Automated thermal slide debonder

An improved apparatus for debonding temporary bonded wafers includes a debonder, a cleaning module and a taping module. A vacuum chuck is used in the debonder for holding the debonded thinned wafer and remains with the thinned debonded wafer during the follow up processes steps of cleaning and mounting onto a dicing tape. In one embodiment the debonded thinned wafer remains onto the vacuum chuck and is moved with the vacuum chuck into the cleaning module and then the taping module. In another embodiment the debonded thinned wafer remains onto the vacuum chuck and first the cleaning module moves over the thinned wafer to clean the wafer and then the taping module moves over the thinned wafer to mount a dicing tape onto the wafer.

FIELD OF THE INVENTION

The present invention relates to an apparatus for temporary semiconductor wafer bonding and debonding, and more particularly to an industrial-scale apparatus for temporary wafer bonding and debonding that comprises an automated thermal slide debonder.

BACKGROUND OF THE INVENTION

Several semiconductor wafer processes include wafer thinning steps. In some applications the wafers are thinned down to a thickness of less than 100 micrometers for the fabrication of integrated circuit (IC) devices. Thin wafers have the advantages of improved heat removal and better electrical operation of the fabricated IC devices. In one example, GaAs wafers are thinned down to 25 micrometers to fabricate power CMOS devices with improved heat removal. Wafer thinning also contributes to a reduction of the device capacitance and to an increase of its impedance, both of which result in an overall size reduction of the fabricated device. In other applications, wafer thinning is used for 3D-Integration bonding and for fabricating through wafer vias.

Wafer thinning is usually performed via back-grinding and/or chemical mechanical polishing (CMP). CMP involves bringing the wafer surface into contact with a hard and flat rotating horizontal platter in the presence of a liquid slurry. The slurry usually contains abrasive powders, such as diamond or silicon carbide, along with chemical etchants such as ammonia, fluoride, or combinations thereof. The abrasives cause substrate thinning, while the etchants polish the substrate surface at the submicron level. The wafer is maintained in contact with the abrasives until a certain amount of substrate has been removed in order to achieve a targeted thickness.

For wafer thicknesses of over 200 micrometers, the wafer is usually held in place with a fixture that utilizes a vacuum chuck or some other means of mechanical attachment. However, for wafer thicknesses of less than 200 micrometer and especially for wafers of less than 100 micrometers, it becomes increasingly difficult to mechanically hold the wafers and to maintain control of the planarity and integrity of the wafers during thinning. In these cases, it is actually common for wafers to develop microfractures and to break during CMP.

An alternative to mechanical holding of the wafers during thinning involves attaching a first surface of the device wafer (i.e., wafer processed into a device) onto a carrier wafer and thinning down the exposed opposite device wafer surface. The bond between the carrier wafer and the device wafer is temporary and is removed (i.e., debonded) upon completion of the thinning processing steps.

Several temporary bonding techniques have been suggested including using of adhesive compounds that are chemically dissolved after processing or using of adhesive tapes or layers that are thermally or via radiation decomposed after processing. Most of these adhesive-based temporary bonding techniques are followed by a thermal slide debonding process where the device wafer and the carrier wafer are held by vacuum chucks while heat is applied to the bonded wafer pair and the wafers slide apart from each other. In the current thermal slide debonding process the separated thinned device wafer is held via a secondary support mechanism for further processing. This secondary support mechanism usually adds cost and complications to the processing equipment. It is desirable to reduce the added cost and complications.

SUMMARY OF THE INVENTION

An improved apparatus for temporary wafer bonding and debonding100includes a temporary bonder110, a wafer thinning station120, a debonder150, a cleaning module170and a taping module180, as shown inFIG. 2andFIG. 3. Usually a secondary carrier is used for moving the thinned wafer from the debonder120to the cleaning170and taping 180 modules. The present invention eliminates the need for a secondary carrier by allowing a vacuum chuck152used in the thermal slide debonder150to remain with the thinned wafer20during the follow up processes steps of cleaning (52) and mounting onto a dicing tape (53). In one embodiment the thinned wafer20remains onto the vacuum chuck152and is moved with the vacuum chuck152into the various process stations, shown inFIG. 2. In another embodiment the thinned wafer20remains onto the vacuum chuck152and the various process stations170,180move over the thinned wafer20to perform the various process steps, shown inFIG. 3.

