Patents by Inventor David K. Carlson

David K. Carlson 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: 11960665
    Abstract: A drape for an input control console of an elongate device may comprise a main drape section configured to fit over the input control console via a main opening at one end of the main drape section. The drape may also comprise a plurality of pockets. Each of the plurality of pockets may include a pocket opening that is attached to a respective secondary opening in the main drape section. Each of the plurality of pockets may be configured to be anchored, at the pocket opening, to a side surface of a respective raised ring or bezel on the input control console using a respective tightening element.
    Type: Grant
    Filed: August 20, 2021
    Date of Patent: April 16, 2024
    Assignee: INTUITIVE SURGICAL OPERATIONS, INC.
    Inventors: David W. Bailey, Federico Barbagli, Reuben D. Brewer, Christopher R Carlson, Vincent Duindam, Tania K. Morimoto, Michael D. Paris, Oliver J. Wagner
  • Publication number: 20220162756
    Abstract: Embodiments of the present disclosure generally relate to semiconductor processing, and specifically to methods and apparatus for surface modification of substrates. In an embodiment, a substrate modification method is provided. The method includes positioning a substrate within a processing chamber; and depositing a material on a portion of the substrate by a deposition process, wherein the deposition process comprises: thermally heating the substrate to a temperature of less than about 500° C.; delivering a first electromagnetic energy from an electromagnetic energy source to the substrate to modify a first region of the substrate, the first region of the substrate being at or near an upper surface of the substrate; and depositing a first material on the first region while delivering the first electromagnetic energy.
    Type: Application
    Filed: November 12, 2021
    Publication date: May 26, 2022
    Inventors: David K. CARLSON, Stephen MOFFATT
  • Patent number: 10837121
    Abstract: Embodiments described herein generally relate to a susceptor support for supporting a susceptor in a deposition process. The susceptor support includes a shaft, a plate with a first major surface coupled to the shaft, and a support element extending from a second major surface of the plate. The plate may be made of a material that is optically transparent to the radiation energy from a plurality of energy sources disposed below the plate. The plate may have a thickness that is small enough to minimize radiation transmission loss and large enough to be thermally and mechanically stable to support the susceptor during processing. The thickness of the plate may range from about 2 mm to about 20 mm.
    Type: Grant
    Filed: March 27, 2017
    Date of Patent: November 17, 2020
    Assignee: Applied Materials, Inc.
    Inventors: Richard O. Collins, Errol Antonio C. Sanchez, David K. Carlson, Mehmet Tugrul Samir
  • Patent number: 10586744
    Abstract: Increasing efficiency of absorbers is provided herein. In some embodiments, a method of processing a substrate may include determining a quantity of a removal species in an effluent stream flowing from a semiconductor processing chamber, wherein determining comprises: detecting or predicting a quantity of the removal species upstream of a chamber abatement apparatus in the effluent stream flowing from the semiconductor processing chamber; and removing the removal species from the effluent stream with the chamber abatement apparatus if the determined quantity of the removal species exceeds a threshold value of the removal species.
    Type: Grant
    Filed: March 23, 2018
    Date of Patent: March 10, 2020
    Assignee: APPLIED MATERIALS, INC.
    Inventor: David K. Carlson
  • Patent number: 10557203
    Abstract: Systems, methods and an apparatus used for delivery of chemical precursors, and more particularly to an ampoule for containing chemical precursors are provided. In one implementation, an apparatus for generating a chemical precursor used in a vapor deposition processing system is provided. The apparatus comprises a canister comprising a sidewall, a top, and a bottom surface encompassing an interior volume therein, an adhesion layer disposed over an outside surface of the sidewall and bottom surface, a thermally conductive coating disposed over the adhesion layer, an insulator layer disposed over the thermally conductive coating, wherein the thermally conductive coating over the bottom surface remains exposed and an inlet port and an outlet port in fluid communication with the interior volume.
    Type: Grant
    Filed: December 8, 2017
    Date of Patent: February 11, 2020
    Assignee: APPLIED MATERIALS, INC.
