Process kit for deposition and etching

Variable geometry process kits for use in semiconductor process chambers have been provided herein. In some embodiments, a process kit for use in a semiconductor process chamber includes: an annular body configured to rest about a periphery of a substrate support; a first ring positioned coaxially with the annular body and supported by the annular body; a second ring positioned coaxially with the first ring and supported by the first ring; and an annular shield comprising a horizontal leg positioned coaxially with the second ring such that a portion of the horizontal leg is aligned with and below portions of the first ring and second ring.

FIELD

Embodiments of the present invention generally relate to semiconductor processing equipment, and more particularly, to process kits for use in semiconductor process chambers.

BACKGROUND

During semiconductor processing in a process chamber, a substrate resting on a substrate support may undergo processes that deposit material on the substrate and to remove, or etch, portions of the material from the substrate, often in succession or in alternating processes. It is typically desirable to have uniform deposition and etching rates across the surface of the substrate. However, the inventors have noted that process non-uniformities often exist across the surface of the substrate and may be significant at the perimeter edge of the substrate. These non-uniformities at the perimeter are attributable to electric field termination effects and are sometimes referred to as edge effects.

During deposition, a process kit containing at least a deposition ring is sometimes provided to favorably influence the edge effects causing the non-uniformity at the substrate edge. The deposition ring generally is positioned around the substrate and rests on a portion of the substrate support. The deposition ring and other chamber components may also separate a processing volume of the chamber from a non-processing volume of the chamber, beneficially protecting some surfaces of the chamber from the processing environment.

Similarly, during etching, a ring is often provided around the substrate to, among other things, beneficially influence the removal of material from the substrate.

Deposition rings and etch rings, however, typically have different profiles and are positioned differently with respect to the substrate. In processes comprising a series of deposition/etching steps in rapid succession, process specific rings are not practical. Accordingly, the overall process suffers because a less than optimal ring configuration is used for each process.

Accordingly, the inventors have devised embodiments of an improved process kit for use in deposition and etching processes.

SUMMARY

A process kit for use with a substrate support of a process chamber is provided herein. In some embodiments the process kit may comprising an annular body having an inner wall and a bottom surface configured for support on a portion of a substrate support; a first ring comprising a first bottom surface and a first outer edge including a downwardly directed first projection, the first ring positioned coaxially with the annular body such that at least a portion of the first bottom surface is supported by an upper surface of the annular body; a second ring comprising a second bottom surface and a second outer edge including a downwardly directed second projection positioned coaxially with the first ring such that a portion of the second bottom surface is supported by an upper surface of the first ring; and an annular shield comprising a generally vertical leg, an inwardly directed horizontal leg including an upwardly directed third lip, the shield positioned coaxially with the second ring such that a portion of an upper surface of the horizontal leg is aligned with and below the second projection and a portion of the third lip is aligned with and below a portion of the first projection.

In some embodiments, an apparatus for processing a semiconductor substrate may include a process chamber body enclosing a processing volume and having a substrate support supported for vertical displacement disposed within the processing volume, the substrate support having a substrate support surface; and a process kit disposed in the processing volume, the process kit comprising an annular body having an inner wall defining an opening corresponding to the substrate support surface, and a bottom surface configured for support on a portion of a substrate support; a first ring comprising a first bottom surface and a first outer edge including a downwardly directed first projection, the first ring positioned coaxially with the annular body such that at least a portion of the first bottom surface is supported by an upper surface of the annular body; a second ring comprising a second bottom surface and a second outer edge including a downwardly directed second projection positioned coaxially with the first ring such that a portion of the second bottom surface is supported by an upper surface of the first ring; and an annular shield comprising a generally vertical leg having a top portion coupled to the chamber body, an inwardly directed horizontal leg including an upwardly directed third lip, the shield positioned coaxially with the second ring such that a portion of an upper surface of the horizontal leg is aligned with and below the second projection and a portion of the third lip is aligned with and below a portion of the first projection, such that a first vertical displacement of the substrate support in a first direction changes the relative position of the third top surface with respect to the substrate support surface and maintains the relative position of upper surface, the first top surface, and the second top surface with respect to the substrate support surface; a second vertical displacement of the substrate support in the first direction changes the relative position of the third top surface and second top surface with respect to the substrate support surface and maintains the relative position of the upper surface and the first top surface with respect to the substrate support surface; and a third vertical displacement of the substrate support in the first direction changes the relative position of the first top surface, the second top surface, and the third top surface with respect to the substrate support surface and maintains the relative position of the upper surface with respect to the substrate support surface.

