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).

  • Publication number: 20230010602
    Abstract: Semiconductor devices and corresponding methods of manufacture are disclosed. A method includes forming a stack of layers on a substrate. The stack includes a first sacrificial dielectric layer, a first metal layer, a second sacrificial dielectric layer, and a second metal layer vertically stacked on top of one another. The stack is etched to form a vertical opening. The opening is filled with a vertical structure. The vertical structure includes a first sacrificial semiconductor segment, a first semiconductor segment, a second sacrificial semiconductor segment, and a second semiconductor segment. The first and second sacrificial semiconductor segments are removed. Silicide layers are formed in the vertical structure to connect thereto.
    Type: Application
    Filed: July 8, 2022
    Publication date: January 12, 2023
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Publication number: 20230010879
    Abstract: Vertical transistors and methods of manufacturing vertical transistors are disclosed. The method can include forming a stack of layers include a first layer stack of a first transistor structure including at least three layers of a conductive material separated by one or more layers of at least one dielectric material. The stack of layers can include a second layer stack of a second transistor structure including at least three layers of a conductive material separated by one or more layers of at least one dielectric material, the second layer stack associated with a second transistor structure. The first and second transistor structures are separated by one or more dielectric materials. The method can include forming a channel opening in the stack. The method includes selectively forming a first channel structure within the channel opening and selectively forming a second channel structure within the channel opening.
    Type: Application
    Filed: November 17, 2021
    Publication date: January 12, 2023
    Applicant: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford, Partha Mukhopadhyay
  • Patent number: 11552080
    Abstract: In a method of forming a semiconductor device, an epitaxial layer stack is formed over a substrate. The epitaxial layer stack includes intermediate layers, one or more first nano layers and one or more second nano layers positioned below the one or more first nano layers. Trenches are formed in the epitaxial layer stack to separate the epitaxial layer stack into sub-stacks, the one of more first nano layers into first nano-channels, and the one or more second nano layers into second nano-channels. The intermediate layers are recessed so that one or more first nano-channels of the first nano-channels and one or more second nano-channels of the second nano-channels in each of the sub-stacks protrude from sidewalls of the intermediate layers. Bottom source/drain (S/D) regions are formed in the trenches to connect the second nano-channels. Top S/D regions are formed in the trenches to connect the first nano-channels.
    Type: Grant
    Filed: July 21, 2021
    Date of Patent: January 10, 2023
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner
  • Publication number: 20230006068
    Abstract: Vertical transistors and methods of manufacturing vertical transistors are disclosed. The method can include forming a stack of layers. The stack of layers includes a first sub-stack for a first transistor structure. The first sub-stack includes at least three layers of a conductive material separated by one or more layers of a dielectric material. The stack of layers includes a second sub-stack for a second transistor structure. The second sub-stack includes at least three layers of a conductive material separated by one or more layers of a dielectric material. The first and second sub-stacks are separated by dielectric materials. The method includes forming a channel opening in the stack, and providing a first channel structure that includes a semiconductive oxide material aligned with the first transistor structure. The method includes selectively forming a capping layer on the first channel structure, and providing a second channel structure within the channel opening.
    Type: Application
    Filed: November 17, 2021
    Publication date: January 5, 2023
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Patent number: 11527545
    Abstract: Techniques herein include methods of forming circuits by combining multiple substrates. High voltage devices are fabricated on a first wafer, and low voltage devices and/or memory are then fabricated on a second wafer and/or third wafer.
    Type: Grant
    Filed: August 31, 2020
    Date of Patent: December 13, 2022
    Assignee: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner
  • Patent number: 11521972
    Abstract: A semiconductor device is provided. The semiconductor device can include a bottom substrate, a device plane over the bottom substrate, a dielectric layer over the device plane, localized substrates over the dielectric layer, and semiconductor devices over the localized substrates. The localized substrates can be separated from each other along a top surface of the bottom substrate. A method of microfabrication is provided. The method can include forming a target layer over a bottom substrate where the target layer includes one or more localized regions that include one or more semiconductor materials. The method can also include performing a thermal process to change crystal structures of the one or more localized regions of the target layer. The method can further include forming semiconductor devices over the localized regions of the target layer.
    Type: Grant
    Filed: November 13, 2020
    Date of Patent: December 6, 2022
    Assignee: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford
  • Patent number: 11515306
    Abstract: A method of forming a semiconductor device is presented. A layer stack of alternating epitaxial materials including one or more layers is formed. The layer stack of alternating epitaxial materials into a first region of nano sheets and a second region of nano sheets is divided. A first field effect transistor on a working surface of a substrate using the nano sheets in the first region of nano sheets is formed. A stack of field effect transistors on the working surface of the substrate using the nano sheets in the second region of nano sheets is formed.
