Patents by Inventor Sony Varghese

Sony Varghese has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11380691
    Abstract: Disclosed are 3-D DRAM devices and methods of forming 3-D DRAM devices. One method may include forming a stack of DRAM device layers, forming a MOS substrate directly atop the stack of alternating DRAM device layers, and forming a trench through the MOS substrate and the stack of DRAM device layers. The method may further include depositing a protection layer over the MOS substrate, wherein the protection layer is deposited at a non-zero angle of inclination relative to a vertical extending from a top surface of the MOS substrate.
    Type: Grant
    Filed: April 14, 2021
    Date of Patent: July 5, 2022
    Assignee: Applied Materials, Inc.
    Inventors: Sony Varghese, Fred Fishburn
  • Publication number: 20220199627
    Abstract: Examples herein relate to three-dimensional (3D) dynamic random access memory (DRAM) devices and replacement channel processes for fabricating 3D DRAM devices. In an example, a gate dielectric layer is formed on a sacrificial material, and a gate electrode is formed on the gate dielectric layer. After the gate electrode is formed, the sacrificial material is removed and replaced by a semiconductor material. A channel region of a device (e.g., a transistor) that includes the gate dielectric layer and gate electrode is formed in the semiconductor material. The channel region can be vertical or horizontal with respect to a main surface of a substrate on which the device is formed. A capacitor can be formed, such as before or after the semiconductor material is formed, and is electrically connected to the semiconductor material. The device and the capacitor together can form at least part of a 3D DRAM cell.
    Type: Application
    Filed: December 15, 2021
    Publication date: June 23, 2022
    Inventors: Fredrick FISHBURN, Arvind KUMAR, Sony VARGHESE
  • Publication number: 20220122883
    Abstract: Disclosed are approaches for forming a semiconductor device. In some embodiments, a method may include a method may include providing a semiconductor device including plurality of patterning structures over a device stack, each of the plurality of patterning structures including a first sidewall, a second sidewall, and an upper surface. The method may further include forming a seed layer along just the first sidewall and the upper surface of each of the plurality of patterning structures, forming a metal layer atop the seed layer, forming a fill material between each of the plurality of patterning structures, and removing the plurality of patterning structures.
    Type: Application
    Filed: October 16, 2020
    Publication date: April 21, 2022
    Applicant: Applied Materials, Inc.
    Inventors: Sony Varghese, M. Arif Zeeshan, Shantanu Kallakuri, Kelvin Chan
  • Publication number: 20220093458
    Abstract: Embodiments herein include void-free material depositions on a substrate (e.g., in a void-free trench-filled (VFTF) component) obtained using directional etching to remove predetermined portions of a seed layer covering the substrate. In several embodiments, directional etching followed by selective deposition can enable fill material (e.g., metal) patterning in tight spaces without any voids or seams. Void-free material depositions may be used in a variety of semiconductor devices, such as transistors, dual work function stacks, dynamic random-access memory (DRAM), non-volatile memory, and the like.
    Type: Application
    Filed: September 22, 2020
    Publication date: March 24, 2022
    Applicant: Applied Materials, Inc.
    Inventors: M. Arif Zeeshan, Kelvin Chan, Shantanu Kallakuri, Sony Varghese, John Hautala
  • Publication number: 20220068923
    Abstract: In one embodiment, a method of selectively forming a deposit may include providing a substrate, the substrate having a plurality of surface features, extending at a non-zero angle of inclination with respect to a perpendicular to a plane of the substrate. The method may include directing a reactive beam to the plurality of surface features, the reactive beam defining a non-zero angle of incidence with respect to a perpendicular to the plane of the substrate, wherein a seed layer is deposited on a first portion of the surface features, and is not deposited on a second portion of the surface features. The method may further include exposing the substrate to a reactive deposition process after the directing the reactive ion beam, wherein a deposit layer selectively grows over the seed layer.
    Type: Application
    Filed: September 3, 2020
    Publication date: March 3, 2022
    Applicant: Applied Materials, Inc.