The drawings have been simplified for clarity and are not drawn to scale. To facilitate understanding, identical reference numerals have been used, wherever possible, to designate identical elements that are common to the figures. It is contemplated that some elements of one embodiment may be beneficially incorporated in other embodiments.

DETAILED DESCRIPTION

Embodiments of process kits for use in semiconductor process chambers are provide herein. Embodiments of the inventive process kit advantageously may provide a more uniform electric field near the edge of the substrate during processing which may include deposition and etching processes is succession. The more uniform electric field has been observed to reduce undesired process non-uniformities in both deposition and etching across the substrate.

Process kits in accordance with the present invention comprise a plurality of components cooperating to provide a first geometry to advantageously influence the electric field termination effect (or edge effect) at the wafer edge during deposition processes. The plurality of components also cooperate to provide a second geometry to advantageously influence the edge effect at the wafer edge during etching processes. The disclosed process kits react to vertical positioning of a substrate support to modify the edge geometry.

The embodiments described in this disclosure are drawn to generally ring-shaped or annular elements. Accordingly, “inner” or “inwardly directed” mean directed to towards the radial center point of the annular elements. The use of “downward” or “downwardly”, or “upward” or “upwardly” as used in this application are intended to refer to the vertical direction with respect to the orientation of elements when positioned for use in a processing chamber where a substrate is supported horizontally on a substrate support disposed at a bottom of the processing chamber. Other substrate supporting orientations may also be used with the process kit maintaining the same relative orientation as disclosed herein.

FIG. 1depicts a side sectional schematic view of a process kit102positioned coaxially about a centerline101according to a non-limiting embodiment of the present invention. The centerline may correspond to the centerline of a substrate support103, illustrated with a substrate105supported in a substrate support surface103afor clarity. The support surface103ais sized to support a substrate105thereupon, for example a 200 mm, 300 mm, or 450 mm diameter semiconductor wafer or other suitable substrate. Elements of the process kit102are depicted spaced apart to more clearly illustrate their features.

The substrate support103is supported by a shaft107for at least vertical displacement along central axis101within a processing chamber by a lifting mechanism108. The process kit102comprises an annular body104comprising a bottom surface106adapted to rest upon a portion of a substrate support103for support. The body104has an inner wall110forming a central opening corresponding to the substrate support surface103a. The annular body104may include an upwardly directed lip112and a radially outwardly directed portion114, an upper surface116, and an outer wall118.

As illustrated inFIG. 1, a portion of the substrate105supported upon substrate support surface103aoverlaps a portion of the upwardly directed lip112. The substrate105supported on the may extend over some or all of the upwardly directed lip112. The surface of lip112may be coplanar with the substrate support surface103aor may be offset a distance below the substrate support surface103asuch that the substrate does not contact the lip112when the substrate is disposed on the substrate support surface103a.

A first ring120is coaxially disposed about an outer periphery of the annular body104. The first ring120has first inner edge122including an upwardly directed first lip124, a first top surface128, and a first bottom surface126partially overlapping the top surface116of the body104. The first outer edge130includes a downwardly directed first projection132having a surface134.

A second ring140is coaxially disposed about an outer periphery of the first ring120. The second ring has a second inner edge142including an upwardly directed second lip144, a second top surface146, and a second bottom surface148partially overlapping the top surface128of the first ring120. The second outer edge150of the second ring140includes a downwardly directed second projection152including a lower surface154and a second inner wall156.

The process kit102comprises an annular shield160having a generally L-shaped cross section coaxially disposed about a periphery of the second ring140. The shield160has a vertical leg162, with an upper portion162a, and an inwardly directed horizontal leg164at a lower portion162bof the vertical leg162. The horizontal leg164has an upper surface170and an inner edge166including an upwardly directed third lip168having a top surface174at an inner portion of the horizontal leg164. The shield160is disposed about the outer periphery of the second ring140and positioned such that the upper surface170of the horizontal leg164is below the lower surface154of the second ring140and an outer edge172of the upwardly directed third lip168is adjacent to the inner wall156.

