This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2012-042279, filed Feb. 28, 2012; the entire contents of which are incorporated herein by reference.
Embodiments described herein relate to a light emitting diode (LED) and its manufacturing method.
In the case in which the upper surface of an LED is the light extraction surface, if the electrode (through which current will be injected) is configured to have a thin and long shape, then shading by the luminous layer will be reduced to increase brightness.
For example, if a contact layer is the ground layer of the thin electrode then forward voltage will be reduced. In the case in which a thin electrode is patterned onto the top of the contact layer, taking into account mask alignment error, the contact layer width will be greater than the electrode width. In this case, a contact layer that contains a high impurity concentration will have high light absorption for certain wavelengths. The contact layer material will work as an absorption layer, thus reducing brightness.
Conversely, when a thin electrode is used as an etching mask, the etching leaves behind only a lower contact layer—all of which, or nearly all of which, is in contact with the electrode. By over-etching, however, the width of the contact layer becomes less than the width of the electrode. From this result, an increase in forward voltage or electrode separation is more likely to occur, leading to difficulty in maintaining stable production. This disclosure describes techniques which provide for the removal of parts of the contact region that otherwise would reduce brightness. These techniques also mitigate the problems associated with over-etching.
In general, for each embodiment, refer to the drawings provided to further explain the mode for carrying out the invention.
According to a first embodiment, there is provided an LED—and its manufacturing method—that can easily and stably increase its brightness while maintaining low forward voltage.
The manufacturing method for the LED of the first embodiment includes a process to form a first insulator film on a surface of a semiconductor layer, a process to form a laminated body containing a first electrode and mask layer, a process to form a second insulator film, a process to anisotropically etch the second insulator film, a process to expose the semiconductor surface, a process to eliminate the mask layer, and a process to form a clear conducting layer. The process to form a laminated body includes a process of forming a bonding pad unit provided on a first surface of the first insulator film, forming a first electrode having a thin wire unit projecting from the bonding pad unit, and forming a mask layer provided on top of the first electrode. The process of forming the insulator film includes the process of forming the second insulator film covering the laminated body and the first region, the region within the first surface that does not form the laminated body.
The process of anisotropic etching includes the process of etching the second insulator film by leaving a portion of the second insulator film as a lateral insulator film by covering two lateral surfaces of the thin wire unit while exposing the mask layer and the second region, which is the region within the first surface that does not form the thin wire unit and lateral insulator film. The process of exposing the surface of the semiconductor layer includes the process of leaving the region within the first insulator film (in which the thin wire unit and lateral insulator film are arranged into a predetermined position) as the ground layer while eliminating the second region of the first insulator film to expose the surface of the semiconductor layer. The process of eliminating the mask layer includes the process of eliminating the mask layer above the first electrode. The process of forming the clear conducting layer includes the process of forming the clear conducting layer by covering the lateral insulator surface, designated regions of both sides of the ground layer of the exposed surface of the semiconductor layer, and the surface of the thin wire unit.
Semiconductor layer 58 includes luminous layer 40, first conductivity type, layer 30, and second conductivity type layer 50. Second conductivity type layer 50 is set in between luminous layer 40 and first electrode 60. Additionally, first conductivity type layer 30 is set on a side of luminous layer 40 which is opposite the side on which second conductivity type layer 50 is set.
First electrode 60, which includes bonding pad unit 60a and thin wire unit 60b (which is projected outward from bonding pad 60a), is set on top of second conductivity type layer 50. Additionally, lateral insulator film 73 is disposed on two lateral surfaces of thin wire unit 60b. The lateral insulator film 73 is configured to be permeable to light emitted from luminous layer 40.
First conductivity type layer 30 may include, for example, a clad layer, a current diffusion layer, and a first contact layer 30a, in this order. Second conductivity type layer 50 may include a clad layer 52, a current diffusion layer 54, and a ground layer 57 disposed in the order recited, starting on the luminous layer 40 side.
Clear conducting layer 26 may be set on the bottom surface of first conductivity type layer 30, and reflective metal layer 25 may be disposed below the clear conducting layer 26. The semiconductor layer 58 wafer, which is composed of material such as Si, is bonded to supporting basal plate 10 through metal junction layer 22. Additionally, on the opposite side of the supporting basal plate 10, back electrode 62 is set.
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In terms of current-feed, it is favorable to set the conductivity type of ground layer 57 to the same conductivity type as the surface layer of semiconductor layer 58. That is, in the example from
In this embodiment, ground layer 57 is formed using a self-alignment process, thus it is almost symmetrical on both sides of line B-B, which is a centerline through thin wire unit 60b. Additionally, the amount of sideward extension of the ground layer 57 from each of two lateral surfaces SS of thin wire unit 60b can be substantially equivalent, and can be an extension of less than 1 μm. With ground layer 57 being symmetrical on both sides of centerline B-B through thin wire unit 60b, the left and right conductive layers of ground layer 57 provide uniform resin coverage, leading to improvement in device characteristics and reliability.
In this embodiment, as a response, there can be a reduction of the lateral extension of ground layer 57 in the sideward direction beyond lateral surface SS of thin wire unit 60. This reduction leads to reducing unnecessary light absorption by ground layer 57. Because of this, light extraction efficiency can be increased to about 120% of the efficiency of the LED in the comparative example. Also, according to an experiment by the inventors, decreasing the amount of projection did not cause an increase in forward voltage VF.
