The present invention relates to a nitride-based semiconductor light-emitting element and more particularly relates to a semiconductor light-emitting element, of which the principal surface is an m plane.
A nitride semiconductor including nitrogen (N) as a Group V element is a prime candidate for a material to make a short-wave light-emitting element because its bandgap is sufficiently wide. Among other things, gallium nitride-based compound semiconductors have been researched and developed particularly extensively. As a result, blue-ray-emitting light-emitting diodes (LEDs), green-ray-emitting LEDs and semiconductor laser diodes made of gallium nitride based semiconductors have already been used in actual products (see Patent Documents Nos. 1 and 2).
In the following description, gallium nitride based compound semiconductors will be referred to herein as “nitride-based semiconductors”. Nitride-based semiconductors include compound semiconductors, of which Ga is replaced either partially or entirely with at least one of aluminum (Al) and indium (In), and are represented by the compositional formula AlxGayInzN (where 0≦x, y, z≦1 and x+y+z=1).
By replacing Ga with Al or In, the band gap can be made either wider or narrower than that of GaN. As a result, not only short-wave light rays such as blue and green rays but also orange and red rays can be emitted as well. That is why by using a nitride-based semiconductor, a light-emitting element that emits a light ray, of which the wavelength is arbitrarily selected from the entire visible radiation range, is realizable theoretically speaking, and therefore, they hope to apply such nitride-based semiconductor light-emitting elements to image display devices and illumination units.
A nitride-based semiconductor has a wurtzite crystal structure.
In the related art, in fabricating a semiconductor element using nitride-based semiconductors, a c-plane substrate, i.e., a substrate of which the principal surface is a (0001) plane, is used as a substrate on which nitride-based semiconductor crystals will be grown. In that case, as can be seen from
As a result, a piezoelectric field is generated in the c-axis direction in the InGaN quantum well of the active layer of a nitride-based semiconductor light-emitting element. Then, some positional deviation occurs in the distributions of electrons and holes in the active layer. Consequently, due to the quantum confinement Stark effect of carriers, the internal quantum efficiency of the active layer decreases, thus increasing the threshold current in a semiconductor laser diode and increasing the power dissipation and decreasing the luminous efficacy in an LED. Meanwhile, as the density of injected carriers increases, the piezoelectric field is screened, thus varying the emission wavelength, too.
As the In mole fraction of the active layer is increased in order to emit light rays falling within long wavelength ranges such as green, orange and red rays, the intensity of the piezoelectric field further increases and the internal quantum efficiency decreases steeply. That is why in an LED that uses a c-plane active layer, the wavelength of a light ray that can be emitted from it is said to be approximately 550 nm at most.
Thus, to overcome such a problem, people proposed that a light-emitting element be fabricated using a substrate, of which the principal surface is an m plane that is a non-polar plane (which will be referred to herein as an “m-plane GaN based substrate”). As shown in
c) shows the positions of Ga and N atoms in a nitride-based semiconductor crystal in a plane that intersects with the m plane at right angles. Ga atoms and N atoms are on the same atomic plane as shown in
In addition, since the In mole fraction of the active layer can be increased significantly, LEDs and laser diodes which can emit not only a blue ray but also green, orange, red and other rays with longer wavelengths can be made using the same kind of materials.
Furthermore, as disclosed in Non-Patent Document No. 1, for example, an LED which uses an active layer that has been formed on an m plane will have its polarization property affected by the structure of its valence band. More specifically, the active layer formed on an m plane mainly emits a light ray, of which the electric field intensity is biased toward a direction that is parallel to the a-axis. In the present description, a light ray, of which the electric field intensity is biased toward a particular direction, will be referred to herein as a “polarized light ray”. For example, a biased light ray, of which the electric field intensity becomes outstandingly high in a direction parallel to the X-axis, will be referred to herein as a “light ray polarized in the X-axis direction” and a direction that is parallel to the X-axis will be referred to herein as “polarization direction”. Also, if when a polarized light ray is incident on an interface, the light ray transmitted through the interface is still a polarized light ray, of which the electric field intensity is still as biased as the incident polarized light ray, then the light ray is regarded herein as “maintaining its polarization property”. On the other hand, if the transmitted light ray becomes a polarized light ray, of which the electric field intensity is less biased than the incident polarized light ray, then the light ray is regarded herein as “having had its polarization property lessened”. And if the transmitted light ray becomes a polarized light ray, of which the electric field intensity is no longer biased, then the light ray is regarded herein as “having had its polarization property eliminated”.
