Patents by Inventor Robert D. Clark

Robert D. Clark 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: 12588434
    Abstract: Dielectric films for semiconductor devices and methods of forming. A processing method includes forming a first film of a first dielectric material on a substrate by performing a first plurality of cycles of atomic layer deposition and, thereafter, heat-treating the first film, where a thickness of the first film is below a threshold thickness needed for spontaneous polarization in the first dielectric material. The processing method further includes forming a second film of a second dielectric material on the substrate by performing a second plurality of cycles of atomic layer deposition and, thereafter, heat-treating the second film, where a thickness of the second film is greater than the thickness of the first film, and the second film is ferroelectric or antiferroelectric. The first and second dielectric materials can include at least one metal oxide, for example zirconium oxide, hafnium oxide, or a laminate or mixture thereof.
    Type: Grant
    Filed: July 30, 2021
    Date of Patent: March 24, 2026
    Assignee: Tokyo Electron Limited
    Inventors: Dina H. Triyoso, Robert D. Clark, Steven P. Consiglio, Kandabara N. Tapily
  • Patent number: 12588435
    Abstract: A method for processing a substrate includes treating the substrate with a small molecular inhibitor (SMI), the substrate including a recess formed in a dielectric layer and a first metal layer in the recess, the SMI covering a surface of the first metal layer. The method further includes, after treating the substrate with the SMI, treating the substrate with a large molecular inhibitor (LMI), the LMI covering sidewalls of the dielectric layer in the recess. The method further includes heating the substrate to remove the SMI from the first metal layer and to expose the first metal layer in the recess, where the LMI remains on the sidewalls after removing the SMI from the first metal layer. The method further includes depositing a second metal over the first metal layer in the recess, where the LMI covering the sidewalls prevents deposition of the second metal on the dielectric layer.
    Type: Grant
    Filed: January 18, 2023
    Date of Patent: March 24, 2026
    Assignee: Tokyo Electron Limited
    Inventors: Kai-Hung Yu, Robert D. Clark, Ryota Yonezawa, Hiroaki Niimi, Hidenao Suzuki, Kandabara Tapily, Takahiro Miyahara, Cory Wajda
  • Patent number: 12550696
    Abstract: A method of processing a substrate that includes: selectively depositing a self-assembled monolayer (SAM) on a metal line of the substrate, the SAM being in contact with the metal line, a surface of the substrate further including a first dielectric material that surrounds the metal line; selectively depositing a second dielectric material over the first dielectric material; forming a dielectric layer by depositing a third dielectric material over the second dielectric material and the SAM; and patterning the dielectric layer.
    Type: Grant
    Filed: August 24, 2022
    Date of Patent: February 10, 2026
    Assignee: Tokyo Electron Limited
    Inventors: Dina H. Triyoso, Robert D. Clark, Hirokazu Aizawa
  • Patent number: 12532719
    Abstract: A method of forming a semiconductor device includes providing a substrate having a patterned film including manganese; depositing a graphene layer over exposed surfaces of the patterned film; depositing a dielectric layer containing silicon and oxygen over the graphene layer; and heat-treating the substrate to form a manganese-containing diffusion barrier region between the graphene layer and the dielectric layer.
    Type: Grant
    Filed: July 13, 2022
    Date of Patent: January 20, 2026
    Assignee: TOKYO ELECTRON LIMITED
    Inventor: Robert D. Clark
  • Patent number: 12500191
    Abstract: A structure of a semiconductor package is disclosed. The structure includes a first substrate including a first interconnect structure. The structure includes a second substrate including a second interconnect structure, the second substrate bonded to the first substrate. The structure includes a connection pad interposed between the first interconnect structure and the second interconnect structure. The connection pad includes a material configured to switch between a high resistance state and a low resistance state. The material of the connection pad includes a phase change material.
