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: 12648376
    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. A substrate with a metal surface, a dielectric surface and an aluminum oxide surface has a blocking layer deposited on the metal surface using an alkylsilane.
    Type: Grant
    Filed: February 14, 2023
    Date of Patent: June 2, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Aaron Dangerfield, Jesus Candelario Mendoza-Gutierrez, Bhaskar Jyoti Bhuyan, Mark Saly
  • Patent number: 12644180
    Abstract: Methods for the formation of films comprising Si, C, O and N are provided. Certain methods involve sequential exposures of a hydroxide terminated substrate surface to a silicon precursor and an alcohol-amine to form a film with hydroxide terminations. Certain methods involved sequential exposures of hydroxide terminated substrate surface to a silicon precursor and a diamine to form a film with an amine terminated surface, followed by sequential exposures to a silicon precursor and a diol to form a film with a hydroxide terminated surface.
    Type: Grant
    Filed: November 30, 2022
    Date of Patent: June 2, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Bhaskar Jyoti Bhuyan, Mark Saly
  • Patent number: 12642015
    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 metal precursor and an oxidant to form a transition metal oxide film; the transition metal oxide film is exposed to a chalcogenide precursor to form the transition metal dichalcogenide film.
    Type: Grant
    Filed: December 27, 2021
    Date of Patent: May 26, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Chandan Das, Susmit Singha Roy, Bhaskar Jyoti Bhuyan, Supriya Ghosh, Jiecong Tang, John Sudijono, Abhijit Basu Mallick, Mark Saly
  • Patent number: 12635429
    Abstract: Methods of forming SiCON films comprising sequential exposure to a silicon precursor and a mixture of alkanolamine and amine reactants and an optional plasma are described. Methods of forming a silicon-containing film comprising sequential exposure to a silicon precursor and an epoxide with an optional plasma exposure are also described.
    Type: Grant
    Filed: October 11, 2023
    Date of Patent: May 19, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Mark Saly, David Thompson, Thomas Knisley, Bhaskar Jyoti Bhuyan
  • Publication number: 20260130143
    Abstract: Methods of depositing thermally conductive polymeric films are described. Each of the methods include flowing a first precursor over a substrate; removing a first precursor effluent comprising the first precursor; flowing a second precursor over the substrate to react with the first precursor to form the polymeric film on the substrate; and removing a second precursor effluent comprising the second precursor. The methods may include performing a metal deposition process. The methods may include performing a post-treatment process, such as a heat treatment process.
    Type: Application
    Filed: November 7, 2024
    Publication date: May 7, 2026
    Applicant: Applied Materials, Inc.
    Inventors: Xinke Wang, Mark Saly, John Sudijono, Vicknesh Sahmuganathan, Feng Q. Liu, Bhaskar Jyoti Bhuyan
  • Patent number: 12618153
    Abstract: Embodiments disclosed herein include a method of forming a metal-oxo photoresist. In an embodiment, the method comprises flowing a first precursor into a chamber, where the first precursor comprises a first metal. In an embodiment, the method further comprises flowing a second precursor into the chamber, where the second precursor comprises a second metal that is different than the first metal. In an embodiment, the method further comprises depositing the metal-oxo photoresist on a substrate in the chamber using a dry deposition process using the first precursor and the second precursor.
    Type: Grant
    Filed: January 3, 2024
    Date of Patent: May 5, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Lakmal Kalutarage, Madhur Sachan, Mark Saly, Zhenxing Han
  • Publication number: 20260123303
    Abstract: Methods of depositing a reflowable polymeric film on a semiconductor substrate are described. Exemplary processing methods may include flowing a first precursor over a semiconductor substrate to form a first portion of polymeric film on the structure. The methods may include removing a first precursor effluent from the semiconductor substrate. A second precursor may then be flowed over the semiconductor substrate to react with the first portion of the polymeric film. The methods may include removing a second precursor effluent from the semiconductor substrate. The methods may include reflowing the polymeric film by exposing the polymeric film to a heat treatment.
    Type: Application
    Filed: September 23, 2024
    Publication date: April 30, 2026
    Applicants: Applied Materials, Inc., National University of Singapore
    Inventors: Xinke Wang, Rudy James Wojtecki, Bekele Worku, Nasrin Kazem, Wei Shi, Vicknesh Sahmuganathan, John Sudjono, Mark Saly
  • Patent number: 12610791
    Abstract: Methods of depositing a conformal carbon-containing spacer layer are described. Exemplary processing methods may include flowing a first precursor over a patterned surface and a substrate to form a first portion of an initial carbon-containing film on the structure. A second precursor may then be flowed over the substrate to react with the first portion of the initial carbon-containing film. The methods may include etching the substrate to remove a portion of the carbon-containing film and expose a top surface of the patterned surface and expose the substrate between the patterned surfaces. The patterned surface may be an EUV photoresist pattern, and the carbon-containing film may be formed on the sidewall to reduce the critical dimension (CD). The carbon-containing film may act as an etch protection layer for the sidewall of the nanostructures. When no etch is performed, the carbon-containing film may act as a liner material.