The shield160is illustrated as an angular L-shape for ease of illustration. In other embodiments, the shield160may have a J-shape cross section with the lower portion (corresponding to horizontal leg164illustrated inFIG. 1) comprised of curved sections rather than linear portions. Other suitable cross sectional shapes are contemplated.

The components of the process kit102, i.e., the body104, the first ring120, the second ring140and the shield160may be formed from process compatible materials including non-limiting examples such as coated or uncoated aluminum (Al), stainless steel, titanium (Ti), or ceramic. Coatings may include such non-limiting examples as Al arc-spray, or Ti coating, or the like.

The inventors have observed non-uniformities in both deposition and etching at a substrate edge. In particular, in deposition processes, a higher deposition rate is typically found at the edge of the substrate. In etching processes, the etching rate is significantly higher at the substrate edge, and can be as much as four times the etching rate at other areas of the substrate. Collectively, these phenomena are referred to as the edge effect.

The inventors have noted that during deposition, a process ring placed adjacent to the substrate edge beneficially influences the edge effects during deposition. Through experimentation and investigation, the inventors have observed that by modifying the geometry or configuration of a raised lip at the substrate edge, deposition thicknesses variations at the edge of the substrate, as compared to deposition thickness toward the center of the substrate, can be reduced, or eliminated.

When used in a process chamber, the process ring profile for deposition processes according to the present invention may also be in a configuration to separate a non-processing volume of a chamber, for example the volume below the substrate support surface103a, from process gases and deposition materials.

However, the inventors have noted that a process ring configuration favorable to deposition does not necessarily provide the same beneficial results in etching processes.

The inventors have observed that the edge effects during etching processes can be favorably influenced by providing a process ring at or above the substrate edge. Some process ring configurations, different from those favorably used in deposition processes, have been shown to reduce the greater etching rate at the substrate edge, and in some cases, can even reverse the edge etch rate to be less than the etching rate at other areas of the substrate.

Through investigation and study, the inventors have developed a variable geometry process kit that provides enhanced performance in deposition processes in a first configuration and, in a second configuration, provides enhanced performance in etching processes. The inventive process kit may provide improved performance in both deposition and etching operations over conventional process kits.

In practicing the present invention for both deposition and etching operations, the lower surface106of annular body104rests, or is supported, on a portion of the substrate support103with inner wall110adjacent to the substrate support surface103aas depicted inFIG. 1. In some instances in which the substrate support surface103ais raised, the upper surface of the lip112does not extend beyond the plane of the substrate support surface103a. In other embodiments, the upper surface of the lip112does extend beyond the plane of the substrate support surface103a. The annular body104may be removably coupled to the substrate support103.

FIG. 2is illustrative of a process kit according to an embodiment of the present invention in a first configuration that may be favorable for a first substrate process, for example, a deposition process. The annular body104is supported upon the substrate support103about the substrate support surface103a.

The first ring120is disposed coaxially and above a portion of the annular body104such that at least a portion of the first bottom surface126is supported on at least a portion of the upper surface116of the annular body104. The first upwardly directed lip124may extend beyond (i.e., above) the upwardly directed lip112of the annular body104. In some embodiments, the first ring120may be formed such that the first upwardly directed lip124is below the underside of the substrate105supported in the substrate support surface103a. In other embodiments, the first ring120may be formed such that the first upwardly directed lip124is co-planar with the underside of the substrate105or may extend above the bottom surface of the substrate105.

The second ring140is coaxially disposed above a portion of the first ring120such that at least a portion of the second bottom surface148is supported on at least a portion of the first top surface128. The second ring140may be formed and positioned such that the second lip144is disposed at a location along the first top surface128. The second lip144may extend above the plane of the first lip124and the lip112of the annular body. In other embodiments, the second lip144may be coplanar with, or offset below, the plane of the first lip124or the plane of the lip112of the annular body.

The inventors have observed that some combinations of lip height, lip shape, and thickness in a radial direction favorably influence the edge effects at the edge of a substrate105supported on the substrate support surface103afor processing, for example a deposition process. The upwardly directed lip112, the first lip124, and the second lip144are illustrated as rectangular in cross section for ease of illustration only. The cross sectional shape of one or more of the lips112,124, and144may advantageously have one or more different shapes, including non-limiting examples such as semi-circular, or polygonal shapes such as trapezoidal, triangular, or rhomboid.