    Inventors: M. Arif Zeeshan, Kelvin Chan, Shantanu Kallakuri, Sony Varghese
  • Publication number: 20220044966
    Abstract: Disclosed are approaches for forming a semiconductor device. In some embodiments, a method may include providing a plurality of patterning structures over a device layer, each of the plurality of patterning structures including a first sidewall, a second sidewall, and an upper surface, and forming a mask by depositing a masking material at a non-zero angle of inclination relative to a perpendicular to a plane defined by a top surface of the device layer. The mask may be formed over the plurality of patterning structures without being formed along the second sidewall. The method may further include selectively forming a metal layer along the second sidewall of each of the plurality of patterning structures.
    Type: Application
    Filed: August 10, 2020
    Publication date: February 10, 2022
    Applicant: Applied Materials, Inc.
    Inventor: Sony Varghese
  • Publication number: 20220005812
    Abstract: Disclosed are DRAM devices and methods of forming DRAM devices. One non-limiting method may include providing a device, the device including a plurality of angled structures formed from a substrate, a bitline and a dielectric between each of the plurality of angled structures, and a drain disposed along each of the plurality of angled structures. The method may further include providing a plurality of mask structures of a patterned masking layer over the plurality of angled structures, the plurality of mask structures being oriented perpendicular to the plurality of angled structures. The method may further include etching the device at a non-zero angle to form a plurality of pillar structures.
    Type: Application
    Filed: September 17, 2021
    Publication date: January 6, 2022
    Applicant: Applied Materials, Inc.
    Inventor: Sony Varghese
  • Patent number: 11217491
    Abstract: Methods herein may include forming a gate dielectric within a set of trenches in a stack of layers. A first work function (WF) metal may be formed atop the gate dielectric, and a capping layer may be formed over the first WF metal using an angled ion implant deposition, the capping layer extending across the trenches.
    Type: Grant
    Filed: July 18, 2019
    Date of Patent: January 4, 2022
    Assignee: Varian Semiconductor Equipment Associates, Inc.
    Inventors: Min Gyu Sung, Naushad K. Variam, Sony Varghese, Johannes Van Meer, Jae Young Lee
  • Publication number: 20210351188
    Abstract: Disclosed are DRAM devices and methods of forming DRAM devices. One non-limiting method may include providing a device, the device including a plurality of angled structures formed from a substrate, a bitline and a dielectric between each of the plurality of angled structures, and a drain disposed along each of the plurality of angled structures. The method may further include providing a plurality of mask structures of a patterned masking layer over the plurality of angled structures, the plurality of mask structures being oriented perpendicular to the plurality of angled structures. The method may further include etching the device at a non-zero angle to form a plurality of pillar structures.
    Type: Application
    Filed: May 7, 2020
    Publication date: November 11, 2021
    Applicant: Applied Materials, Inc.
    Inventor: Sony Varghese
  • Patent number: 11152373
    Abstract: Disclosed are DRAM devices and methods of forming DRAM devices. One non-limiting method may include providing a device, the device including a plurality of angled structures formed from a substrate, a bitline and a dielectric between each of the plurality of angled structures, and a drain disposed along each of the plurality of angled structures. The method may further include providing a plurality of mask structures of a patterned masking layer over the plurality of angled structures, the plurality of mask structures being oriented perpendicular to the plurality of angled structures. The method may further include etching the device at a non-zero angle to form a plurality of pillar structures.
    Type: Grant
    Filed: May 7, 2020
    Date of Patent: October 19, 2021
    Assignee: Applied Materials, Inc.
    Inventor: Sony Varghese
  • Publication number: 20210265357
    Abstract: Disclosed are DRAM devices and methods of forming DRAM devices. One method may include forming a plurality of trenches and angled structures, each angled structure including a first sidewall opposite a second sidewall, wherein the second sidewall extends over an adjacent trench. The method may include forming a spacer along a bottom surface of the trench, along the second sidewall, and along the first sidewall, wherein the spacer has an opening at a bottom portion of the first sidewall. The method may include forming a drain in each of the angled structures by performing an ion implant, which impacts the first sidewall through the opening at the bottom portion of the first sidewall. The method may include removing the spacer from the first sidewall, forming a bitline over the spacer along the bottom surface of each of the trenches, and forming a series of wordlines along the angled structures.