    Type: Grant
    Filed: June 24, 2022
    Date of Patent: December 16, 2025
    Assignee: Tokyo Electron Limited
    Inventor: Robert D. Clark
  • Patent number: 12469696
    Abstract: A method of processing a substrate that includes: loading the substrate having a raised feature with at least two sidewalls exposed in a processing chamber; depositing a first layer over the substrate to cover a first portion of the two sidewalls; depositing a second layer over the first layer to cover a second portion of the two sidewalls; depositing a third layer over the second layer and the raised feature to cover a third portion of the sidewalls and a top surface of the raised feature; performing an anisotropic dry etching that removes portions of the second layer and the third layer, a remainder of the second layer forming a second sidewall spacer and a remainder of the third layer forming a third sidewall spacer; and performing an isotropic etching that selectively removes the second sidewall spacer to expose portions of the sidewalls of the raised feature.
    Type: Grant
    Filed: August 23, 2022
    Date of Patent: November 11, 2025
    Assignee: Tokyo Electron Limited
    Inventor: Robert D. Clark
  • Publication number: 20250343187
    Abstract: A process for forming a semiconductor package is disclosed. The process includes providing a first substrate including a first dielectric layer. The process includes overlaying a first surface of the first dielectric layer with a first bonding layer that includes aluminum. The process includes providing a second substrate including a second dielectric layer. The process includes overlaying a second surface of the second dielectric layer with a second bonding layer that includes alkoxy-siloxide. The process includes forming a third bonding layer by combining the first bonding layer and the second bonding layer so as to bond the first substrate to the second substrate.
    Type: Application
    Filed: July 11, 2025
    Publication date: November 6, 2025
    Applicant: Tokyo Electron Limited
    Inventor: Robert D. CLARK
  • Patent number: 12421604
    Abstract: A method of processing a substrate that includes: loading the substrate in a processing chamber, the substrate including a raised feature of a semiconductor; forming a conformal dopant layer on the raised feature by atomic layer deposition (ALD); forming a metal layer over the raised feature; thermally treating the dopant layer to form an ultra-shallow dopant region in the raised feature by diffusion of a dopant from the dopant layer into the raised feature; and thermally treating the metal layer to form an ohmic contact region in the raised feature by diffusion of a metal from the metal layer into the raised feature.
    Type: Grant
    Filed: August 9, 2022
    Date of Patent: September 23, 2025
    Assignee: Tokyo Electron Limited
    Inventor: Robert D. Clark
  • Patent number: 12406887
    Abstract: A method of processing a substrate that includes: loading the substrate in a processing system, the substrate including a metal having a metal surface and a first dielectric material having a dielectric material surface, the metal surface and the dielectric material surface being at the same level; etching the metal to form a recessed metal surface below the dielectric material surface; selectively forming a self-assembled monolayer (SAM) on the recessed metal surface using a spin-on process; and depositing a dielectric film including a second dielectric material on the dielectric material surface.
    Type: Grant
    Filed: June 30, 2022
    Date of Patent: September 2, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Dina H. Triyoso, Lior Huli, Corey Lemley, Robert D. Clark, Gerrit Leusink
  • Patent number: 12362304
    Abstract: A process for forming a semiconductor package is disclosed. The process includes providing a first substrate including a first dielectric layer. The process includes overlaying a first surface of the first dielectric layer with a first bonding layer that includes aluminum. The process includes providing a second substrate including a second dielectric layer. The process includes overlaying a second surface of the second dielectric layer with a second bonding layer that includes alkoxy-siloxide. The process includes forming a third bonding layer by combining the first bonding layer and the second bonding layer so as to bond the first substrate to the second substrate.
    Type: Grant
    Filed: July 28, 2022
    Date of Patent: July 15, 2025
    Assignee: Tokyo Electron Limited
    Inventor: Robert D. Clark
  • Publication number: 20250185253
    Abstract: A method of forming a ferroelectric device includes forming a first electrode material layer over a substrate; forming a ferroelectric material layer over the first electrode material layer; forming a first non-ferroelectric material layer over the ferroelectric material layer; and forming a second electrode material layer over the first non-ferroelectric material layer, the second electrode material layer including tungsten, the ferroelectric device being formed by a stack including the first electrode material layer, the ferroelectric material layer, the first non-ferroelectric material layer, and the second electrode material layer.
