Patents by Inventor Mark Saly

Mark 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).

  • Patent number: 12291779
    Abstract: Methods of depositing a film selectively onto a first substrate surface relative to a second substrate surface are described. The methods include exposing the substrate surfaces to a blocking compound to selectively form a blocking layer on at least a portion of the first surface over the second surface. The substrate is sequentially exposed to a metal precursor with a kinetic diameter in excess of 21 angstroms and a reactant to selectively form a metal-containing layer on the second surface over the blocking layer or the first surface. The relatively larger metal precursors of some embodiments allow for the use of blocking layers with gaps or voids without the loss of selectivity.
    Type: Grant
    Filed: October 17, 2023
    Date of Patent: May 6, 2025
    Assignee: Applied Materials, Inc.
    Inventors: Bhaskar Jyoti Bhuyan, Mark Saly, David Thompson, Tobin Kaufman-Osborn, Kurt Fredrickson, Thomas Knisley, Liqi Wu
  • Publication number: 20250132165
    Abstract: Methods of removing molybdenum oxide from a surface of a substrate comprise exposing the substrate having a molybdenum oxide layer on the substrate to a halide etchant having the formula RmSiX4-m, wherein m is an integer from 1 to 3, X is selected from iodine (I) and bromine (Br) and R is selected from the group consisting of a methyl group, ethyl group, propyl group, butyl group, cyclohexyl group and cyclopentyl group. The methods may be performed in a back-end-of-the line (BEOL) process, and the substrate contains a low-k dielectric material.
    Type: Application
    Filed: October 20, 2023
    Publication date: April 24, 2025
    Applicant: Applied Materials, Inc.
    Inventors: Jiajie Cen, Feng Q. Liu, Zheng Ju, Zhiyuan Wu, Kevin Kashefi, Mark Saly, Xianmin Tang
  • Patent number: 12281382
    Abstract: Methods of selectively depositing blocking layers on conductive surfaces over dielectric surfaces are described. In some embodiments, a 4-8 membered substituted heterocycle is exposed to a substrate to selectively form a blocking layer. In some embodiments, a layer is selectively deposited on the dielectric surface after the blocking layer is formed. In some embodiments, the blocking layer is removed.
    Type: Grant
    Filed: May 24, 2023
    Date of Patent: April 22, 2025
    Assignee: Applied Materials, Inc.
    Inventors: Lakmal C. Kalutarage, Bhaskar Jyoti Bhuyan, Aaron Dangerfield, Feng Q. Liu, Mark Saly, Michael Haverty, Muthukumar Kaliappan
  • Patent number: 12281387
    Abstract: Organometallic precursors and methods of depositing high purity metal films are discussed. Some embodiments utilize a method comprising exposing a substrate surface to an organometallic precursor comprising one or more of molybdenum (Mo), tungsten (W), osmium (Os), technetium (Tc), manganese (Mn), rhenium (Re) or ruthenium (Ru), and an iodine-containing reactant comprising a species having a formula RIx, where R is one or more of a C1-C10 alkyl, C3-C10 cycloalkyl, C2-C10 alkenyl, or C2-C10 alkynyl group, I is an iodine group and x is in a range of 1 to 4 to form a carbon-less iodine-containing metal film. Some embodiments advantageously provide methods of forming metal films having low carbon content (e.g., having greater than or equal to 95% metal species on an atomic basis), without using an oxidizing agent or a reductant.
    Type: Grant
    Filed: December 30, 2021
    Date of Patent: April 22, 2025
    Assignee: Applied Materials, Inc.
    Inventors: Feng Q. Liu, Mark Saly, David Thompson, Annamalai Lakshmanan, Avgerinos V. Gelatos, Joung Joo Lee
  • Publication number: 20250125195
    Abstract: Embodiments of the disclosure relate to methods using an oligomer film to protect a substrate surface. The oligomer film is formed on the substrate surface with a first feature and a second feature each having a feature depth. The first feature has a first critical dimension (CD) and the second feature has a second CD. The semiconductor substrate surface is exposed to one or more monomers to form the oligomer film, and the oligomer film forms selectively on the bottom and fills a portion of the feature depth. The oligomer film fills the feature depth to substantially the same or the same height in each of the first feature and the second feature. Methods of forming semiconductor devices using the oligomer film are also disclosed.
    Type: Application
    Filed: October 11, 2023
    Publication date: April 17, 2025
    Applicant: Applied Materials, Inc.