An LED which uses an active layer that has been formed on an m plane (which will be referred to herein as an “m-plane light-emitting element”) emits mainly a light ray polarized in the a-axis direction as described above but also emits light rays which are polarized in c- and m-axis directions. However, those light rays that are polarized in the c- and m-axis directions have lower intensities than the light ray polarized in the a-axis direction. That is why in this description, the following discussion will be focused on the light ray polarized in the a-axis direction.
An m-plane light-emitting element has such a polarization property. However, if a light-emitting element with a polarization property is used as a light source, then the quantity of the light reflected at the surface of an object changes, and the object looks different, according to the polarization direction (i.e., the direction in which the LED is arranged), which is a problem. This phenomenon arises because a P-polarized light ray and an S-polarized light ray have mutually different reflectances (specifically, the S-polarized light ray has the higher reflectance). In this description, the “P-polarized light ray” refers herein to a light ray with an electric field component that is parallel to the plane of incidence, while the “S-polarized light ray” refers herein to a light ray with an electric field component that is perpendicular to the plane of incidence. That is why although is important to increase the degree of polarization of the light emitted from the LED in applications in which the polarization property needs to be used, the polarization property needs to be lessened as much as possible when the light is used for ordinary illumination purposes.
Also, when used as illumination, the LED is required to have high luminance. For that purpose, in making an m-plane light-emitting element, it is important to extract the light emitted from the active layer to an external device with high light extraction efficiency.
Non-Patent Document No. 2 teaches increasing the light extraction efficiency by providing a random micro structure for the light-emitting face of the light-emitting element. If the light that has come from the active layer is incident on the light-emitting face at an angle that is smaller than the angle of total reflection, then the light cannot be extracted to an external device from the light-emitting face. That is why by providing such a random micro structure, the percentage of light rays that are incident on the emitting facet at angles that are larger than the angle of total reflection can be increased, and therefore, the light extraction efficiency can be increased. The random micro structure can not only increase the light extraction efficiency but also change the polarization direction randomly as well. That is why by providing a similar structure for the light-emitting face of an m-plane light-emitting element, an m-plane light-emitting element with no polarization property could be realized.
Non-Patent Document No. 2 teaches forming a random micro structure by a method that uses a self-assembled gold nano-mask (which will be referred to herein as an “SA-Au process”). According to the SA-Au process, a metal thin film is deposited on the light-emitting face and then heated to coagulate the metal thin film and turn it into islands of a sub-micron size. And by performing a dry etching process using the coagulated metal as a hard mask, a random micro structure can be formed. However, according to the SA-Au process, there is an in-plane variation in the process step of heating and coagulating the metal thin film, and therefore, it is difficult to form such a random micro structure with good reproducibility. For that reason, it is difficult to make a light-emitting element with high light extraction efficiency at a good yield by the method disclosed in Non-Patent Document No. 2.
Meanwhile, a method for forming such a random micro structure on the light-emitting face of a semiconductor light-emitting element that uses a c plane as its principal surface (which will be referred to herein as a “c-plane light-emitting element”) by performing a wet etching process using crystal anisotropy has also been proposed. However, it is difficult to form such a random micro structure on the light-emitting face of an m-plane light-emitting element by wet etching process. This is because the light-emitting face of an m plane light-emitting element has a different crystal plane from the light-emitting face of a semiconductor light-emitting element that uses a c plane as its principal surface and the anisotropy in the crystal orientation proposed cannot be used.
Patent Document No. 3 discloses a technique for minimizing a decrease in light emission efficiency by providing striped grooves which run perpendicularly to the polarization direction of the light emitted from a light-emitting element, which is made of a semiconductor that uses either a non-polar plane or a semi-polar plane as its principal surface. Meanwhile, Patent Document No. 4 discloses a light-emitting diode device in which an uneven structure that runs perpendicularly to the polarization direction of the light-emitting element is provided for the light-emitting face as in Patent Document No. 3 in order to improve the distribution of the light extracted. According to Patent Document No. 3, the p-wave component of the light incident on the light-emitting face at a Brewster angle can be transmitted through the light-emitting face without being reflected (i.e., at a reflectance of zero). That is why if the plane that defines the striped groove that runs perpendicularly to the polarization direction of the light to extract is used as the light-emitting face, the polarization direction of the light agrees with the direction of the p-wave component, and therefore, the transmittance of the polarized light should be increased, according to Patent Document No. 3. However, the present inventors discovered via experiments that there is very little light to be incident on the light-emitting face at the Brewster angle, and therefore, such an effect of increasing the transmittance of polarized light is very limited.
