Patents by Inventor Mark J. Saly
Mark J. Saly 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).
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Patent number: 12606579Abstract: Exemplary methods of semiconductor processing, such as methods of depositing a molybdenum-containing material on a substrate, may include providing a molybdenum-containing precursor to a processing region of a semiconductor processing chamber in which the substrate is located. The molybdenum-containing precursor may include a molybdenum complex according to Compound I: R may be methyl or ethyl, R? may be methyl or ethyl, R? may be methyl, ethyl, or propyl, and n may be equal to 1 or 2. Contacting the substrate with the molybdenum-containing precursor may deposit the molybdenum-containing material on the substrate.Type: GrantFiled: June 13, 2023Date of Patent: April 21, 2026Assignee: Applied Materials, Inc.Inventors: Feng Q. Liu, Mark J. Saly, David Thompson
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Publication number: 20260107710Abstract: The present disclosure provides methods of depositing dielectric films in processing chambers. The methods include disposing a substrate on a susceptor disposed within a processing chamber. A first precursor-containing gas mixture is provided into the processing chamber. The first precursor-containing gas mixture includes a boron-containing precursor and a carrier gas selected from the group consisting of argon, nitrogen, and helium. A second precursor-containing gas mixture is provided into the processing chamber.Type: ApplicationFiled: October 15, 2024Publication date: April 16, 2026Inventors: Lakmal C. KALUTARAGE, Mark J. SALY, Bhaskar Jyoti BHUYAN, Lisa J. ENMAN, SeyedMahmoud HOSSEINI, Arkaprava DAN, Chi-Chou LIN
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Publication number: 20260032985Abstract: A processing method includes forming an interfacial layer on a surface of a channel comprising silicon (Si) located between a source and a drain on a semiconductor substrate including a low-? dielectric layer, and selectively depositing a high-? dielectric layer directly on the interfacial layer relative to the low-? dielectric layer by exposing the semiconductor substrate to a metal-containing precursor, a purge gas, an alcohol, and the purge gas.Type: ApplicationFiled: June 27, 2025Publication date: January 29, 2026Inventors: Daniel Wei Ming BEH, Zachary J. DEVEREAUX, Thomas KNISLEY, Bhaskar Jyoti BHUYAN, Mark J. SALY, Steven C. H. HUNG
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Publication number: 20260011569Abstract: An etch chamber includes a substrate support assembly for holding a base structure, and a showerhead comprising a plurality of gas delivery holes for delivering thionyl chloride. The etch chamber is configured to dry etch a target layer of the base structure at a sub-zero degree Celsius temperature using the thionyl chloride delivered by the showerhead in order to obtain a processed base structure. The processed base structure includes a plurality of features and a plurality of openings defined by an etch mask disposed on the target layer.Type: ApplicationFiled: September 10, 2025Publication date: January 8, 2026Inventors: Zhonghua Yao, Qian Fu, Mark J. Saly, Yang Yang, Jeffrey W. Anthis, David Knapp, Rajesh Sathiyanarayanan
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Patent number: 12486559Abstract: Disclosed herein is a method for forming metal-oxides in the photoresist to improve profile control. The method includes infiltrating a metal oxide in a photoresist layer by pressurizing a methyl-containing material in a processing environment proximate a film stack. The film stack includes the photoresist layer, the photoresist layer being disposed on top of and in contact with an underlayer. The underlayer disposed on top of a substrate. The method includes etching the film stack including the photoresist layer implanted with the metal oxide.Type: GrantFiled: May 10, 2022Date of Patent: December 2, 2025Assignee: APPLIED MATERIALS, INC.Inventors: Nancy Fung, Mark J. Saly