    Type: Application
    Filed: April 23, 2021
    Publication date: August 26, 2021
    Applicant: APPLIED Materials, Inc.
    Inventors: Sony Varghese, Min Gyu Sung
  • Patent number: 11101183
    Abstract: Disclosed are methods of forming a CMOS device. One non-limiting method may include providing a gate structure atop a substrate, and forming a first spacer over the gate structure. The method may include removing the first spacer from just an upper portion of the gate structure by performing an angled reactive ion etch or angled implantation disposed at a non-zero angle of inclination with respect to a perpendicular to a plane of the substrate. The method may further include forming a second spacer over the upper portion of the gate structure and the first spacer along a lower portion of the gate structure. A thickness of the first spacer and the second spacer along the lower portion of the gate structure may be greater than a thickness of the second spacer along the upper portion of the gate structure.
    Type: Grant
    Filed: July 17, 2018
    Date of Patent: August 24, 2021
    Assignee: Varian Semiconductor Equipment Associates, Inc.
    Inventors: Min Gyu Sung, Sony Varghese
  • Publication number: 20210225690
    Abstract: Some embodiments include a construction having a horizontally-extending layer of fluorocarbon material over a semiconductor construction. Some embodiments include methods of filling openings that extend into a semiconductor construction. The methods may include, for example, printing the material into the openings or pressing the material into the openings. The construction may be treated so that surfaces within the openings adhere the material provided within the openings while surfaces external of the openings do not adhere the material. In some embodiments, the surfaces external of the openings are treated to reduce adhesion of the material.
    Type: Application
    Filed: April 6, 2021
    Publication date: July 22, 2021
    Applicant: Micron Technology, Inc.
    Inventors: Gurtej S. Sandhu, Sony Varghese, John A. Smythe, Hyun Sik Kim
  • Patent number: 11037788
    Abstract: The present disclosure relates to a method for creating regions of different device types. The substrate is divided into a first device region and a second device region. A target etch layer is formed on a substrate. A bottom mandrel layer is formed on the target etch layer. A plurality of first pillars of a top mandrel material is formed on the bottom mandrel layer in the first device region, having a first pitch. A plurality of first spacers is formed along sidewalls of each of the plurality of first pillars. An optical planarization layer (OPL) is formed over the plurality of first pillars, the plurality of first spacers, and a top surface of the bottom mandrel layer in the first device region. A plurality of second pillars of the top mandrel material is formed on the bottom mandrel layer in the second device region, having a second pitch.
    Type: Grant
    Filed: November 18, 2019
    Date of Patent: June 15, 2021
    Assignee: Applied Materials, Inc.
    Inventors: Min Gyu Sung, Sony Varghese
  • Patent number: 11018138
    Abstract: Disclosed are DRAM devices and methods of forming DRAM devices. One method may include forming a plurality of trenches and angled structures, each angled structure including a first sidewall opposite a second sidewall, wherein the second sidewall extends over an adjacent trench. The method may include forming a spacer along a bottom surface of the trench, along the second sidewall, and along the first sidewall, wherein the spacer has an opening at a bottom portion of the first sidewall. The method may include forming a drain in each of the angled structures by performing an ion implant, which impacts the first sidewall through the opening at the bottom portion of the first sidewall. The method may include removing the spacer from the first sidewall, forming a bitline over the spacer along the bottom surface of each of the trenches, and forming a series of wordlines along the angled structures.
    Type: Grant
    Filed: October 25, 2019
    Date of Patent: May 25, 2021
    Assignee: APPLIED Materials, Inc.
