Patents by Inventor Mark Van Dal

Mark Van Dal 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: 11908922
    Abstract: A semiconductor structure includes a substrate, a first epitaxial layer, a second epitaxial layer, and a transistor. The substrate includes a first pyramid protrusion, a second pyramid protrusion, a third pyramid protrusion, and a fourth pyramid protrusion. The first and second pyramid protrusions are arranged along a first direction, the second and fourth pyramid protrusions are arranged along the first direction, and the first and third pyramid protrusions are arranged along a second direction crossing the first direction. The first epitaxial layer is over the substrate and in contact with the first, second, third, and fourth pyramid protrusions. The second epitaxial layer is over the first epitaxial layer. The transistor is over the second epitaxial layer.
    Type: Grant
    Filed: October 26, 2020
    Date of Patent: February 20, 2024
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Carlos H. Diaz, Mark Van Dal, Martin Christopher Holland
  • Publication number: 20230387306
    Abstract: In a method of manufacturing a semiconductor device, an opening is formed in an interlayer dielectric layer such that a source/drain region is exposed in the opening. A first semiconductor layer is formed to fully cover the exposed source/drain region within the opening. A heating process is performed to make an upper surface of the first semiconductor layer substantially flat. A conductive contact layer is formed over the first semiconductor layer.
    Type: Application
    Filed: August 10, 2023
    Publication date: November 30, 2023
    Inventors: Blandine DURIEZ, Mark van DaL, Martin Christopher HOLLAND, Gerben DOORNBOS
  • Patent number: 11830947
    Abstract: In a method of manufacturing a semiconductor device, an opening is formed in an interlayer dielectric layer such that a source/drain region is exposed in the opening. A first semiconductor layer is formed to fully cover the exposed source/drain region within the opening. A heating process is performed to make an upper surface of the first semiconductor layer substantially flat. A conductive contact layer is formed over the first semiconductor layer.
    Type: Grant
    Filed: April 18, 2022
    Date of Patent: November 28, 2023
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD.
    Inventors: Blandine Duriez, Mark van Dal, Martin Christopher Holland, Gerben Doornbos
  • Publication number: 20230335446
    Abstract: A fin including a bottom portion, a first sacrificial layer disposed over the bottom portion, a first semiconductor layer disposed over the first sacrificial layer, a second sacrificial layer disposed over the first semiconductor layer and a second semiconductor layer disposed over the second sacrificial layer, is formed. The second semiconductor layer protrudes from a first insulating layer. A dummy gate is formed over the second semiconductor layer. A sidewall spacer layer is formed on side faces of the dummy gate. A first dielectric layer is formed over the dummy gate and the sidewall spacer layer. The dummy gate is removed, thereby forming a gate space. The first insulating layer is etched in the gate space, thereby exposing the first semiconductor layer and the first and second sacrificial layers. The first and second sacrificial layers are removed. A gate dielectric layer and a gate electrode layer are formed.
    Type: Application
    Filed: June 23, 2023
    Publication date: October 19, 2023
    Inventors: Mark VAN DAL, Gerben DOORNBOS
  • Patent number: 11784219
    Abstract: Methods for forming semiconductor structures are provided. The method includes forming a fin structure over a substrate and forming a dummy gate structure across the fin structure. The method further includes forming a spacer layer on a sidewall of the fin structure at a source/drain region. The method further includes removing at least a portion of the spacer layer to enlarge the source/drain region and forming a source/drain structure in the source/drain region.
    Type: Grant
    Filed: June 4, 2021
    Date of Patent: October 10, 2023
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD.
    Inventors: Mark Van Dal, Gerben Doornbos, Chung-Te Lin
  • Patent number: 11728222
    Abstract: A fin including a bottom portion, a first sacrificial layer disposed over the bottom portion, a first semiconductor layer disposed over the first sacrificial layer, a second sacrificial layer disposed over the first semiconductor layer and a second semiconductor layer disposed over the second sacrificial layer, is formed. The second semiconductor layer protrudes from a first insulating layer. A dummy gate is formed over the second semiconductor layer. A sidewall spacer layer is formed on side faces of the dummy gate. A first dielectric layer is formed over the dummy gate and the sidewall spacer layer. The dummy gate is removed, thereby forming a gate space. The first insulating layer is etched in the gate space, thereby exposing the first semiconductor layer and the first and second sacrificial layers. The first and second sacrificial layers are removed. A gate dielectric layer and a gate electrode layer are formed.
    Type: Grant
    Filed: May 28, 2021
    Date of Patent: August 15, 2023
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD.
    Inventors: Mark Van Dal, Gerben Doornbos
  • Publication number: 20230207562
    Abstract: In a method of manufacturing a semiconductor device, a fin structure protruding from a first isolation insulating layer is formed. A second isolation insulating layer made of different material than the first isolation insulating layer is formed so that a first upper portion of the fin structure is exposed. A dummy gate structure is formed over the exposed first upper portion of the first fin structure. The second isolation insulating layer is etched by using the dummy gate structure as an etching mask. The dummy gate structure is removed so that a gate space is formed. The second isolation insulating layer is etched in the gate space so that a second upper portion of the fin structure is exposed from the first isolation insulating layer. A gate dielectric layer and a gate electrode layer are formed over the exposed second portion of the fin structure.
