etching process. The first block is a first hardmask material that can be plasma etched using a first gas, and the second block is a second hardmask material that can be plasma etched using a second gas separate from the first gas. The first hardmask material is not plasma etched using the second gas, and the second hardmask material is not plasma etched using the first gas.
    Type: Grant
    Filed: November 13, 2019
    Date of Patent: February 23, 2021
    Assignee: Tessera, Inc.
    Inventors: John Christopher Arnold, Sean D. Burns, Yann Alain Marcel Mignot, Yongan Xu
  • Patent number: 10613438
    Abstract: Lithographic patterning methods are provided which implement directed self-assembly (DSA) of block copolymers to enable self-aligned cutting of features. A first layer and second layer of material are formed on a substrate. The second layer of material is lithographically patterning to form a guiding pattern. A DSA process is performed to form a block copolymer pattern around the guiding pattern, which comprises a repeating block chain that includes at least a first block material and a second block material, which have etch selectivity with respect to each other. A selective etch process is performed to selectively etching one of the first block material and the second block material to form self-aligned openings in the block copolymer pattern which expose portions of the first layer of material. The first layer of material is patterned by etching the exposed portions of the first layer of material.
    Type: Grant
    Filed: January 15, 2018
    Date of Patent: April 7, 2020
    Assignee: International Business Machines Corporation
    Inventors: Sean D. Burns, Sivananda K Kanakasabapathy, Kafai Lai, Chi-Chun Liu, Kristin Schmidt, Ankit Vora
  • Publication number: 20200090985
    Abstract: A method of forming a self-aligned pattern of vias in a semiconductor device comprises forming a first layer of mandrels, then forming a second layer of mandrels orthogonal to the first layer of mandrels. The layout of the first and second layers of mandrels defines a pattern that can be used to create vias in a semiconductor material. Other embodiments are also described.
    Type: Application
    Filed: November 25, 2019
    Publication date: March 19, 2020
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Nicole Saulnier
  • Publication number: 20200083045
    Abstract: Selective gas etching for self-aligned pattern transfer uses a first block and a separate second block formed in a sacrificial layer to transfer critical dimensions to a desired final layer using a selective gas etching process. The first block is a first hardmask material that can be plasma etched using a first gas, and the second block is a second hardmask material that can be plasma etched using a second gas separate from the first gas. The first hardmask material is not plasma etched using the second gas, and the second hardmask material is not plasma etched using the first gas.
    Type: Application
    Filed: November 13, 2019
    Publication date: March 12, 2020
    Inventors: John Christopher ARNOLD, Sean D. BURNS, Yann Alain Marcel MIGNOT, Yongan XU
  • Publication number: 20200075336
    Abstract: A method of forming a structure for etch masking that includes forming first dielectric spacers on sidewalls of a plurality of mandrel structures and forming non-mandrel structures in space between adjacent first dielectric spacers. Second dielectric spacers are formed on sidewalls of an etch mask having a window that exposes a connecting portion of a centralized first dielectric spacer. The connecting portion of the centralized first dielectric spacer is removed. The mandrel structures and non-mandrel structures are removed selectively to the first dielectric spacers to provide an etch mask. The connecting portion removed from the centralized first dielectric spacer provides an opening connecting a first trench corresponding to the mandrel structures and a second trench corresponding to the non-mandrel structures.
    Type: Application
    Filed: November 6, 2019
    Publication date: March 5, 2020
    Inventors: Sean D. Burns, Lawrence A. Clevenger, Matthew E. Colburn, Nelson M. Felix, Sivananda K. Kanakasabapathy, Christopher J. Penny, Roger A. Quon, Nicole A. Saulnier
  • Patent number: 10559467
    Abstract: Selective gas etching for self-aligned pattern transfer uses a first block and a separate second block formed in a sacrificial layer to transfer critical dimensions to a desired final layer using a selective gas etching process. The first block is a first hardmask material that can be plasma etched using a first gas, and the second block is a second hardmask material that can be plasma etched using a second gas separate from the first gas. The first hardmask material is not plasma etched using the second gas, and the second hardmask material is not plasma etched using the first gas.
    Type: Grant
    Filed: June 6, 2018
    Date of Patent: February 11, 2020
    Assignee: INTERNATIONAL BUSINESS MACHINES COPORATION
    Inventors: John Christopher Arnold, Sean D. Burns, Yann Alain Marcel Mignot, Yongan Xu