Patents by Inventor Mark I. Gardner

Mark I. Gardner 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: 12598734
    Abstract: A semiconductor device includes a stack of dynamic random access memory (DRAM) cell units over a substrate in a vertical direction perpendicular to a working surface of the substrate. At least one DRAM cell unit includes a transistor and a capacitor. The capacitor includes a first metal layer, a capacitor dielectric layer positioned on the first metal layer, and a second metal layer positioned on the capacitor dielectric layer. The capacitor is elongated in a horizontal direction parallel to the working surface of the substrate. The second metal layer has a first end and a second end in the horizontal direction. The transistor includes a channel structure, and a gate structure disposed all around the channel structure. The first metal layer extends in the horizontal direction beyond the first end of the second metal layer to form a drain region and a source region of the transistor.
    Type: Grant
    Filed: December 1, 2022
    Date of Patent: April 7, 2026
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Publication number: 20260088690
    Abstract: A substrate processing apparatus includes a substrate holder configured to receive a substrate, a shaft connected to the substrate holder at one end of the shaft and configured to rotate the substrate holder, a plate attached to the shaft and configured to rotate with the shaft, magnets integrated with the substrate holder, the plate or both, and a coiled wire positioned between the substrate holder and the plate and configured to generate an electrical current when the shaft rotates. A method of energy generation includes providing the substrate processing apparatus and rotating the shaft to generate the electrical current.
    Type: Application
    Filed: September 23, 2024
    Publication date: March 26, 2026
    Applicant: Tokyo Electron Limited
    Inventors: Mark I. GARDNER, H. Jim FULFORD, Daniel FULFORD
  • Patent number: 12581898
    Abstract: An apparatus for measuring bow of a wafer includes a substrate holder including a support surface configured to support a wafer, and an air flow system including a plurality of air outlets in the support surface which are configured to output air for elevating the wafer above the substrate holder. A capacitor array unit including a plurality of electrodes laterally spaced from one another in the capacitor array unit, each electrode facing the support surface and being spaced a respective fixed distance from the support surface such that each electrode can form a capacitor with an opposing area of a wafer elevated by the substrate holder.
    Type: Grant
    Filed: November 16, 2023
    Date of Patent: March 17, 2026
    Assignee: Tokyo Electron Limited
    Inventors: Daniel Fulford, Mark I. Gardner, H. Jim Fulford
  • Publication number: 20260060040
    Abstract: A method of wafer handling includes providing a wafer on a wafer carrier on a wafer chuck on a vacuum plate. The wafer carrier includes a permanent magnet. The wafer chuck includes an electromagnet. The wafer is raised against a gravity direction by flowing an electrical current through the electromagnet so that the wafer carrier is repelled from the wafer chuck while the wafer remains on the wafer carrier. While keeping the wafer raised, wafer alignment is adjusted by moving the wafer chuck, the wafer carrier or both. The electrical current is reduced to zero so that the wafer carrier contacts the wafer chuck. The wafer is connected to the vacuum plate via a first vacuum cavity of the wafer chuck and a third vacuum cavity of the wafer carrier. The wafer carrier is connected to the vacuum plate via the second vacuum cavity of the wafer chuck.
    Type: Application
    Filed: August 22, 2024
    Publication date: February 26, 2026
    Applicant: Tokyo Electron Limited
    Inventors: Henry Jim FULFORD, Mark I. GARDNER, Daniel FULFORD
  • Patent number: 12543369
    Abstract: A method of fabricating a semiconductor device includes receiving a first wafer including a first substrate on a backside of the first wafer, and a first semiconductor-on-insulator (SOI) stack on a front side of the first wafer. The first SOI stack includes a first semiconductor. A second wafer is received that includes a second substrate on a backside of the second wafer, and a second SOI stack on a front side of the second wafer. The second SOI stack includes a second semiconductor. The front side of the first wafer is bonded to the front side of the second wafer, via at least one dielectric bonding material, to form a bonded wafer. The second substrate is removed. A stack of transistor devices is formed with the first semiconductor used as a first channel for a first transistor and the second semiconductor used as a second channel for a second transistor.
    Type: Grant
    Filed: August 9, 2022
    Date of Patent: February 3, 2026
    Assignee: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford
  • Patent number: 12538520
    Abstract: A method of microfabrication includes forming an initial stack of semiconductor layers by epitaxial growth over a substrate. The initial stack of semiconductor layers is surrounded by a sidewall structure. The initial stack of semiconductor layers includes channel structures and sacrificial gate layers stacked alternatingly in a vertical direction substantially perpendicular to a working surface of the substrate. The channel structures include a first channel structure and a second channel structure positioned above the first channel structure. First portions of the sidewall structure are removed to uncover first sides of the initial stack. Source/drain (S/D) regions are formed on uncovered side surfaces of the channel structures from the first sides of the initial stack. Second portions of the sidewall structure are removed to uncover second sides of the initial stack. The sacrificial gate layers are replaced with gate structures from the second sides of the initial stack.