The present inventors perfected our invention in order to overcome at least one of these problems with the related art, and an object of the present invention is to provide, first and foremost, an m-plane nitride semiconductor light-emitting element that can increase the light extraction efficiency with its polarization property lessened. Another object of the present invention is to provide an m-plane nitride semiconductor light-emitting element that can emit light with the light distribution characteristic improved.
A semiconductor light-emitting element according to the present invention includes: an n-type nitride semiconductor layer; a p-type nitride semiconductor layer; an active layer region which includes an m-plane nitride semiconductor layer and which is interposed between the n-type nitride semiconductor layer and the p-type nitride semiconductor layer; an n-type electrode which is electrically connected to the n-type nitride semiconductor layer; a p-type electrode which is electrically connected to the p-type nitride semiconductor layer; a light-emitting face, through which polarized light that has been produced in the active layer region is extracted out of this element; and a striped structure which is provided for the light-emitting face and which has a plurality of projections that run in a direction that defines either an angle of 5 degrees to 80 degrees or an angle of −80 degrees to −5 degrees with respect to the a-axis direction of the m-plane nitride semiconductor layer.
Another semiconductor light-emitting element according to the present invention includes: an n-type nitride semiconductor layer; a p-type nitride semiconductor layer; an active layer region which includes an m-plane nitride semiconductor layer and which is interposed between the n-type nitride semiconductor layer and the p-type nitride semiconductor layer; an n-type electrode which is electrically connected to the n-type nitride semiconductor layer; a p-type electrode which is electrically connected to the p-type nitride semiconductor layer; a light-emitting face, through which polarized light that has been produced in the active layer region is extracted out of this element; and a striped structure which is provided for the light-emitting face and which has a plurality of projections that run in a direction that defines either an angle of 30 degrees to 60 degrees or an angle of −60 degrees to −30 degrees with respect to the a-axis direction of the m-plane nitride semiconductor layer.
In one embodiment, the plurality of projections have at least one slope which is not parallel to the light-emitting face.
In one embodiment, the polarized light is produced in the active layer region so as to have a light distribution characteristic, of which the angle of radiation is wider in a c-axis direction than in the a-axis direction.
In one embodiment, the semiconductor light-emitting element further includes an n-type nitride semiconductor substrate which has first and second principal surfaces, the first principal surface is in contact with the n-type nitride semiconductor layer, and the light-emitting face is the second principal surface.
In one embodiment, the p-type nitride semiconductor layer has first and second principal surfaces, the second principal surface is located closer to the active layer region, and the light-emitting face is the first principal surface.
In one embodiment, the semiconductor light-emitting element further includes: an n-type nitride semiconductor substrate which is provided in contact with the n-type nitride semiconductor layer; and a light output member which has first and second principal surfaces. The first principal surface is in contact with the other surface of the n-type nitride semiconductor substrate which is opposite from the surface that contacts with the n-type nitride semiconductor layer. And the light-emitting face is the second principal surface.
In one embodiment, the light output member has a refractive index of greater than one.
In one embodiment, the plurality of projections have a period of 300 nm or more.
In one embodiment, the plurality of projections have a period of 8 μm or less.
A method for fabricating a semiconductor light-emitting element according to the present invention includes the steps of: forming a semiconductor multilayer structure on a substrate, the multilayer structure including an n-type nitride semiconductor layer, a p-type nitride semiconductor layer, and an active layer region which is interposed between the n-type and p-type nitride semiconductor layers and which includes an m-plane nitride semiconductor layer; forming an n-type electrode which is electrically connected to the n-type nitride semiconductor layer and a p-type electrode which is electrically connected to the p-type nitride semiconductor layer; and forming a striped structure, including a plurality of projections that run in a direction that defines either an angle of 5 degrees to 80 degrees or an angle of −80 degrees to −5 degrees with respect to the a-axis direction of the m-plane nitride semiconductor layer, on another surface of the substrate on which the semiconductor multilayer structure has not been formed.
