Substrate support with improved processing uniformity - Patents.com

Abstract

To provide substrate support for optimal edge performance, processing uniformity and yield. A substrate support (10) for supporting a substrate (26) in a substrate processing system includes a base plate (14) and a ceramic layer (18) disposed above the base plate (14). The ceramic layer (18) is surrounded at its outer periphery by an edge ring (34). The outer radius of the ceramic layer (18) is greater than the inner radius of the edge ring (34) such that the outer edge of the ceramic layer (18) extends below the edge ring (34).

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Patent Application No. 15 / 399,244, filed January 5, 2017, the entire disclosure of which is incorporated herein by reference.

[0002] The present disclosure relates to a substrate support in a substrate processing system. [Background technology]

[0003] The description of the background art provided herein is intended to provide a general background to the present disclosure, and the work of the inventors named herein, to the extent described in this Background Art, together with aspects of the description that would not ordinarily be considered prior art at the time of filing, are not admitted, expressly or impliedly, as prior art to the present disclosure.

[0004] Substrate processing systems may be utilized to process substrates, such as semiconductor wafers. Examples of processes that may be performed on a substrate include, but are not limited to, chemical vapor deposition (CVD), atomic layer deposition (ALD), conductor etching, dielectric etching, and / or other etching, deposition, or cleaning processes. The substrate may be disposed on a substrate support (pedestal, electrostatic chuck (ESC), etc.) in a processing chamber of the substrate processing system. During etching, a gas mixture including one or more precursors may be introduced into the processing chamber, and a plasma may be utilized to initiate a chemical reaction.

[0005] The substrate support may include a ceramic layer configured to support a substrate, for example, the substrate may be clamped to the ceramic layer during processing, and an edge ring disposed around an outer periphery of the ceramic layer and the substrate for optimal edge performance and yield. Summary of the Invention

[0006] A substrate support for supporting a substrate in a substrate processing system includes a base plate and a ceramic layer disposed above the base plate. The ceramic layer has an outer periphery surrounded by an edge ring. The outer radius of the ceramic layer is defined by an edge ring. Top The ceramic layer has an outer edge that is larger than the inner radius of the edge ring such that the outer edge extends under the edge ring. Top surface of the ceramic layer and an insert disposed within the annular groove.

[0007] The method for processing a substrate includes the steps of providing a base plate, disposing a ceramic layer above the base plate, and disposing an edge ring disposed around an outer periphery of the ceramic layer. Top The outer edge extends below the edge ring. The ceramic layer is Top surface of the ceramic layer and an insert disposed within the annular groove. The method further comprises performing at least one processing step on the substrate.

[0008] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. [Brief description of the drawings]

[0009] The present disclosure can be more fully understood from the detailed description and accompanying drawings set forth below.

[0010] [Figure 1] FIG. 2 illustrates an example of a substrate support.

[0011] [Diagram 2] FIG. 2 is a functional block diagram of an example processing chamber according to the present disclosure.

[0012] [Diagram 3]1 illustrates an example of a substrate support with a ceramic layer in accordance with the principles of the present disclosure.

[0013] [Figure 4] 1 illustrates a top view of an example substrate support with a ceramic layer in accordance with the principles of the present disclosure.

[0014] [Diagram 5] 1 is a top view of an example ceramic layer in accordance with the principles of the present disclosure;

[0015] [Figure 6] 1 illustrates another example of a substrate support with a ceramic layer in accordance with the principles of the present disclosure.

[0016] [Figure 7] 1A-1D illustrate steps of an exemplary method for processing a substrate in accordance with the principles of the present disclosure.

[0017] In the drawings, the same numbers may be used to identify similar and / or identical elements. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Referring now to FIG. 1 , an example of a substrate support 10 (such as an electrostatic chuck (ESC)) is shown. The substrate support 10 includes an electrically conductive base plate 14 supporting a ceramic layer 18. A thermally resistive layer 22 (e.g., a bond layer) may be disposed between the ceramic layer 18 and the base plate 14. A substrate 26 is disposed on the ceramic layer 18 of the substrate support 10. The substrate support 10 may include an edge assembly 30 surrounding an outer periphery of the substrate 26. In some examples, the edge assembly 30 may include an inner edge ring 34 and an outer insulating ring 38. A gap 42 may be provided between the outer periphery of the substrate 26 and the edge ring 34. The substrate support 10 may include one or more additional ring structures 48, 52, 56, 60 surrounding the base plate 14 and supporting the edge ring 34. The structures 48, 52, 56, and 60 may be provided to achieve characteristics related to process uniformity (such as a desired thermal conductivity, a desired electrical or RF connection, etc.).