    Inventors: Feng Q. Liu, Xinke Wang, Liqi Wu, Qihao Zhu, Mark Saly, Jiang Lu, John Sudijono, David Thompson
  • Patent number: 12272551
    Abstract: Embodiments of the disclosure relate to methods for selectively removing metal material from the top surface and sidewalls of a feature. The metal material which is covered by a flowable polymer material remains unaffected. In some embodiments, the metal material is formed by physical vapor deposition resulting in a relatively thin sidewall thickness. Any metal material remaining on the sidewall after removal of the metal material from the top surface may be etched by an additional etch process. The resulting metal layer at the bottom of the feature facilitates selective metal gapfill of the feature.
    Type: Grant
    Filed: May 25, 2022
    Date of Patent: April 8, 2025
    Assignee: Applied Materials, Inc.
    Inventors: Liqi Wu, Feng Q. Liu, Bhaskar Jyoti Bhuyan, James Hugh Connolly, Zhimin Qi, Jie Zhang, Wei Dou, Aixi Zhang, Mark Saly, Jiang Lu, Rongjun Wang, David Thompson, Xianmin Tang
  • Patent number: 12261049
    Abstract: Described herein is a method for selectively cleaning and/or etching a sample. The method includes selectively forming a film in a trench of a substrate such that the trench may be selectively etched. A polymer film is deposited on the bottom surface of the trench without being deposited on the side wall. A second film is selectively formed in the trench without forming the second film on the polymer film. The polymer is then removed from the bottom surface of the trench and then etching is performed on the bottom surface of the trench using an etch chemistry, wherein the second film protects the side wall from being etched.
    Type: Grant
    Filed: June 9, 2022
    Date of Patent: March 25, 2025
    Assignee: Applied Materials , Inc.
    Inventors: David Thompson, Bhaskar Jyoti Bhuyan, Mark Saly, Lisa Enman, Aaron Dangerfield, Jesus Candelario Mendoza, Jeffrey W. Anthis, Lakmal Kalutarage
  • Publication number: 20250028248
    Abstract: Embodiments disclosed herein include a method of dry developing a metal-oxide photoresist. In an embodiment, a method of patterning a metal-oxide photoresist, such as a Sn-based photoresist, includes depositing the metal-oxide photoresist over a substrate, exposing the metal-oxide photoresist with an extreme ultra-violet (EUV) exposure to form exposed regions and non-exposed regions, and developing the exposed metal-oxide photoresist using an electron-donor ligand-based dry etch process.
    Type: Application
    Filed: May 2, 2024
    Publication date: January 23, 2025
    Inventors: NASRIN KAZEM, LAKMAL CHARIDU KALUTARAGE, MADHUR SACHAN, MARK SALY, ANDREA LEONCINI, DOREEN WEI YING YONG
  • Publication number: 20250006485
    Abstract: Embodiments of the disclosure relate to methods of selectively depositing polysilicon after forming a flowable polymer film to protect a substrate surface within a feature. A first silicon (Si) layer is deposited by physical vapor deposition (PVD). The flowable polymer film is formed on the first silicon (Si) layer on the bottom. A portion of the first silicon (Si) layer is selectively removed from the top surface and the at least one sidewall. The flowable polymer film is removed. In some embodiments, a second silicon (Si) layer is selectively deposited on the first silicon (Si) layer to fill the feature. In some embodiments, the remaining portion of the first silicon (Si) layer on the bottom is oxidized to form a first silicon oxide (SiOx) layer on the bottom, and a silicon (Si) layer or a second silicon oxide (SiOx) layer is deposited on the first silicon oxide (SiOx) layer.
    Type: Application
    Filed: June 29, 2023
    Publication date: January 2, 2025
    Applicant: Applied Materials, Inc.
    Inventors: Mark Saly, Feng Q. Liu, Bhaskar Jyoti Bhuyan, Jeffrey W. Anthis, David Thompson
  • Publication number: 20250006555
    Abstract: Embodiments of the disclosure relate to methods of selectively depositing a metal after use of a flowable polymer to protect a substrate surface within a feature. A first metal layer is deposited by physical vapor deposition (PVD). The semiconductor substrate surface is exposed to one or more monomers to form a flowable and flexible polymer film on the first metal layer within the at least one feature. The flowable polymer film forms on the first metal layer on the bottom. The one or more monomers are selected from one or more of amines with bi-functional groups, aldehydes with bi-functional groups, cyanates with bi-functional groups, ketones with bi-functional groups, and alcohols with bi-functional groups. At least a portion of the first metal layer is selectively removed from the top surface and the at least one sidewall. The flowable polymer film is removed.