    Inventor: David K. Carlson
  • Patent number: 10500614
    Abstract: Embodiments of the present disclosure generally relate to a methods and apparatuses for cleaning exhaust systems, such as exhaust systems used with process chambers for the formation of epitaxial silicon. The exhaust system includes a remote plasma source for supplying ionized gas through the exhaust system, and one or more temperature sensors positioned downstream of the remote plasma source.
    Type: Grant
    Filed: April 5, 2017
    Date of Patent: December 10, 2019
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Martin A. Hilkene, David K. Carlson, Matthew D. Scotney-Castle
  • Patent number: 10458040
    Abstract: Embodiments provided herein generally relate to an apparatus for delivering gas to a semiconductor processing chamber. An upper quartz dome of an epitaxial semiconductor processing chamber has a plurality of holes formed therein and precursor gases are provided into a processing volume of the chamber through the holes of the upper dome. Gas delivery tubes extend from the holes in the dome to a flange plate where the tubes are coupled to gas delivery lines. The gas delivery apparatus enables gases to be delivered to the processing volume above a substrate through the quartz upper dome.
    Type: Grant
    Filed: November 10, 2017
    Date of Patent: October 29, 2019
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Paul Brillhart, Anzhong Chang, Edric Tong, Kin Pong Lo, James Francis Mack, Zhiyuan Ye, Kartik Shah, Errol Antonio C. Sanchez, David K. Carlson, Satheesh Kuppurao, Joseph M. Ranish
  • Patent number: 10119194
    Abstract: Apparatus for use in a substrate processing chamber are provided herein. In some embodiments, an indexed jet injector may include a body having a substantially cylindrical central volume, a gas input port disposed on a first surface of the body, a gas distribution channel formed in the body and fluidly coupled to the gas input port and to the cylindrical central volume, a gas distribution drum disposed within the cylindrical central volume and rotatably coupled to the body, the gas distribution drum having a plurality of jet channels formed through the gas distribution drum, and a plurality of indexer output ports formed on a second surface of the body, wherein each of the plurality of jet channels fluidly couple the gas input port to at least one of the plurality of indexer output ports at least once per 360° rotation of the gas distribution drum.
    Type: Grant
    Filed: February 18, 2014
    Date of Patent: November 6, 2018
    Assignee: APPLIED MATERIALS, INC.
    Inventor: David K. Carlson
  • Patent number: 10119192
    Abstract: Embodiments described herein relate to a base ring assembly for use in a substrate processing chamber. In one embodiment, the base ring assembly comprises a ring body sized to be received within an inner circumference of the substrate processing chamber, the ring body comprising a loading port for passage of the substrate, a gas inlet, and a gas outlet, wherein the gas inlet and the gas outlet are disposed at opposing ends of the ring body, and an upper ring configured to dispose on a top surface of the ring body, and a lower ring configured to dispose on a bottom surface of the ring body, wherein the upper ring, the lower ring, and the ring body, once assembled, are generally concentric or coaxial.
    Type: Grant
    Filed: April 22, 2016
    Date of Patent: November 6, 2018
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Steve Aboagye, Paul Brillhart, Surajit Kumar, Anzhong Chang, Satheesh Kuppurao, Mehmet Tugrul Samir, David K. Carlson
  • Publication number: 20180277455
    Abstract: Increasing efficiency of absorbers is provided herein. In some embodiments, a method of processing a substrate may include determining a quantity of a removal species in an effluent stream flowing from a semiconductor processing chamber, wherein determining comprises: detecting or predicting a quantity of the removal species upstream of a chamber abatement apparatus in the effluent stream flowing from the semiconductor processing chamber; and removing the removal species from the effluent stream with the chamber abatement apparatus if the determined quantity of the removal species exceeds a threshold value of the removal species.
