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The present invention pertains to apparatus and methods for electroplanarization of metal surfaces having both recessed and raised features, over a large range of feature sizes. The invention accomplishes this by use of a flexible planar cathode and a spacing pad thereon. Methods of the invention ar

The present invention pertains to apparatus and methods for electroplanarization of metal surfaces having both recessed and raised features, over a large range of feature sizes. The invention accomplishes this by use of a flexible planar cathode and a spacing pad thereon. Methods of the invention are electropolishing methods. During electroplanarization, the flexible planar cathode conforms to the global contour of the work piece (e.g. a wafer) while the spacing pad conforms to local topography of the metal layer being planarized. In this way, dishing is reduced in the final planarized metal layer.

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1. A method of electroplanarizing a metal layer disposed on a wafer work surface, said metal layer having a plurality of recessed and raised regions, the method comprising:(a) positioning the wafer work surface and a flexible planar cathode into close proximity with each other, said flexible planar

1. A method of electroplanarizing a metal layer disposed on a wafer work surface, said metal layer having a plurality of recessed and raised regions, the method comprising:(a) positioning the wafer work surface and a flexible planar cathode into close proximity with each other, said flexible planar cathode comprising a spacing pad on its work surface, said spacing pad and the metal layer contacting each other;(b) applying a substantially uniform force per unit area to the back side of the flexible planar cathode, thereby compressing the spacing pad between the flexible planar cathode and the metal layer;(c) passing an ionic electrical current from the metal layer, through an electrolyte solution contained at least in the spacing pad, and to a reclaim cathode, such that the metal is electrolytically removed from the surface of the metal layer; and(d) stopping the passage of current at a point where all or a majority of the metal layer is removed from the field of the wafer work surface. 2. The method of claim 1, further comprising substantially maintaining a predefined separation distance between the flexible planar cathode and the wafer work surface during electroplanarization. 3. The method of claim 1, further comprising creating a relative movement between the wafer work surface and the spacing pad prior to (d). 4. The method of claim 3, wherein the relative movement between the wafer work surface and the spacing pad comprises at least one of: rotating the wafer, the flexible planar cathode, or both about an axis substantially perpendicular to the wafer work surface, moving the wafer, the flexible planar cathode, or both via linear movements along one or more axes substantially parallel to the wafer work surface, orbiting the wafer, the flexible planar cathode, or both substantially parallel to the wafer work surface, and combinations thereof. 5. The method of claim 4, wherein the spacing pad comprises a porous material. 6. The method of claim 1, wherein the spacing pad is non-abrasive. 7. The method of claim 1, wherein the spacing pad comprises a plurality of pores. 8. The method of claim 7, wherein the plurality of pores have a mean diameter of between about 0.02 μm and 10 μm. 9. The method of claim 1, wherein the electrolyte contains coppers ions. 10. The method of claim 7, wherein the spacing pad has a void volume of between about 20 and 80 percent. 11. The method of claim 1, wherein the spacing pad, when uncompressed, is at least about three times as thick as the largest variation in height between the plurality of recessed and raised regions in the metal layer. 12. The method of claim 1, wherein the spacing pad is between about 3 and 20 microns thick. 13. The method of claim 1, wherein the flexible planar cathode comprises a flexible substrate coated with a conductive material. 14. The method of claim 13, wherein the flexible substrate comprises at least one of silicon, polyimide, Kapton, polyurethane, polyethylene, mica, polycarbonate, stainless steel, molybdenum, tungsten, tantalum, or a coated nickel-based alloy. 15. The method of claim 13, wherein the conductive material comprises at least one of platinum, copper, gold, palladium, ruthenium, platinum-rhodium alloys, platinum-iridium alloys. 16. The method of claim 1, wherein the reclaim electrode comprises a conductive substrate on which metal plates during electroplanarization. 