The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
Description will be given below in detail to semiconductor light emitting elements, a manufacturing method therefor and compound semiconductor light emitting diodes of the present invention in embodiments with reference to drawings.
The LED has a main body 1750, an n-GaP transparent substrate 1701 placed under the main body 1750, and a p-GaP transparent substrate 1708 placed on top of the main body 1750. It is noted that the n-GaP transparent substrate 1701 is one example of the first transparent substrate, and that the p-GaP transparent substrate 1708 is one example of the second transparent substrate.
The main body 1750 is constructed of an n-Al0.6Ga0.4As current diffusion layer 1702, an n-Al0.5In0.5P cladding layer 1703, an AlGaInP active layer 1704, a p-Al0.5In0.5P cladding layer 1705, a p-GaInP interlayer 1706, and a p-GaP contact layer 1707. It is noted that the AlGaInP light emitting layer 1705 is one example of the light emitting layer. Moreover, the n-Al0.6Ga0.4As current diffusion layer 1702 and the n-Al0.5In0.5P cladding layer 1703 constitute examples of a first conductive type semiconductor layer. The p-Al0.5In0.5P cladding layer 1705, the p-GaInP interlayer 1706 and the p-GaP contact layer 1707 constitute examples of a second conductive type semiconductor layer.
The AlGaInP light emitting layer 1705 is a quaternary system light emitting layer that emits light of an emission wavelength of a red color. The n-GaP transparent substrate 1701 and the p-GaP transparent substrate 1708 have transparency with respect to light emitted from the AlGaInP light emitting layer 1705.
An electrode 1709 is formed beneath the n-GaP transparent substrate 1701. An electrode 1710 is formed on the p-GaP transparent substrate 1708.
The manufacturing method of the LED is described below.
First of all, as shown in
The AlGaInP active layer 1704 has a quantum well structure. More in detail, the AlGaInP active layer 1704 is formed by alternately layering an (Al0.05Ga0.95)0.5In0.5p well layer and an (Al0.5Ga0.5)0.5In0.5P barrier layer. Then, eight pairs of the (Al0.05Ga0.95)0.5In0.5P well layer and the (Al0.5Ga0.5)0.5In0.5P barrier layer are provided.
The substrate and the layers have thickness dimensions provided as: 250 μm of the n-GaAs substrate 1801; 1.0 μm of the GaAs buffer layer 1802; 5.0 μm of the n-Al0.6Ga0.4As current diffusion layer 1702; 1.0 μm of the n-Al0.5In0.5P cladding layer 1703; 0.5 μm of the AlGaInP active layer 1704; 1.0 μm of the p-Al0.5In0.5P cladding layer 1705; 1.0 μm of the p-GaInP interlayer 1706; and 4.0 μm of the p-GaP contact layer 1707.
In the substrate or the layers, Te is used as an n-type dopant, while Mg is used as a p-type dopant.
The substrate and the layers have carrier densities provided as: 1.0×1018 cm−3 of the n-GaAs substrate 1801; 5×1017 cm−3 of the n-GaAs buffer layer 1802; 1.0×1018 cm−3 of the n-Al0.6Ga0.4As current diffusion layer 1702; 5×1017 cm−3 of the n-Al0.5In0.5P cladding layer 1703; nondoped AlGaInP active layer 1704; 5×1017 cm−3 of the p-Al0.5In0.5P cladding layer 1705; 1.0×1018 cm−3 of the p-GaInP interlayer 1706; and 2.0×1018 cm−3 of the p-GaP contact layer 1707.
Next, a half dicing groove is formed by half dicing at a prescribed pitch on the epitaxial surface of the wafer 20. At this time, a depth of about 10 to 50 μm is appropriate for the half dicing groove in the point that the strength of the LED structure wafer is maintained.
Next, the p-GaP transparent substrate 1708 is bonded directly to the epitaxial surface (upper surface of the p-GaP contact layer 1707) of the LED structure wafer 1850 by using an affixing jig 1950 made of quartz as shown in
The jig 1950 has a first quartz plate 1951 that supports the wafer, a second quartz plate 1952 located on top of the first quartz plate 1951, and a pressurizing section 1953 that receives a force of a prescribed magnitude to pressurize the second quartz plate 1952.
The pressurizing section 1953 is guided in the vertical direction by a frame 1954 that has a roughly bracket-like shape when viewed from the front. The frame 1954 is engaged with the first quartz plate 1951, so that a force is appropriately transferred to the second quartz plate 1952 located between the first quartz plate 1951 and the pressurizing section 1953.
A carbon sheet 1955 is placed between the first quartz plate 1951 and the LED structure wafer 1850. A carbon sheet 1956 and a PBN (pyrolytic boron nitride) plate 1957 are placed between the second quartz plate 1952 and the p-GaP transparent substrate 1708.