In general, in one aspect, the invention features an apparatus for processing a temporary bonded wafer pair comprising a device wafer and a carrier wafer. The apparatus includes a debonder for debonding the device wafer from the carrier wafer after it has been thinned, a cleaning module for cleaning the debonded thinned device wafer, a taping module for applying a tape onto the debonded thinned device wafer and a vacuum chuck. The vacuum chuck is used in the debonder and includes means for holding the debonded thinned device wafer. The apparatus also includes means for moving the vacuum chuck with the debonded thinned device wafer into and out of the cleaning module and into and out of the taping module.

In general, in another aspect, the invention features an apparatus for processing a temporary bonded wafer pair comprising a device wafer and a carrier wafer. The apparatus includes a debonder for debonding the device wafer from the carrier wafer after it has been thinned, a cleaning module for cleaning the debonded thinned device wafer, a taping module, and a vacuum chuck used in the debonder and including means for holding the debonded thinned device wafer during debonding, cleaning and taping. The cleaning module includes means for moving over the debonded thinned wafer in the debonder for cleaning the debonded thinned wafer. The taping module includes means for moving over the debonded thinned wafer in the debonder for applying the tape onto the debonded thinned wafer.

Implementations of these aspects of the invention may include one or more of the following features. The debonder includes a top chuck assembly, a bottom chuck assembly, a static gantry supporting the top chuck assembly, an X-axis carriage drive supporting the bottom chuck assembly and an X-axis drive control configured to drive horizontally the X-axis carriage drive and the bottom chuck assembly from a loading zone to a process zone under the top chuck assembly and from the process zone back to the loading zone, and the bottom chuck assembly includes the vacuum chuck. The top chuck assembly includes a top support chuck bolted to the static gantry, a heater support plate in contact with the bottom surface of the top support chuck, a heater being in contact with the bottom surface of the heater support plate, a top wafer plate in contact with the heater, a Z-axis drive for moving the top wafer plate in the Z-direction and placing the top wafer plate in contact with the unbonded surface of the carrier wafer and a plate leveling system for leveling the top wafer plate and for providing wedge error compensation of the top wafer plate. The apparatus further includes a lift pin assembly for raising and lowering the wafer pair onto the bottom chuck assembly. The bonder further includes a base plate supporting the X-axis carriage drive and the static gantry and the base plate includes one of a honeycomb structure with vibration isolation supports or a granite plate. The apparatus further includes means for twisting the device wafer at the same time the horizontal motion is initiated. The X-axis carriage drive includes an air bearing carriage drive. The debonder further includes two parallel lateral carriage guidance tracks guiding the X-axis carriage drive in its horizontal motion along the X-axis. The carrier wafer is held by the top chuck assembly via vacuum pulling. The plate leveling system includes three guide shafts connecting the heater to the top support chuck and three pneumatically actuated split clamps. The heater includes two independently controlled concentric heating zones configured to heat wafers having a diameter of 200 or 300 millimeters, respectively. The apparatus further includes a bonder for temporary bonding the wafer pair and a wafer thinning module for thinning the device wafer of the temporarily bonded wafer pair.

In general, in another aspect, the invention features a method for debonding and processing two via an adhesive layer temporary bonded wafers. The method includes the following steps. First, providing a bonder comprising a top chuck assembly, a bottom chuck assembly, a static gantry supporting the top chuck assembly, an X-axis carriage drive supporting the bottom chuck assembly and an X-axis drive control configured to drive horizontally the X-axis carriage drive and the bottom chuck assembly from a loading zone to a process zone under the top chuck assembly and from the process zone back to the loading zone. The bottom chuck assembly comprises a vacuum chuck. Next, loading a wafer pair comprising a carrier wafer bonded to a device wafer via an adhesive layer upon the bottom chuck assembly at the loading zone oriented so that the unbonded surface of the device wafer is in contact with the bottom chuck assembly. Next, driving the X-axis carriage drive and the bottom chuck assembly to the process zone under the top chuck assembly. Next, placing the unbonded surface of the carrier wafer in contact with the top chuck assembly and holding the carrier wafer by the top chuck assembly. Next, heating the carrier wafer with a heater comprised in the top chuck assembly to a temperature around or above the adhesive layer's melting point. Next, initiating horizontal motion of the X-axis carriage drive along the X-axis by the X-axis drive control while heat is applied to the carrier wafer and while the carrier wafer is held by the top chuck assembly and the device wafer is held by the bottom chuck assembly and thereby causing the device wafer to separate and slide away from the carrier wafer. Next, moving the vacuum chuck with the debonded thinned device wafer into a cleaning station and removing any residual adhesive off the device wafer and then moving the vacuum chuck with the cleaned debonded thinned device wafer into a taping module and applying a tape to a surface of the debonded thinned device wafer. Finally, removing the taped debonded device wafer from the vacuum chuck and placing it into a device wafer cassette. The residual adhesive is removed by using a solvent and applying spin cleaning techniques. The top chuck assembly further includes a top support chuck bolted to the static gantry, a heater support plate in contact with the bottom surface of the top support chuck, a heater being in contact with the bottom surface of the heater support plate, a top wafer plate in contact with the heater, a Z-axis drive for moving the top wafer plate in the Z-direction and placing the top wafer plate in contact with the unbonded surface of the carrier wafer and a plate leveling system for leveling the top wafer plate and for providing wedge error compensation of the top wafer plate.

In general, in another aspect, the invention features a method for debonding and processing two via an adhesive layer temporary bonded wafers. The method includes the following steps. First, providing a chamber comprising a top chuck assembly, a bottom chuck assembly, an X-axis carriage drive supporting the bottom chuck assembly and an X-axis drive control configured to drive horizontally the X-axis carriage drive and the bottom chuck assembly from a loading zone to a process zone and from the process zone back to the loading zone. Next, loading a wafer pair comprising a carrier wafer bonded to a device wafer via an adhesive layer upon the bottom chuck assembly at the loading zone oriented so that the unbonded surface of the device wafer is in contact with the bottom chuck assembly. Next, driving the X-axis carriage drive and the bottom chuck assembly to the process zone and placing the top chuck assembly on top of the bottom chuck assembly. Next, placing the unbonded surface of the carrier wafer in contact with the top chuck assembly and holding the carrier wafer by the top chuck assembly. Next, heating the carrier wafer with a heater comprised in the top chuck assembly to a temperature around or above the adhesive layer's melting point. Next, initiating horizontal motion of the X-axis carriage drive along the X-axis by the X-axis drive control while heat is applied to the carrier wafer and while the carrier wafer is held by the top chuck assembly and the device wafer is held by the bottom chuck assembly and thereby causing the device wafer to debond and slide away from the carrier wafer. Next, moving the top chuck assembly with the debonded carrier wafer away from the process zone. Next, moving a cleaning station module into the chamber over the debonded device wafer and removing any residual adhesive off the device wafer. Next, moving the cleaning station module out of the chamber after any residual adhesive is removed off the device wafer. Next, moving a taping module into the chamber over the debonded and cleaned device wafer and applying a tape to a surface of the debonded device wafer and then removing the taped debonded device wafer from the bottom chuck assembly and placing it into a device wafer cassette. The residual adhesive is removed by using a solvent and applying spin cleaning techniques. The top chuck assembly further includes a top support chuck bolted to the static gantry, a heater support plate in contact with the bottom surface of the top support chuck, a heater being in contact with the bottom surface of the heater support plate, a top wafer plate in contact with the heater, a Z-axis drive for moving the top wafer plate in the Z-direction and placing the top wafer plate in contact with the unbonded surface of the carrier wafer and a plate leveling system for leveling the top wafer plate and for providing wedge error compensation of the top wafer plate.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIG. 1, an apparatus for temporary wafer bonding100includes a temporary bonder210, a wafer thinning module120, a thermal slide debonder150′, a wafer cleaning station170and a wafer taping station180. Bonder210facilitates the temporary bonding processes60a, shown inFIG. 1Aand debonder150′ facilitates the thermal slide debonding processes60b, shown inFIG. 1A.

Referring toFIG. 1A, temporary bond process60aincludes the following steps. First, device wafer20is coated with a protective coating21(62), the coating is then baked and chilled (63) and then the wafer is flipped (64). A carrier wafer30is coated with an adhesive layer31(65) and then the coating is baked and chilled (66). In other embodiments, a dry adhesive film is laminated onto the carrier wafer, instead of coating an adhesive layer. Next, the flipped device wafer20is aligned with the carrier wafer30so that the surface of the device wafer with the protective coating20ais opposite to the surface of the carrier wafer with the adhesive layer30a(67) and then the two wafers are bonded (68) in the temporary bonder module210, shown inFIG. 1B. The bond is a temporary bond between the protective layer21and the adhesive layer31. In other embodiments, no protective coating is applied onto the device wafer surface and the device wafer surface20ais directly bonded with the adhesive layer31. Examples of device wafers include GaAs wafers, silicon wafers, or any other semiconductor wafer that needs to be thinned down to less than 100 micrometers. These thin wafers are used in military and telecommunication applications for the fabrication of power amplifiers or other power devices where good heat removal and small power factor are desirable. The carrier wafer30is usually made of a non-contaminating material that is thermally matched with the device wafer, i.e., has the same coefficient of thermal expansion (CTE). Examples of carrier wafer materials include silicon, glass, sapphire, quartz or other semiconductor materials. The diameter of the carrier wafer30is usually the same as or slightly larger than the diameter of the device wafer20, in order to support the device wafer edge and prevent cracking or chipping of the device wafer edge. In one example, the carrier wafer thickness is about 1000 micrometers and the total thickness variation (TTV) is 2-3 micrometers. Carrier wafers are recycled and reused after they are debonded from the device wafer. In one example, adhesive layer31is an organic adhesive WaferBOND™ HT-10.10, manufactured by Brewer Science, Missouri, USA. Adhesive31is applied via a spin-on process and has a thickness in the range of 9 to 25 micrometers. The spin speed is in the rage of 1000 to 2500 rpm and the spin time is between 3-60 second. After the spin-on application, the adhesive layer is baked for 2 min at a temperature between 100° C. to 150° C. and then cured for 1-3 minutes at a temperature between 160° C. to 220° C. WaferBOND™ HT-10.10 layer is optically transparent and is stable up to 220° C. The bonded wafer stack10is placed in a thinning module120. After the thinning120of the exposed device wafer surface20bthe carrier wafer30is debonded via the debond process60b, shown inFIG. 1A. Debond process60b, includes the following steps. First heating the wafer stack10until the adhesive layer31softens and the carrier wafer30slides off from the thinned wafer (69). The WaferBOND™ HT-10.10 debonding time is less than 5 minutes. The thinned wafer20is then moved to a cleaning station170where any adhesive residue is stripped away (52) and then the thinned wafer20is moved to a taping station180placed in a dicing frame25(53).

The temporary bonding (68) of the carrier wafer30to the device wafer20takes place in temporary bonder module,210. Referring toFIG. 1B, the device wafer20is placed in a fixture chuck and the fixture chuck is loaded in the chamber210. The carrier wafer30is placed with the adhesive layer facing up directly on the bottom chuck210aand the two wafers20,30are stacked and aligned. The top chuck210bis lowered down onto the stacked wafers and a low force is applied. The chamber is evacuated and the temperature is raised to 200° C. for the formation of the bond between the protective coating layer21and the adhesive layer31. Next, the chamber is cooled and the fixture with the bonded wafer stack10is unloaded.

The debond process60bis a thermal slide debond process and includes the following steps, shown inFIG. 1A. The bonded wafer stack10is heated causing the adhesive layer31to become soft. The carrier wafer is then twisted around axis169and then slid off the wafer stack under controlled applied force and velocity (69). The separated device wafer20is then moved into the cleaning station170and cleaned (52) and then it is moved into the taping station180where it is mounted onto a dicing frame25(53).

In cases where the thinned device wafer is thicker than about 100 micrometers usually no additional support is needed for moving the thinned wafer20from the thermal slide debonder150to the further processing stations170,180. However, in cases where the thinned device wafer20is thinner than 100 micrometers a secondary support mechanism is required to prevent breaking or cracking of the thinned device wafer. Currently, the secondary support mechanism includes an electrostatic carrier or a carrier comprising a Gelpak™ acrylic film on a specially constructed wafer. As was mentioned above, these secondary support mechanism add complications and cost to the process.

The present invention eliminates the need for a secondary carrier by allowing a vacuum chuck152used in the thermal slide debonder150to remain with the thinned wafer20during the follow up processes steps of cleaning (52) and mounting onto a dicing tape (53). In one embodiment the thinned wafer20remains onto the vacuum chuck152and is moved with the vacuum chuck into the various process stations. In another embodiment the thinned wafer20remains onto the vacuum chuck152and the various process stations170,180move over the thinned wafer20to perform the various process steps.

Referring toFIG. 2andFIG. 2A, the bonded wafer pair10is loaded into the vacuum chuck152(shown inFIG. 4andFIG. 14) of debonder150and the thermal debonding process60bis applied. The vacuum chuck152with the debonded device wafer20moves into the cleaning station170where a solvent is used to clean the residual adhesive off the wafer via a spin cleaning technique. Next, the chuck152with the cleaned device wafer20moves to the taping station180where a tape/frame assembly is attached to the thinned device wafer20surface. Finally, the taped thinned wafer20is moved to a cassette and the carrier wafer30is moved to a different cassette.

Referring toFIG. 3andFIG. 3A, in another embodiment, the thinned wafer stack10is placed in the vacuum chuck152and the chuck152is loaded in a chamber122. Next, thermal slide debonder150moves into position over the vacuum chuck152with the bonded wafer pair10and performs the thermal debonding process60b. Next, the thermal slide debonder150moves out of the chamber122and the cleaning module170moves into the chamber122and cleans the residual adhesive off the device wafer20. Once the cleaning step is completed, the cleaning module170is removed and the taping module180is moved over the thinned and cleaned device wafer20and applies the tape/frame assembly onto the device wafer20. Finally, the taped thinned device wafer20is moved to a cassette and the carrier wafer30is moved to a different cassette.

Referring toFIG. 5-FIG.11, temporary bond module210includes a housing212having a load door211, an upper block assembly220and an opposing lower block assembly230. The upper and lower block assemblies220,230are movably connected to four Z-guide posts242. In other embodiments, less than four or more than four Z-guide posts are used. A telescoping curtain seal235is disposed between the upper and lower block assemblies220,230. A temporary bonding chamber202is formed between the upper and lower assemblies220,230and the telescoping curtain seal235. The curtain seal235keeps many of the process components that are outside of the temporary bonding chamber area202insulated from the process chamber temperature, pressure, vacuum, and atmosphere. Process components outside of the chamber area202include guidance posts242, Z-axis drive243, illumination sources, mechanical pre-alignment arms460a,460band wafer centering jaws461a,461b, among others. Curtain235also provides access to the bond chamber202from any radial direction.

Referring toFIG. 7, the lower block assembly230includes a heater plate232supporting the wafer20, an insulation layer236, a water cooled support flange237a transfer pin stage238and a Z-axis block239. Heater plate232is a ceramic plate and includes resistive heater elements233and integrated air cooling234. Heater elements233are arranged so the two different heating zones are formed. A first heating zone233B is configured to heat a 200 mm wafer or the center region of a 300 mm wafer and a second heating zone233A is configured to heat the periphery of the 300 mm wafer. Heating zone233A is controlled independently from heating zone233B in order to achieve thermal uniformity throughout the entire bond interface405and to mitigate thermal losses at the edges of the wafer stack. Heater plate232also includes two different vacuum zones for holding wafers of 200 mm and 300 mm, respectively. The water cooled thermal isolation support flange237is separated from the heater plate by the insulation layer236. The transfer pin stage238is arranged below the lower block assembly230and is movable supported by the four posts242. Transfer pin stage238supports transfer pins240arranged so that they can raise or lower different size wafers. In one example, the transfer pins240are arranged so that they can raise or lower 200 mm and 300 mm wafers. Transfer pins240are straight shafts and, in some embodiments, have a vacuum feed opening extending through their center, as shown inFIG. 11. Vacuum drawn through the transfer pin openings holds the supported wafers in place onto the transfer pins during movement and prevents misalignment of the wafers. The Z-axis block239includes a precision Z-axis drive243with ball screw, linear cam design, a linear encoder feedback244for submicron position control, and a servomotor246with a gearbox, shown inFIG. 8.

Referring toFIG. 9, the upper block assembly220includes an upper ceramic chuck222, a top static chamber wall221against which the curtain235seals with seal element235a, a 200 mm and a 300 mm membrane layers224a,224b, and three metal flexure straps226arranged circularly at 120 degrees. The membrane layers224a,224b, are clamped between the upper chuck222and the top housing wall213with clamps215a,215b, respectively, and form two separate vacuum zones223a,223bdesigned to hold 200 mm and 300 mm wafers, respectively, as shown inFIG. 10. Membrane layers224a,224bare made of elastomer material or metal bellows. The top ceramic chuck222is highly flat and thin. It has low mass and is semi-compliant in order to apply uniform pressure upon the wafer stack10. The top chuck222is lightly pre-loaded with membrane pressure against three adjustable leveling clamp/drive assemblies216. Clamp/drive assemblies216are circularly arranged at 120 degrees. The top chuck222is initially leveled while in contact with the lower ceramic heater plate232, so that it is parallel to the heater plate232. The three metal straps226act a flexures and provide X-Y-T (Theta) positioning with minimal Z-constraint. The clamp/drive assemblies216also provide a spherical Wedge Error Compensating (WEC) mechanism that rotates and/or tilts the ceramic chuck222around a center point corresponding to the center of the supported wafer without translation.