Another method for fabricating a semiconductor light-emitting element according to the present invention includes the steps of: forming a semiconductor multilayer structure on a substrate, the multilayer structure including an n-type nitride semiconductor layer, a p-type nitride semiconductor layer, and an active layer region which is interposed between the n-type and p-type nitride semiconductor layers and which includes an m-plane nitride semiconductor layer; forming an n-type electrode which is electrically connected to the n-type nitride semiconductor layer and a p-type electrode which is electrically connected to the p-type nitride semiconductor layer; and forming a striped structure, including a plurality of projections that run in a direction that defines either an angle of 30 degrees to 60 degrees or an angle of −60 degrees to −30 degrees with respect to the a-axis direction of the m-plane nitride semiconductor layer, on another surface of the substrate on which the semiconductor multilayer structure has not been formed.
In a semiconductor light-emitting element according to the present invention, a striped structure that runs in a direction that defines an angle of either 5 degrees or more or −5 degrees or less with respect to the a-axis is provided for the light-emitting face through which the light emitted from the active layer region is extracted. Thus, polarized light can be incident as a composite wave of p- and s-waves on the slope of projections that form the striped structure. The light that has been incident as such a composite wave of p- and s-waves has its polarization direction changed and is transmitted. Also, the percentage of the p- and s-waves of the light that has been incident on the slope can be varied in a wide range by the striped structure. As a result, the polarization direction is also changed into various directions and the polarization property of the light emitted from the semiconductor light-emitting element can be lessened.
In addition, since the striped structure is oriented in a direction that defines an angle of either 80 degrees or less or −80 degrees or more with respect to the a-axis, most of the light emitted from the active layer region can be made incident on the slope of the striped structure. As a result, the light extraction efficiency can be increased. Furthermore, since the incident light gets refracted at the boundary between the slope of the projections and the outside so as to go closer to the m-axis, the degree of asymmetry of the light distribution characteristic can be improved.
a) is a perspective view schematically illustrating a unit cell of GaN and (b) and (c) illustrate the crystal structures of a c plane and an m plane, respectively.
a) is a perspective view illustrating the striped structure of the first embodiment, (b) is a schematic cross-sectional view illustrating a projection of the striped structure, and (c) and (d) are schematic top views showing the direction in which the stripes run.
a) through (c) are schematic cross-sectional views illustrating exemplary projections of the striped structure.
a) and (b) are schematic top views illustrating other examples of the striped structure.
a) schematically shows the propagation vector of light that is polarized in the a-axis direction, and (b) shows the light distribution characteristics in the a- and c-axis directions as viewed along the m-axis.
a) is a top view illustrating a striped structure and (b) shows the apparent pitch Pr of the striped structure.
a) and (b) schematically show examples of light incident on, and transmitted through, the light-emitting face of a semiconductor light-emitting element having a flat light-emitting face as viewed in the a- and c-axis directions, respectively, and (c) schematically shows exemplary light incident on, and transmitted through, the light-emitting face of a nitride-based semiconductor light-emitting element according to the first embodiment.
a) schematically illustrates a cross-sectional shape of the striped structures of Examples 1 and 2, Reference Examples 1 and 2 and Comparative Examples 1 and 2, and (b) schematically illustrates a cross-sectional shape of the striped structures of Example 3 and Reference Example 3.
a) shows the light distribution characteristic of a semiconductor light-emitting element having a flat light-emitting face and (b) and (c) schematically illustrate the results shown in (a).
The present inventors carried out an extensive research on the relation between the polarization property and light distribution characteristic of the light emitted from an active layer in an m-plane nitride-based semiconductor light-emitting element and the light-emitting face. As a result, the present inventors discovered that the polarization property of the extracted light should depend on the relation between the direction of the major electric field vector of the polarized light produced in the active layer of the nitride-based semiconductor light-emitting element and the shape of the light-emitting face. The present inventors also discovered that the light distribution characteristic of the light extracted should depend on the relation between the direction of the major propagation vector of the polarized light and the shape of the light-emitting face. And based on these discoveries, the present inventors invented a nitride-based semiconductor light-emitting element that could increase the efficiency to extract the light while lessening its polarization property and that could improve its light distribution characteristic at the same time by optimizing the shape of the light-emitting face. Hereinafter, embodiments of a light-emitting element according to the present invention will be described with reference to the accompanying drawings. In the following description, any pair of components shown in multiple drawings and having substantially the same function will be identified by the same reference numeral for the sake of simplicity. It should be noted that the present invention is in no way limited to the embodiments to be described below.
