Patents by Inventor Eric Hudson

Eric Hudson 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: 20250364233
    Abstract: A wafer is supported on a wafer support structure such that a lower peripheral open region exists between a peripheral portion of a bottom surface of the wafer and an edge ring structure. The edge ring structure is configured to circumscribe both the wafer support structure and the wafer. A plasma is generated above a top surface of the wafer. The plasma causes accumulation of byproduct material within the lower peripheral open region. A byproduct volatizing gas is supplied to the lower peripheral open region to control the accumulation of the byproduct material within the lower peripheral open region during generation of the plasma. Use of the byproduct volatizing gas to control the accumulation of the byproduct material within the lower peripheral open region serves to prevent electrical arcing and particle contamination.
    Type: Application
    Filed: August 6, 2025
    Publication date: November 27, 2025
    Inventors: Leonid Belau, Alexei Marakhtanov, Eric Hudson, John Patrick Holland
  • Patent number: 12412736
    Abstract: A wafer is supported on a wafer support structure such that a lower peripheral open region exists between a peripheral portion of a bottom surface of the wafer and an edge ring structure. The edge ring structure is configured to circumscribe both the wafer support structure and the wafer. A plasma is generated above a top surface of the wafer. The plasma causes accumulation of byproduct material within the lower peripheral open region. A byproduct volatizing gas is supplied to the lower peripheral open region to control the accumulation of the byproduct material within the lower peripheral open region during generation of the plasma. Use of the byproduct volatizing gas to control the accumulation of the byproduct material within the lower peripheral open region serves to prevent electrical arcing and particle contamination.
    Type: Grant
    Filed: September 28, 2018
    Date of Patent: September 9, 2025
    Assignee: Lam Research Corporation
    Inventors: Leonid Belau, Alexei Marakhtanov, Eric Hudson, John Patrick Holland
  • Patent number: 12406852
    Abstract: A method for etching features in a silicon containing stack below a patterned mask is provided. The stack is partially etched by providing a halogen containing etch gas and forming the halogen containing etch gas into a halogen containing plasma, wherein the halogen containing plasma partially etches features with an etch front. A metal catalyst containing layer is deposited on the etch front of the features by providing a metal catalyst containing gas, forming the metal catalyst containing gas into a plasma, and selectively depositing more of the metal catalyst containing layer on the etch front and bottoms of the features than tops of the features. The features are further etched by providing a fluorine containing etch gas and forming a fluorine containing plasma, wherein the plasma selectively etches sidewalls adjacent to the etch front of the features with respect to sidewalls adjacent to tops of the features.
    Type: Grant
    Filed: December 8, 2021
    Date of Patent: September 2, 2025
    Assignee: Lam Research Corporation
    Inventors: Leonid Belau, Eric Hudson
  • Publication number: 20250210364
    Abstract: A method for performing an etch process on a substrate includes applying a bias signal and a source signal to an electrode of a plasma processing system. The bias signal and the source signal are pulsed RF signals that together define a repeated pulsed RF cycle, wherein each pulsed RF cycle sequentially includes a first state, a second state, a third state, and a fourth state. The power level of the bias signal in the first state is greater than in the third state, which is greater than in the second state, which is greater than in the fourth state. The power level of the source signal in the first state is greater than in the third state, which is greater than in the second state, which is greater than in the fourth state.
    Type: Application
    Filed: March 7, 2025
    Publication date: June 26, 2025
    Inventors: Aniruddha Joi, Nikhil Dole, Merrett Wong, Eric Hudson, Jay Sheth
  • Publication number: 20250191926
    Abstract: Fabricating a semiconductor substrate by (a) vertical etching a feature having sidewalls and a depth into one or more layers formed on the semiconductor substrate and (b) depositing an amorphous carbon liner onto the sidewalls of the feature. Steps (a) and optionally (b) are iterated until the vertical etch feature has reached a desired depth. With each iteration of (a), the feature is vertical etched deeper into the one or more layers, while the amorphous carbon liner resists lateral etching of the sidewalls of the feature. With each optional iteration of (b), the deposited amorphous carbon liner on the sidewalls of the feature is replenished.