By using the jig 1950 described above, the p-GaP transparent substrate 1708 is brought in contact with the p-GaP contact layer 1707, and then a force of, for example, 0.3 to 0.8 N·m is applied to the pressurizing section 1953 so as to make a compression force take effect on the contact plane of the p-GaP transparent substrate 1708 and the p-GaP contact layer 1707. The jig 1950 in the state is set in a heating furnace and heated for about 30 minutes at a temperature of about 800° C. under a hydrogen atmosphere. Then, the p-GaP transparent substrate 1708 is bonded directly to the LED structure wafer 1850.
Next, the LED structure wafer 1850 and the p-GaP transparent substrate 1708 are cooled down, and thereafter the jig 1950 is taken from the heating furnace. The n-GaAs substrate 1801 and the n-GaAs buffer layer 1802 are removed by dissolution with a liquid mixture of ammonia water, oxygenated water and water.
Next, the n-GaP transparent substrate 1701 is bonded directly to the surface (AlGaAs surface) exposed by removing the n-GaAs substrate 1801 and the n-GaAs buffer layer 1802. The bonding of the n-GaP transparent substrates 1701 is performed by processing under pressure and heating as in the case of the p-GaP transparent substrate 1708. Moreover, the carrier density of the n-GaP transparent substrate 1701 is set at 5.0×1017 cm−3.
Subsequently, electrode forming and chip-making process, which belong to the general manufacturing method of a semiconductor light emitting element, are carried out. Thereby, a high-intensity red LED of an emission wavelength of 640 nm as shown in
According to the above-stated LED, the n-GaP transparent substrate 1701, which has transparency with respect to light emitted from the AlGaInP active layer 1704, is placed under the main body 1750. The p-GaP transparent substrate 1708, which has transparency with respect to the light emitted from the AlGaInP active layer 1704, is placed on top of the main body 1750. Thereby, light can efficiently be taken to the outside via the n-GaP transparent substrate 1701 and the p-GaP transparent substrate 1708. That is, the optical extraction efficiency can be improved.
In the present embodiment, an electrode material of AuSi/Au is selected as the material of the electrode 1709, and AuBe/Au is selected as the material of the electrode 1710. That is, in the present embodiment, the electrodes 1709 and 1710 are obtained by processing the AuSi/Au layer and the AuBe/Au layer into arbitrary shapes by the photolithography method and wet etching.
Moreover, after forming the electrodes 1709 and 1710, half dicing is carried out for separation into a prescribed chip size. At this time, by selecting a bevelable dicing blade, the side surface of the element can easily be processed into a slope shape. As a result, the side surface of one of the n-GaP transparent substrate 1701 and the p-GaP transparent substrate 1708 is allowed to have a slope shape.
The process with the bevelable dicing blade is carried out on a surface opposite from the surface that has previously undergone half dicing, this time. Thereby, the other side surface of the n-GaP transparent substrate 1701 and the p-GaP transparent substrate 1708 is allowed to have a slope shape.
The materials and techniques selected as above are not limited, and all sorts of materials and techniques of, for example, wet etching and dry etching can be selected. However, the technique of dicing seems to be appropriate in the point that it does not select (depend on) the material.
The manufacturing process of the present embodiment is applied to not only LED having the quaternary system light emitting layer made of AlGaInP but also any of the light emitting layer formed of semiconductor crystals.
In the present embodiment, the n-GaP transparent substrate 1701 and the p-GaP transparent substrate 1708 are affixed to the main body 1750 via a metal.
That is, the LED of the present embodiment has a first metal thin film 2001 formed under the n-Al0.6Ga0.4As current diffusion layer 1702 and a second metal thin film 2002 formed on top of the p-GaP contact layer 1707. It is noted that the first metal thin film 2001 is one example of the first metal material layer, and the second metal thin film 2002 is one example of the second metal material layer.
The manufacturing method of the LED is described below.
First of all, a LED structure wafer 1850 is formed as in the case of the first embodiment. In the case of the present embodiment, it is not necessity to preparatorily form a groove on the LED structure wafer 1850.
Next, by using the vapor deposition method or the sputtering method, a thin film is formed on the epitaxial surface (upper surface of the p-GaP contact layer 1707) of the LED structure wafer 1850 or on the bonding plane (plane to be faced with the LED structure wafer 1850) of the p-GaP transparent substrate 1708.
The thin film may be made of either one of gold, silver, aluminum and titanium; or a compound of gold, silver, aluminum or titanium; or an alloy that contains at least one of gold, silver, aluminum and titanium.
Next, the second metal thin film 2002 is formed by processing the thin film into an arbitrary shape with the photolithography method and wet etching. At this time, the second metal thin film 2002 has an area of not larger than 10% of the element area in forming the element. Thereby, the loss of light at the bonding interface can be suppressed to a minimum.