    Type: Application
    Filed: March 23, 2018
    Publication date: September 27, 2018
    Inventor: David K. CARLSON
  • Patent number: 10043870
    Abstract: Embodiments of the present disclosure generally relate to a film stack including layers of group III-V semiconductor materials. The film stack includes a phosphorous containing layer deposited over a silicon substrate, a GaAs containing layer deposited on the phosphorous containing layer, and an aluminum containing layer deposited on the GaAs containing layer. The GaAs containing layer between the phosphorous containing layer and the aluminum containing layer improves the surface smoothness of the aluminum containing layer.
    Type: Grant
    Filed: October 21, 2015
    Date of Patent: August 7, 2018
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Zhiyuan Ye, Xinyu Bao, Errol Antonio C. Sanchez, David K. Carlson, Keun-Yong Ban
  • Publication number: 20180209043
    Abstract: Apparatus for processing a substrate in a process chamber are provided here. In some embodiments, a gas injector for use in a process chamber includes a first set of outlet ports that provide an angled injection of a first process gas at an angle to a planar surface, and a second set of outlet ports proximate the first set of outlet ports that provide a pressurized laminar flow of a second process gas substantially along the planar surface, the planar surface extending normal to the second set of outlet ports.
    Type: Application
    Filed: March 22, 2018
    Publication date: July 26, 2018
    Inventors: SHU-KWAN LAU, ZHEPENG CONG, MEHMET TUGRUL SAMIR, ZHIYUAN YE, DAVID K. CARLSON, XUEBIN LI, ERROL ANTONIO C. SANCHEZ, SWAMINATHAN SRINIVASAN
  • Publication number: 20180163307
    Abstract: Implementations described herein generally relate to systems, methods and an apparatus used for delivery of chemical precursors, and more particularly to an ampoule for containing chemical precursors. Implementations described herein generally relate to systems, methods and an apparatus used for delivery of chemical precursors, and more particularly to an ampoule for containing chemical precursors. In one implementation, an apparatus for generating a chemical precursor used in a vapor deposition processing system is provided.
    Type: Application
    Filed: December 8, 2017
    Publication date: June 14, 2018
    Inventor: David K. CARLSON
  • Publication number: 20180066382
    Abstract: Embodiments provided herein generally relate to an apparatus for delivering gas to a semiconductor processing chamber. An upper quartz dome of an epitaxial semiconductor processing chamber has a plurality of holes formed therein and precursor gases are provided into a processing volume of the chamber through the holes of the upper dome. Gas delivery tubes extend from the holes in the dome to a flange plate where the tubes are coupled to gas delivery lines. The gas delivery apparatus enables gases to be delivered to the processing volume above a substrate through the quartz upper dome.
    Type: Application
    Filed: November 10, 2017
    Publication date: March 8, 2018
    Inventors: Paul BRILLHART, Anzhong CHANG, Edric TONG, Kin Pong LO, James Francis MACK, Zhiyuan YE, Kartik SHAH, Errol Antonio C. Sanchez, David K. CARLSON, Satheesh KUPPURAO, Joseph M. RANISH
  • Publication number: 20180019121
    Abstract: The present disclosure generally relate to methods for forming an epitaxial layer on a semiconductor device, including a method of forming a tensile-stressed silicon antimony layer. The method includes heating a substrate disposed within a processing chamber, wherein the substrate comprises silicon, and exposing a surface of the substrate to a gas mixture comprising a silicon-containing precursor and an antimony-containing precursor to form a silicon antimony alloy having an antimony concentration of 5×1020 to 5×1021 atoms per cubic centimeter or greater on the surface.
    Type: Application
    Filed: June 23, 2017
    Publication date: January 18, 2018
    Inventors: Xinyu BAO, Chun YAN, Zhiyuan YE, Errol Antonio C. SANCHEZ, David K. CARLSON
  • Publication number: 20180005856
    Abstract: Embodiments of the invention relate to a dome assembly. The dome assembly includes an upper dome comprising a central window, and an upper peripheral flange engaging the central window at a circumference of the central window, wherein a tangent line on an inside surface of the central window that passes through an intersection of the central window and the upper peripheral flange is at an angle of about 8° to about 16° with respect to a planar upper surface of the peripheral flange, a lower dome comprising a lower peripheral flange and a bottom connecting the lower peripheral flange with a central opening, wherein a tangent line on an outside surface of the bottom that passes through an intersection of the bottom and the lower peripheral flange is at an angle of about 8° to about 16° with respect to a planar bottom surface of the lower peripheral flange.