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Patent number: 12469715Abstract: A method includes providing, within an etch chamber, a base structure including a target layer disposed on a substrate, and an etch mask disposed on the target layer, dry etching, within the etch chamber, the target layer using thionyl chloride to obtain a processed base structure, and after forming the plurality of features. The processed base structure includes a plurality of features and a plurality of openings defined by the etch mask. The method further includes removing the processed base structure from the etch chamber. In some embodiments, the target layer includes carbon. In some embodiments, the dry etching is performed at a sub-zero degree temperature.Type: GrantFiled: July 12, 2023Date of Patent: November 11, 2025Assignee: Applied Materials, Inc.Inventors: Zhonghua Yao, Qian Fu, Mark J. Saly, Yang Yang, Jeffrey W. Anthis, David Knapp, Rajesh Sathiyanarayanan
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Patent number: 12438050Abstract: A method includes selectively forming at least one passivation layer on at least one first conductive layer disposed in a first interlevel dielectric (ILD) layer, selectively forming at least one catalyst layer on the at least one passivation layer, wherein the at least one passivation layer prevents formation of the at least one catalyst layer on the first conductive layer, and selectively forming at least one supplemental dielectric layer using the at least one catalyst layer. The at least one catalyst layer induces formation of the at least one supplemental dielectric layer, and the at least one supplemental dielectric layer includes a dielectric material having a dielectric constant of less than or equal to about 4.Type: GrantFiled: February 14, 2023Date of Patent: October 7, 2025Assignee: Applied Materials, Inc.Inventors: Zachary J. Devereaux, Bhaskar Jyoti Bhuyan, Thomas Joseph Knisley, Zeqing Shen, Susmit Singha Roy, Mark J. Saly, Abhijit Basu Mallick
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Publication number: 20250283251Abstract: Embodiments generally relate to methods for depositing silicon-phosphorous materials, and more specifically, relate to using silicon-phosphorous compounds in vapor deposition processes (e.g., epitaxy, CVD, or ALD) to deposit silicon-phosphorous materials. In one or more embodiments, a method for forming a silicon-phosphorous material on a substrate is provided and includes exposing the substrate to a deposition gas containing one or more silicon-phosphorous compounds during a deposition process and depositing a film containing the silicon-phosphorous material on the substrate. The silicon-phosphorous compound has the chemical formula [(R3-vHvSi)—(R2-wHwSi)n]xPHyR?z, where each instance of R and each instance of R? are independently an alkyl or a halogen, n is 0, 1, or 2; v is 0, 1, 2, or 3; w is 0, 1, or 2; x is 1, 2, or 3; y is 0, 1, or 2; z is 0, 1, or 2, and where x+y+z=3.Type: ApplicationFiled: May 27, 2025Publication date: September 11, 2025Inventors: Errol Antonio C. SANCHEZ, Mark J. SALY, Schubert CHU, Abhishek DUBE, Srividya NATARAJAN
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Patent number: 12394620Abstract: A method includes forming a first layer and a second layer on a substrate, forming a passivation layer on a surface of the first layer without forming the passivation layer on a surface of the second layer by exposing the first layer and the second layer to a benzyl compound, and after forming the passivation layer on the first layer, performing at least one of: depositing a third layer on the second layer, or etching the second layer.Type: GrantFiled: October 28, 2022Date of Patent: August 19, 2025Assignee: Applied Materials, Inc.Inventors: Feng Q. Liu, Mark J. Saly, David Thompson
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Patent number: 12338547Abstract: Embodiments generally relate to methods for depositing silicon-phosphorous materials, and more specifically, relate to using silicon-phosphorous compounds in vapor deposition processes (e.g., epitaxy, CVD, or ALD) to deposit silicon-phosphorous materials. In one or more embodiments, a method for forming a silicon-phosphorous material on a substrate is provided and includes exposing the substrate to a deposition gas containing one or more silicon-phosphorous compounds during a deposition process and depositing a film containing the silicon-phosphorous material on the substrate. The silicon-phosphorous compound has the chemical formula [(R3-vHvSi)—(R2-wHwSi)n]xPHyR?z, where each instance of R and each instance of R? are independently an alkyl or a halogen, n is 0, 1, or 2; v is 0, 1, 2, or 3; w is 0, 1, or 2; x is 1, 2, or 3; y is 0, 1, or 2; z is 0, 1, or 2, and where x+y+z=3.Type: GrantFiled: April 5, 2023Date of Patent: June 24, 2025Assignee: APPLIED MATERIALS, INC.Inventors: Errol Antonio C. Sanchez, Mark J. Saly, Schubert Chu, Abhishek Dube, Srividya Natarajan