The annular shield160is oriented such that the upper portion162amay be coupled to a portion of a chamber body (504inFIG. 5), at a point above the substrate support surface103a. In a position favorable for a deposition process as depicted inFIG. 2, second ring140is supported such that the lower surface154of the second projection152is spaced above the upper surface170of the horizontal leg164.

In a first configuration depicted inFIG. 2, the components of the process kit102(i.e., the annular body104, the first ring120, the second ring140, and the shield162) cooperate to favorably influence a substrate processing step, for example a deposition process. In particular, the inventive process kit102has been observed to minimize deposition non-uniformities (edge effect) at the edge of a substrate105supported on a substrate support surface103a.

FIG. 3depicts a second configuration for the inventive process kit102that may advantageously modify the edge effects in steps used to process substrates, e.g., a second process, such as a deposition or etching process. As illustrated, the substrate support103has been displaced in a first vertical direction, i.e., downwardly, from the configuration ofFIG. 2by action of the lifting mechanism108. The downward displacement of the substrate support103also displaced the annular body104and the first ring120by equal amounts. Thus, the relative position of the annular body104, and the first ring120with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103ais unchanged from the relative position of the first configuration depicted inFIG. 2.

The displacement of the substrate support103is sufficient to bring the lower surface154of the second ring140into contact with the upper surface170of horizontal leg164, arresting further downward displacement of the second ring140. Rather than have the second bottom surface148supported on a portion of the first top surface128as in the first configuration illustrated inFIG. 2, the lower surface154of the second projection152is supported on the upper surface170of the horizontal leg164of the shield162. In the second configuration as illustrated inFIG. 3, the relative position of the second ring140and the shield160with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103ahas changed from the first configuration depicted inFIG. 2. The relative position of the upper surface116and the first top surface128with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103aremains unchanged from that of the first configuration illustrated inFIG. 2.

Although a particular second configuration is illustrated inFIG. 3, other second configurations are possible by vertically displacing the substrate support103, the annular ring104, the first ring120and the substrate105, either upwardly or downwardly, while maintaining the lower surface154of the second projection152in supporting contact with upper surface170of horizontal leg164. With such movement, the relative position of the shield160and the second ring with respect to the first ring120, the annular body104, the substrate support103, and the substrate105may be altered to beneficially influence the edge effects at the edge of the substrate105.

The inventors have observed that the second configuration illustrated inFIG. 3, as well as variations to the second configuration, may beneficially influence the edge effects of both deposition process and etching processes.

FIG. 4depicts a third configuration for the inventive process kit102that may advantageously influence the edge effects in steps used to process substrates, such as in an etching process. As illustrated, the substrate support103has been displaced by a second displacement in a first vertical direction, i.e., downwardly, from the second configuration depicted inFIG. 3by action of the lifting mechanism108. The second downward displacement of the substrate support103also displaced the annular body104by an equal amount. Thus, the relative position of the annular body104with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103is unchanged from the relative position of the second configuration depicted inFIG. 3.

The displacement of the substrate support103between the second configuration illustrated inFIG. 3and the third configuration illustrated inFIG. 4was sufficient to bring the lower surface134of the first projection132in contact with the upper surface174of the third lip168, arresting further downward displacement of the first ring120. Rather than have the first bottom surface126supported on a portion of the upper surface116as in the first and second configurations illustrated inFIGS. 2 and 3, respectively, the lower surface134of the first projection132is supported on the top surface174of the third lip168of the shield162. In the third configuration illustrated inFIG. 4, the relative position of the first ring120, the second ring140, and the shield160with respect to the annular body104, the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103ahas changed. The relative position of the annular ring104with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103ahas not changed.

Although a third configuration is illustrated inFIG. 4, other third configurations are possible by vertically displacing the substrate support103, the annular ring104, and the substrate105, either upwardly or downwardly, while maintaining the lower surface154of the second projection152in supporting contact with upper surface170of horizontal leg164and the lower surface134of the first projection132in supporting contact with the top surface174of the third lip168. With such movement, the relative position of the shield160, the second ring140, and the first ring120with respect to the annular body104, the substrate support103, and the substrate105may be altered to beneficially influence the edge effects at the edge of the substrate105.