    Type: Grant
    Filed: June 14, 2022
    Date of Patent: April 21, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Xinke Wang, Zeqing Shen, Susmit Singha Roy, Abhijit Basu Mallick, Bhaskar Jyoti Bhuyan, Jiecong Tang, John Sudijono, Mark Saly
  • Publication number: 20260103800
    Abstract: Methods of depositing metal-containing films having a composition gradient (i.e., gradient films) are described. The gradient films may be deposited by an atomic layer deposition (ALD) process or a chemical vapor deposition (CVD) process. The gradient film includes at least one metal selected from the group consisting of aluminum (Al), ruthenium (Ru), cobalt (Co), zinc (Zn), molybdenum (Mo), titanium (Ti), tungsten (W), tantalum (Ta), manganese (Mn), iridium (Ir), and copper (Cu). A metallic film is deposited on the gradient film, the metallic film including one or more of copper (Cu), ruthenium (Ru), cobalt (Co), tungsten (W), or molybdenum (Mo).
    Type: Application
    Filed: October 10, 2024
    Publication date: April 16, 2026
    Applicant: Applied Materials, Inc.
    Inventors: Lisa J. Enman, Lakmal C. Kalutarage, Feng Q. Liu, Mark Saly, Jeffrey W. Anthis, Parmish Kaur, Anjali Sood, Brice Jean Eychenne, Chandan Das
  • Publication number: 20260101732
    Abstract: Methods of manufacturing interconnect structures as part of a microelectronic device fabrication process are described. Methods of selectively depositing iridium-containing films are also described. The methods include exposing a substrate including a metallic material and a dielectric material to an iridium-containing precursor and a reactant to form the iridium-containing film. The iridium-containing film selectively grows on the metallic material relative to the dielectric material.
    Type: Application
    Filed: October 4, 2024
    Publication date: April 9, 2026
    Applicant: Applied Materials, Inc.
    Inventors: Chandan Das, Feng Q. Liu, Zhiyuan Wu, Jiecong Tang, John Sudijono, Mark Saly
  • Patent number: 12598969
    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: Grant
    Filed: June 29, 2023
    Date of Patent: April 7, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Feng Q. Liu, Xinke Wang, Liqi Wu, Qihao Zhu, Bhaskar Jyoti Bhuyan, Mark Saly, David Thompson
  • Patent number: 12593629
    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: Grant
    Filed: June 29, 2023
    Date of Patent: March 31, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Mark Saly, Feng Q. Liu, Bhaskar Jyoti Bhuyan, Jeffrey W. Anthis, David Thompson
  • Patent number: 12568803
    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 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: Grant
    Filed: March 3, 2023
    Date of Patent: March 3, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Muthukumar Kaliappan, Bhaskar Jyoti Bhuyan, Yong Jin Kim, Carmen Leal Cervantes, Xiangjin Xie, Jesus Candelario Mendoza-Gutierrez, Aaron Dangerfield, Michael Haverty, Mark Saly, Kevin Kashefi
  • Publication number: 20260042789
    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: October 17, 2025
    Publication date: February 12, 2026
    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
  • Patent number: 12545998
    Abstract: Methods for depositing rhenium-containing thin films on a substrate are described. The substrate is exposed to a rhenium precursor and a reducing agent to form the rhenium-containing film (e.g., metallic rhenium, rhenium nitride). The exposures can be sequential or simultaneous.
    Type: Grant
    Filed: May 14, 2020
    Date of Patent: February 10, 2026
    Assignees: Applied Materials, Inc., Wayne State University
    Inventors: Thomas Knisley, Keenan N. Woods, Mark Saly, Stefan Cwik, Charles H. Winter
  • Patent number: 12543523
    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: Grant
    Filed: October 20, 2023
    Date of Patent: February 3, 2026
    Assignee: Applied Materials, Inc.
    Inventors: Jiajie Cen, Feng Q. Liu, Zheng Ju, Zhiyuan Wu, Kevin Kashefi, Mark Saly, Xianmin Tang
  • Publication number: 20260026270
    Abstract: Methods of selectively depositing a low-k dielectric film are described. In one or more embodiments, the methods include exposing a substrate to a blocking compound, the substrate including a first surface and a second surface, the first surface including hydrogen-terminated silicon, the blocking compound selectively depositing on the first surface to form a blocked first surface; and selectively depositing the low-k dielectric film on the second surface. Methods of forming an inner spacer layer are described.
    Type: Application
    Filed: July 17, 2024
    Publication date: January 22, 2026
    Applicant: Applied Materials, Inc.
    Inventors: Lisa J. Enman, Bhaskar Jyoti Bhuyan, Aaron Dangerfield, Sai Hooi Yeong, Mark Saly, Lakmal C. Kalutarage, Seyed Mahmoud Hosseini
  • Publication number: 20260011547
    Abstract: Methods of depositing silicon-containing films by plasma-enhanced vapor deposition, e.g., plasma-enhanced chemical vapor deposition (PECVD) or plasma-enhanced atomic layer deposition (PEALD), are disclosed. Exemplary methods include exposing a substrate in a processing system to a silicon-containing precursor; exposing the substrate to an oxygen-containing reagent; and exposing the substrate to a plasma of an inert gas.
    Type: Application
    Filed: July 5, 2024
    Publication date: January 8, 2026
    Applicant: Applied Materials, Inc.
    Inventors: Zachary J. Devereaux, Thomas Joseph Knisley, Bhaskar Jyoti Bhuyan, Mark Saly, Akhil Singhal
  • Patent number: 12473316
    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: Grant
    Filed: June 14, 2024
    Date of Patent: November 18, 2025
    Assignees: 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
  • Patent number: 12435411
    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: Grant
    Filed: May 9, 2023
    Date of Patent: October 7, 2025
    Assignees: Applied Materials, Inc., Wayne State University
    Inventors: Thomas Joseph Knisley, Bhaskar Jyoti Bhuyan, Mark Saly, Shalini Tripathi, Charles H. Winter, Zachary J. Devereaux