Patent ID: 8065789

Claim:
A method of forming a substrate support, comprising: providing a body having at least one groove formed in a surface thereof; inserting a heater element into the groove, wherein the heater element comprises at least one resistive element encased in an insulating material and covered with a sheath, wherein the sheath is encased in a cladding with substantially no air pockets trapped between the cladding and the sheath, wherein the cladding comprises a thickness sufficient to prevent hot spots on the heater element, wherein the cladding is formed from a thermally conductive material that is more malleable than the body such that the cladding deforms upon insertion in the groove to prevent deformation of the body and to allow substantially complete contact between the cladding and the body; disposing an insert into the groove over the cladding; and inserting a cap into the groove, wherein an outer surface of the cap is disposed substantially flush with an outer surface of the body.