The inventors has observed that the third configuration illustrated inFIG. 4, as well as variations to the second configuration, may beneficially influence the edge effects of substrate processes such as etching processes.

A first vertical displacement in a second direction, i.e., upwardly, from the third configuration illustrated inFIG. 4engages a portion of the upper surface116with a portion of the first bottom surface126, vertically displacing the first ring120such that the relative position of the first top surface128and the upper surface116with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103ais maintained and changing the relative position of the second top surface144and the third top surface174with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103a, placing the apparatus in the second configuration for the second substrate process ofFIG. 3.

A second vertical displacement of the substrate support103in the second direction, i.e., upwardly, from the second configuration illustrated inFIG. 3engages a portion of the first top surface128with a portion of the second bottom surface148, vertically displacing the second ring140such that the relative position of the second top surface146, the first top surface128, and the upper surface116with respect to the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103a, is maintained and changing the relative position of the third top surface174with respect the substrate support103, the substrate support surface103a, and the substrate105supported on the substrate support surface103a, placing the apparatus in the first configuration for the first substrate process, e.g., a deposition process.

FIG. 5depicts a simplified, cross-sectional schematic diagram of an illustrative process chamber500of the kind that may be used to practice embodiments of the invention discussed herein. For example, the chamber may be a physical vapor deposition (PVD) chamber, having a magnetron assembly in accordance with some embodiments of the present invention. The specific configuration of the PVD chamber is illustrative and PVD chambers, or other process chambers, having other configurations may also benefit from modification in accordance with the teachings provided herein. Examples of suitable process chambers include any of the Cirrus®, AURA®, or AVENIR® lines of PVD processing chambers, commercially available from Applied Materials, Inc., of Santa Clara, Calif. Other processing chambers from Applied Materials, Inc. or other manufactures may also benefit from the inventive apparatus disclosed herein.

In practicing some embodiments of the present invention, the process chamber500includes a chamber lid501disposed atop a chamber body504and removable from the chamber body504. The chamber lid501generally includes a target assembly502and a grounding assembly503disposed about the target assembly502. The chamber lid501rests on the ledge540of the upper grounded enclosure wall516. The upper grounded enclosure wall516may provide a portion of the RF return path between the upper grounded enclosure wall516and the grounding assembly503of the chamber lid501. However, other RF return paths are possible.

The target assembly502may include a source distribution plate558opposing a backside of the target514and electrically coupled to the target514along a peripheral edge of the target514. The target514may comprise a source material513to be deposited on a substrate, such as the substrate105during a deposition process, such as a metal, metal oxide, metal alloy, magnetic material, or the like. In some embodiments, the target514may include a backing plate562to support the source material513. The backing plate562may comprise a conductive material, such as copper-zinc, copper-chrome, or the same material as the target, such that RF, and optionally DC, power can be coupled to the source material513via the backing plate562. Alternatively, the backing plate562may be non-conductive and may include conductive elements (not shown) such as electrical feedthroughs or the like.

The target assembly502may include a cavity570disposed between the backside of the target514and the source distribution plate558. The cavity570may at least partially house a magnetron assembly596. The cavity570is at least partially defined by the inner surface of a conductive member564, a target facing surface of the source distribution plate558, and a source distribution plate facing surface (e.g., backside) of the target514(or backing plate562). One or more portions of a magnetron assembly596may be disposed at least partially within the cavity570. The magnetron assembly provides a rotating magnetic field proximate the target to assist in plasma processing within the process chamber504. In some embodiments, the magnetron assembly596may include a motor576, a motor shaft574, a gearbox578, a gearbox shaft584, and a rotatable magnet (e.g., a plurality of magnets588coupled to a magnet support member572).

The grounding assembly503may include a grounding plate556having a first surface557that may be generally parallel to and opposite a backside of the target assembly502. A grounding shield512may extend from the first surface557of the grounding plate556and surround the target assembly502. The grounding assembly503may include a support member575to support the target assembly502within the grounding assembly503.

The chamber body504contains a substrate support103for receiving a substrate105thereon. The substrate support103is configured to support a substrate such that a center of the substrate is aligned with a central axis586of the process chamber500. The substrate support103may be located within a lower grounded enclosure wall510, which may be a wall of the chamber body504. The lower grounded enclosure wall510may be electrically coupled to the grounding assembly503of the chamber lid501such that an RF return path is provided to an RF power source582disposed above the chamber lid501. The RF power source582may provide RF energy to the target assembly502.