Lateral insulator film 73 acts as a protection layer as well. An example of this effect occurs when thin wire unit 60b contains a barrier metal layer to restrain diffusion of an element such as Ga from semiconductor layer 58 to thin wire unit 60b. In this case, the barrier metal layer may peel off due to, say, corrosion. Lateral insulator film 73 acts as a protective layer against such corrosion.
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In semiconductor layer 58, second conductivity type layer 50 is on top of luminous layer 40. Second conductivity type layer 50 is n-type, and includes clad layer 52, current diffusion layer 54, and second contact layer 56. Clad layer 52 is covered by current diffusion layer 54. Current diffusion layer 54 is composed of InGaAlP based material, and, in turn, is covered by second contact layer 56, which is composed of GaAs. In addition, first conductivity type layer 30 contains first contact layer 30a on its side which faces the metal junction layer 22.
A photo resist pattern is formed on a first surface 56a of second contact layer 56. On first surface 56a, a first metal layer composed of material such as AuGe/Au and a film composed of material such as Ti may be formed. The formation may involve a method such as the evaporation method. By lift-off technology, first electrode 60 composed of AuGe/Au and mask layer 70 composed of Ti set above forms a laminated body.
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If packaging with improved airtight characteristics is used, lateral insulator film 73 may be removed like in
When insulator film 72 thickness T3 is 0.1 μm prior to etching, side wall width T2 will be small, roughly 0.05 μm. As insulator film 72 thickness T3 increases, side wall width T2 increases. For example, when insulator film 72 thickness T3 is 1.5 μm, side wall width T2 is 0.94 μm.
For this embodiment, it is preferred that insulator film 72 thickness prior to etching T3 be in the range of 0.1 to 1.5 μm. Additionally, it is even more preferable for insulator film 72 thickness T3 to be in the range of 0.12 to 1 μm, so as to keep side wall width T2 as small as 0.06 to 0.6 μm, thereby maintaining the effectiveness of the protection layer. Furthermore, using this range, it is easier to reduce light absorption by the contact layer than it is in the comparative example (
Semiconductor layer 87 may be made of InGaAlN based material, InGaAlP based material, or AlGaAs based material. Semiconductor layer 87 includes luminous layer 82, first conductivity type layer 80, and second conductivity type layer 86. Second conductivity type layer 86 is set between luminous layer 82 and first electrode 60. Additionally, first conductivity type layer 80 is set on the same side of luminous layer 82, opposite where second conductivity type layer 86 is set.
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Semiconductor layer 87 wafer is bonded to supporting basal plate 10 through metal junction layer 22. On the back side of the supporting basal plate 10, back electrode 62 is fixed.
First electrode 60 is set on top of ground layer 89, which is composed of insulator film. Clear conducting layer 90 is set in a way that covers the upper portion of the near field NW region of thin wire unit 60b and the upper surface of semiconductor layer 87. By configuring the conducting layer in this manner, current J (represented by a dotted line) can be injected into semiconductor layer 87 within the NW region byway of clear conducting layer 90. Because of this current, light is emitted from luminous layer 82 at a locating below thin wire unit 60b. In this case, lateral insulator film 73 and clear conducting layer 90 form a convex shape that extends upwards, but which may also have a flattened cavity part positioned slightly below the uppermost point of the lateral insulator film 73.
If either the clear conducting layer 90 or lateral insulator film 73 has a refractive index greater than the refractive index of the sealing resin layer, emitted light G from luminous layer 82 can be easily concentrated at the upper portion of thin wire unit 60b. Additionally, clear conducting layer 90 has curved sides R1 at positions above the left and right corner sections where the layer begins to turn upwards. Because of this configuration, adhesion is improved between the sealing resins.
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When etching the second insulator film 72, insulator film 88 is etched away at the second region 88c. The result is that ground layer 89 remains, in a position such that on top of ground layer 89, thin wire unit 60b and lateral insulation film 73 form a laminated structure. This is how surfaces 85a of first contact layer 85 are exposed. Also, when the first insulation film 88 and second insulation film 72 are formed of Si3N4, the etching solution can be a hydrofluoric acid based chemical.
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Clear conducting layer 90 is formed so as to cover the surface of lateral insulation film 73, the exposed surface 85a of second contact layer 85, and thin wire unit 60b. Using ITO (Indium tin oxide) or tin oxide to form clear conducting layer 90 makes it difficult to form an alloy layer when the second contact layer 85 is composed of GaN. Because of this, light absorption is restrained while keeping forward voltage VF low.
Additionally, if ground layer 89 isn't patterned in a self-aligned manner, the distance between the upper surface of thin wire unit 60b and surfaces 85a of second contact layer 85 will be longer than when self-alignment is used, thereby leading to an increase in voltage drop caused by clear conducting layer 90, and an increase in forward voltage VF. Because of this, ohmic loss will increase.
Here, the lateral insulation film 73 is removed from the two lateral surfaces SS of thin wire unit 60b, as depicted in
For the first and second embodiment and the accompanying modification of the LED, the thin wire unit where the current is injected is arranged above the self-aligned ground layer 89b. The disposition of these components is such that the ground layer is wider than the thin wire unit, which enables it to be more compact while maintaining the designated width. This increases LED brightness while enabling the LED to maintain low forward voltage. Additionally, due to the self-alignment process, an LED containing a thin wire electrode can be manufactured with high mass productivity.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
Number | Date | Country | Kind |
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P2012-042279 | Feb 2012 | JP | national |