Patent Application
20130082295
This nonprovisional application is based on Japanese Patent Application No. 2011-220137 filed on Oct. 4, 2011 with the Japan Patent Office, the entire contents of which are hereby incorporated by reference.
1. Field of the Invention
The present invention relates to a light-emitting element including a light-emitting layer sandwiched between two semiconductor layers.
2. Description of the Background Art
Since a light-emitting diode has a high photoelectric conversion efficiency, and emission of blue light has become possible in recent years, a light-emitting diode is attracting attention as a next-generation illumination light source with a low environmental load. In order to take sufficient advantage of a high photoelectric conversion efficiency of the light-emitting diode, extraction of a light beam generated at a PN-junction without loss is important. However, since a compound semiconductor generally enabling fabrication of a light-emitting diode has a high refractive index, a light beam is absorbed by an electrode made of metal and a semiconductor layer as total reflection of the light beam is repeated in a chip, thus the light beam extracted from the chip is reduced.
A blue light-emitting diode currently on the mainstream is fabricated using a GaN semiconductor. However, since GaN has a refractive index of 2.5, the critical angle becomes 3.6° in the case of placing GaN in the air, thus a light beam extracted from the chip remain at about 10%.
The efficiency in extracting a generated light beam from a chip is generally referred to as a light-extraction efficiency. As a technology for improving the light-extraction efficiency, Japanese Patent Laying-Open No. 10-163525 (PTL 1) proposes a configuration provided with irregularities on a transparent electrode of a chip, as shown in
An n-type electrode 107 is formed on n-type electrode forming region 104, and a p-type electrode 108 is formed on p-type electrode forming region 105. Since p-type electrode forming region 105 is usually wider than n-type electrode forming region 104, a transparent electrode of a transparent conductive film, not illustrated, made of ITO or the like is formed on p-type electrode forming region 105, and a p-type electrode 108 is formed on the transparent electrode.
On substantially the entire region of light-extraction surface 106, a light scattering layer 109 made of silicon dioxide (SiO2) is formed. Light scattering layer 109 has an irregular surface with a width and a level difference of about 0.3 Since irregularities are formed on the surface of light scattering layer 109, light beam incident at an incident angle greater than the critical angle is extracted from the chip by diffraction. As a result, the light-extraction efficiency is improved.
Further, improvement of the light-extraction efficiency by providing an irregularity structure on the transparent electrode has also been considered. An example is disclosed in Japanese Patent Laying-Open No. 2008-294306 (PTL 2).
As shown in
On p-contact layer 115, a translucent electrode 120 is formed. Translucent electrode 120 is made of niobium titanium oxide (niobium 3%) and has irregularities 120s. On an exposed surface of n-contact layer 111, an electrode 130 is formed. Electrode 130 is constituted by a vanadium (V) film having a thickness of about 20 nm and an aluminum (Al) film having a thickness of about 2 μm. At a part on translucent electrode 120, an electrode pad 125 made of gold (Au) alloy is formed.
In the art disclosed in PTL 2, an optical output has been improved by 30%, as compared to the case where no irregularities 120s are present.
However, the niobium titanium oxide disclosed in PTL 2 needs to be adjusted such that its crystal orientation (C axis) becomes perpendicular to the film surface to obtain a conductivity similar to that of general ITO (Indium Tin Oxide). However, the general sputtering method causes the crystal axis to be randomly oriented, thus a resistance value of the niobium titanium oxide becomes equal to or greater than twice the resistance value of ITO. This causes a bias in the current density distribution on the element, resulting in inconvenience such as increase in non-effective power consumption or rise in the operating voltage.
In PTL 2, as a structure of a light-emitting element compensating for the above-described disadvantage, the structure shown in
In this structure, translucent conductive layer 121 made of ITO with a low resistivity compensates for a high lateral diffusion resistance of niobium titanium oxide. To suppress the total reflection at the interface between translucent conductive layer 121 made of ITO with a low refractive index and p-contact layer 115 made of p-type GaN with a high refractive index, the thickness of translucent conductive layer 121 made of ITO needs to be set less than ¼ of the light emission wavelength.