    Type: Application
    Filed: February 19, 2025
    Publication date: June 12, 2025
    Inventors: Jon HENRI, Karthik S. COLINJIVADI, Francis Sloan ROBERTS, Kapu Sirish REDDY, Samantha SiamHwa TAN, Shih-Ked LEE, Eric HUDSON, Todd SHROEDER, Jialing YANG, Huifeng ZHENG
  • Publication number: 20250191882
    Abstract: A method for applying RF power in a plasma process chamber is provided, including: generating a first RF signal; generating a second RF signal; generating a third RF signal; wherein the first, second, and third RF signals are generated at different frequencies; combining the first, second and third RF signals to generate a combined RF signal, wherein a wave shape of the combined RF signal is configured to approximate a sloped square wave shape; applying the combined RF signal to a chuck in the plasma process chamber.
    Type: Application
    Filed: February 14, 2025
    Publication date: June 12, 2025
    Inventors: Ranadeep Bhowmick, Felix Kozakevich, Alexei Marakhtanov, John Holland, Eric Hudson
  • Publication number: 20250140565
    Abstract: A method for multi-state pulsing to achieve a balance between bow control and mask selectivity is described. The method includes generating a primary radio frequency (RF) signal. The primary RF signal pulses among three states including a first state, a second state, and a third state. The method further includes generating a secondary RF signal. The secondary RF signal pulses among the three states. During the first state, the primary RF signal has a power level that is greater than a power level of the secondary RF signal. Also, during the second state, the secondary RF signal has a power level that is greater than a power level of the primary RF signal. During the third state, power levels of the primary and secondary RF signals are approximately equal.
    Type: Application
    Filed: January 6, 2025
    Publication date: May 1, 2025
    Inventors: Nikhil Dole, Merrett Tinlok Wong, Eric Hudson, Sangheon Lee, Xiaoqiang Yao
  • Patent number: 12278112
    Abstract: A method for performing an etch process on a substrate includes applying a bias signal and a source signal to an electrode of a plasma processing system. The bias signal and the source signal are pulsed RF signals that together define a repeated pulsed RF cycle, wherein each pulsed RF cycle sequentially includes a first state, a second state, a third state, and a fourth state. The power level of the bias signal in the first state is greater than in the third state, which is greater than in the second state, which is greater than in the fourth state. The power level of the source signal in the first state is greater than in the third state, which is greater than in the second state, which is greater than in the fourth state.
    Type: Grant
    Filed: June 16, 2022
    Date of Patent: April 15, 2025
    Assignee: Lam Research Corporation
    Inventors: Aniruddha Joi, Nikhil Dole, Merrett Wong, Eric Hudson, Jay Sheth
  • Patent number: 12255052
    Abstract: A method for applying RF power in a plasma process chamber is provided, including: generating a first RF signal; generating a second RF signal; generating a third RF signal; wherein the first, second, and third RF signals are generated at different frequencies; combining the first, second and third RF signals to generate a combined RF signal, wherein a wave shape of the combined RF signal is configured to approximate a sloped square wave shape; applying the combined RF signal to a chuck in the plasma process chamber.
    Type: Grant
    Filed: July 6, 2021
    Date of Patent: March 18, 2025
    Assignee: Lam Research Corporation
    Inventors: Ranadeep Bhowmick, Felix Kozakevich, Alexei Marakhtanov, John Holland, Eric Hudson
  • Patent number: 12249514
    Abstract: Fabricating a semiconductor substrate by (a) vertical etching a feature having sidewalls and a depth into one or more layers formed on the semiconductor substrate and (b) depositing an amorphous carbon liner onto the sidewalls of the feature. Steps (a) and optionally (b) are iterated until the vertical etch feature has reached a desired depth. With each iteration of (a), the feature is vertical etched deeper into the one or more layers, while the amorphous carbon liner resists lateral etching of the sidewalls of the feature. With each optional iteration of (b), the deposited amorphous carbon liner on the sidewalls of the feature is replenished.