The semiconductor multilayer structure 20 includes not only the active layer region 22 but also an n-type nitride semiconductor layer 21 and a p-type nitride semiconductor layer 23. And the active layer region 22 is interposed between the n-type nitride semiconductor layer 21 and the p-type nitride semiconductor layer 23. Although not shown in
The semiconductor light-emitting element 101 further includes an n-type electrode 30 and a p-type electrode 40, which are electrically connected to the n-type nitride semiconductor layer 21 and the p-type nitride semiconductor layer 23, respectively. In this embodiment, by making a recess 31 in the semiconductor multilayer structure 20, the n-type nitride semiconductor layer 21 is partially exposed and the n-type electrode 30 is arranged on that exposed part of the n-type nitride semiconductor layer 21. The n-type electrode 30 may be a stack (Ti/Pt) of Ti and Pt layers, for example. Meanwhile, the p-type electrode 40 is arranged on the p-type nitride semiconductor layer 23. The p-type electrode 40 suitably covers almost the entire surface of the p-type nitride semiconductor layer 23. The p-type electrode 40 may be a stack (Pd/Pt) of Pd and Pt layers, for example.
As for the substrate 10, a member on which the semiconductor multilayer structure 20 can be formed suitably is selected. Specifically, the substrate 10 does not have to be a GaN substrate but may also be a gallium oxide substrate, an SiC substrate, an Si substrate or a sapphire substrate, for example. To grow epitaxially the semiconductor multilayer structure 20 including the active layer region, of which the principal surface is an m-plane, on the substrate 10, the plane orientation of the SiC or sapphire substrate is suitably an m plane, too. However, it was reported that a-plane GaN could grow on an r-plane sapphire substrate. That is why to grow the active layer region 22, of which the principal surface is an m plane, the surface of the substrate 10 does not have to be an m plane. Optionally, after the semiconductor multilayer structure 20 has been formed on another substrate, instead of this substrate 10, the semiconductor multilayer structure 20 may be removed from that another substrate and transferred onto this substrate 10.
The n-type nitride semiconductor layer 21 may be made of n-type AluGavInwN (where u+v+w=1, u≧0, v≧0 and w≧0), for example. As the n-type dopant, silicon (Si) may be used, for example.
The p-type nitride semiconductor layer 23 may be made of a p-type AlsGatN (where s+t=1, s≧0 and t≧0) semiconductor, for example. As the p-type dopant, magnesium (Mg) may be used, for example. Examples of other p-type dopants include zinc (Zn) and beryllium (Be). In the p-type nitride semiconductor layer 23, the mole fraction s of Al may be either constant in the thickness direction or vary continuously or stepwise in the thickness direction. Specifically, the p-type nitride semiconductor layer 23 may have a thickness of approximately 0.2 μm to 2 μm.
In the p-type nitride semiconductor layer 23, in the vicinity of the first principal surface 23a (i.e., in the vicinity of the interface with the p-type electrode 40), the mole fraction s of Al is suitably equal to zero, i.e., the p-type nitride semiconductor layer 23 is suitably made of GaN there. In that case, the GaN portion is heavily doped with a p-type dopant and suitably functions as a contact layer. Although not shown in
The active layer region 22 is the light-emitting region of this semiconductor light-emitting element 101 and includes a nitride semiconductor layer which has been formed on an m plane in order to emit polarized light with high luminous efficacy. The light emitted in the active layer region 22 becomes light that is polarized in the a-axis direction. The growing direction of this active layer region 22 is perpendicular to an m plane and the first and second principal surfaces 22a and 22b of the active layer region are both m planes. However, the first and second principal surfaces 22a and 22b do not have to be perfectly parallel to the m plane but may define a predetermined tilt angle with respect to the m plane. Specifically, the tilt angle is defined to be the angle formed between a normal to the first or second principal surface 22a or 22b and a normal to the m plane. The absolute value of the tilt angle θ may be 5 degrees or less, and is suitably 1 degree or less, in both the c- and a-axis directions. If the tilt angle falls within such a range, the first or second principal surface 22a or 22b of the active layer region is tilted overall with respect to the m plane but should be made up of a plurality of steps, each of which is as high as one to a few atomic layers, and should include a lot of m-plane regions, speaking microscopically. That is why a plane that defines a tilt angle of 5 degrees or less (in absolute value) with respect to the m plane should have the same property as the m plane. Thus, the m-plane nitride semiconductor layer of this embodiment includes a nitride semiconductor layer that has been formed on a surface which defines a tilt angle of 5 degrees or less (in absolute value) with respect to an m plane. If the absolute value of the tilt angle θ were greater than 5 degrees, then the internal quantum efficiency would decrease due to a piezoelectric field. For that reason, the absolute value of the tilt angle θ is set to be 5 degrees or less.