    Inventors: Sony Varghese, Min Gyu Sung
  • Patent number: 10998221
    Abstract: Some embodiments include a construction having a horizontally-extending layer of fluorocarbon material over a semiconductor construction. Some embodiments include methods of filling openings that extend into a semiconductor construction. The methods may include, for example, printing the material into the openings or pressing the material into the openings. The construction may be treated so that surfaces within the openings adhere the material provided within the openings while surfaces external of the openings do not adhere the material. In some embodiments, the surfaces external of the openings are treated to reduce adhesion of the material.
    Type: Grant
    Filed: July 14, 2017
    Date of Patent: May 4, 2021
    Assignee: Micron Technology, Inc.
    Inventors: Gurtej S. Sandhu, Sony Varghese, John A. Smythe, Hyun Sik Kim
  • Publication number: 20210125994
    Abstract: Disclosed are DRAM devices and methods of forming DRAM devices. One method may include forming a plurality of trenches and angled structures, each angled structure including a first sidewall opposite a second sidewall, wherein the second sidewall extends over an adjacent trench. The method may include forming a spacer along a bottom surface of the trench, along the second sidewall, and along the first sidewall, wherein the spacer has an opening at a bottom portion of the first sidewall. The method may include forming a drain in each of the angled structures by performing an ion implant, which impacts the first sidewall through the opening at the bottom portion of the first sidewall. The method may include removing the spacer from the first sidewall, forming a bitline over the spacer along the bottom surface of each of the trenches, and forming a series of wordlines along the angled structures.
    Type: Application
    Filed: October 25, 2019
    Publication date: April 29, 2021
    Applicant: APPLIED Materials, Inc.
    Inventors: Sony Varghese, Min Gyu Sung
  • Publication number: 20210111031
    Abstract: A method may include forming in a substrate a first array of a first material of first linear structures, interspersed with a second array of a second material, of second linear structures, the first and second linear structures elongated along a first axis. The method may include generating a chop pattern in the first layer, comprising a third linear array, interspersed with a fourth linear array. The third and fourth linear arrays may be elongated along a second axis, forming a non-zero angle of incidence with respect to the first axis. The third linear array may include alternating portions of the first and second material, while the fourth linear array comprises an array of cavities, arranged within the patterning layer. The method may include elongating a first set of cavities along the first axis, to form a first set of elongated cavities bounded by the first material.
    Type: Application
    Filed: December 21, 2020
    Publication date: April 15, 2021
    Applicant: Varian Semiconductor Equipment Associates, Inc.
    Inventor: Sony Varghese
  • Patent number: 10971403
    Abstract: A method for forming a semiconductor device. The method may include providing a transistor structure, where the transistor structure includes a fin array, the fin array including a plurality of semiconductor fins, disposed on a substrate. A liner may be disposed on the plurality of semiconductor fins. The method may include directing first angled ions to the fin array, wherein the liner is removed in an upper portion of the plurality of semiconductor fins, and wherein the liner remains in a lower portion of the at least one of the plurality of semiconductor fins, and wherein the upper portion comprises an active fin region to form a transistor device.
    Type: Grant
    Filed: December 13, 2019
    Date of Patent: April 6, 2021
    Assignee: Varian Semiconductor Equipment Associates, Inc.
    Inventors: Min Gyu Sung, Naushad K. Variam, Sony Varghese, Johannes Van Meer, Jae Young Lee
  • Patent number: 10930735
    Abstract: A method of forming a three-dimensional transistor device. The method may include providing a fin array on a substrate, the fin array comprising a plurality of fin structures, formed from a monocrystalline semiconductor, and disposed subjacent to a hard mask layer. The method may include directing angled ions at the fin array, wherein the angled ions form a non-zero angle of incidence with respect to a perpendicular to a plane of the substrate. The angled ions may etch the plurality of fin structures to form a stack of isolated nanowires, within a given fin structure.
    Type: Grant
    Filed: February 18, 2020
    Date of Patent: February 23, 2021
    Assignee: Applied Materials, Inc.
    Inventors: Min Gyu Sung, Sony Varghese, Anthony Renau, Morgan Evans, Joseph C. Olson