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Patent number: 12315733Abstract: A method includes performing a dry etch process to remove a portion of a first layer disposed on a second layer of a stack of alternating layers. The first layer includes a first material and the second layer includes a second material different from the first material, and the dry etch process forms a passivation layer including a byproduct on surfaces of the second material. A amount of first material of the portion of the first layer remains after performing the dry etch process, The method further includes introducing a halide gas to enhance the passivation layer on the surfaces of the second material.Type: GrantFiled: February 1, 2024Date of Patent: May 27, 2025Assignee: Applied Materials, Inc.Inventors: David Knapp, Feng Qiao, Hailong Zhou, Junkai He, Qian Fu, Mark J. Saly, Jeffrey Anthis, Jayoung Choi
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Publication number: 20250046602Abstract: A method includes obtaining a base structure of an electronic device, the base structure including at least one opening, and forming, using a reactive-ion deposition process, a dielectric material within the at least one opening.Type: ApplicationFiled: August 3, 2023Publication date: February 6, 2025Inventors: Bhaskar Jyoti Bhuyan, Mark J. Saly, Lakmal Charidu Kalutarage, Feng Q. Liu, Jeffrey W. Anthis, Abhijit Basu Mallick, Akhil Singhal
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Publication number: 20240425536Abstract: Exemplary methods of semiconductor processing, such as methods of depositing a molybdenum-containing material on a substrate, may include providing a molybdenum-containing precursor to a processing region of a semiconductor processing chamber in which the substrate is located. The molybdenum-containing precursor may include a molybdenum complex according to Compound I: R may be methyl or ethyl, R? may be methyl or ethyl, R? may be methyl, ethyl, or propyl, and n may be equal to 1 or 2. Contacting the substrate with the molybdenum-containing precursor may deposit the molybdenum-containing material on the substrate.Type: ApplicationFiled: June 13, 2023Publication date: December 26, 2024Applicant: Applied Materials, Inc.Inventors: Feng Q. Liu, Mark J. Saly, David Thompson
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Publication number: 20240360549Abstract: A method includes performing a reactant step of a deposition cycle of a deposition process to form a molybdenum (Mo)-based material, performing a Mo precursor step of the deposition cycle, and performing a treatment step of the deposition cycle. Performing the reactant step includes introducing a reactant, performing the Mo precursor step includes introducing a Mo precursor, and performing the treatment step includes introducing a treatment gas. The deposition process is performed at a temperature that is less than or equal to about 450° C.Type: ApplicationFiled: April 27, 2023Publication date: October 31, 2024Inventors: Feng Q. Liu, Byunghoon Yoon, Joung-Joo Lee, Avgerinos V. Gelatos, Mark J. Saly
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Publication number: 20240332001Abstract: Exemplary methods of semiconductor processing may include providing a first precursor to a semiconductor processing chamber. A substrate may be disposed within a processing region of the semiconductor processing chamber. The substrate may define a feature. The methods may include contacting the substrate with the first precursor. The contacting may form a first portion of a silicon-carbon-and-nitrogen-containing material on the substrate. The methods may include providing a second precursor to the semiconductor processing chamber. The methods may include contacting the substrate with the second precursor. The contacting may form the silicon-carbon-and-nitrogen-containing material on the substrate. The silicon-carbon-and-nitrogen-containing material may be void free.Type: ApplicationFiled: March 30, 2023Publication date: October 3, 2024Applicant: Applied Materials, Inc.Inventors: Lakmal C. Kalutarage, Bhaskar Jyoti Bhuyan, Mark J. Saly, Jeffrey W. Anthis