The substrate support surface103afaces a principal surface of a target514and may be raised above the rest of substrate support103. The substrate support surface103asupports the substrate105for processing which may include one or more deposition steps and one or more etching steps. The substrate support103may include a dielectric member505having a substrate support surface103afor supporting the substrate105thereon. In some embodiments, the substrate support103may include one or more conductive members507disposed below the dielectric member505. For example, the dielectric member505and the one or more conductive members507may be part of an electrostatic chuck, RF electrode, or the like which may be used to provide chucking or RF power to the substrate support103.

The substrate support103may support the substrate105in a processing volume520of the chamber body504. The processing volume520is a portion of the inner volume of the chamber body504that is used for processing the substrate105and may be separated from the remainder of the inner volume (e.g., a non-processing volume) during processing of the substrate103(for example, via the process kit102). The processing volume520is defined as the region above the substrate support103during processing (for example, between the target514and the substrate support103when in a processing position).

In some embodiments, the substrate support103may be vertically movable to allow the substrate105to be transferred onto the substrate support103through an opening (such as a slit valve, not shown) in the lower portion of the chamber body504and thereafter vertically displaced to one or more processing positions. In practicing the present invention, the vertical position of the substrate support103also varies the geometry of the process kit102to modify the edge effects as discussed above. A bellows522connected to a bottom chamber wall524may be provided to maintain a separation of the inner volume of the chamber body504from the atmosphere outside of the chamber body504. One or more gases may be supplied from a gas source526through a mass flow controller528into the lower part of the chamber body504. An exhaust port530may be provided and coupled to a pump (not shown) via a valve532for exhausting the interior of the chamber body504and to facilitate maintaining a desired pressure inside the chamber body504.

An RF bias power source534may be coupled to the substrate support103in order to induce a negative DC bias on the substrate105. In addition, in some embodiments, a negative DC self-bias may form on the substrate105during processing. In some embodiments, RF energy supplied by the RF bias power source534may range in frequency from about 2 MHz to about 60 MHz, for example, non-limiting frequencies such as 2 MHz, 13.56 MHz, 40 MHz, or 60 MHz can be used. In some applications, a source frequency of 40 MHz has been observed to be very effective in ionizing the deposition species through electron impact ionization and Penning ionization.

The chamber body504further includes a process kit102comprising an annular body104, a first ring124, a second ring144, and a shield160to surround the processing, or first volume, of the chamber body504and to protect other chamber components from damage and/or contamination from processing. The shield160may be coupled to a portion of an upper grounded enclosure wall516of the chamber body504, for example a ledge540. In other embodiments, and as illustrated inFIG. 5, the shield160may be coupled to the chamber lid501, for example via a retaining ring575. The shield160extends downwardly along, but spaced apart from, the walls516and510to below a top surface of the substrate support103when the substrate support103is in its lowest processing position. The shield160is coupled to a portion of the chamber body504to resist at least vertical displacement relative to the chamber body504during processing. A horizontal leg164is inwardly directed at a lower portion of the vertical leg162. The horizontal leg has an upwardly directed lip168at an inner portion (e.g., forming a U- or L-shaped portion at the bottom of the shield160).

The shield160comprises an inner wall543disposed between the target514and the substrate support103to surround the processing volume520. The height of the shield160depends upon the distance585between the target514and the substrate105when the substrate105is in a position for processing. The vertical position of the substrate support103, and correspondingly, the distance185between the target114and the substrate105, may vary, as discussed above, when the chamber504is used for both deposition and etching processes. The height of the shield160is sufficient, when in cooperation with the annular ring104, the first ring124, and the second ring140, to separate the processing volume520of the chamber from the remaining volume of the chamber504(i.e., the non-processing volume) during, for example, deposition processes.

The process kit102functions within the process chamber as described above to create a variable geometry that may provide enhanced performance in deposition processes in a first configuration and provide enhanced performance in etching processes in a second configuration.

Thus, variable geometry process kits for use in a semiconductor process chambers have been provided herein. The inventive process kit advantageously may affect the electric field near the edge of the substrate during processing, thereby reducing undesired edge effects during, for example, such processes as deposition and etching.