The following relates to the lighting arts. It especially relates to light emitting devices including group III-nitride based light emitting diodes (LEDs) transferred from a deposition substrate to a host substrate or sub-mount using a laser lift-off process, and to methods for fabricating same, and will be described with particular reference thereto. However, the following will also find application in conjunction with other light emitting semiconductor devices that include semiconductor layers transferred from a deposition substrate to a host substrate or sub-mount.
Group III-nitride based LEDs are used for generating green, blue, violet, and ultraviolet light emission. These LEDs include a stack of layers typically including layers of gallium nitride (GaN), aluminum nitride (AlN), indium nitride (InN), and ternary or quaternary alloys thereof, which define a pn diode. By coupling such an
LED with suitable phosphors, a white LED can be fabricated. For example, the LED die can be coated with a phosphor-containing encapsulant, an array of group Ill-nitride based LEDs can be arranged to irradiate a phosphor-containing or phosphor-coated optic, or so forth.
The deposition substrate for epitaxially growing the group III-nitride layers should substantially comport with the lattice constant, growth temperature, and chemistry of the epitaxially deposited group III-nitride layers. The ideal substrate is a group III-nitride substrate such as a GaN substrate; however, difficulties have been encountered in generating large-area group III-nitride wafers. Most group III-nitride LEDs are presently grown on deposition substrates made of sapphire Al2O3)(or silicon carbide (SiC).
Sapphire and SiC have characteristics that may not be advantageous in the finished device, such as being electrically insulating, exhibiting limited thermal conductivity, or so forth. Accordingly, there is interest in transferring the epitaxially grown group III-nitride pn diode stack from the deposition substrate to a more advantageous host substrate or sub-mount, which provides structural support (and optionally also electrical connectivity) for the final fabricated LED device. Suitable host substrates or sub-mounts can include, for example, silicon or gallium arsenide (GaAs) substrates or sub-mounts, a dielectric-coated metal substrate or sub-mount, or so forth. To perform the lift-off, the surface of the epitaxially grown group III-nitride stack is attached to the host substrate or sub-mount and detached from the sapphire, SiC, or other deposition substrate.
One approach for detaching the stack of group III-nitride semiconductor layers is application of a laser lift-off process. Laser lift-off detachment processes employ a laser whose energy is absorbed near the interface between the group III-nitride stack and the deposition substrate. For example, some excimer lasers produce laser beams that are highly transparent in sapphire but strongly absorbed by GaN. With the group III-nitride layers bonded to the host substrate, the excimer laser impinges upon the sapphire substrate. Because the sapphire is transparent to the laser beam, it passes through the sapphire substrate substantially without attenuation, and is absorbed at the GaN/sapphire interface, causing detachment of the sapphire substrate.
Although laser lift-off provides a host substrate or sub-mount having advantageous characteristics, light extraction from the detached stack of group III-nitride layers is degraded by the lift-off. The lifted-off stack of group III-nitride layers is thin (typical thicknesses for the stack are around a few microns to around a few tens of microns) with substantially larger lateral dimensions (typically hundreds of microns to a centimeter or larger). The new surface created by the laser lift-off is smooth. Moreover, the refractive index of group III-nitride materials is high. The high aspect ratio dimensions, smooth surface, and high refractive index cooperate to cause substantial total internal reflection and waveguiding of light generated in the lifted-off stack of group Ill-nitride layers; which substantially reduces light extraction.
According to one aspect, a light emitting device is disclosed, including a stack of semiconductor layers defining a light emitting pn junction and a dielectric layer disposed over the stack of semiconductor layers. The dielectric layer has a refractive index substantially matching a refractive index of the stack of semiconductor layers. The dielectric layer has a principal surface distal from the stack of semiconductor layers. The distal principal surface includes patterning, roughening, or texturing configured to promote extraction of light generated in the stack of semiconductor layers.
According to another aspect, a method is disclosed for fabricating a light emitting device. A stack of semiconductor layers is formed defining a light emitting pn junction. A dielectric layer is disposed over the stack of semiconductor layers. The dielectric layer has a refractive index substantially matching a refractive index of the stack of semiconductor layers. The dielectric layer has a principal surface distal from the stack of semiconductor layers. The distal principal surface includes patterning, roughening, or texturing configured to promote extraction of light generated in the stack of semiconductor layers.
