Patent ID: 8020750

Claim:
A method of fabricating a semiconductor processing apparatus including a processing gas delivery system, said method comprising: simultaneously diffusion bonding together at least a portion of said processing gas delivery system to include at least partial integration of at least one component device, wherein at least one metal sheet consisting essentially of a corrosion-resistant metal which forms part of said component device, and a plurality of metal sheets consisting essentially of a corrosion-resistant metal, which sheets include at least one shaped opening which passes through at least a portion of said plurality of metal sheets, are simultaneously diffusion bonded to form said at least a portion of said processing gas delivery system by subjecting said at least one metal sheet of said component device and said plurality of metal sheets to a temperature ranging from 1000° C. to 1300° C., at a pressure ranging from 3000 psi to 10000 psi, for a time period ranging from 3 hours to 6 hours, so that said processing gas delivery system meets the requirements of a SEMI standard for fluid flow apparatus, wherein a helium outleakage rate for a period of at least 15 seconds at a pressure differential of one atmosphere is 1×10 −9 cc/sec or less wherein said diffusion bonding to achieve the at least partial integration of said component device includes diffusion bonding said component device directly to more than one of said plurality of metal sheets.