    Type: Application
    Filed: June 29, 2023
    Publication date: January 2, 2025
    Applicant: Applied Materials, Inc.
    Inventors: Feng Q. Liu, Xinke Wang, Liqi Wu, Qihao Zhu, Bhaskar Jyoti Bhuyan, Mark Saly, David Thampson
  • Patent number: 12131900
    Abstract: Methods of enhancing selective deposition are described. In some embodiments, a blocking layer is deposited on a metal surface before deposition of a dielectric. In some embodiments, a metal surface is functionalized to enhance or decrease its reactivity.
    Type: Grant
    Filed: July 26, 2022
    Date of Patent: October 29, 2024
    Assignee: Applied Materials, Inc.
    Inventors: Bhaskar Jyoti Bhuyan, Mark Saly, Lakmal C. Kalutarage, Thomas Joseph Knisley
  • Publication number: 20240355675
    Abstract: Methods of forming semiconductor devices by enhancing selective deposition are described. In some embodiments, a blocking layer is deposited on a metal surface before deposition of a barrier layer. The methods include exposing a substrate with a metal surface, a dielectric surface and an aluminum oxide surface or an aluminum nitride surface to a blocking molecule, such as a boron-containing compound, to form the blocking layer selectively on the metal surface over the dielectric surface and one of the aluminum oxide surface or the aluminum nitride surface.
    Type: Application
    Filed: April 9, 2024
    Publication date: October 24, 2024
    Applicant: Applied Materials, Inc.
    Inventors: Muthukumar Kaliappan, Yong Jin Kim, Carmen Leal Cervantes, Bhaskar Jyoti Bhuyan, Xiangjin Xie, Michael Haverty, Kevin Kashefi, Mark Saly, Aaron Dangerfield, Jesus Candelario Mendoza-Gutierrez
  • Publication number: 20240343748
    Abstract: Molybdenum(0) coordination complexes comprising ligands which each coordinate to the metal center by nitrogen or phosphorous are described. Methods for depositing molybdenum-containing films on a substrate are described. The substrate is exposed to a molybdenum precursor and a reactant to form the molybdenum-containing film (e.g., elemental molybdenum, molybdenum oxide, molybdenum carbide, molybdenum silicide, molybdenum nitride). The exposures can be sequential or simultaneous.
    Type: Application
    Filed: June 14, 2024
    Publication date: October 17, 2024
    Applicants: Applied Materials, Inc., National University of Singapore
    Inventors: Andrea Leoncini, Paul Mehlmann, Nemanja Dordevic, Han Vinh Huynh, Doreen Wei Ying Yong, Mark Saly, Bhaskar Jyoti Bhuyan
  • Publication number: 20240339358
    Abstract: Methods of forming devices comprise forming a dielectric layer on a substrate, the dielectric layer comprising at least one feature defining a gap including sidewalls and a bottom. The methods include selectively depositing a self-assembled monolayer (SAM) on the bottom of the gap. The SAM has a general formula I to XIX, wherein R, R?, R1, R2, R3, R4, and R5 are independently selected from hydrogen (H), alkyl, alkene, alkyne, and aryl, n is from 1 to 20, m is from 1 to 20, x is from 1 to 2, and y is from 1 to 2. A barrier layer is formed on the SAM before selectively depositing a metal liner on the barrier layer. The SAM is removed after selectively depositing the metal liner on the barrier layer.
    Type: Application
    Filed: April 7, 2023
    Publication date: October 10, 2024
    Applicant: Applied Materials, Inc.
    Inventors: Jesus Candelario Mendoza-Gutierrez, Aaron Dangerfield, Bhaskar Jyoti Bhuyan, Mark Saly, Yang Zhou, Yong Jin Kim, Carmen Leal Cervantes, Ge Qu, Zhiyuan Wu, Feng Chen, Kevin Kashefi
  • Patent number: 12110584
    Abstract: Transition metal dichalcogenide films and methods for depositing transition metal dichalcogenide films on a substrate are described. Methods for converting transition metal oxide films to transition metal dichalcogenide films are also described. The substrate is exposed to a precursor and a chalcogenide reactant to form the transition metal dichalcogenide film. The exposures can be sequential or simultaneous.
    Type: Grant
    Filed: June 28, 2021
    Date of Patent: October 8, 2024
    Assignee: Applied Materials, Inc.
    Inventors: Chandan Das, Susmit Singha Roy, Bhaskar Jyoti Bhuyan, John Sudijono, Abhijit Basu Mallick, Mark Saly
  • Publication number: 20240332014
    Abstract: Molecular layer deposition (MLD) is used to provide conformal and uniform doping technology for HAR and reentrant structures. MLD is used to deposit a conformal carbon-based film that contains a doping element. Thermal annealing is then used to make the doping element diffuse into the semiconductor material. For HAR structures, a conformal layer is used with low temperature doping, precise control, and the carbon-based film can be easily removed during doping or after doping. The amount of doping can be controlled by changing the thickness of MLD carbon-based film.
    Type: Application
    Filed: March 22, 2024
    Publication date: October 3, 2024
    Applicants: Applied Materials, Inc., National University of Singapore
    Inventors: Xinke Wang, Long Liu, Mark Saly, Bhaskar Jyoti Bhuyan, Jiecong Tang, John Sudijono
  • Publication number: 20240322073
    Abstract: Method for cleaning and encapsulating microLED features are disclosed. Some embodiments provide for a wet clean process and a dry clean process to remove contaminants from the microLED feature. Some embodiments provide for the encapsulation of a clean microLED feature. Some embodiments provide improved crystallinity of the microLED feature and the capping layer. Some embodiments provide improved EQE of microLED devices formed from the disclosed microLED features.
    Type: Application
    Filed: June 6, 2024
    Publication date: September 26, 2024
    Applicant: Applied Materials, Inc.
    Inventors: Thomas Joseph Knisley, Bhaskar Jyoti Bhuyan, Mark Saly, Mingwei Zhu
  • Patent number: 12094766
    Abstract: Methods for selectively depositing on metallic surfaces are disclosed. Some embodiments of the disclosure utilize a hydrocarbon having at least two functional groups selected from alkene, alkyne, ketone, hydroxyl, aldehyde, or combinations thereof to form a self-assembled monolayer (SAM) on metallic surfaces.
    Type: Grant
    Filed: October 21, 2022
    Date of Patent: September 17, 2024
    Assignee: Applied Materials, Inc.
    Inventors: Michael L. McSwiney, Bhaskar Jyoti Bhuyan, Mark Saly, Drew Phillips, Aaron Dangerfield, David Thompson, Kevin Kashefi, Xiangjin Xie
  • Publication number: 20240301549
    Abstract: Metal complexes with nitrile ligands of the type MO2X2L2, where M is molybdenum or tungsten, X is a halogen, each L is independently an organonitrile ligand with the general formula NCR, where each R is independently a C2-C18 group. Metal complexes with dinitrile bidentate ligands of the type MO2X2L?, where L? is a dintrile ligand, and dinitrile bridging ligands of the type (MO2X2)2L?, where L? is a dinitrile bridging ligand connecting the two metal atoms. Methods of making and using the metal complexes are described.
    Type: Application
    Filed: May 9, 2023
    Publication date: September 12, 2024
    Applicants: Applied Materials, Inc., Wayne State University
    Inventors: Thomas Joseph Knisley, Bhaskar Jyoti Bhuyan, Mark Saly, Shalini Tripathi, Charles H. Winter, Zachary J. Devereaux
  • Patent number: 12084464
    Abstract: Halide ligand free rhenium complexes are described as well as methods for depositing rhenium-containing films. Some embodiments provide a rhenium complex with a general formula of O3ReO-M-R1R2R3, where M is a group IV element, R1 is selected from H, alkyl, alkenyl, alkynyl, an aromatic ring, or alkoxy, and R2 and R3 are each independently selected from H, alkyl, alkenyl, alkynyl, an aromatic ring, or alkoxy, or R2 and R3 join together to form a ring structure or an oxo group. Some embodiments provide a rhenium complex with a general formula of Re(NR?)3(NHR?), where R? and R? are independently selected from H, alkyl, alkenyl, alkynyl, or an aromatic ring.
    Type: Grant
    Filed: November 20, 2020
    Date of Patent: September 10, 2024
    Assignees: Applied Materials, Inc., Wayne State University
    Inventors: Thomas Knisley, Keenan N. Woods, Mark Saly, Charles H. Winter, Stefan Cwik