    Type: Grant
    Filed: March 16, 2020
    Date of Patent: March 11, 2025
    Assignee: Lam Research Corporation
    Inventors: Jon Henri, Karthik S. Colinjivadi, Francis Sloan Roberts, Kapu Sirish Reddy, Samantha Siamhwa Tan, Shih-Ked Lee, Eric Hudson, Todd Shroeder, Jialing Yang, Huifeng Zheng
  • Patent number: 12217972
    Abstract: A method for multi-state pulsing to achieve a balance between bow control and mask selectivity is described. The method includes generating a primary radio frequency (RF) signal. The primary RF signal pulses among three states including a first state, a second state, and a third state. The method further includes generating a secondary RF signal. The secondary RF signal pulses among the three states. During the first state, the primary RF signal has a power level that is greater than a power level of the secondary RF signal. Also, during the second state, the secondary RF signal has a power level that is greater than a power level of the primary RF signal. During the third state, power levels of the primary and secondary RF signals are approximately equal.
    Type: Grant
    Filed: December 3, 2020
    Date of Patent: February 4, 2025
    Assignee: Lam Research Corporation
    Inventors: Nikhil Dole, Merrett Tinlok Wong, Eric Hudson, Sangheon Lee, Xiaoqiang Yao
  • Publication number: 20250014909
    Abstract: A method for selectively etching at least one feature in a silicon oxide region with respect to a lower oxygen containing region is provided. An etch gas is provided comprising a fluorocarbon gas and at least one of a metalloid halide gas or metal halide gas. The etch gas is formed into a plasma. At least one feature is selectively etched in the silicon oxide region with respect to the lower oxygen containing region, while simultaneously forming a metalloid or metal containing hardmask over the lower oxygen containing region.
    Type: Application
    Filed: November 28, 2022
    Publication date: January 9, 2025
    Inventors: Eric HUDSON, Prabhat KUMAR
  • Patent number: 12188960
    Abstract: An active noise isolation apparatus and method for cancelling vibration noise from the probe signal of a scanning tunneling microscope by generating a correction signal by convolution based on the probe signal and the sensor signal, which is based on the ambient vibration that adds noise to the probe signal.
    Type: Grant
    Filed: January 24, 2019
    Date of Patent: January 7, 2025
    Assignee: The Penn State Research Foundation
    Inventors: Eric Hudson, Lavish Pabbi
  • Publication number: 20240429063
    Abstract: A method of etching recessed features in a stack with a silicon containing layer over a wafer on a substrate support is provided. The substrate support is maintained at a temperature below about 30° C. An etch ga, comprising an organochloride source selected from the group consisting of carbon tetrachloride (CCl4), CxHyClz (where x>0 and z>0), and combinations thereof, a carbon source, a fluorine source, and a hydrogen source is flowed. The etch gas is formed into a plasma. The stack is exposed to the plasma to etch recessed features into the stack.
    Type: Application
    Filed: November 1, 2022
    Publication date: December 26, 2024
    Inventors: Ilya PISKUN, Gregory Clinton VEBER, Daksh AGARWAL, Taner OZEL, Amit MUKHOPADHYAY, Chen CHEN, Andrew Clark SERINO, Eric HUDSON, Walter Thomas RALSTON, Qing XU, Merrett WONG
  • Publication number: 20240420964
    Abstract: A method for stripping a polymer containing sidewall film from etch features and a polymer containing deposition layer from a backside of a bevel of a wafer with a stack with at least one silicon nitride containing layer is provided. A plasma is formed from a stripping gas, the stripping gas comprising a hydrogen (H2) containing gas and at least one of CO2, CO, N2O, NO, or NO2, wherein the plasma creates radicals from the stripping gas. The wafer is exposed to the radicals, wherein the radicals remove the polymer containing sidewall film and the polymer containing deposition layer.
    Type: Application
    Filed: October 17, 2022
    Publication date: December 19, 2024
    Inventors: Leonid BELAU, Eric HUDSON
  • Publication number: 20240120205
    Abstract: A method for performing an etch process on a substrate includes applying a bias signal and a source signal to an electrode of a plasma processing system. The bias signal and the source signal are pulsed RF signals that together define a repeated pulsed RF cycle, wherein each pulsed RF cycle sequentially includes a first state, a second state, a third state, and a fourth state. The power level of the bias signal in the first state is greater than in the third state, which is greater than in the second state, which is greater than in the fourth state. The power level of the source signal in the first state is greater than in the third state, which is greater than in the second state, which is greater than in the fourth state.
    Type: Application
    Filed: June 16, 2022
    Publication date: April 11, 2024
    Inventors: Aniruddha Joi, Nikhil Dole, Merrett Wong, Eric Hudson, Jay Sheth
  • Patent number: 11935730
    Abstract: Systems and methods for cleaning an edge ring pocket are described herein. One of the methods includes providing one or more process gases to a plasma chamber, supplying a low frequency (LF) radio frequency (RF) power to an edge ring that is located adjacent to a chuck of the plasma chamber. The LF RF power is supplied while the one or more process gases are supplied to the plasma chamber to maintain plasma within the plasma chamber. The supply of the LF RF power increases energy of plasma ions near the edge ring pocket to remove residue in the edge ring pocket. The LF RF power is supplied during the time period in which a substrate is not being processed within the plasma chamber.
    Type: Grant
    Filed: July 22, 2020
    Date of Patent: March 19, 2024
    Assignee: Lam Research Corporation
    Inventors: Eric Hudson, Scott Briggs, John Holland, Alexei Marakhtanov, Felix Leib Kozakevich, Kenneth Lucchesi
  • Publication number: 20230369061
    Abstract: A method for etching features in a silicon containing stack below a patterned mask in an etch chamber is provided. The stack is partially etched by providing a halogen containing etch gas and forming the halogen containing etch gas into a halogen containing plasma, wherein the halogen containing plasma partially etches features into the stack, wherein the features have an etch front. A metal catalyst containing layer is deposited on the etch front of the features by providing a metal catalyst containing gas, forming the metal catalyst containing gas into a metal catalyst containing plasma, and selectively depositing more of the metal catalyst containing layer on the etch front and bottoms of the features than tops of the features.
    Type: Application
    Filed: December 8, 2021
    Publication date: November 16, 2023
    Inventors: Leonid BELAU, Eric HUDSON
  • Publication number: 20230317412
    Abstract: Embodiments for processing a substrate in a pulsed plasma chamber are provided. A processing apparatus with two chambers, separated by a plate fluidly connecting the chambers, includes a continuous wave (CW) controller, a pulse controller, and a system controller. The CW controller sets the voltage and the frequency for a first radio frequency (RF) power source coupled to a top electrode. The pulse controller is operable to set voltage, frequency, ON-period duration, and OFF-period duration for a pulsed RF signal generated by a second RF power source coupled to the bottom electrode. The system controller is operable to regulate the flow of species between the chambers to assist in the negative-ion etching, to neutralize excessive positive charge on the wafer surface during afterglow in the OFF-period, and to assist in the re-striking of the bottom plasma during the ON -period.
    Type: Application
    Filed: June 6, 2023
    Publication date: October 5, 2023
    Inventors: Alexei Marakhtanov, Rajinder Dhindsa, Eric Hudson, Andrew D. Bailey, III
  • Publication number: 20230268192
    Abstract: A method for selectively etching at least one feature in a first region with respect to a second region of a stack is provided. The first region is selectively etched with respect to the second region to form at least one partial feature in the first region, the at least one partial feature having a depth with respect to a surface of the second region. An in-situ a fluorine-free, non-conformal, carbon-containing mask is deposited over the first region and the second region, wherein the carbon-containing mask is selectively deposited on the second region at a second thickness with respect to the first region at a first thickness, the second thickness being greater than the first thickness. The first region is further etched in-situ to etch the at least one partial feature and wherein the carbon-containing mask acts as an etch mask for the second region.
    Type: Application
    Filed: June 13, 2022
    Publication date: August 24, 2023
    Inventors: Eric HUDSON, Kapu Sirish REDDY, Ragesh PUTHENKOVILAKAM, Shashank DESHMUKH, Prabhat KUMAR, Prabhakara GOPALADASU, Seokmin YUN, Xin ZHANG