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Publication number: 20240282632Abstract: A method includes selectively forming at least one passivation layer on at least one first conductive layer disposed in a first interlevel dielectric (ILD) layer, selectively forming at least one catalyst layer on the at least one passivation layer, wherein the at least one passivation layer prevents formation of the at least one catalyst layer on the first conductive layer, and selectively forming at least one supplemental dielectric layer using the at least one catalyst layer. The at least one catalyst layer induces formation of the at least one supplemental dielectric layer, and the at least one supplemental dielectric layer includes a dielectric material having a dielectric constant of less than or equal to about 4.Type: ApplicationFiled: February 14, 2023Publication date: August 22, 2024Inventors: Zachary J. Devereaux, Bhaskar Jyoti Bhuyan, Thomas Joseph Knisley, Zeqing Shen, Susmit Singha Roy, Mark J. Saly, Abhijit Basu Mallick
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Publication number: 20240266180Abstract: A method includes performing a dry etch process to remove a portion of a first layer disposed on a second layer of a stack of alternating layers. The first layer includes a first material and the second layer includes a second material different from the first material, and the dry etch process forms a passivation layer including a byproduct on surfaces of the second material. A amount of first material of the portion of the first layer remains after performing the dry etch process, The method further includes introducing a halide gas to enhance the passivation layer on the surfaces of the second material.Type: ApplicationFiled: February 1, 2024Publication date: August 8, 2024Inventors: David Knapp, Feng Qiao, Hailong Zhou, Junkai He, Qian Fu, Mark J. Saly, Jeffrey Anthis, Jayoung Choi
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Patent number: 12014925Abstract: Exemplary deposition methods may include delivering a ruthenium-containing precursor and a hydrogen-containing precursor to a processing region of a semiconductor processing chamber. At least one of the ruthenium-containing precursor or the hydrogen-containing precursor may include carbon. The methods may include forming a plasma of all precursors within the processing region of a semiconductor processing chamber. The methods may include depositing a ruthenium-and-carbon material on a substrate disposed within the processing region of the semiconductor processing chamber.Type: GrantFiled: May 25, 2021Date of Patent: June 18, 2024Assignee: Applied Materials, Inc.Inventors: Eswaranand Venkatasubramanian, Bhaskar Jyoti Bhuyan, Mark J. Saly, Abhijit Basu Mallick
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Publication number: 20240145232Abstract: A method includes forming a first layer and a second layer on a substrate, forming a passivation layer on a surface of the first layer without forming the passivation layer on a surface of the second layer by exposing the first layer and the second layer to a benzyl compound, and after forming the passivation layer on the first layer, performing at least one of: depositing a third layer on the second layer, or etching the second layer.Type: ApplicationFiled: October 28, 2022Publication date: May 2, 2024Inventors: Feng Q. Liu, Mark J. Saly, David Thompson
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Publication number: 20240128091Abstract: A method includes providing, within an etch chamber, a base structure including a target layer disposed on a substrate, and an etch mask disposed on the target layer, dry etching, within the etch chamber, the target layer using thionyl chloride to obtain a processed base structure, and after forming the plurality of features. The processed base structure includes a plurality of features and a plurality of openings defined by the etch mask. The method further includes removing the processed base structure from the etch chamber. In some embodiments, the target layer includes carbon. In some embodiments, the dry etching is performed at a sub-zero degree temperature.Type: ApplicationFiled: July 12, 2023Publication date: April 18, 2024Inventors: Zhonghua Yao, Qian Fu, Mark J. Saly, Yang Yang, Jeffrey W. Anthis, David Knapp, Rajesh Sathiyanarayanan