    Type: Application
    Filed: September 18, 2017
    Publication date: January 4, 2018
    Inventors: Anzhong CHANG, Paul BRILLHART, Surajit KUMAR, Satheesh KUPPURAO, Mehmet Tugrul SAMIR, David K. CARLSON, Steve ABOAGYE, Anh N. NGUYEN, Kailash Kiran PATALAY, Joseph M. RANISH, Oleg V. SEREBRYANOV, Dongming IU, Shu-Kwan LAU, Zuoming ZHU, Herman DINIZ
  • Patent number: 9857028
    Abstract: In one embodiment, a pressure control assembly includes a cylindrical hollow body having an opening to receive a ballast gas, a first and second flange, and a first and second cone. The first flange is coupled to a first end of the body, and a second flange is coupled to an opposing end of the body. The first cone is coupled to the first flange, and the second cone is coupled to the second flange. A method for controlling pressure in a chamber includes measuring a pressure of the chamber and a pressure of an exhaust system coupled to the chamber. The method includes dynamically adjusting the pressure in the exhaust system in order to adjust the pressure in the chamber, by creating a first pressure drop that is greater than a second pressure drop in the exhaust system.
    Type: Grant
    Filed: December 29, 2016
    Date of Patent: January 2, 2018
    Assignee: APPLIED MATERIALS, INC.
    Inventor: David K. Carlson
  • Patent number: 9845550
    Abstract: Embodiments provided herein generally relate to an apparatus for delivering gas to a semiconductor processing chamber. An upper quartz dome of an epitaxial semiconductor processing chamber has a plurality of holes formed therein and precursor gases are provided into a processing volume of the chamber through the holes of the upper dome. Gas delivery tubes extend from the holes in the dome to a flange plate where the tubes are coupled to gas delivery lines. The gas delivery apparatus enables gases to be delivered to the processing volume above a substrate through the quartz upper dome.
    Type: Grant
    Filed: February 3, 2015
    Date of Patent: December 19, 2017
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Paul Brillhart, Anzhong Chang, Edric Tong, Kin Pong Lo, James Francis Mack, Zhiyuan Ye, Kartik Shah, Errol Antonio C. Sanchez, David K. Carlson, Satheesh Kuppurao, Joseph M. Ranish
  • Publication number: 20170304877
    Abstract: Embodiments of the present disclosure generally relate to a methods and apparatuses for cleaning exhaust systems, such as exhaust systems used with process chambers for the formation of epitaxial silicon. The exhaust system includes a remote plasma source for supplying ionized gas through the exhaust system, and one or more temperature sensors positioned downstream of the remote plasma source.
    Type: Application
    Filed: April 5, 2017
    Publication date: October 26, 2017
    Inventors: Martin A. HILKENE, David K. CARLSON, Matthew D. SCOTNEY-CASTLE
  • Patent number: 9799737
    Abstract: A method for forming a conformal group III/V layer on a silicon substrate and the resulting substrate with the group III/V layers formed thereon. The method includes removing the native oxide from the substrate, positioning a substrate within a processing chamber, heating the substrate to a first temperature, cooling the substrate to a second temperature, flowing a group III precursor into the processing chamber, maintaining the second temperature while flowing a group III precursor and a group V precursor into the processing chamber until a conformal layer is formed, heating the processing chamber to an annealing temperature, while stopping the flow of the group III precursor, and cooling the processing chamber to the second temperature. Deposition of the III/V layer may be made selective through the use of halide gas etching which preferentially etches dielectric regions.
    Type: Grant
    Filed: June 17, 2016
    Date of Patent: October 24, 2017
    Assignee: APPLIED MATERIALS, INC.
    Inventors: Xinyu Bao, Errol Antonio C. Sanchez, David K. Carlson, Zhiyuan Ye