    Type: Application
    Filed: March 6, 2023
    Publication date: June 29, 2023
    Inventors: Gerben DOORNBOS, Mark VAN DAL
  • Patent number: 11682587
    Abstract: In a method of manufacturing a semiconductor device, a fin structure having a bottom portion, an intermediate portion disposed over the bottom portion and an upper portion disposed over the intermediate portion is formed. The intermediate portion is removed at a source/drain region of the fin structure, thereby forming a space between the bottom portion and the upper portion. An insulating layer is formed in the space. A source/drain contact layer is formed over the upper portion. The source/drain contact layer is separated by the insulating layer from the bottom portion of the fin structure.
    Type: Grant
    Filed: March 8, 2021
    Date of Patent: June 20, 2023
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Mark Van Dal, Gerben Doornbos
  • Patent number: 11677004
    Abstract: Various strained channel transistors are disclosed herein. An exemplary semiconductor device includes a substrate and a fin structure disposed over the substrate. The fin structure includes a first epitaxial layer disposed on the substrate, a second epitaxial layer disposed on the first epitaxial layer, and a third epitaxial layer disposed on the second epitaxial layer. The second epitaxial layer includes a relaxed transversal stress component and a longitudinal compressive stress component, and the third epitaxial layer has uni-axial strain. A gate structure is disposed on a channel region of the fin structure, such that the gate structure interposes a source region and a drain region of the fin structure.
    Type: Grant
    Filed: August 25, 2017
    Date of Patent: June 13, 2023
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD.
    Inventors: Mark Van Dal, Gerben Doornbos, Georgios Vellianitis, Tsung-Lin Lee, Feng Yuan
  • Patent number: 11600616
    Abstract: In a method of manufacturing a semiconductor device, a fin structure protruding from a first isolation insulating layer is formed. A second isolation insulating layer made of different material than the first isolation insulating layer is formed so that a first upper portion of the fin structure is exposed. A dummy gate structure is formed over the exposed first upper portion of the first fin structure. The second isolation insulating layer is etched by using the dummy gate structure as an etching mask. The dummy gate structure is removed so that a gate space is formed. The second isolation insulating layer is etched in the gate space so that a second upper portion of the fin structure is exposed from the first isolation insulating layer. A gate dielectric layer and a gate electrode layer are formed over the exposed second portion of the fin structure.
    Type: Grant
    Filed: September 27, 2019
    Date of Patent: March 7, 2023
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Gerben Doornbos, Mark Van Dal
  • Publication number: 20220367824
    Abstract: In a method of forming a gate-all-around field effect transistor (GAA FET), a bottom support layer is formed over a substrate and a first group of carbon nanotubes (CNTs) are disposed over the bottom support layer. A first support layer is formed over the first group of CNTs and the bottom support layer such that the first group of CNTs are embedded in the first support layer. A second group of carbon nanotubes (CNTs) are disposed over the first support layer. A second support layer is formed over the second group of CNTs and the first support layer such that the second group of CNTs are embedded in the second support layer. A fin structure is formed by patterning at least the first support layer and the second support layer.
    Type: Application
    Filed: July 27, 2022
    Publication date: November 17, 2022
    Inventors: Timothy VASEN, Mark VAN DAL, Gerben DOORNBOS, Matthias PASSLACK
  • Publication number: 20220352320
    Abstract: Various strained channel transistors are disclosed herein. An exemplary semiconductor device includes a substrate and a fin structure disposed over the substrate. The fin structure includes a first epitaxial layer disposed on the substrate, a second epitaxial layer disposed on the first epitaxial layer, and a third epitaxial layer disposed on the second epitaxial layer. The second epitaxial layer includes a relaxed transversal stress component and a longitudinal compressive stress component, and the third epitaxial layer has uni-axial strain. A gate structure is disposed on a channel region of the fin structure, such that the gate structure interposes a source region and a drain region of the fin structure.
    Type: Application
    Filed: July 7, 2022
    Publication date: November 3, 2022
    Inventors: MARK VAN DAL, GERBEN DOORNBOS, GEORGIOS VELLIANITIS, TSUNG-LIN LEE, FENG YUAN
  • Patent number: 11437594
    Abstract: In a method of forming a gate-all-around field effect transistor (GAA FET), a bottom support layer is formed over a substrate and a first group of carbon nanotubes (CNTs) are disposed over the bottom support layer. A first support layer is formed over the first group of CNTs and the bottom support layer such that the first group of CNTs are embedded in the first support layer. A second group of carbon nanotubes (CNTs) are disposed over the first support layer. A second support layer is formed over the second group of CNTs and the first support layer such that the second group of CNTs are embedded in the second support layer. A fin structure is formed by patterning at least the first support layer and the second support layer.