As described above, the niobium titanium oxide disclosed in PTL 2 has a conductivity, and a refractive index of 2.4 close to that of GaN can be achieved. However, to obtain the conductivity similar to that of general ITO in a direction parallel to the film surface, adjustment is necessary to allow the crystal orientation (C axis) to be perpendicular to the film surface. However, the technology of forming the niobium titanium oxide film while adjusting the crystal orientation to be perpendicular to the film surface has not yet been ready for application to mass production. On the other hand, in a case where the niobium titanium oxide film is formed by the general sputtering, a crystal axis is randomly oriented, thus the resistance value of niobium titanium oxide becomes equal to or greater than twice the resistance value of ITO having the same thickness. Thus, the thickness must be twice or greater to adopt niobium titanium oxide and have the resistance value substantially equal to the case of using ITO. The general sputtering requires twice or longer time period for forming a film to achieve this, thus the time required for production is extended disadvantageously.
To compensate for this, as shown in
For the reasons described above, the industrial use of niobium titanium oxide is difficult. As a result, in fact, no option is present other than selecting ITO as a material of a translucent conductive layer for a mass-produced product required to be produced at a low cost.
An object of the present invention is to provide a light-emitting element having an improved light-extraction efficiency.
To achieve the object described above, the light-emitting element in accordance with the present invention includes a substrate, a light-emitting layer arranged on a surface of the substrate in a state of being sandwiched in a thickness direction between two semiconductor layers having conductivity types different from one another, a transparent electrode layer arranged so as to overlap with one of the two semiconductor layers located farther away from the substrate, and a flat layer made of a transparent material with a refractive index higher than the transparent electrode layer and provided so as to cover at least a part of an upper surface of the transparent electrode layer. An irregularity layer is provided on an upper side of the flat layer.
According to the present invention, setting the thickness of the flat layer to be equal to or greater than the thickness allowing guidance of a light beam, in other words, a cut-off thickness, enables activation of a waveguide mode for allowing propagation in this flat layer for a light beam incident at an angle equal to or greater than a critical angle from the light emitting layer to the transparent electrode layer, thus the optical power of the light-emitting layer is shifted to the waveguide mode. This operation enables extraction of the optical power from the light emitting layer to a flat layer with a high refractive index even when the thickness of the transparent electrode layer is equal to or greater than ¼ of the wavelength. Further, the irregularity structure of irregularity layer 9 present on the upper side of the flat layer interferes with the waveguide mode, so that the waveguide mode is converted to a light beam emitted out of the light-emitting element. The operation principle described above improves the light-extraction efficiency.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
A light-emitting element in accordance with the first embodiment of the present invention will be described with reference to
N-type semiconductor layer 2 is, for example, an n-type gallium nitride (n-GaN) layer. P-type semiconductor layer 4 is, for example, a p-type gallium nitride (p-GaN) layer. Transparent electrode layer 5 is, for example, an indium tin oxide (ITO) film.
Light-emitting element 501 is provided with a p-side electrode 6 and an n-side electrode 7. P-side electrode 6 is arranged on the upper surface of transparent electrode layer 5, and n-side electrode 7 is arranged on a region exposing the upper surface of n-type semiconductor layer 2.
Preferably, the refractive index of flat layer 8 is close to the refractive index of n-type semiconductor layer 2 or of p-type semiconductor layer 4. In a case where n-type semiconductor layer 2 is an n-type nitride gallium layer, or in a case where p-type semiconductor layer 4 is a p-type nitride gallium layer, it is preferable to set the refractive index of flat layer 8 is preferably set to be equal to or greater than 2.2, or more preferably equal to greater than 2.4.
