Edge-clamped and mechanically fastened inner electrode of showerhead electrode assembly

1. A thermally and electrically conductive gasket of a gasket set configured to be mounted between a faceplate and backing plate of a showerhead electrode assembly, the gasket set comprising:

an inner gasket configured to be mounted on an inner electrode of the showerhead electrode assembly, the inner gasket comprising a plurality of concentric flat rings connected by a plurality of spokes;

a first annular gasket configured to surround and be concentric with the inner gasket and be mounted on the inner electrode, the first annular gasket comprising a flat annular ring having a plurality of cutouts;

a second annular gasket configured to surround and be concentric with the first annular gasket and be mounted on an outer electrode of the showerhead electrode assembly, the second annular gasket comprising a flat annular ring having a plurality of cutouts; and

a third annular gasket configured to surround and be concentric with the second annular gasket and be mounted on an annular shroud of the showerhead electrode assembly, the third annular gasket comprising a flat annular ring having a plurality of cutouts;

wherein the gasket accommodates gas injection holes, alignment pin holes, an alignment ring groove, and/or threaded holes.

2. The gasket of claim 1 , wherein the concentric flat rings in the inner gasket are continuous or segmented.

3. The gasket of claim 1 , wherein the inner gasket comprises at least six concentric flat rings having a thickness of about 0.006 inch and a width of at least 0.1 inch, wherein the at least six concentric flat rings include a first ring, a second ring, a third ring, a fourth ring, a fifth ring, and a sixth ring, wherein the first ring has an inner diameter of at least 0.44 inch and an outer diameter of at most 1.35 inches; the second ring has an inner diameter of at least 1.35 inches and an outer diameter of at most 2.68 inches; the third ring has an inner diameter of at least 2.68 inches and an outer diameter of at most 4.23 inches; the fourth ring has an inner diameter of at least 4.23 inches and an outer diameter of at most 5.79 inches; the fifth ring has an inner diameter of at least 5.79 inches and an outer diameter of at most 7.34 inches; and the sixth ring has an inner diameter of at least 7.34 inches and an outer diameter of at most 8.89 inches.

4. The gasket of claim 1 , wherein:

(a) the first annular gasket has three cutouts on an outer perimeter configured to accommodate fastening mechanisms and three cutouts on an inner perimeter configured to accommodate alignment pins;

(b) the second annular gasket has one cutout on an inner perimeter and a first set of eight holes configured to accommodate fastening mechanisms and a second set of three holes configured to allow tool access, wherein a diameter of the holes in the first set is larger than a diameter of the holes in the second set; and

(c) the third annular gasket has eight cutouts on an outer perimeter configured to accommodate fastening mechanisms and no cutouts on an inner perimeter.

5. The gasket of claim 1 , wherein:

(a) the first annular gasket has a thickness of about 0.006 inch, a width of at least 0.1 inch, an inner diameter of about 11.95 inches and an outer diameter of about 12.47 inches;

(b) the second annular gasket has a thickness of about 0.006 inch, a width of at least 0.1 inch, an inner diameter of about 13.90 inches and an outer diameter of about 16.75 inches; and

(c) the third annular gasket has a thickness of about 0.006 inch, a width of at least 0.1 inch, an inner diameter of 17.29 inches and an outer diameter of about 18.69 inches.

6. The gasket set of claim 1 , wherein the gasket is made of a material which is compliant to accommodate shear at contact points.

7. The gasket of claim 1 , wherein the gasket is made of (a) a silicone-aluminum foil sandwich gasket structure, (b) an elastomer-stainless steel sandwich gasket structure, or (c) an aluminum sheet coated with a thermally and electrically conductive rubber compatible in a vacuum environment.

8. The gasket of claim 1 , wherein the gasket has a thickness of about 0.006 inch.

9. The gasket of claim 1 , wherein a shape of the gasket is knife-cut, stamped, punched or laser-cut from a continuous sheet.

10. The gasket of claim 1 , wherein the inner gasket and the first annular gasket are sized to fit between the inner electrode and the backing plate, the second annular gasket is sized to fit between the outer electrode and a backing plate, and the third annular gasket is sized to fit between the annular shroud and the backing plate.

11. A gasket of a showerhead electrode assembly useful in a plasma processing apparatus, the gasket comprising at least six concentric flat rings having a thickness of about 0.006 inch and a width of at least 0.1 inch, wherein the at least six concentric flat rings include a first ring, a second ring, a third ring, a fourth ring, a fifth ring, and a sixth ring, wherein the first ring has an inner diameter of at least 0.44 inch and an outer diameter of at most 1.35 inches; the second ring has an inner diameter of at least 1.35 inches and an outer diameter of at most 2.68 inches; the third ring has an inner diameter of at least 2.68 inches and an outer diameter of at most 4.23 inches; the fourth ring has an inner diameter of at least 4.23 inches and an outer diameter of at most 5.79 inches; the fifth ring has an inner diameter of at least 5.79 inches and an outer diameter of at most 7.34 inches; and the sixth ring has an inner diameter of at least 7.34 inches and an outer diameter of at most 8.89 inches.

12. A gasket set of a showerhead electrode assembly useful in a plasma processing apparatus, the gasket set comprising:

(a) a first annular gasket having three cutouts on an outer perimeter configured to accommodate fastening mechanisms and three cutouts on an inner perimeter configured to accommodate alignment pins of the showerhead assembly;

(b) a second annular gasket having one cutout on an inner perimeter and a first set of eight holes configured to accommodate fastening mechanisms and a second set of three holes configured to allow tool access, wherein a diameter of the holes in the first set is larger than a diameter of the holes in the second set; and

(c) a third annular gasket having eight cutouts on an outer perimeter configured to accommodate fastening mechanisms and no cutouts on an inner perimeter.

13. The gasket set of claim 12 , wherein the first annular gasket has a thickness of about 0.006 inch, a width of at least 0.1 inch, an inner diameter of about 11.95 inches and an outer diameter of about 12.47 inches.

14. The gasket set of claim 12 , wherein the second annular gasket has a thickness of about 0.006 inch, a width of at least 0.1 inch, an inner diameter of about 13.90 inches and an outer diameter of about 16.75 inches.

15. The gasket set of claim 12 , wherein the third annular gasket has a thickness of about 0.006 inch, a width of at least 0.1 inch, an inner diameter of 17.29 inches and an outer diameter of about 18.69 inches.