    Type: Grant
    Filed: July 27, 2020
    Date of Patent: September 6, 2022
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Timothy Vasen, Mark Van Dal, Gerben Doornbos, Matthias Passlack
  • Publication number: 20220246753
    Abstract: In a method of manufacturing a semiconductor device, an opening is formed in an interlayer dielectric layer such that a source/drain region is exposed in the opening. A first semiconductor layer is formed to fully cover the exposed source/drain region within the opening. A heating process is performed to make an upper surface of the first semiconductor layer substantially flat. A conductive contact layer is formed over the first semiconductor layer.
    Type: Application
    Filed: April 18, 2022
    Publication date: August 4, 2022
    Inventors: Blandine DURIEZ, Mark van DAL, Martin Christopher HOLLAND, Gerben DOORNBOS
  • Patent number: 11309417
    Abstract: In a method of manufacturing a semiconductor device, an opening is formed in an interlayer dielectric layer such that a source/drain region is exposed in the opening. A first semiconductor layer is formed to fully cover the exposed source/drain region within the opening. A heating process is performed to make an upper surface of the first semiconductor layer substantially flat. A conductive contact layer is formed over the first semiconductor layer.
    Type: Grant
    Filed: March 29, 2019
    Date of Patent: April 19, 2022
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Blandine Duriez, Mark van Dal, Martin Christopher Holland, Gerben Doornbos
  • Patent number: 11195913
    Abstract: Semiconductor structures and methods for forming the same are provided. The method includes forming a fin structure over a substrate, and the fin structure includes alternately stacked semiconductor material layers and sacrificial layers. The method further includes forming a dummy gate structure, recessing the fin structure to form an opening, forming first source/drain spacers on sidewalls of the sacrificial layers by performing a first atomic layer deposition (ALD) process, and forming source/drain structure in the opening. The method further includes removing the dummy gate structure and the sacrificial layers to expose the semiconductor material layers and forming a gate structure wrapping around the semiconductor material layers.
    Type: Grant
    Filed: March 23, 2020
    Date of Patent: December 7, 2021
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventors: Mark Van Dal, Gerben Doornbos, Chung-Te Lin
  • Patent number: 11177391
    Abstract: A method includes forming a semiconductor fin over a substrate. A nanowire foundation layer is formed on the semiconductor fin. A nanowire template is formed over the nanowire foundation layer, in which the nanowire template has a through hole exposing a portion of the nanowire foundation layer. A first nanowire is grown from the exposed portion of the nanowire foundation layer, such that the nanowire protrudes out of the through hole. A gate structure is formed over the nanowire foundation layer and wrapping around the first nanowire.
    Type: Grant
    Filed: November 8, 2019
    Date of Patent: November 16, 2021
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING CO., LTD.
    Inventor: Mark Van Dal
  • Publication number: 20210296441
    Abstract: Methods for forming semiconductor structures are provided. The method includes forming a fin structure over a substrate and forming a dummy gate structure across the fin structure. The method further includes forming a spacer layer on a sidewall of the fin structure at a source/drain region. The method further includes removing at least a portion of the spacer layer to enlarge the source/drain region and forming a source/drain structure in the source/drain region.
    Type: Application
    Filed: June 4, 2021
    Publication date: September 23, 2021
    Applicant: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY, LTD.
    Inventors: Mark VAN DAL, Gerben DOORNBOS, Chung-Te LIN
  • Publication number: 20210287946
    Abstract: A fin including a bottom portion, a first sacrificial layer disposed over the bottom portion, a first semiconductor layer disposed over the first sacrificial layer, a second sacrificial layer disposed over the first semiconductor layer and a second semiconductor layer disposed over the second sacrificial layer, is formed. The second semiconductor layer protrudes from a first insulating layer. A dummy gate is formed over the second semiconductor layer. A sidewall spacer layer is formed on side faces of the dummy gate. A first dielectric layer is formed over the dummy gate and the sidewall spacer layer. The dummy gate is removed, thereby forming a gate space. The first insulating layer is etched in the gate space, thereby exposing the first semiconductor layer and the first and second sacrificial layers. The first and second sacrificial layers are removed. A gate dielectric layer and a gate electrode layer are formed.
    Type: Application
    Filed: May 28, 2021
    Publication date: September 16, 2021
    Inventors: Mark VAN DAL, Gerben DOORNBOS
  • Patent number: 11114546
    Abstract: A semiconductor device and methods of formation are provided. The semiconductor device includes a gate over a channel portion of a fin. The fin includes a first active area of the fin having a first active area top surface coplanar with a first shallow trench isolation (STI) top surface of a first STI portion of STI, and a second active area of the fin having a second active area top surface coplanar with a second STI top surface of a second STI portion of the STI. The method herein negates a need to recess at least one of the fin, the first STI portion or the second STI portion during device formation. Negating a need to recess at least one of the fin, the first STI portion or the second STI portion enhances the semiconductor device formation and is more efficient than a semiconductor device formation that requires the recessing of at least one of a fin, a first STI portion or a second STI portion.
    Type: Grant
    Filed: December 9, 2019
    Date of Patent: September 7, 2021
    Assignee: TAIWAN SEMICONDUCTOR MANUFACTURING COMPANY LIMITED
    Inventors: Blandine Duriez, Mark van Dal