[0019] Manufacturing tolerances associated with components of the substrate 26 and / or the substrate support 10 can lead to processing non-uniformities. For example, the inner radius of the edge ring 34 can be selected to be large enough to accommodate variations in the outer radii of substrates processed on the substrate support 10. Additionally, different substrates can have different gaps 42 between the outer radius of the substrate 26 and the inner radius of the edge ring 34. In some examples (such as those shown in the figures), the outer radius of the substrate 26 can overlap the inner radius of the edge ring 34 and can be larger than the outer radius of the ceramic layer 18 for desired processing performance.

[0020] Variations in the width of the gap 42 can lead to non-uniformities associated with processing multiple substrates. For example, the outer edge of the substrate 26 can be processed differently than an inner portion of the substrate 26 due to temperature non-uniformities, electric field non-uniformities, etc., due to the positional relationship (e.g., distance, relative height, etc.) between the outer edge of the substrate 26 and the edge ring 34 and / or ceramic layer 18. As a result, the substrate 26 can have a non-uniform etch depth, a non-uniform amount of deposited material, etc. at its edge. Additionally, the gap 42 can increase the likelihood of arcing and increase erosion of portions of the ceramic layer 26 exposed to the process gases and plasma. Potential effects such as erosion and arcing can limit the power that can be applied to the substrate support and can cause increased downtime for maintenance, etc.

[0021] Substrate processing systems may be configured to compensate for known processing non-uniformities associated with a particular substrate support and / or processing chamber. However, compensating for these non-uniformities may be difficult when the outer radius of the substrate 26, and thus the relationship between the substrate 26 and the edge ring 34, changes. Systems and methods according to principles of the present disclosure implement a substrate support configured to reduce non-uniformities associated with substrate processing. For example, a ceramic layer of the substrate support may have a large diameter relative to the edge ring and the substrate being processed on the substrate support, and may include replaceable inserts (e.g., sacrificial or consumable inserts).

[0022] 2, an example substrate processing system 100 is shown. By way of example only, the substrate processing system 100 may be used to perform etching and / or other suitable substrate processing using RF plasma. The substrate processing system 100 includes a processing chamber 102 that houses other components of the substrate processing system 100 and confines the RF plasma. The substrate processing chamber 102 includes an upper electrode 104 and a substrate support 106 (such as an electrostatic chuck (ESC)). During operation, a substrate 108 is disposed on the substrate support 106. Although the specific substrate processing system 100 and chamber 102 are shown by way of example, the principles of the present disclosure may be applied to other types of substrate processing systems and chambers, such as substrate processing systems that generate plasma in situ, substrate processing systems that implement remote plasma generation and delivery (e.g., using plasma tubes, microwave tubes, etc.).

[0023] By way of example only, the upper electrode 104 may comprise a gas distribution apparatus (such as a showerhead 109) for introducing and dispersing process gases. The showerhead 109 may comprise a stem portion with one end connected to the top surface of the processing chamber. The base portion is generally cylindrical and flares radially outward from an opposite end of the stem portion away from the top surface of the processing chamber. The substrate-facing surface or faceplate of the showerhead base portion comprises a plurality of holes through which process or purge gases flow. Alternatively, the upper electrode 104 may comprise a conductive plate, and the process gases may be introduced in another manner.

[0024] The substrate support 106 includes an electrically conductive base plate 110 that functions as a lower electrode. The base plate 110 supports a ceramic layer 112. In some examples, the ceramic layer 112 may include a heating layer (such as a ceramic multi-zone heating plate). A thermally resistive layer 114 (e.g., a bond layer) may be disposed between the ceramic layer 112 and the base plate 110. The base plate 110 may include one or more coolant channels 116 for directing coolant to the base plate 110. The substrate support 106 may include an edge ring 118 disposed around the outer periphery of the substrate 108.

[0025] An RF generation system 120 generates and outputs an RF voltage to one of the upper electrode 104 and / or the lower electrode (e.g., the base plate 110 of the substrate support 106). The other of the upper electrode 104 and the base plate 110 may be DC grounded, RF grounded, or floating. By way of example only, the RF generation system 120 may include an RF voltage generator 122 that generates an RF voltage that is supplied to the upper electrode 104 or the base plate 110 by a matching / distribution network 124. In other examples, the plasma may be generated inductively or remotely. As shown for illustrative purposes, the RF generation system corresponds to a capacitively coupled plasma (CCP) system, although the principles of the present disclosure may be implemented in other suitable systems, such as, by way of example only, a transformer coupled plasma (TCP) system, a CCP cathode system, a remote microwave plasma generation / delivery system, etc.

[0026] The gas supply system 130 includes one or more gas sources 132-1, 132-2, ..., and 132-N (collectively, gas sources 132), where N is an integer greater than zero. The gas sources provide one or more precursors and mixtures thereof. The gas sources may provide a purge gas. Vaporized precursors may be used. The gas sources 132 are connected to a manifold 140 by valves 134-1, 134-2, ..., and 134-N (collectively, valves 134) and mass flow controllers 136-1, 136-2, ..., and 136-N (collectively, mass flow controllers 136). The output of the manifold 140 is provided to the process chamber 102. By way of example only, the output of the manifold 140 is provided to a showerhead 109.

[0027] A temperature controller 142 may be connected to a plurality of heating elements (such as thermal control elements (TCEs) 144) disposed on the ceramic layer 112. For example, the heating elements 144 may include, but are not limited to, macro heating elements corresponding to respective sections of a multi-zone heating plate and / or an array of micro heating elements disposed across multiple sections of a multi-zone heating plate. The temperature controller 142 is used to control the plurality of heating elements 144 to control the temperature of the substrate support 106 and the substrate 108. Each of the heating elements 144 according to the principles of the present disclosure may comprise a first material having a positive TCR (temperature coefficient of resistance) and a second material having a negative TCR, as described in more detail below.

[0028] The temperature controller 142 may be in communication with a coolant assembly 146 for controlling the flow of coolant through the passages 116. For example, the coolant assembly 146 may include a coolant pump and a reservoir. The temperature controller 142 operates the coolant assembly 146 to selectively flow coolant through the passages 116 to cool the substrate support 106.

[0029] Valves 150 and pumps 152 may be used to evacuate reactants from the processing chamber 102. A system controller 160 may be used to control the components of the substrate processing system 100. A robot 170 may be used to deliver substrates onto and remove substrates from the substrate support 106. For example, the robot 170 may transfer substrates between the substrate support 106 and a load lock 172. Although shown as a separate controller, the temperature controller 142 may be implemented within the system controller 160. In some examples, a protective seal 176 may be provided around the bond layer 114 between the ceramic layer 112 and the base plate 110.

[0030] The ceramic layer 112 and edge ring 118 of the substrate support 106 according to the principles of the present disclosure have a larger outer diameter than the substrate 108, as described in more detail below. Additionally, the outer radius of the ceramic layer 112 may be larger than the inner radius of the edge ring 118 such that the ceramic layer 112 extends under the edge ring 118. The ceramic layer 112 may include a replaceable insert (not shown in FIG. 2), as described below in FIGS. 3, 4, 5, and 6.

[0031] 3 and 4, an example of a substrate support 300 is shown. The substrate support 300 is shown in cross-section in FIG. 3 and in plan view in FIG. 4. The substrate support 300 includes a conductive base plate 304 supporting a ceramic layer 308. A bond layer 312 may be disposed between the ceramic layer 308 and the base plate 304. A substrate 316 is disposed on the ceramic layer 308. The substrate support 300 includes an edge assembly 320 disposed around an outer periphery of the substrate 316. In some examples, the edge assembly 320 may include an inner edge ring 324 and an outer insulating ring 328. For simplicity, the outer insulating ring 328 is not shown in FIG. 4.

[0032] The diameter and outer radius (and therefore the outer edge 332) of the ceramic layer 308, as well as the inner radius of the edge ring 320, are larger than the substrate to be processed on the substrate support 300. The width of the gap 336 between the substrate 316 and the edge ring 324 may be increased. For example, the outer radius of the ceramic layer 308 may be larger than the outer radius of the largest possible substrate to be processed on the substrate support 300 by a predetermined minimum offset. By way of example only, for a 300 mm substrate (i.e., having a radius of 150 mm), the resulting outer radius may be 150.5 mm, since the manufacturing variation of the substrate may reach 1 mm. Thus, the outer radius of the ceramic layer 308 may be 150.5 mm + offset. In some examples, the offset is at least 1 mm. In other examples, the offset is at least 2 mm. Thus, for a substrate support for processing a 300 mm substrate, the outer radius of the ceramic layer 308 may be 151.5 mm to provide an offset of 1 mm. Similarly, for a substrate support for processing a 450 mm substrate, the outer radius of the ceramic layer 308 may be 226.1 mm to provide an offset of 1 mm. By way of example only, in a configuration for processing a substrate having a diameter d (e.g., d mm) and a manufacturing variation of v mm, the ceramic layer may have an outer radius that is greater than or equal to the sum of (d+v) / 2 and a predetermined offset.

[0033] Although offsets of 1 mm and 2 mm are provided merely as examples, the offset may be of any amount sufficient to extend the ceramic layer 308 under the edge ring 324. For example, the ceramic layer 308 may have an outer radius that is a minimum amount larger than the inner radius of the edge ring 324. For example, the outer radius of the ceramic layer 308 may be 1 mm, 2 mm, 3 mm, etc. larger than the inner radius of the edge ring 324. Thus, the ceramic layer 308 extends under the edge ring 324, and the outer edge 332 of the ceramic layer 308 is disposed under the edge ring 324 (i.e., the edge ring 324 overlaps the outer edge 332 of the ceramic layer 308).

[0034] Because the ceramic layer 308 extends below the edge ring 324 and is larger than the substrate 316, a portion of the ceramic layer 308 is not covered by either the substrate 316 or the edge ring 324. Thus, the ceramic layer 308 may include a replaceable insert 340. For example, the insert 340 may be annular and disposed in an annular slot or groove 344 in the upper surface of the ceramic layer 308 below the edge ring 324. By way of example only, the insert 340 may be disposed at the interface between the portion of the ceramic layer 308 below the edge ring 324 and the portion of the ceramic layer 308 that is exposed to the process gases and plasma (i.e., that portion of the ceramic layer 308 is not covered by either the substrate 316 or the edge ring 324). This portion of the ceramic layer 308 that corresponds to the insert 340 may experience greater wear and erosion due to greater exposure to the process gases (e.g., plasma). Thus, without the replaceable insert 340, the increased exposure to plasma caused by the gap 336 would lead to increased erosion of the ceramic layer 308, requiring frequent replacement.

[0035] Instead, replacement of the replaceable insert 340 may provide lower costs, less system downtime, and more efficient disassembly and reassembly of the substrate support 300. For example, the insert 340 may be replaced by removing the inner edge ring 324 of the edge assembly 320 and then removing the insert 340. By way of example only, the insert 340 may comprise the same material (e.g., any suitable ceramic) as the ceramic layer 308. Thus, exposure to process gases may cause corrosion of the insert 340. As such, the insert 340 may be characterized as a sacrificial or consumable insert.

[0036] In some examples, the substrate support 300 may eliminate and / or simplify structures such as ring structures 48, 52, 56, and 60 shown in Figure 1. For example, having a larger outer radius for the ceramic layer 308 than for the substrate 316 may improve process uniformity at the edge of the substrate 316, making additional structures provided to improve process uniformity unnecessary. By way of example only, the ring structures 52, 56, and 60 directly below the edge ring 34 of Figure 1 have been eliminated in the example shown in Figure 3.

[0037] 5, an example ceramic layer 308 is shown with a replaceable insert 340. In some examples, the insert 340 may include one or more tapped holes (e.g., threaded tapped holes) 348 for attaching the insert 340 to the ceramic layer 308. The ceramic layer 308 may include one or more notches 352 to facilitate removal of the insert 340 from the groove 344 in the ceramic layer 308. For example, the notches 352 may be configured to receive a tool to remove the insert 340 from the groove 344.

[0038] 6, another example of a substrate support 320 is shown. In this example, the insert 340 is wider than the example shown in FIG. 3. Thus, the insert 340 extends from beneath the edge ring 324, through the gap 336, and beneath the outer edge of the substrate 316. In other words, the insert 340 fills the entire portion of the ceramic layer 308 that is exposed to process gases in the gap 336.