    Type: Grant
    Filed: December 2, 2020
    Date of Patent: November 29, 2022
    Assignee: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford
  • Patent number: 11508625
    Abstract: A semiconductor device includes a first n-type transistor and a first p-type transistor that are positioned side by side over a substrate. The first n-type transistor includes a first n-type source/drain (S/D) region, a first n-type channel region, and a second n-type S/D region that are formed based on a first continuous channel structure extending along a horizontal direction parallel to the substrate. The first n-type channel region is positioned between the first n-type S/D region and the second n-type S/D region. The first p-type transistor includes a first p-type S/D region, a first p-type channel region, and a second p-type S/D region that are formed based on the first continuous channel structure. The first p-type channel region is positioned between the first p-type S/D region and the second p-type S/D region. The second n-type S/D region is in contact with the first p-type S/D region.
    Type: Grant
    Filed: December 16, 2020
    Date of Patent: November 22, 2022
    Assignee: TOKYO ELECTRON LIMITED
    Inventors: H. Jim Fulford, Mark I. Gardner
  • Publication number: 20220367289
    Abstract: Aspects of the present disclosure provide a method for forming a semiconductor structure having separated vertical channel structures. The method can include forming a layer stack on a substrate, the layer stack including alternating metal layers and dielectric layers. The method can further include forming vertically stacked lower and upper vertical channel structures vertically extending through the layer stack, the lower and upper vertical channel structures being separated by a sacrificial layer. The method can further include forming source, drain and gate connections to the lower and upper vertical channel structures, the source, drain and gate connections extending horizontally from the lower and upper vertical channel structures and then vertically to a location above the upper vertical channel structure.
    Type: Application
    Filed: September 21, 2021
    Publication date: November 17, 2022
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim FULFORD, Mark I. GARDNER, Partha MUKHOPADHYAY
  • Publication number: 20220367290
    Abstract: Structures and methods are disclosed in which a layer stack can be formed with a plurality of layers of a metal, where each of the layers of metal can be separated by a layer of a dielectric. An opening in the layer stack can be formed such that a semiconductor layer beneath the plurality of layers of the metal is uncovered. One or more vertical channel structures can be formed within the opening by epitaxial growth. The vertical channel structure can include a vertically oriented transistor. The vertical channel structure can include an interface of a silicide metal with a first metal layer of the plurality of metal layers. The interface can correspond to one of a source or a drain connection of a transistor. The silicide metal can be annealed above a temperature threshold to form a silicide interface between the vertical channel structure and the first metal layer.
    Type: Application
    Filed: April 14, 2022
    Publication date: November 17, 2022
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Publication number: 20220359312
    Abstract: A method of microfabrication includes epitaxially growing a first vertical channel structure of silicon-containing material on a first sacrificial layer of silicon containing material, the first sacrificial layer having etch selectivity with respect to the vertical channel structure. A core opening is directionally etched through the vertical channel structure to expose the first sacrificial layer, and the first sacrificial layer is isotropically etched through the core opening to form a first isolation opening for isolating the first vertical channel structure.
    Type: Application
    Filed: November 2, 2021
    Publication date: November 10, 2022
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim FULFORD, Mark I. GARDNER, Partha MUKHOPADHYAY
  • Publication number: 20220359294
    Abstract: A method of microfabrication includes forming an initial vertical channel structure of semiconductor material protruding from a surface of a substrate such that the initial vertical channel structure has a current flow path that is perpendicular to the surface of the substrate. The initial vertical channel structure is segmented lengthwise into a plurality of independent vertical channel structure segments, each vertical channel structure segment having a respective current flow path that is perpendicular to the surface of the substrate.
    Type: Application
    Filed: November 8, 2021
    Publication date: November 10, 2022
    Applicant: Tokyo Electron Limited
    Inventors: Mark I. GARDNER, H. Jim FULFORD
  • Publication number: 20220344209
    Abstract: Semiconductor devices and corresponding methods of manufacture are disclosed. The method includes forming vertical channel structures on a substrate. The vertical channel structures are formed within a layer stack of alternating layers of a first metal and a first dielectric. The vertical channel structures are channels of field effect transistors that have a current flow path perpendicular to a surface of the substrate. The vertical channel structures have a dielectric core. The method includes forming openings on the substrate that uncover a region of the layer stack adjacent to the vertical channel structures. The method includes, for each vertical channel structure, forming a corresponding staircase region in the layer stack, and forming metal contacts within each staircase region.
    Type: Application
    Filed: April 11, 2022
    Publication date: October 27, 2022
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Publication number: 20220344332
    Abstract: According to an aspect of the disclosure, a semiconductor device is provided. The semiconductor device includes a stack of insulating layers and interconnect layers that are positioned alternatingly over a substrate. The semiconductor device includes a channel structure extending from the substrate and further through the insulating layers and the interconnect layers. The channel structure includes a first channel section positioned over the substrate and coupled to a first group of the interconnect layers, and a second channel section positioned over the first channel section and coupled to a second group of the interconnect layers. The semiconductor device also includes a plurality of contact structures extending from and coupled to the interconnect layers in a staircase configuration such that each of the plurality of contact structures extends from a respective interconnect layer.