    Type: Grant
    Filed: April 6, 2022
    Date of Patent: January 27, 2026
    Assignee: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford, Partha Mukhopadhyay
  • Publication number: 20260022929
    Abstract: A system for testing metal recess depths into a wafer includes a test structure formed in the wafer, and probe pads positioned vertically over the test structure. The test structure includes a first region and a second region laterally adjacent to each other. The first region includes a dielectric layer having a top surface and a metal layer formed under the top surface. The second region includes the dielectric layer, the metal layer, and a first metal pad and a second metal pad laterally separated, vertically extend into the dielectric layer from the top surface, and in contact with the metal layer. The probe pads include a first and a second probe pads configured to be vertically over the first region, and a third and a fourth probe pads configured to be vertically over the second region and to align with the first and the second metal pads, respectively.
    Type: Application
    Filed: July 22, 2024
    Publication date: January 22, 2026
    Inventors: Partha MUKHOPADHYAY, Henry Jim FULFORD, Mark I. GARDNER
  • Patent number: 12529965
    Abstract: A method of processing a substrate, including forming a photomask based on a layout of a first surface of a wafer including at least one opaque region and at least one transparent region and the first surface of the wafer being coated with a photosensitive resist; providing the photomask at a first photomask location between the first surface of the wafer and a source of radiation at a predetermined wavelength, the at least one opaque region of the photomask covering a first region of the first surface of the wafer and the at least one transparent region of the photomask exposing a second region of the first surface of the wafer; and exposing the first surface of wafer to a first pattern of radiation, the first pattern of radiation including the second region of the wafer exposed by the at least one transparent region of the photomask.
    Type: Grant
    Filed: January 30, 2024
    Date of Patent: January 20, 2026
    Assignee: Tokyo Electron Limited
    Inventors: Anton J. Devilliers, Daniel J. Fulford, Mark I. Gardner, H. Jim Fulford
  • Publication number: 20260020222
    Abstract: Aspects of the present disclosure provide a semiconductor structure, which can include a lower transistor including a lower channel that is elongated horizontally and includes a lower doped first-type semiconductor layer of a lower doped semiconductor layer, an upper transistor vertically stacked over the lower transistor and including an upper channel that is elongated horizontally and includes an upper doped first-type semiconductor layer of an upper doped semiconductor layer, a lower capacitor electrically connected to and horizontally elongated from the lower transistor and including a first lower plate that includes a lower doped second-type semiconductor layer of the lower doped semiconductor layer, and an upper capacitor vertically stacked over the lower capacitor and electrically connected to and horizontally elongated from the upper transistor and including a first upper plate that includes an upper doped second-type semiconductor layer of the upper doped semiconductor layer.
    Type: Application
    Filed: September 24, 2025
    Publication date: January 15, 2026
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim FULFORD, Mark I. GARDNER, Partha MUKHOPADHYAY
  • Patent number: 12513983
    Abstract: Semiconductor devices and corresponding methods of manufacturing the same are disclosed. For example, a plurality of first semiconductor channels vertically spaced from one another and a plurality of second semiconductor channels vertically spaced from one another can be provided. The plurality of first semiconductor channels each have a first sidewall in contact with a dielectric structure and the plurality of second semiconductor channels each have a first sidewall in contact with the dielectric structure. Gate structures can be formed around at least a top surface, a bottom surface, and a second sidewall of the first and second semiconductor channels.
    Type: Grant
    Filed: August 22, 2022
    Date of Patent: December 30, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford
  • Publication number: 20250391808
    Abstract: A method of hybrid bonding includes accessing first dies sourced from a first wafer and second dies sourced from one or more second wafers. First overlay registration values (ORVs) of the first dies and second ORVs of the second dies are measured. A die pairing process is executed that matches the first dies with the second dies to form paired dies based on the first ORVs and the second ORVs. A hybrid bonding process is executed to bond the paired dies.
    Type: Application
    Filed: January 6, 2025
    Publication date: December 25, 2025
    Applicant: TOKYO ELECTRON LIMITED
    Inventors: Partha MUKHOPADHYAY, H. Jim FULFORD, Anton DEVILLIERS, Mark I. GARDNER, Zuriel CARIBE
  • Patent number: 12507431
    Abstract: A semiconductor structure includes semiconductor layers stacked vertically over a substrate. The structure includes a gate structure interleaved with the semiconductor layers, where the gate structure wraps around a first end portion of each semiconductor layer. The structure includes dielectric layers stacked vertically over the substrate and interleaved with the semiconductor layers, where a first end portion of each dielectric layer is aligned with a second end portion of each semiconductor layer, which is laterally opposite to the first end portion of each semiconductor layer. The structure includes a metal contact extending vertically to contact the second end portion of each semiconductor layer.
    Type: Grant
    Filed: October 27, 2022
    Date of Patent: December 23, 2025
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner
  • Patent number: 12507447
    Abstract: One or more 3D transistor structures that use one or more 2D materials as transistor channels along with methods for fabricating the same are disclosed. A 3D transistor can include a source contact, a drain contact, a 2D material forming a channel between the source and drain contacts and surrounding a carrier nanosheet forming a first p-n junction with the source contact and a second p-n junction with the drain contact, and a gate structure comprising a gate dielectric and a gate contact contacting at least a portion of the channel between the first p-n junction and the second p-n junction. The source and drain contacts can comprise a doped semiconductor material and a channel having a first curved profile extending along the source contact and a second curved profile extending along the drain contact.