Next, the p-GaP contact layer 1707 and the p-GaP transparent substrate 1708 are bonded together by means of the bonding jig 1950 (see
Next, the substrate and the buffer layer are removed as in the case of first embodiment. Thereafter, the first metal thin film 2001 is formed on the lower surface of the n-Al0.6Ga0.4As current diffusion layer 1702 or on the bonding plane (plane to be faced with the LED structure wafer 1850) of the n-GaP transparent substrate 1702 as in the case of the second metal thin film 2002.
Subsequently, as in the case of the p-GaP transparent substrate 1708 sated above, affixation of the n-GaP transparent substrate 1702 is carried out. Thereafter, electrode forming and chip-making process, which belong to the general manufacturing method of a semiconductor light emitting element, are carried out, so that the LED of the present embodiment is completed.
The LED of the present embodiment corresponds to a case where one of two transparent substrates is made of an insulator. That is, the LED of the present embodiment has a main body 2150, a glass substrate 2101 placed under the main body 2150, and an n-GaP transparent substrate 2107 placed on top of the main body 2150. It is noted that the glass substrate 2101 is one example of the first transparent substrate, and the n-GaP transparent substrate 2107 is one example of the first transparent substrate.
The main body 2150 is constructed of a p-GaP contact layer 2102, a p-AlInP cladding layer 2103, an AlGaInP active layer 2104, an n-AlInP cladding layer 2105 and an n-GaP contact layer 2106. It is noted that the AlGaInP active layer 2104 is one example of the light emitting layer. Moreover, the p-GaP contact layer 2102 and the p-AlInP cladding layer 2103 constitute one example of the first conductive type semiconductor layer. Then, the n-AlInP cladding layer 2105 and the n-GaP contact layer 2106 constitute one example of the second conductive type semiconductor layer.
The p-AlInP cladding layer 2103 has an exposed part. An electrode 2108 is formed on top of the exposed part. Moreover, an electrode 2109 is formed on top of the n-GaP transparent substrate 2107.
The manufacturing method of the LED is described below.
First of all, as shown in
Next, the n-GaP transparent substrate 2107 is bonded directly to the epitaxial surface (upper surface of the n-GaP contact layer 2105) of the LED structure wafer 2250. That is, the bonding of the n-GaP transparent substrate is carried out without using an adhesive or the like.
The direct bonding of the n-GaP transparent substrate 2107 can be carried out by a method similar to that of the first embodiment.
The surface of the n-GaP transparent substrate has preliminarily been processed for patterning by the photolithography method (using a mask of an oxide of SiO2 etc.), wet etching (by aqua regia, sulfuric acid, oxygenated water mixture solution, etc.) so that a prescribed chip shape can be provided.
Next, the p-GaAs substrate 2111 is removed to provide a state as shown in
Next, half dicing is carried out along the pattern of the n-GaP transparent substrate 2107, so that the side surfaces of the n-GaP transparent substrate 2107 are formed to have a slope shape, as shown in
The half dicing is carried out by a bevelable blade. Thereby, the side surfaces of the n-GaP transparent substrate 2107 can be formed to have a slope shape.
Next, etching is carried out until the p-GaP contact layer 2102 is exposed with the patterned n-GaP transparent substrate 2107 used as a mask. Etching is conducted by using a mixed liquor of phosphoric acid, sulfuric acid, oxygenated water and water.
Next, as shown in
As one similar to the LED of the present embodiment, there is a LED wherein the transparent substrate and the semiconductor layer, which is affixed to the substrate, have mutually different conductive types, and wherein no electrical connection is provided between the transparent substrate and the semiconductor layer.
This LED is a LED in which the n-GaP transparent substrate 1701 in the first embodiment is replaced by the p-GaP transparent substrate.
Specifically, the LED is obtained by directly bonding of a p-GaP transparent substrate (carrier density: 5.0×1017 cm−3) for example, as one example of the first transparent substrate, to the n-Al0.6Ga0.4As current diffusion layer 1702 exposed by the removal of the n-GaAs substrate 1801 in the first embodiment.
There is no electrical connection between the p-GaP transparent substrate and the n-Al0.6Ga0.4As current diffusion layer 1702 at the normal LED driving voltage (not higher than 10 V).
The first through third embodiments of the present invention have been described above, the present invention is not limited to the quaternary system LED but applicable to all sorts of semiconductor light emitting elements.
The invention being thus described, it will be obvious that the invention may be varied in many ways. Such variations are not be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
Number | Date | Country | Kind |
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2006-169700 | Jun 2006 | JP | national |
This nonprovisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 2006-169700 filed in Japan on 20 Jun. 2006, the entire contents of which are incorporated herein by reference.