According to another aspect, a light emitting device is disclosed, including a stack of semiconductor layers defining a light emitting pn junction and a host substrate or sub-mount on which is disposed the stack of semiconductor layers. The host substrate or sub-mount is different from a deposition substrate on which the stack of semiconductor layers was formed. Patterning, roughening, or texturing configured to promote extraction of light generated in the stack of semiconductor layers is formed, on a distal principal surface of the stack of semiconductor layers that is distal from the host substrate or sub-mount.
According to another aspect, a method is disclosed for fabricating a light emitting device. A stack of semiconductor layers defining a light emitting pn junction is formed on a deposition substrate. The formed stack of semiconductor layers is transferred from the deposition substrate to a host substrate or sub-mount. The transferring exposes a new principal surface of the stack of semiconductor layers that was not exposed when the stack of semiconductor layers was formed on the deposition substrate. Patterning, roughening, or texturing configured to promote extraction of light generated in the stack of semiconductor layers is generated on the new principal surface of the stack of semiconductor layers.
With reference to
In some embodiments, the deposition substrate 12 is sapphire or SiC, which are advantageously closely lattice-matched to GaN. However, other deposition substrates can be used. The deposition substrate should be closely lattice-matched to the stack of group III-nitride semiconductor layers. However, some lattice mismatch therebetween can be tolerated. Optionally, techniques such as graded epitaxial semiconductor buffers or use of thin, compliant deposition substrates can be employed to accommodate lattice mismatch between the deposited stack and the deposition substrate.
After formation, the second principal surface 16 of the stack of group III-nitride semiconductor layers 10 is attached to a host substrate or sub-mount 20, such as a silicon sub-mount. The illustrated host substrate or sub-mount 20 includes bonding bumps 22 electrically connecting with the stack of semiconductor layers 10 to enable electrical energizing of the light-emitting pn junction. Typically, the bonding bumps 22 electrically contact metallic or other highly conductive electrode layers (not shown) which were deposited on the second principal surface 16 of the stack of semiconductor layers 10 prior to the attachment. The illustrated host substrate or sub-mount 20 further includes conductive vias 24 electrically connected with the bonding bumps 22 by front-side conductive traces 26 so as to provide back-side electrical contact for the device. Optionally, an underfill material 28 is disposed between the attached stack of semiconductor layers 10 and the host substrate or sub-mount 20 in-between the bonding bumps 22. The underfill material can provide benefits such as improved attachment, thermal conduction from the stack of semiconductor layers 10 to the host substrate or sub-mount 20, or so forth. The underfill material 28 should be electrically insulating, and can be either thermally insulating, or thermally conductive to promote heat transfer from the stack of semiconductor layers 10 to the host substrate or sub-mount 20.
After attachment of the second principal surface 16 of the stack of group III-nitride semiconductor layers 10 to the host substrate or sub-mount 20, the stack of group La-nitride semiconductor layers 10 is detached from the deposition substrate 12. In some embodiments, laser lift-off is used to effectuate this detachment. In a suitable laser lift-off approach, a laser beam 30 (diagrammatically indicated by block arrows in
With reference to
With reference to
In some embodiments, the patterning, roughening, or texturing 50, 50′ is substantially random and non-periodic. In other embodiments, the patterning, roughening, or texturing 50, 50′ defines microlenses. In yet other embodiments, the patterning, roughening, or texturing 50, 50′ has slanted surfaces or other structure that biases extracted light toward a selected viewing angle. The patterning, roughening, or texturing 50, 50′ reduces the planarity of the distal principal surface 44, 44′ to enhance light extraction by reducing total internal reflection and waveguiding effects. The patterning, roughening, or texturing 50, 50′ includes feature sizes that enhance light extraction based on the wavelength of light emitted by the stack of semiconductor layers 10 defining the light emitting pn junction.