    Type: Grant
    Filed: February 15, 2022
    Date of Patent: December 23, 2025
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Patent number: 12501602
    Abstract: Semiconductor devices and corresponding methods of manufacturing the same are disclosed. For example, a semiconductor device includes a first transistor comprising a first channel region. The first channel region includes one or more first nanostructures formed of a semiconductor material. The semiconductor device includes a second transistor disposed vertically with respect to the first transistor and comprising a second channel region. The second channel region includes one or more second nanostructures formed of a conductive oxide material.
    Type: Grant
    Filed: July 15, 2022
    Date of Patent: December 16, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford, Partha Mukhopadhyay
  • Patent number: 12495604
    Abstract: Semiconductor devices and corresponding methods of manufacturing the same are disclosed. For example, a plurality of first semiconductor channels vertically spaced from one another and a plurality of second semiconductor channels vertically spaced from one another, wherein different materials are simultaneously epitaxial-grown for the first semiconductor channels and the second semiconductor channels, can be provided. The plurality of first semiconductor channels each have a first sidewall in contact with a dielectric structure and the plurality of second semiconductor channels each have a first sidewall in contact with the dielectric structure. Gate structures can be formed around at least a top surface, a bottom surface, and a second sidewall of the first and second semiconductor channels.
    Type: Grant
    Filed: September 15, 2022
    Date of Patent: December 9, 2025
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner
  • Patent number: 12464703
    Abstract: A semiconductor device includes a stack of dynamic random access memory (DRAM) cell units over a substrate in a vertical direction perpendicular to a working surface of the substrate. Each DRAM cell unit includes a respective transistor, a respective capacitor and a respective bridge structure. Each bridge structure is configured to electrically couple the respective transistor to the respective capacitor. Each capacitor is elongated in a horizontal direction parallel to the working surface of the substrate.
    Type: Grant
    Filed: September 16, 2022
    Date of Patent: November 4, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford
  • Patent number: 12464704
    Abstract: Aspects of the present disclosure provide a semiconductor structure, which can include a lower transistor including a lower channel that is elongated horizontally and includes a lower doped first-type semiconductor layer of a lower doped semiconductor layer, an upper transistor vertically stacked over the lower transistor and including an upper channel that is elongated horizontally and includes an upper doped first-type semiconductor layer of an upper doped semiconductor layer, a lower capacitor electrically connected to and horizontally elongated from the lower transistor and including a first lower plate that includes a lower doped second-type semiconductor layer of the lower doped semiconductor layer, and an upper capacitor vertically stacked over the lower capacitor and electrically connected to and horizontally elongated from the upper transistor and including a first upper plate that includes an upper doped second-type semiconductor layer of the upper doped semiconductor layer.
    Type: Grant
    Filed: November 17, 2022
    Date of Patent: November 4, 2025
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Patent number: 12455511
    Abstract: Aspects of the present disclosure provide a method for optimizing wafer shape. For example, the method can include receiving a wafer having a working surface for one or more devices to be fabricated thereon and a backside surface opposite to the working surface, measuring the wafer to identify bow measurement of the wafer, and forming a stress-modification film on the backside surface of the wafer. The stress-modification film can be reactive to heat such that applied heat modifies an internal stress of the stress-modification film. The method can also include applying a pattern of heat onto the stress-modification film to modify the internal stress of the stress-modification film, the pattern of heat corresponding to the bow measurement.
    Type: Grant
    Filed: August 17, 2022
    Date of Patent: October 28, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Daniel J. Fulford, Anthony R. Schepis, Mark I. Gardner, H. Jim Fulford, Anton J. DeVilliers
  • Patent number: 12457768
    Abstract: A semiconductor device may include a transistor structure. The transistor structure may include a metal structure extending along a vertical direction; a gate dielectric layer around the metal structure; a channel layer around the gate dielectric layer; a first metal electrode disposed below the metal structure and in electrical contact with a first end of the channel layer; a second metal electrode disposed above the metal structure and in electrical contact with a second end of the channel layer; and a third metal electrode disposed above and in electrical contact with the metal structure.
    Type: Grant
    Filed: May 20, 2022
    Date of Patent: October 28, 2025
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Patent number: 12439641
    Abstract: A semiconductor device includes a first transistor and a second transistor. The first transistor includes a first channel structure positioned over a substrate, first source/drain (S/D) regions positioned on ends of the first channel structure, and a first gate structure disposed all around the first channel structure. The second transistor includes a second channel structure positioned over the first channel structure, second S/D regions positioned on ends of the second channel structure, and a second gate structure disposed all around the second channel structure. The second channel structure has a smaller dimension than the first channel structure in a horizontal direction substantially parallel to a working surface of the substrate.
    Type: Grant
    Filed: April 6, 2022
    Date of Patent: October 7, 2025
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay