Anchoring inserts, electrode assemblies, and plasma processing chambers

1. A silicon-based showerhead electrode comprising a backside, a frontside, a plurality of showerhead passages, a plurality of backside recesses, and a plurality of backside inserts, wherein:

the plurality of showerhead passages extend from the backside of the silicon-based showerhead electrode to the frontside of the silicon-based showerhead electrode;

the plurality of backside recesses are formed in the backside of the silicon-based showerhead electrode, the backside recesses leaving a thickness of silicon-based electrode material between the recess and the frontside of the silicon-based showerhead electrode;

the backside inserts are positioned in the backside recesses along the backside of the silicon-based showerhead electrode;

the backside inserts comprise a threaded outside diameter, a threaded inside diameter, and a tool engaging portion formed in the threaded inside diameter;

the tool engaging portion is formed such that the backside insert further comprises one or more lateral shielding portions between the tool engaging portion and the threaded outside diameter to prevent a tool engaged with the tool engaging portion of the backside insert from extending beyond the threaded outside diameter of the insert wherein the silicon-based electrode material comprises single crystal silicon.

2. A silicon-based showerhead electrode as claimed in claim 1 wherein:

the tool engaging portion of the backside insert comprises a plurality of torque-receiving slots arranged about an axis of rotation of the backside insert; and

the torque-receiving slots are arranged to avoid on-axis rotation of the backside insert via opposing pairs of torque receiving slots.

3. A silicon-based showerhead electrode as claimed in claim 1 wherein:

the tool engaging portion of the backside insert comprises three torque-receiving slots arranged about an axis of rotation of the backside insert as three opposing pairs of torque receiving slots; and

the torque-receiving slots are arranged to avoid on-axis rotation of the backside insert via each of the three opposing pairs of torque receiving slots.

4. A silicon-based showerhead electrode as claimed in claim 1 wherein:

the tool engaging portion of the backside insert comprises n torque-receiving slots arranged about an axis of rotation of the backside insert as n(n−1)/2 opposing pairs of torque receiving slots; and

the torque-receiving slots are arranged to avoid on-axis rotation of the backside insert via each of the n(n−1)/2 opposing pairs of torque receiving slots.

5. A silicon-based showerhead electrode as claimed in claim 4 wherein the torque-receiving slots are spaced equidistantly about the axis of rotation and n=3 or n=5.

6. A silicon-based showerhead electrode as claimed in claim 4 wherein the torque-receiving slots are spaced equidistantly or non-equidistantly about the axis of rotation and 3≦n≦5.

7. A silicon-based showerhead electrode as claimed in claim 1 wherein the torque receiving slots define a progressively non-constrictive cross sectional profile along a direction parallel to the axis of rotation of the backside insert.

8. A silicon-based showerhead electrode as claimed in claim 1 wherein the torque receiving slots are defined by apex-free side walls that extend parallel to the axis of rotation.

9. A silicon-based showerhead electrode as claimed in claim 1 wherein the hardness of the backside inserts does not exceed the hardness of the silicon-based electrode material.

10. A silicon-based showerhead electrode as claimed in claim 1 wherein the backside inserts comprise polyetheretherketone (PEEK) formulated and manufactured such that the hardness of the backside inserts does not exceed the hardness of the silicon-based electrode material.

11. A silicon-based showerhead electrode as claimed in claim 1 wherein the backside inserts are positioned in the backside recesses such that they are inset relative to the backside of the silicon-based showerhead electrode.

12. A silicon-based showerhead electrode as claimed in claim 1 wherein at least one of the backside inserts is configured as an anchor in one of the backside recesses formed in the backside of the silicon-based showerhead electrode.

13. A silicon-based showerhead electrode as claimed in claim 12 wherein the backside insert is anchored in the backside recess by a threaded portion formed in the silicon-based electrode material.

14. A silicon-based showerhead electrode as claimed in claim 1 wherein the silicon-based electrode material comprises polysilicon, silicon nitride, silicon carbide, boron carbide, aluminum nitride, aluminum oxide, or combinations thereof.

15. A silicon-based showerhead electrode as claimed in claim 1 wherein the silicon-based showerhead electrode comprises a single-piece, circular showerhead construction or a multi-component, circular showerhead construction comprising a circular central electrode and one or more peripheral electrodes arranged about the circumference of the central electrode.

16. A silicon-based showerhead electrode comprising a backside, a frontside, a plurality of showerhead passages, a plurality of backside recesses, and a plurality of backside inserts, wherein:

the plurality of showerhead passages extend from the backside of the silicon-based showerhead electrode to the frontside of the silicon-based showerhead electrode;

the plurality of backside recesses are formed in the backside of the silicon-based showerhead electrode, the backside recesses leaving a thickness of silicon-based electrode material between the recess and the frontside of the silicon-based showerhead electrode;

the backside inserts are positioned in the backside recesses along the backside of the silicon-based showerhead electrode;

the backside inserts comprise a threaded outside diameter, a threaded inside diameter, and a tool engaging portion formed in the threaded inside diameter;

the tool engaging portion of the backside insert comprises a plurality of torque-receiving slots arranged about an axis of rotation of the backside insert; and

the torque-receiving slots are arranged to avoid on-axis rotation of the backside insert via opposing pairs of torque receiving slots wherein the silicon-based electrode material comprises single crystal silicon.

17. A silicon-based showerhead electrode comprising a backside, a frontside, a plurality of showerhead passages, a plurality of backside recesses, and a plurality of backside inserts, wherein:

the plurality of showerhead passages extend from the backside of the silicon-based showerhead electrode to the frontside of the silicon-based showerhead electrode;

the plurality of backside recesses are formed in the backside of the silicon-based showerhead electrode, the backside recesses leaving a thickness of silicon-based electrode material between the recess and the frontside of the silicon-based showerhead electrode;

the backside inserts are positioned in the backside recesses along the backside of the silicon-based showerhead electrode;

the backside inserts comprise a threaded outside diameter, a threaded inside diameter, and a tool engaging portion formed in the threaded inside diameter;

the tool engaging portion of the backside insert comprises n torque-receiving slots arranged about an axis of rotation of the backside insert as n(n−1)/2 opposing pairs of torque receiving slots;

the torque-receiving slots are arranged to avoid on-axis rotation of the backside insert via each of the n(n−1)/2 opposing pairs of torque receiving slots, define a progressively non-constrictive cross sectional profile along a direction parallel to the axis of rotation of the backside insert, and comprise apex-free side walls that extend parallel to the axis of rotation wherein the silicon-based electrode material comprises single crystal silicon.