    Type: Application
    Filed: October 19, 2021
    Publication date: October 27, 2022
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner, Partha Mukhopadhyay
  • Publication number: 20220320079
    Abstract: Aspects of the present disclosure provide 3D semiconductor apparatus and a method for fabricating the same. The 3D semiconductor apparatus can include a first semiconductor device including first S/D regions, a first gate region sandwiched by the first S/D regions, and a first channel surrounded by the first S/D regions and the first gate region; a second semiconductor device stacked on the first semiconductor device that includes second S/D regions, a second gate region sandwiched by the second S/D regions, and a second channel surrounded by the second S/D regions and the second gate region and formed vertically in-situ on the first channel; and silicide formed between the first and second semiconductor devices where the first and second channels interface and coupled to an upper one of the first S/D regions of the first semiconductor device and a lower one of the second S/D regions of the second semiconductor device.
    Type: Application
    Filed: June 20, 2022
    Publication date: October 6, 2022
    Inventors: Mark I. Gardner, H. Jim Fulford
  • Publication number: 20220293523
    Abstract: A semiconductor device includes a buried power rail (BPR) over a substrate and a semiconductor structure over the BPR. The semiconductor structure is tube-shaped and extends along a vertical direction. The semiconductor structure includes a first source/drain (S/D) region over the BPR, a gate region over the first S/D region, and a second S/D region over the gate region. The semiconductor device includes a first S/D interconnect structure extending from the BPR and further into the semiconductor structure such that a top portion of the first S/D interconnect structure is surrounded by the first S/D region. The semiconductor device includes a gate structure that includes (i) a gate oxide formed along an inner surface of the gate region and (ii) a gate electrode formed along sidewalls of the gate oxide in the gate region. The semiconductor device includes a second S/D interconnect structure positioned over the second S/D region.
    Type: Application
    Filed: November 4, 2021
    Publication date: September 15, 2022
    Applicant: Tokyo Electron Limited
    Inventors: Mark I. Gardner, H. Jim Fulford
  • Publication number: 20220293789
    Abstract: Systems and methods for manufacturing semiconductor devices. The system can include a semiconductor device. The semiconductor device can include a semiconductor shell that extends along a vertical direction. The semiconductor device can include a first metal structure surrounded by a lower portion of the semiconductor shell. The semiconductor device can include a dielectric structure above the first metal structure. The semiconductor device can include a second metal structure through the dielectric structure.
    Type: Application
    Filed: March 10, 2022
    Publication date: September 15, 2022
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim Fulford, Mark I. Gardner
  • Publication number: 20220277957
    Abstract: A method of forming transistor devices is described that includes forming a first transistor plane on a substrate, the first transistor plane including at least one layer of epitaxial film adaptable for forming channels of field effect transistors, depositing a first insulator layer on the first transistor plane, depositing a first layer of polycrystalline silicon on the first insulator layer, annealing the first layer of polycrystalline silicon using laser heating. The laser heating increases grain size of the first layer of polycrystalline silicon. The method further includes forming a second transistor plane on the first layer of polycrystalline silicon, the second transistor plane being adaptable for forming channels of field effect transistors, depositing a second insulator layer on the second transistor plane, depositing a second layer of polycrystalline silicon on the second insulator layer, and annealing the second layer of polycrystalline silicon using laser heating.
    Type: Application
    Filed: July 29, 2020
    Publication date: September 1, 2022
    Inventors: H. Jim Fulford, Mark I. Gardner, Jeffrey Smith, Lars Liebmann, Daniel Chanemougame
  • Publication number: 20220254690
    Abstract: A method of microfabrication is provided. The method includes forming shell structures above a first layer including a first semiconductor material. The shell structures are electrically isolated from each other and electrically isolated from the first layer. The shell structures include at least one type of semiconductor material and each include a dielectric core structure. Each shell structure is configured to include a top source/drain (S/D) region, a channel region and a bottom S/D region serially connected in a vertical direction perpendicular to the first layer and have a current flow path in the vertical direction. A bottom contact structure connected to a respective bottom S/D region of each shell structure is formed. A gate structure is formed on a sidewall of a respective channel region of each shell structure.
    Type: Application
    Filed: September 21, 2021
    Publication date: August 11, 2022
    Applicant: Tokyo Electron Limited
    Inventors: H. Jim FULFORD, Mark I. GARDNER
  • Publication number: 20220254689
    Abstract: A method of microfabrication includes providing a substrate having a first layer including a first semiconductor material. A second layer of a second semiconductor material is formed over the first layer. The second layer is directionally etched using a mask to form independent core structures of the second semiconductor material on the first semiconductor material. A third layer of a first dielectric material is formed on an exposed surface of the first layer to cover a lower portion of a respective sidewall of each core structure. A shell structure is formed on an upper portion of a respective sidewall of each core structure to form shell structures including at least one semiconductor material. The core structures are removed such that each shell structure forms a vertical semiconductor structure extending vertically from the first layer and electrically isolated from the first semiconductor material by the first dielectric material.
    Type: Application
    Filed: September 21, 2021
    Publication date: August 11, 2022
    Applicant: Tokyo Electron Limited
    Inventors: Mark I. GARDNER, H. Jim FULFORD