17. The method of claim 1, wherein dishing, across any region of the metal layer surface greater than 20 μm in diameter, is less than 100 nanometers deep. 18. The method of claim 1, wherein dishing, across any region of the metal layer surface equal to 20 μm in diameter, is less than 50 nanometers deep. 19. The method of claim 1, wherein the substantially uniform force per unit area to the back side of the flexible planar cathode is between about 0.2 and 2 psi. 20. The method of claim 1, wherein the substantially uniform force per unit area to the back side of the f lexible planar cathode is less than 1 psi. 21. The method of claim 1, wherein the flexible planar cathode comprises a porous matrix configured to allow electrolyte to flow through it. 22. The method of claim 21, wherein the substantially uniform force per unit area to the back side of the flexible planar cathode is provided by at least one of: a fluid pressure differential in the electrolyte due to restricted flow of the electrolyte from the back side of the flexible planar cathode through the porous matrix and the spacing pad, and a compressive material contacting the back side of the flexible planar cathode. 23. The method of claim 1, further comprising recycling the electrolyte during electroplanarization by:(i) removing at least a portion of the electrolyte from a vessel in which the electroplanarization occurs;(ii) adjusting the electrolyte composition; and(iii) returning the electrolyte to the vessel. 24. The method of claim 23, wherein returning the electrolyte to the vessel comprises delivering at least a portion of the electrolyte onto a portion of the spacing pad. 25. The method of claim 1, wherein the spacing pad comprises at least one of a perfluoroalkoxy material, urethane material and polyvinyl alcohol (PVA). 26. An electroplanarizing apparatus for removing a portion of a metal layer disposed on a wafer work surface, the apparatus comprising:(a) a wafer holder for holding the wafer such that the metal layer is exposed, said wafer holder configured to supply an anodic electrical current to the metal layer;(b) a flexible planar cathode having a spacing pad on its surface;(c) a movement assembly configured to position the wafer work surface and the flexible planar cathode into close proximity with each other, whereby at least a pre-defined separation distance between the flexible planar cathode and wafer work surface can be maintained throughout an electroplanarization process;(d) an electrolyte delivery mechanism configured to provide an electrolyte the spacing pad while the wafer is in contact with the spacing pad; and(e) a mechanism for applying a substantially uniform force per unit area to the back side of the flexible planar cathode, thereby compressing the spacing pad between the flexible planar cathode and the wafer work surface. 27. The apparatus of claim 26, wherein the movement assembly further comprises a mechanism for creating a lateral relative movement between the wafer work surface and the spacing pad work surface. 28. The apparatus of claim 27, wherein the lateral relative movement between the wafer work surface and the spacing pad work surface comprises at least one of: rotating the wafer, the flexible planar cathode, or both about an axis substantially perpendicular to the wafer work surface, moving the wafer, the flexible planar cathode, or both via linear movements along one or more axes substantially parallel to the wafer work surface, orbiting the wafer, the flexible planar cathode, or both substantially parallel to the wafer work surface; and combinations thereof. 29. The apparatus of claim 28, wherein the spacing pad comprises a porous material. 30. The apparatus of claim 26, wherein the spacing pad is non-abrasive. 31. The apparatus of claim 26, wherein the spacing pad comprises a plurality of pores. 32. The apparatus of claim 31, wherein the plurality of pores have a mean diameter of between about 0.02 μm and 10 μm. 33. The apparatus of claim 31, wherein the spacing pad has a void volume of between about 20 and 80 percent. 34. The apparatus of claim 26, wherein the spacing pad, when uncompressed, is at least about three times as thick as the largest variation in height between a plurality of recessed regions and raised regions in the metal layer disposed on the wafer work surface. 35. The apparatus of claim 26, wherein the spacing pad is between about 3 and 20 microns thick. 36. The apparatus of claim 26, wherein the spacing pad comprises at least one of a perfluoroalkoxy mater ial, urethane material and polyvinyl alcohol (PVA). 37. The apparatus of claim 26, wherein the flexible planar cathode comprises a flexible substrate coated with a conductive material. 38. The apparatus of claim 37, wherein the flexible substrate is between about 15 and 300 μm thick. 39. The apparatus of claim 37, wherein the flexible electrode comprises at least one of silicon, polyimide, Kapton, polyurethane, polyethylene, mica, polycarbonate, stainless steel, molybdenum, tungsten, tantalum, or a coated nickel-based alloy. 40. The apparatus of claim 37, wherein the conductive material comprises at least one of platinum, copper, gold, palladium, ruthenium, platinum-rhodium alloys, platinum-iridium alloys. 