The dielectric layer 40, 40′ can be substantially any transparent dielectric material with a refractive index comparable with that of the semiconductor material. One suitable dielectric material is silicon nitride (SiNx). The refractive index of SiNx depends upon the stoichiometry, and tends to increase with increasing Si/N ratio. The inventors have deposited SiNx by plasma-enhanced chemical vapor deposition (PECVD), and have measured a refractive index of greater than 2.4 at 680 nm. This refractive index is sufficiently high to substantially match the refractive index of GaN at 680 nm, which has been reported to be about 2.3. See Zauner et al., MRS Internet J. Nitride Semicond. Res. 3, 17 (1998), pp. 1-4. Other suitable dielectric materials include, for example, silicon oxides (SiOx) and silicon oxynitrides (SixNy),
The refractive index of the dielectric layer 40, 40′ should substantially match the refractive index of the stack of semiconductor layers 10 so as to reduce reflections as light passes from the semiconductor material into the dielectric material. The critical angle θc references to the interface normal for total internal reflection is given by sin(θc)=nd/ns where nd is the refractive index of the dielectric layer 40, 40′ and ns is the refractive index of the semiconductor. For nd≧ns, total internal reflection does not occur for light passing from the stack of semiconductor layers 10 into the dielectric layer 40, 40′. Accordingly, any dielectric material having a refractive index about the same as, or greater than, the refractive index of the semiconductor material is considered to substantially match the refractive index of the semiconductor material. That is, the condition for the refractive index of the dielectric layer 40, 40′ to substantially match the refractive index of the stack of semiconductor layers 10 is either nd˜ds or nd>ns.
The dielectric layer 40, 40′ including the distal principal surface 44, 44′ having the patterning, roughening, or texturing 50, 50′ can be produced in various ways. In one approach, the dielectric layer is deposited substantially uniformly across the first principal surface 14 of the stack of semiconductor layers 10. An etch down process, such as a plasma etch, is then applied using a mask to form the patterning, roughening, or texturing 50, 50′. The mask can be a non-contact mask suitable for patterning devices after attachment to the host substrate or sub-mount 20. A non-contact mask suitable for photolithography, x-ray lithography, or e-beam lithography can be used. The mask can be used to form a resist pattern (such as a photoresist pattern) on the deposited dielectric layer; the resist pattern serves to define the etched and unetched regions. Alternatively, the mask can be used as a shadow mask in a directional dry etching process.
Another approach is to deposit small polystyrene members, such as polystyrene spheres, on the surface of the deposited dielectric layer, and using those members or spheres as a plasma etch mask. This approach typically provides a random or non-periodic patterning, roughening, or texturing. Yet another approach for generating the patterning, roughening, or texturing 50 is to use grating lithography. This approach typically provides a periodic roughening.
These etch-down approaches can produce either the patterning, roughening, or texturing 50 which does not pass entirely through the dielectric layer 40, or the patterning, roughening, or texturing 50′ which does pass entirely through the dielectric layer 40′ so as to define openings in the dielectric layer 40′. The difference is merely in how deep the etch-down process penetrates. If etch-down processing is used to produce the dielectric layer 40′ including openings, then an etching is preferably selected that does not attack the semiconductor material making up the stack of semiconductor layers 10.
A lift-off process can also be used to define the patterning, roughening, or texturing 50. The mask is used first to define a resist pattern (such as a photoresist pattern) on the first principal surface 14 of the stack of semiconductor layers 10. The dielectric layer with index of refraction matched to the semiconductor material is then deposited on top of the first principal surface 14 and the resist pattern, followed by a liftoff process that removes the resist pattern along with those portions of the deposited dielectric layer disposed on the resist.
The lift-off process can be readily performed in a manner which does not damage the stack of semiconductor layers 10, so as to produce the dielectric layer 40′ including openings. For example, the resist pattern can be a photoresist pattern produced by light exposure that does not damage the semiconductor material. To produce the dielectric layer 40 using a lift-off process, a continuous layer of dielectric material can be first deposited, followed by masked resist pattern definition on top of the continuous dielectric layer, followed by a second dielectric layer deposition and lift-off of the selected portions of the second dielectric layer.
In yet another approach, the mask is used first to define the resist pattern, and then an etch-down process is used to form pattern directly on the semiconductor material. However, this approach has the disadvantage that the etching of the semiconductor material can damage the stack of semiconductor layers 10, leading to degraded LED performance.
Patterns with desired shapes may be created after patterning. The shapes of the dielectric (or semiconductor) islands and the island array may effectively form microlenses to optimize optical output power. Optionally, selected island shapes and pattern sidewall angles can be formed to engineer viewing angles. Optionally, the distal principal surface 44, 44′ is coated with an anti-reflection coating after patterning to further enhance light extraction efficiency. An anti-reflection coating is particularly useful when the semiconductor refractive index ns is high and the dielectric material accordingly has a high refractive index nd substantially matching the high refractive index ns of the stack of semiconductor layers.
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof
The appended claims follow:
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US06/27205 | 7/11/2006 | WO | 00 | 3/30/2010 |
Number | Date | Country | |
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60698032 | Jul 2005 | US |