The loading and pre-alignment of the wafers is facilitated with the mechanical centering device460, shown inFIG. 12. Centering device460includes two pre-alignment arms460a,460b, shown in the open position inFIG. 12and in the closed position inFIG. 13. At the ends of each arm460a,460bthere are mechanical jaws461a,461b. The mechanical jaws461a,461bhave tapered surfaces462and463that conform to the curved edge of the 300 mm wafer and 200 mm wafer, respectively.

Referring toFIG. 14, thermal slide debonder150includes a top chuck assembly151, a bottom chuck assembly152, a static gantry153supporting the top chuck assembly151, an X-axis carriage drive154supporting the bottom chuck assembly152, a lift pin assembly155designed to raise and lower wafers of various diameters including diameters of 200 mm and 300 mm, and a base plate163supporting the X-axis carriage drive154and gantry153.

Referring toFIG. 15, the top chuck assembly151includes a top support chuck157bolted to gantry153, a heater support plate158in contact with the bottom surface of the top support chuck157, a top heater159in contact with the bottom surface of the heater plate158, a Z-axis drive160and a plate leveling system for leveling the upper wafer plate/heater bottom surface164. The plate leveling system includes three guide shafts162that connect the top heater159to the top support chuck157and three pneumatically actuated split clamps161. The plate leveling system provides a spherical Wedge Error Compensating (WEC) mechanism that rotates and/or tilts the upper wafer plate164around a center point corresponding to the center of the supported wafer without translation. The heater159is a steady state heater capable to heat the supported wafer stack10up to 350° C. Heater159includes a first heating zone configured to heat a 200 mm wafer or the center region of a 300 mm wafer and a second heating zone configured to heat the periphery of the 300 mm wafer. The first and second heating zones are controlled independently from each other in order to achieve thermal uniformity throughout the entire bond interface of the wafer stack and to mitigate thermal losses at the edges of the wafer stack. The heater support plate158is water cooled in order to provide thermal isolation and to prevent the propagation of any thermal expansion stresses that may be generated by the top heater159.

Referring toFIG. 16, the bottom chuck152is made of a low thermal mass ceramic material and is designed to slide along the X-axis149on top of the air bearing carriage drive154. The carriage drive154is guided in this X-axis motion by two parallel lateral carriage guidance tracks156. Bottom chuck152is also designed to rotate along its Z-axis169. A Z-axis rotation by a small angle (i.e., twisting) is used to initiate the separation of the wafers, as will be described below. The base plate163is vibration isolated. In one example, base plate is made of granite. In other examples base plate156has a honeycomb structure and is supported by pneumatic vibration isolators (not shown).

Referring toFIG. 17A,FIG. 17B, the debonding operation with the thermal slide debonder150ofFIG. 16includes the following steps. First, the temporary bonded wafer stack10is loaded on the primary lift pins155arranged so that the carrier wafer30is on the top and the thinned device wafer20is on the bottom (171). Next, the wafer stack10is lowered so that the bottom surface of the thinned device wafer20is brought into contact with the bottom chuck152(172). The bottom chuck152is then moved along the165adirection until it is under the top heater159(174). Next, the Z-axis160of the top chuck151moves down and the bottom surface164of the top heater159is brought into contact with the top surface of the carrier wafer30and then air is floated on top heater159and carrier wafer30until the carrier wafer stack30reaches a set temperature. When the set temperature is reached, vacuum is pulled on the carrier wafer30so that is held by the top chuck assembly151and the guide shafts162are locked in the split clamps162(175). At this point the top chuck151is rigidly held while the bottom chuck152is compliant and the thermal slide separation is initiated (176) by first twisting the bottom chuck152and then moving the X-axis carriage154toward the165bdirection away from the rigidly held top chuck assembly151(177). The debonded thinned device wafer20is carried by the X-axis carriage154on top of chuck152to the unload position. Next, chuck152with the thinned debonded wafer20is moved to stations170and180for cleaning and taping, respectively (178). Alternatively, stations170and180are moved over chuck152with the debonded wafer20for cleaning and taping to take place (179).