[0039] 7, an example substrate processing method 700 begins at step 704. At step 708, a substrate support with a ceramic layer is provided. The substrate support is configured for processing substrates (i.e., wafers) having standard sizes such as 200 mm, 300 mm, 450 mm, etc. The ceramic layer has an outer radius that is greater than the outer radius of a substrate to be processed on the substrate support, as described above. For example, if the substrate support is configured for processing a standard substrate having a diameter d and a manufacturing variation v, the ceramic layer may have an outer radius that is greater than or equal to the sum of (d+v) / 2 and a predetermined offset. At step 712, a substrate is placed on the ceramic layer. At step 716, one or more substrate processing steps are performed on the substrate. Method 700 ends at step 720.

[0040] The above description is merely exemplary in nature and is not intended to limit the disclosure, its applications, or uses. The broad teachings of the present disclosure may be embodied in various forms. Thus, while the present disclosure includes certain examples, the true scope of the present disclosure is not limited to those examples, as other variations will become apparent upon study of the drawings, the specification, and the following claims. It should be understood that one or more steps included in a method may be performed in a different order (or simultaneously) without altering the principles of the present disclosure. Furthermore, although each of the embodiments is described as having certain features, any one or more of the features described with respect to any embodiment of the present disclosure may be implemented in any of the other embodiments and / or combined with any of the features of any of the other embodiments, even if the combination is not expressly described. In other words, the above-described embodiments are not mutually exclusive, and it is within the scope of the present disclosure to substitute one or more of the embodiments for one another.

[0041] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers) are described using various terms such as "connected," "engaged," "coupled," "adjacent," "adjacent," "on top of," "above," "below," and "disposed." When describing a relationship between a first and second element in this disclosure, unless expressly described as "direct," the relationship may be a direct relationship where no other intervening elements exist between the first and second elements, but may also be an indirect relationship where one or more intervening elements exist (spatially or functionally) between the first and second elements. As used herein, the phrase "at least one of A, B, and C" should be interpreted to mean the logic (A or B or C) using a non-exclusive logical OR, and not to mean "at least one of A, at least one of B, and at least one of C."

[0042] In some embodiments, the controller is part of a system, which may be part of the examples described above. Such systems may include semiconductor processing equipment, such as one or more processing tools, one or more chambers, one or more platforms for processing, and / or specific processing components (wafer pedestal, gas flow system, etc.). These systems may be integrated with electronics for controlling the operation of the system before, during, and after processing of a semiconductor wafer or substrate. The electronics may be referred to as a "controller" and may control various components or sub-components of the system. The controller may be programmed to control any of the processes disclosed herein, such as supply of process gases, temperature settings (e.g., heating and / or cooling), pressure settings, vacuum settings, power settings, radio frequency (RF) generator settings, RF matching circuit settings, frequency settings, flow settings, fluid supply settings, position and motion settings, and wafer movement in and out of tools and other moving tools and / or load locks connected or coupled to the specific system, depending on the processing requirements and / or type of system.

[0043] In general, a controller may be defined as electronic equipment having various integrated circuits, logic, memory, and / or software that receive instructions, issue instructions, control operations, enable cleaning operations, enable endpoint measurements, etc. Integrated circuits may include chips in the form of firmware that store program instructions, digital signal processors (DSPs), chips defined as application specific integrated circuits (ASICs), and / or one or more microprocessors or microcontrollers that execute program instructions (e.g., software). Program instructions may be instructions that are communicated to the controller in the form of various individual settings (or program files) that define operational parameters for performing a particular process on or for a semiconductor wafer, or for a system. The operational parameters, in some embodiments, may be part of a recipe defined by a process engineer to accomplish one or more process steps during processing of one or more layers, materials, metals, oxides, silicon, silicon dioxide, surfaces, circuits, and / or dies of a wafer.

[0044] The controller may be part of or connected to a computer that is integrated with, connected to, or otherwise networked with the system, or a combination thereof, in some embodiments. For example, the controller may be in the "cloud" or may be all or part of a fab host computer system that may enable remote access of wafer processing. The computer may enable remote access to the system to monitor the current progress of a manufacturing operation, look at the history of past manufacturing operations, or look at trends or performance indicators from multiple manufacturing operations, to change parameters of a current process, set up a process step according to a current process, or start a new process. In some examples, a remote computer (e.g., a server) may provide a process recipe to the system over a network (which may include a local network or the Internet). The remote computer may include a user interface that allows for entry or programming of parameters and / or settings, which are communicated to the system from the remote computer. In some examples, the controller receives instructions in the form of data, where the instructions specify parameters for each of the process steps to be performed during one or more operations. It should be understood that the parameters may be specific to the type of process being performed as well as the type of tool the controller is configured to interface with or control. Thus, as described above, the controller may be distributed, such as by having one or more separate controllers that are networked and operate toward a common purpose (such as the process and control described herein). One example of a distributed controller for such purposes is one or more integrated circuits on the chamber that communicate with one or more remotely located integrated circuits (such as at the platform level or located as part of a remote computer) that cooperate to control the process in the chamber.

[0045] Without being limited thereto, example systems may include a plasma etch chamber or module, a deposition chamber or module, a spin rinse chamber or module, a metal plating chamber or module, a cleaning chamber or module, a bevel edge etch chamber or module, a physical vapor deposition (PVD) chamber or module, a chemical vapor deposition (CVD) chamber or module, an atomic layer deposition (ALD) chamber or module, an atomic layer etch (ALE) chamber or module, an ion implantation chamber or module, a track chamber or module, and any other semiconductor processing system that may be associated with or utilized in the fabrication and / or manufacturing of semiconductor wafers.

[0046] As described above, depending on the processing step or steps being performed by the tool, the controller may communicate with one or more of other tool circuits or modules, other tool components, cluster tools, other tool interfaces, adjacent tools, nearby tools, tools located throughout the factory, a main computer, another controller, or tools used in material transport to carry containers of wafers to or from tool locations and / or load ports within a semiconductor manufacturing factory. The present disclosure may be realized in the following forms. [Form 1] 1. A substrate support for supporting a substrate in a substrate processing system, comprising: A base plate; a ceramic layer disposed above the base plate, the ceramic layer having an outer periphery surrounded by an edge ring; Equipped with A substrate support, wherein an outer radius of the ceramic layer is greater than an inner radius of the edge ring such that an outer edge of a top surface of the ceramic layer extends below the edge ring. [Form 2] 2. A substrate support as described in claim 1, wherein the ceramic layer comprises: (i) an annular groove disposed on the top surface of the ceramic layer; and (ii) an insert disposed within the annular groove. [Form 3] 3. The substrate support of claim 2, wherein the insert comprises a ceramic. [Form 4] 3. The substrate support of claim 2, wherein the insert is disposed at least partially below the edge ring. [Form 5] 3. The substrate support of claim 2, wherein the insert extends from below the edge ring to a portion of the ceramic layer configured to support a substrate. [Form 6] 2. The substrate support of claim 1, wherein the substrate support is configured to support a 300 mm substrate and the ceramic layer has an outer radius of at least 151.5 mm. [Form 7] 2. The substrate support of claim 1, wherein the substrate support is configured to support a 450 mm substrate and the ceramic layer has an outer radius of at least 226.5 mm. [Form 8] 2. A substrate support as described in claim 1, wherein the substrate support is configured to support a substrate having a diameter of d mm, a manufacturing variation associated with the substrate is v mm, and the ceramic layer has an outer radius greater than or equal to the sum of (d+v) / 2 and a predetermined offset. [Form 9] 1. A substrate support for supporting a substrate in a substrate processing system, comprising: A base plate; a ceramic layer disposed above the base plate; an edge ring disposed around an outer periphery of the ceramic layer, an outer radius of the ceramic layer being greater than an inner radius of the edge ring such that an outer edge of a top surface of the ceramic layer extends below the edge ring; Equipped with The ceramic layer comprises: (i) an annular groove disposed in the top surface of the ceramic layer; and (ii) an insert disposed within the annular groove. [Form 10] 10. The substrate support of claim 9, wherein the insert comprises a ceramic. [Form 11] 10. The substrate support of claim 9, wherein the insert is positioned at least partially below the edge ring. [Form 12] 10. The substrate support of claim 9, wherein the insert extends from below the edge ring to a portion of the ceramic layer configured to support a substrate. [Form 13] 10. The substrate support of claim 9, wherein the substrate support is configured to support a 300 mm substrate and the ceramic layer has an outer radius of at least 151.5 mm. [Form 14] 10. The substrate support of claim 9, wherein the substrate support is configured to support a 450 mm substrate and the ceramic layer has an outer radius of at least 226.5 mm. [Form 15] 10. A substrate support as described in claim 9, wherein the substrate support is configured to support a substrate having a diameter of d mm, a manufacturing variation associated with the substrate is v mm, and the ceramic layer has an outer radius greater than or equal to the sum of (d+v) / 2 and a predetermined offset. [Form 16] A method for processing a substrate, comprising: Providing a base plate; disposing a ceramic layer over the base plate; providing an edge ring disposed around an outer periphery of the ceramic layer; an outer radius of the ceramic layer is greater than an inner radius of the edge ring such that an outer edge of a top surface of the ceramic layer extends below the edge ring; the ceramic layer comprising: (i) an annular groove disposed in the top surface of the ceramic layer; and (ii) an insert disposed within the annular groove; disposing a substrate over the ceramic layer; performing at least one processing step on the substrate; A substrate processing method comprising:

Claims

1. 1. A substrate support for supporting a substrate in a substrate processing system, comprising: A base plate; a ceramic layer disposed above the base plate, the ceramic layer having an outer periphery surrounded by an edge ring; Equipped with an outer radius of the ceramic layer is greater than an inner radius of the edge ring such that an outer edge of a top surface of the ceramic layer extends below the edge ring; the ceramic layer comprising: (i) an annular groove disposed in the top surface of the ceramic layer; and (ii) an insert disposed within the annular groove; The insert is configured to be removable and replaceable; The insert is disposed at a portion of the ceramic layer below the edge ring at an interface with a portion of the ceramic layer exposed to process gases and plasma for processing the substrate.

2. The substrate support of claim 1 , wherein the insert is disposed at least partially below the edge ring.

3. The substrate support of claim 1 , wherein the insert extends from below the edge ring to a portion of the ceramic layer configured to support a substrate.

4. 10. The substrate support of claim 1, wherein the substrate support is configured to support a 300 mm substrate and the ceramic layer has an outer radius of at least 151.5 mm.

5. 10. The substrate support of claim 1, wherein the substrate support is configured to support a 450 mm substrate and the ceramic layer has an outer radius of at least 226.5 mm.

6. 2. The substrate support of claim 1 , wherein the substrate support is configured to support a substrate having a diameter of d mm, a manufacturing variation associated with the substrate is v mm, and the ceramic layer has an outer radius greater than or equal to the sum of (d+v) / 2 and a predetermined offset.

7. 1. A substrate support for supporting a substrate in a substrate processing system, comprising: A base plate; a ceramic layer disposed above the base plate; an edge ring disposed around an outer periphery of the ceramic layer, an outer radius of the ceramic layer being greater than an inner radius of the edge ring such that an outer edge of a top surface of the ceramic layer extends below the edge ring; Equipped with the ceramic layer comprising: (i) an annular groove disposed in the top surface of the ceramic layer; and (ii) an insert disposed within the annular groove; The insert is configured to be removable and replaceable; The insert is disposed at a portion of the ceramic layer below the edge ring at an interface with a portion of the ceramic layer exposed to process gases and plasma for processing the substrate.

8. The substrate support of claim 7 , wherein the insert is disposed at least partially below the edge ring.

9. The substrate support of claim 7 , wherein the insert extends from beneath the edge ring to a portion of the ceramic layer configured to support a substrate.

10. 8. The substrate support of claim 7, wherein the substrate support is configured to support a 300 mm substrate and the ceramic layer has an outer radius of at least 151.5 mm.

11. 8. The substrate support of claim 7, wherein the substrate support is configured to support a 450 mm substrate and the ceramic layer has an outer radius of at least 226.5 mm.

12. 8. The substrate support of claim 7, wherein the substrate support is configured to support a substrate having a diameter of d mm, a manufacturing variation associated with the substrate is v mm, and the ceramic layer has an outer radius greater than or equal to the sum of (d+v) / 2 and a predetermined offset.

13. A method for processing a substrate, comprising: Providing a base plate; disposing a ceramic layer over the base plate; providing an edge ring disposed around an outer periphery of the ceramic layer; an outer radius of the ceramic layer is greater than an inner radius of the edge ring such that an outer edge of a top surface of the ceramic layer extends below the edge ring; the ceramic layer comprising: (i) an annular groove disposed on the top surface of the ceramic layer; and (ii) an insert disposed within the annular groove, the insert configured to be removable and replaceable, the insert disposed at a portion of the ceramic layer below the edge ring at an interface with a portion of the ceramic layer exposed to process gases and plasma for processing the substrate; disposing a substrate over the ceramic layer; performing at least one processing step on the substrate; A substrate processing method comprising:

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