    Type: Application
    Filed: September 30, 2024
    Publication date: June 5, 2025
    Inventors: Kandabara Tapily, Dina H. Triyoso, Robert D. Clark
  • Publication number: 20250154643
    Abstract: Method for area selective deposition (ASD) on a substrate containing a growth surface that is exposed and a non-growth surface that is exposed. The method includes cyclical exposures of a deposition gas containing a metal carbonyl precursor, the metal carbonyl precursor decomposing on the growth surface such that a metal film is deposited on the growth surface and carbon monoxide (CO) gas is released, and an inhibitor gas after stopping the flow of the deposition gas to the substrate. The cycling between flowing the deposition gas to the substrate and flowing the inhibitor gas to the substrate is repeated to selectively form the metal film on the growth surface relative to the non-growth surface, where the inhibitor gas increases the selectivity of the metal film formed on the growth surface when compared to the selectivity of the metal film formed on the growth surface without the inhibitor gas.
    Type: Application
    Filed: November 5, 2024
    Publication date: May 15, 2025
    Inventors: Kai-Hung Yu, Ryota Yonezawa, Yuji Otsuki, Hidenao Suzuki, Robert D. Clark, Gyanaranjan Pattanaik
  • Publication number: 20250140551
    Abstract: A method of forming a memory device on a substrate includes depositing a first electrode layer within a recessed feature of the substrate using a first atomic layer deposition process, and depositing an amorphous transition metal oxide layer over the first electrode layer using a second atomic layer deposition process at a first substrate temperature. And the method further includes, while maintaining an amorphous state of the amorphous transition metal oxide layer, depositing a second electrode layer over the amorphous transition metal oxide layer using a third atomic layer deposition process at a second substrate temperature, the second substrate temperature being lower than a recrystallization temperature of an amorphous transition metal oxide material of the amorphous transition metal oxide layer, and the first electrode layer, the amorphous transition metal oxide layer, and the second electrode layer forming a memory layer stack.
    Type: Application
    Filed: August 27, 2024
    Publication date: May 1, 2025
    Inventors: Dina H. Triyoso, Ryota Yonezawa, Robert D. Clark
  • Publication number: 20250120154
    Abstract: A method of fabricating a semiconductor device includes placing a semiconductor wafer into a first deposition chamber of a manufacturing platform, the semiconductor wafer comprising a first conductive layer, depositing a dielectric layer on the first conductive layer in the first deposition chamber, placing the semiconductor wafer in a second deposition chamber of the manufacturing platform, and depositing a second conductive layer on the dielectric layer in the second deposition chamber. The method further includes placing the semiconductor wafer into a processing chamber of an electric-field annealer of the manufacturing platform, and in the processing chamber, applying an electrical bias voltage across the dielectric layer by coupling the first conductive layer to a first potential and coupling the second conductive layer to a second potential, and annealing the semiconductor wafer while applying the electrical bias voltage.
    Type: Application
    Filed: December 20, 2024
    Publication date: April 10, 2025
    Inventors: Dina H. Triyoso, Robert D. Clark, David Hurley, Ian Colgan
  • Patent number: 12272601
    Abstract: A backside reveal method includes providing a semiconductor material substrate, depositing an epitaxial high-k etch stop layer on the semiconductor material substrate, forming an integrated circuit device layer on the epitaxial high-k etch stop layer, and attaching a carrier substrate to a front side of the integrated circuit device layer. The method further includes removing a portion of a thickness of the semiconductor material substrate to leave a remaining portion of the thickness of the semiconductor material substrate, removing, by a first selective etching, the remaining portion of the semiconductor material substrate, and removing, by a second selective etching, the epitaxial high-k etch stop layer to expose a backside of the integrated circuit device layer. The epitaxial high-k etch stop layer has good lattice match and high etch selectivity relative to the semiconductor material substrate.