Preferably, flat layer 8 has a thickness allowing propagation of light in flat layer 8. This is because the propagation of light in flat layer 8 can improve the light-extraction efficiency.
Light-emitting element 501 in the present embodiment is provided with flat layer 8 with a high refractive index on transparent electrode layer 5, and irregularity layer 9 is formed on an upper side of flat layer 8. Setting a thickness of flat layer 8 to be equal to or greater than the thickness allowing guidance of light, in other words, equal to or greater than a cut-off thickness enables activation of the waveguide mode to allow propagation of light, incident at an angle equal to or greater than a critical angle from light emitting layer 3 to transparent electrode layer 5, in flat layer 8, thus the optical power of light emitting layer 3 is shifted to the waveguide mode. This operation enables extraction of the optical power from light emitting layer 3 to flat layer 8 with a high refractive index even when the thickness of transparent electrode layer 5 is equal to or greater than ¼ of the wavelength. Further, the irregularity structure of irregularity layer 9 on an upper side of flat layer 8 interferes with the waveguide mode, so that the optical power is converted into a light beam irradiated out from light-emitting element 501. The operation principle described above improves the light-extraction efficiency.
As described above, preferably, the refractive index of the material of flat layer 8 is equal to or greater than 2.2. The materials capable of achieving this includes TiO2 (n=2.6-2.9), ZrO2 (n=2.2), Ta2O5 (n=2.3), and diamond (n=2.4). The number indicated in the parenthesis represents a refractive index “n” of each material.
TiO2 is the most suitable for the material of flat layer 8 because it has the highest refractive index and incurs low cost. Thus, flat layer 8 is preferably formed of TiO2 as a main material.
Preferably, the thickness of flat layer 8 is equal to or greater than 30 nm and equal to or less than 150 nm. Here, the condition “equal to or greater than 30 nm” is provided because flat layer 8 needs a thickness equal to or greater than 30 nm to allow propagation of light in flat layer 8. Further, the condition “equal to or less than 150 nm” is provided because, as a result of calculation conducted by the inventors, the effect is saturated or even degraded when the thickness of flat layer 8 is greater than 150 nm. As a result of the calculation conducted by the inventors, it is found out that when the thickness of flat layer 8 is set to be 150 nm, the effect is substantially equal to the level of 100 nm or slightly degraded. This will be described in detail hereinafter.
The irregularity structure of irregularity layer 9 is a grating or a dot pattern having a cycle of pitch substantially equal to or less than a light emission wavelength of 450 nm. Preferably, the pitch of irregularity structure is, for example, 200-500 nm.
In the example shown in
Alternatively, irregularity layer 9 may be formed of a material different from flat layer 8. For example, flat layer 8 may be formed of TiO2, and irregularity layer 9 may be formed of a film of SiO2 and provided on flat layer 8. When the layers are formed of different materials as described above, a pattern difficult to be formed directly on the material of flat layer 8 can be formed easily. In the case of forming irregularity layer 9 with material different from flat layer 8, irregularity layer 9 may have the structure having a thick portion and a thin portion alternately repeated one another, instead of the structure having protrusion and space alternately repeated one another.
Referring to
Generally, at the interface between the first medium and the second medium having different refractive indices, when a light beam satisfying the condition of total reflection proceeds from the side of the first medium and then is reflected, in a precise sense, the central axis of the light beam is misaligned horizontally from a geometrically expected position. This is because the light beam proceeded from the side of the first medium enters into the second medium by a small depth of the wavelength order, and then is reflected to proceed to the side of the first medium. This phenomenon is known as Goos-Haenchen effect. The misalignment of the optical axis at this time is referred to as “Goos-Haenchen shift”. A depth of slight entry of the light beam into the second medium at the time of this reflection is also referred to as “seepage depth”.
Considering the Goos-Haenchen effect in light-emitting element 501, when the light beam generated in light emitting layer 3 passes through p-type semiconductor layer 4, and then enters transparent electrode layer 5 at an angle exceeding the critical angle, light seeps out with a minute depth of wavelength order into transparent electrode layer 5 and then is reflected back into p-type semiconductor 4.
