This invention relates to forming vertical light emitting diodes (LEDs) and, in particular, to forming GaN-based vertical LEDs having one or more epitaxially grown conductive oxide electrodes.
GaN-based LEDs are sometimes formed to a have a deposited indium tin oxide (ITO) transparent conductive layer over the light emitting surface of the LED semiconductor layer, followed by depositing an opaque metal electrode. The metal electrode is patterned to form a center small dot, an array of dots, lines, an asterisk shape, or other shapes to allow most of the light to escape the top surface of the LED. The transparent conductive layer spreads the current from the metal electrode.
A transparent contact over the LED semiconductor layers is important for maximizing optical efficiency. There is usually a tradeoff between transparency and electrical performance. Contact potential and resistance between the contact material and the semiconductor determines the electrical performance. The electron and hole concentration in the semiconductors tends to be imbalanced such that either the p-type or n-type is more difficult to contact. Similarly, lower mobility in either the p-type or n-type requires low sheet resistance contact layers so that injected current remains uniform over large areas. Opaque metal contacts achieve low sheet resistance but at the cost of increased optical loss.
Transparent conductive oxides such as ITO are commonly used for transparent contacts to GaN. These contacts are physically deposited (not epitaxially grown) at a nominal thickness of 100 nm. Depending on the crystal structure of the resulting film, the resistance and transparency can be poor. Increasing the film thickness in excess of 1 um to reduce resistivity creates an optical loss that is too high for most applications.
Using more expensive vapor deposited films (not epitaxially grown) typically yields higher quality, higher transparency, and higher conductivity. The added cost tends to be restrictive for many applications, or the thickness must be limited to less than a practical minimum.
What is needed is an improved transparent contact for a GaN-based LED that has excellent transparency, low resistivity, and is inexpensive to manufacture.
Epitaxially grown, transparent conductive oxide contacts for GaN LEDs having high optical transmissivity and high electrical conductivity are described. The integration of forming epitaxially grown electrical contacts with the epitaxially grown LED semiconductor layers yields high material quality and also reduces device fabrication costs. Suitable transparent conductive oxide contacts include ZnO, MgO, CdO, MnO, CoO, and other transparent conductive oxides that have Wurtzite crystal structures that are similar to GaN, which enables the GaN-based LED layers to be epitaxially grown directly over the bottom conductive oxide layer, and enables the top conductive oxide layer to be epitaxially grown over the top GaN-based LED layer. Several integration and device fabrication methods are described.
In one embodiment, an electrical conductor, supplying power, directly contacts the transparent conductive oxide layer of the LED die. In another embodiment, a small metal bump contact may be formed over the transparent conductive oxide layer, where the bump is connected to the electrical conductor and the conductive oxide layer spreads the current. A metal mirror layer may also be used as an electrode contacting the conductive oxide layer, where light exits the opposite surface of the vertical LED or from the sides.
Nucleation layers can be used between a first layer of conductive oxide and the epitaxial growth substrate (e.g., sapphire). Intermediate contact layers, such as tunneling contacts between the conductive oxide layers and the p-type and n-type GaN layers are also described. Also, multiple novel selective growth techniques are described for forming isolated devices on the substrate during epitaxial growth, which also reduces device fabrication cost.
The resulting LED dies may be microscopic and printed as an ink over a bottom conductive layer. The LED dies are sandwiched between the bottom conductive layer and a top transparent conductive layer for connecting the printed LED dies in parallel. The conductive layers may directly contact the transparent oxide contacts or contact the bump or mirror layer described above.
Elements that are similar or identical in the various figures are labeled with the same numeral.
The starting substrate 12 may be any growth substrate that is suitable for growing GaN LED layers, such a sapphire, GaN, SiC, etc.
Over the substrate 12 is epitaxially grown a transparent conductive oxide layer 14, such as by chemical vapor deposition, annealed physical vapor deposition, solution deposition, and/or sol-gel techniques, so that the conductive oxide layer 14 has a crystalline structure compatible with growing GaN layers. Suitable transparent conductive oxides include ZnO, MgO, CdO, MnO, CoO, and other conductive oxides that have Wurtzite crystal structures (approximately a=3.2 A and c=5.2 A) that are similar to GaN. Epitaxially growing conductive oxides such as ZnO are known to those skilled in the art. For example, see Structural characterization of two-step growth of epitaxial ZnO films on sapphire substrates at low temperatures, by P Pant et al., JOURNAL OF PHYSICS D: APPLIED PHYSICS 42 (2009) 105409 (8pp), incorporated herein by reference.
The oxide layer 14 may range from 10 nm to 10 um.
ZnO is particularly unique since its 3.3 eV bandgap is similar to the 3.4 eV bandgap of GaN. ZnO is intrinsically an n-type semiconductor. Doped and alloyed oxides are also possible. Al, In, Ga, Sn are some dopants of ZnO. Mg, Mn, Co can be alloyed with ZnO. Electronic and magnetic properties of doped and alloyed oxides can be selected for a given application.
The epitaxial grown, crystalline conductive oxides in this embodiment can be used as optically transmissive electrical contacts to both p-type and n-type GaN. Such contacts may also be electrodes if they serve as the outer layer of the LED die that is connected to a conductor of power to the LED die.
An n-type GaN layer 16 is then epitaxially grown (e.g., using MOCVD or MBE) on this first crystalline conductive oxide layer 14, followed by a GaN-based active layer 18 with quantum wells, and a p-type GaN layer 20. The GaN epitaxy stack is typical of a hetrojunction LED. Each of the GaN layers 16, 18, and 20 may comprise multiple sub-layers. For example, ramped doping levels may be in sub-layers of the n-type GaN layer 16 to reduce stress caused by any lattice mismatch.
A second conductive oxide layer 22 is epitaxially grown on the GaN LED stack, which may be the same as the first conductive oxide layer 14. The conductive oxide layer 14 provides an electrical contact to the n-type GaN layer 16, and the conductive oxide layer 22 provides an electrical contact to the p-type GaN layer 20.
As shown in
An advantage of epitaxially-grown contacts for the p-type side and the n-type side is a simpler device process. Since the epitaxial stack already includes electrical contacts, contact deposition, using a very different method such as spraying or PVD, is not required in a subsequent device fabrication process.
The LED wafer may then be singulated into microscopic LED dies and the LED dies placed into an ink solution for printing. Details of the printing process are described later.
A bump may be formed on either end (prior to singulation) in order for the printing process to orient the LED dies in a particular way.
The bump 24/25 material can be electrically conductive (e.g., metal) or insulating, or optically transmissive (e.g., ITO) or opaque, depending on the application requirements. If the bump 24/25 is conductive, after the LED dies are printed over a bottom first conductive layer, the metal bump can be contacted by a printed top second conductive layer to supply power to the LED dies. If no bump is used, the top second conductive layer directly contacts the conductive oxide layer 14 or 22. The top and/or bottom conductive layers can be transparent to allow light to pass through. Light can exit the LED die from either or both surfaces (and also from its sides), and an opaque bump 24/25 reduces the light emitted from the bump-side. A smaller opaque bump 24/25 increases light extraction from the bump side.
If no bump is used, the LED dies may randomly orient on the bottom first conductive layer when printing, so that approximately 50% will be oriented up and the rest orientated down. Such an array of LED dies connected in parallel between the first and second conductive layers may be driven with an AC voltage so that all the LED dies are energized. If the bottom first conductive layer is reflective (e.g., an aluminum layer), all light will exit upward.
As shown in
Alternatively, as shown in
As shown in
As shown in
A conductive contact layer 40, such as heavily n-doped GaN, between the conductive oxide layer 14 and the n-GaN layer 16 might be necessary. Similarly a contact layer 42 between the conductive oxide layer 22 and the p-GaN layer 20 might be necessary. For example, assume the conductive oxide layer 22 were ZnO. Since ZnO is intrinsically n-type, a hetrojunction would be created between the n-ZnO and the p-GaN layer 20. Since p-type dopants for ZnO are not easily added, n-type ZnO is only available presently. A tunneling contact layer 42 between the n-ZnO and the p-GaN layer 20 is an effective solution. Thin layers (1-50 A) of high work function metals such as Au, Ni, Pt, and Pd can be used to tunnel between the p-GaN layer 20 and the n-ZnO. Thin layers (1-50 A) of heavily doped p-type or n-type of strained semiconductor such as InGaN can also be an effective tunneling contact layer. Thin layers (1-50 A) of heavily doped p-type or n-type conductive oxide such as n+ZnO could also be an effect tunneling contact layer. A thin (1-50 A) layer of insulating material could also be an effective tunneling contact layer.
The removal of the nucleation layer 38, shown in
The LED wafer is then singulated to define the individual LED dies.
In another embodiment, singulation is not performed on the epitaxial layers to define the individual LED dies. As shown in
One method for selective growth is to pattern the nucleation layer 38, as shown in
Another method of selective growth, shown in
Another method of selective growth, shown in
Epitaxial growth of conductive oxides for n-type and p-type GaN contacts has been described. High material quality resulting in higher optical transmissivity and higher conductivity can be achieved by epitaxial oxide growth. Low cost epitaxial growth techniques such as solution deposition and/or sol-gel techniques are possible. The integration of the electrical contacts during the epitaxial growth reduces device fabrication costs. The conductive oxide layers are compatible with other device layers such as bumps and mirrors. Nucleation layers can be used to better interface conductive oxide growth on particular substrates. Intermediate contact layers, such as tunneling contact layers, can be used to better interface the conductive oxides with the p-type and n-type GaN. Several other methods for selective epitaxial growth have also been proposed. The advantages of the selective growth embodiment include device isolation during growth, which reduces device fabrication cost.