41. The apparatus of claim 26, further comprising a reclaim electrode. 42. The apparatus of claim 26, wherein the mechanism for applying a substantially uniform force per unit area to the back side of the flexible planar cathode applies a force of between about 0.2 and 2 psi. 43. The apparatus of claim 26, wherein mechanism for applying a substantially unifonn force per unit area to the back side of the flexible planar cathode applies a force of less than 1 psi. 44. The apparatus of claim 26, wherein the flexible planar cathode comprises a porous matrix configured to allow electrolyte to flow through it. 45. The apparatus of claim 44, wherein the mechanism for applying a substantially uniform force per unit area to the back side of the flexible planar cathode comprises at least one of: a fluid pressure differential in the electrolyte due to restricted flow of the electrolyte from the back side of the flexible planar cathode through the porous matrix and the spacing pad, and a compressive material contacting the back side of the flexible planar cathode. 46. The apparatus of claim 26, further comprising an electrolyte composition adjustment mechanism for controlling the electrolyte's composition. 47. The apparatus of claim 46, further comprising a mechanism for delivering at least a portion of the electrolyte that has passed through the electrolyte composition adjustment mechanism onto a portion of the spacing pad during the electroplanarization process. 48. A flexible planar cathode for electroplanarizing a metal layer disposed on a wafer work surface, said flexible planar cathode comprising:(a) a flexible substrate coated with a conductive material, said flexible substrate having a substantially planar front side surface; and(b) a spacing pad affixed to the substantially planar front side surface of the flexible substrate. 49. The flexible planar cathode of claim 48, wherein the flexible substrate and the spacing pad are made of materials and configured such that, during an electroplanarization process in which a substantially uniform force per unit area is applied to the back side of the flexible substrate, the spacing pad conforms to local surface contours in the metal layer arising from a plurality of recessed and raised regions in the metal layer, while the flexible substrate conforms only to the global contour of the wafer. 50. The flexible planar cathode of claim 49, wherein the spacing pad comprises a porous material. 51. The flexible planar cathode of claim 48, wherein the spacing pad is non-abrasive. 52. The flexible planar cathode of claim 48, wherein the spacing pad comprises a plurality of pores. 53. The flexible planar cathode of claim 52, wherein the plurality of pores in the spacing pad have a mean diameter of between about 0.02 μm and 10 μm. 54. The flexible planar cathode of claim 52, wherein the spacing pad has a void volume of between about 20 and 80 percent. 55. The flexible planar cathode of claim 49, wherein the spacing pad, when uncompressed, is at least about three times as thick as the largest variation in height between the plurality of recessed regions and raised regions in the metal layer disposed on the wafer work surface. 56. The flexible planar cathode of claim 48, wherein the spacing pad is between about 3 and 20 microns thick. 57. The flexible planar cathode of claim 48, wherein the spacing pad comprises at least one of a perfluoroalkoxy material, urethane material and polyvinyl alcohol (PVA). 58. The flexible planar cathode of claim 48, wherein the flexible substrate comprises at least one of silicon, polyimide, Kapton, polyurethane, polyethylene, mica, polycarbonate, stainless steel, molybdenum, tungsten, tantalum, or a coated nickel-based alloy. 59. The flexible planar cathode of claim 48, wherein the conductive material comprises at least one of platinum, copper, gold, palladium, ruthenium, platinum-rhodium alloys, platinum-iridium alloys. 60. The flexible planar cathode of claim 48, wherein the flexible planar cathode is electrically coupled to a high impedance electrical circuit. 61. The flexible planar cathode of claim 49, wherein the substantially uniform force per unit area, when applied to the back side of the flexible substrate, required to conform the flexible substrate to the global contour of the wafer is between about 0.2 and 2 psi. 62. The flexible planar cathode of claim 49, wherein the substantially uniform force per unit area, when applied to the back side of the flexible substrate, required to conform the flexible substrate to the global contour of the wafer is less than 1 psi. 63. The flexible planar cathode of claim 48, wherein the flexible substrate comprises a porous matrix configured to allow electrolyte to flow through it. 64. The flexible planar cathode of claim 48, wherein the flexible substrate is between about 15 and 300 μm thick.