The electric field intensity distribution B in
Generally, the conductive layer using ITO needs to have a thickness of 150 nm or greater to lower the resistance value to a practical value. Along with this idea, when the transparent conductive layer made of ITO has a thickness equal to or greater than 150 nm, providing the irregularity structure on the upper surface of the transparent conductive layer does not cause the light beam incident at an angle equal to or greater than critical angle from the lower surface to interfere, thus the light beam is not extracted.
However, when the flat layer is formed of a material with a high refractive index in accordance with the present invention, the waveguide mode having the electric field intensity distribution A presented in
Next,
Under the assumption that cylindrical protrusions having a refractive index equal to that of flat layer 8 are arranged in the so-called triangular arrangement, the cylinder of irregularity layer 9 was set to have a diameter half the pitch. The “triangular arrangement” referred herein means that a plurality of cylindrical protrusions are present and that the protrusions are arranged across the entire area of the upper flat surface of flat layer 8 such that each of groups including adjacent three protrusions form a regular triangle.
In the actual calculation, for the sake of simplicity in calculation, the calculation was conducted under the assumption that irregularity layer 9 includes an even layer having a thickness equal to the height of the protrusion and having an intermediate refractive index which will be described hereinafter. The “intermediate refractive index” referred herein is the refractive index calculated based on a refractive index of material filling the protrusion and a refractive index of air filling the recess, taking in consideration the volume of the protrusion and the volume of air filling the recess.
Further, in
In the configuration presenting the basis for the calculation shown in
Preferably, that the refractive index of flat layer 8 is close to the refractive index of p-type semiconductor layer 4 or of n-type semiconductor layer 2. However, since there is a practical limitation as described above, the maximum value of the refractive index of an industrially usable flat layer is considered to be 2.5. In
When calculating the behavior of waveguide passage in the case where irregularities are provided on the surface, some methods can be considered in light of how to set a calculation model. Since a significant difference may occur in a result when the calculation model is not appropriate, appropriateness of the calculation model should be confirmed by using various calculation methods. This is the reason why the calculation was conducted based on calculation models differing from one another in
In light-emitting element 501 shown in
The interface between sapphire substrate 1 and n-type semiconductor layer 2 is assumed to have irregularities of dot pattern having a pitch of 2 μm and a height of 1 μm.
As is clear from
As is clear from
As is clear from
As is clear from
According to the calculation results shown in
Preferably, the thickness of transparent electrode layer 5 is equal to or greater than ¼ the wavelength of light supplied from light-emitting layer 3. As the transparent electrode layer has more thickness, the electric power loss is reduced by lowering of the resistance value by that amount. Therefore, although it is considered that the thickness is normally set to be equal to or greater than 150 nm, in the conventional technology, it was necessary to set the thickness of transparent electrode layer 5 to be equal to or less than ¼ of wavelength of light beam in other words, equal to or less than about 50 nm, in order to suppress the total reflection by transparent electrode layer 5. Thus, it was disadvantageous since it was adverse to the power loss reduction in conventional art. It has been considered that setting the thickness of transparent electrode layer 5 to be ¼ or greater of the wavelength of light supplied form light emitting layer 3 cannot be accommodated by conventional art. According to the present invention, since setting the thickness of transparent electrode layer high to be equal to or greater than ¼ of wavelength of light beam is effective, setting the thickness of transparent electrode layer 5 to be within this range provides favorable characteristics which could not be obtained by conventional art.
Particularly, it is preferable to set the thickness of transparent electrode layer 5 to be equal to or greater than 70 nm. Such a large thickness of transparent electrode layer can lower the resistance value, which in turn reduces the power loss.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the scope of the present invention being interpreted by the terms of the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-220137 | Oct 2011 | JP | national |