The LED epitaxial layers may be the same as shown in
Using a mask, trenches 58 are etched through the layers down to the adhesive layer 56 to define the boundaries of the LED dies on the wafer. Alternatively, the selective growth techniques described above may be used to isolate the LEDs. The LED dies may have a width of about 8-10 microns. The width is selected to maximize the efficiency of the microscopic LED while enabling high reliability fabrication of the LED dies. Larger or smaller LED sizes can be used. The thickness of the LEDs is on the order of about 7 microns.
The conductive oxide layer 22 (serving as an anode electrode) is then treated with a fluorine process to create a thin hydrophobic layer 60. This may be done in a CVD process to form a fluorocarbon layer or fluoropolymer layer, or any other suitable hydrophobic layer, or may simply be done by depositing a thin layer of a commercially obtained fluorosurfactant material that is typically used for creating water repellant surfaces. Depositing the hydrophobic layer 60 may be done using printing, spraying, or other suitable process. Forming a super-hydrophobic surface is preferred. This process may be performed before or after the trenches 58 are formed.
The resulting LED dies are singulated by either dissolving the adhesive layer 56 by immersing the wafer in a solvent or by etching or grinding off the carrier wafer 54 until the trenches 58 are reached.
The singulation may be performed in an aqueous medium so the LED dies become uniformly dispersed in the medium to form an LED ink. The LED ink may include a viscosity-modifying polymer resin to form an LED ink suitable for printing using screen printing, flexographic printing, gravure printing, or any other suitable deposition method, including spraying, etc. The ink is to be printed in a thin layer so the LED dies form a monolayer of a predictable density and are randomly but generally uniformly distributed on the printed surface. In one embodiment, the LED dies are printed so that there is an average of about one LED die per square millimeter.
The printing process and light sheet formation process will now be described with respect to
In
The substrate 64 on the roll may be provided with a conductive layer 66, or the conductive layer 66 may be deposited on the substrate 64, such as by printing, spraying, etc., as the substrate 64 is being unrolled in a roll-to-roll process. The conductive layer 66 may be a reflective metal or may be a transparent conductor such as ITO or sintered silver nanowires.
The LED dies 68 are then printed over the conductive layer 66 to form a monolayer of LED dies 68, and the ink is then cured, such as by lamps, to evaporate the aqueous medium. If the LED dies 68 are properly oriented, the conductive oxide layer 14 (serving as a cathode electrode) will electrically contact the conductive layer 66. Any LED dies 68 that are not properly oriented will not affect the operation of the light sheet. The semiconductor LED layers are the combination of the n-type GaN layer 14, the active layer 16, and the p-type GaN layer 20. In one embodiment, the shapes of the LED dies 68 are designed to properly orient the LED dies 68 on the conductive layer 66.
A liquid hydrophilic dielectric material 70 is deposited over the LED dies 68 and the conductive layer 66 to a thickness about equal to the tops of the LED dies 68. The dielectric material 70 may be transparent or contains light-diffusing particles. Hydrophilic dielectric materials are commercially available and generally have the de-wetting characteristics of water relative to a hydrophobic surface. Deposition may be by printing, spraying, etc.
As shown in
In
A top conductor layer 72 is then deposited over the conductive oxide layer 22 and cured to electrically connect all the LED dies 68 in parallel. In one embodiment, the conductive layer 72 is a transparent conductor such as ITO or sintered silver nanowires.
A protective layer (not shown) may then be deposited over the conductive layer 72. A phosphor layer may be deposited to achieve any color. In one embodiment, the phosphor is YAG (yellow) and some blue LED light leaks through the phosphor to create white light.
The resulting light sheet 76 may be any size. For large sizes, thin metal bus lines may create a grid pattern to better distribute the driving voltage. Edges of the light sheet 76 may terminate in robust metal electrodes for connection to a driving voltage.
This technique can also be used for forming an addressable array of printed LEDs. In such an embodiment, the LEDs are printed in an array of small groups as addressable pixels, and addressable XY conductors are energized to energize a pixel at the intersection of the energized conductors.
This technique can also be employed for creating more efficient micro-components that are printed and contacted by conductor layers, such as non-LED silicon diodes, 3-terminal transistors, etc.
The light sheet 76 can be used for general illumination, displays, backlights, indicator lights, etc.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as fall within the true spirit and scope of this invention.
This application claims priority from U.S. provisional application Ser. No. 62/108,927, filed Jan. 28, 2015, assigned to the present assignee and incorporated herein by reference.
Number | Date | Country | |
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62108927 | Jan 2015 | US |