    Type: Grant
    Filed: September 22, 2021
    Date of Patent: April 8, 2025
    Assignee: Tokyo Electron Limited
    Inventor: Robert D. Clark
  • Patent number: 12261209
    Abstract: Methods for the manufacture of semiconductor devices with integrated two-dimensional (2D) materials are disclosed. Aspects can include forming a base structure comprising a seed material with a chemical element; forming source/drain contacts coupled to first and second portions of the base structure, respectively, wherein the source/drain contacts each have at least the chemical element; exposing a third portion of the base structure; selectively growing a 2D material at least coupled to the third portion of the base structure; and forming an active gate coupled to the 2D material.
    Type: Grant
    Filed: February 7, 2022
    Date of Patent: March 25, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Robert D. Clark, H. Jim Fulford, Mark I. Gardner
  • Patent number: 12237216
    Abstract: A method for filling recessed features with a low-resistivity metal. The method includes providing a patterned substrate containing a recessed feature formed in a first layer and a second layer that is exposed in the recessed feature, forming a nucleation enhancement layer on a sidewall of the first layer in the recessed feature and depositing a metal layer in the recessed feature by vapor phase deposition, where the metal layer is deposited on the second layer and on the nucleation enhancement layer. An initial metal layer may be selectively formed on the second layer in the recessed feature before forming the nucleation enhancement layer.
    Type: Grant
    Filed: March 7, 2022
    Date of Patent: February 25, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Kai-Hung Yu, Shihsheng Chang, Ying Trickett, Eric Chih-Fang Liu, Yun Han, Henan Zhang, Cory Wajda, Robert D. Clark, Gerrit J. Leusink, Gyanaranjan Pattanaik, Hiroaki Niimi
  • Patent number: 12211907
    Abstract: A method of fabricating a semiconductor device includes placing a semiconductor wafer into a first deposition chamber of a manufacturing platform, the semiconductor wafer comprising a first conductive layer, depositing a dielectric layer on the first conductive layer in the first deposition chamber, placing the semiconductor wafer in a second deposition chamber of the manufacturing platform, and depositing a second conductive layer on the dielectric layer in the second deposition chamber. The method further includes placing the semiconductor wafer into a processing chamber of an electric-field annealer of the manufacturing platform, and in the processing chamber, applying an electrical bias voltage across the dielectric layer by coupling the first conductive layer to a first potential and coupling the second conductive layer to a second potential, and annealing the semiconductor wafer while applying the electrical bias voltage.
    Type: Grant
    Filed: August 9, 2021
    Date of Patent: January 28, 2025
    Assignee: Tokyo Electron Limited
    Inventors: Dina H. Triyoso, Robert D. Clark, David Hurley, Ian Colgan
  • Publication number: 20240363333
    Abstract: In certain embodiments, a method of microfabrication includes depositing a 2D polymer material over a substrate surface having a first material and a second material such that the 2D polymer adheres to the first material without adhering to the second material. The method further includes depositing a target material over the second material. The 2D material adhered to the first material inhibits deposition of the target material over the first material. The method further includes removing the 2D polymer material.
    Type: Application
    Filed: April 28, 2023
    Publication date: October 31, 2024
    Inventors: Kandabara Tapily, Robert D. Clark, Gerrit Leusink, Charlotte Cutler, Jeffrey Smith
  • Publication number: 20240213093
    Abstract: A method for processing a substrate that includes: treating the substrate with a halogen-containing catalyst, the substrate including a semiconductor layer, a dielectric layer disposed over the semiconductor layer, a recess formed in the dielectric layer, and a layer of a first metal disposed between the dielectric layer and the semiconductor layer, the layer of the first metal being at a bottom of the recess, the halogen-containing catalyst modifying a surface of the layer of the first metal; after treating the substrate with the halogen-containing catalyst, treating the substrate with a molecular inhibitor (MI), the MI covering sidewalls of the dielectric layer in the recess; depositing a second metal over the modified surface of the layer of the first metal in the recess, where the MI covering the sidewalls prevents deposition of the second metal on the dielectric layer.
    Type: Application
    Filed: December 22, 2022
    Publication date: June 27, 2024
    Inventors: Kai-Hung Yu, Hiroak Niimi, Robert D. Clark, Tadahiro Ishizaka