The active layer region 22 has a GaInN/GaN multiple quantum well (MQW) structure in which Ga1-xInxN well layers (where 0<x<1), each of which is an m-plane nitride semiconductor layer with a thickness of approximately 3 nm to nm, and GaN barrier layers, each having a thickness of approximately 5 nm to 30 nm, are stacked alternately. The wavelength of the light emitted from the semiconductor light-emitting element 101 is determined by the magnitude of the band gap of the semiconductor that forms the active layer region 22, more specifically, the In mole fraction x of the composition Ga1-xInxN of the semiconductor that forms the well layers. No piezoelectric field is generated in the active layer region 22 that has been formed on an m plane. That is why even if the In mole fraction is increased, decrease in luminous efficacy can be minimized. As a result, by increasing the In mole fraction significantly, even a semiconductor light-emitting element that uses a nitride-based semiconductor also realizes a red-ray-emitting light-emitting diode.
The substrate 10 has first and second principal surfaces 10a and 10b, and the first principal surface 10a is in contact with the n-type nitride semiconductor layer 21 of the semiconductor multilayer structure 20. The second principal surface 10b becomes a light-emitting face, through which the polarized light emitted from the active layer region 22 is extracted. In this embodiment, the second principal surface 10b has a striped structure 50 in order to extract light with the polarization property lessened. Hereinafter, the striped structure 50 will be described in detail.
a) is a perspective view schematically illustrating the striped structure 50. At the upper left corner of
As a plurality of grooves 50b runs in a direction that defines either an angle of 5 degrees to 80 degrees or an angle of −80 degrees to −5 degrees with respect to the a-axis between those projections 50a, it can also be said that this striped structure 50 has these grooves 50b. In this description, however, in order to discuss the polarized light to be extracted through a member with this striped structure 50, the striped structure 50 is regarded herein as having those “projections”. However, those “projections” may be formed in the striped structure 50 by making those “grooves” in the light-emitting face.
In this embodiment, each projection 50a has an upper surface 53 which is parallel to the second principal surface 10b that is the light-emitting face and at least one slope 52 which is not parallel to the light-emitting face. However, each projection 50a has only to have at least one slope 52 which is not parallel to the second principal surface 10b. Also, as will be described later, the slope 52 may also be curved. The height h of each projection 50a is suitably equal to or greater than λ/(4×n) and more suitably falls within the range of λ/(4×n) to 10 μm, where λ is the emission wavelength of the active layer region and n is the refractive index of the material of the striped structure 50. In this embodiment, n is the refractive index of the material of the substrate 10. For example, supposing the polarized light produced in the active layer region 22 has a wavelength of 450 nm and the material of the striped structure 50 has a refractive index n of 2.5, the height h is suitably equal to or greater than 45 nm.
By setting the height h to be equal to or greater than λ/(4×n), the striped structure 50 can increase the light extraction efficiency. The upper limit of the height h depends on the manufacturing method adopted. For example, if a chemical dry etching process is adopted, the slope of the striped structure is likely to produce crystal planes which form α=approximately 65 degrees, and therefore, the striped structure comes to have an aspect ratio of approximately 1.2. In this example, the aspect ratio is represented as the ratio of the height h of the striped structure 50 to the length b of the bottom of the striped structure 50 as given by the following Equation (1):
aspect ratio=height h/bottom length b (1)
In this case, if the bottom length b is 10 μm, then the upper limit of the height h becomes 12 μm. In this description, the chemical dry etching process means a dry etching process to be carried out under plasma which is highly chemically reactive to a nitride semiconductor (such as chlorine radicals).
On the other hand, if a physical dry etching process is adopted, then the aspect ratio of the striped structure can be increased to approximately 5. In that case, if the bottom length b is 10 μm, then the height h becomes 50 μm. In this description, the physical dry etching process means a dry etching process to be performed physically on a nitride semiconductor under plasma (such as chlorine ions).
Actually, however, the height h cannot be equal to or greater than the thickness of the substrate. Also, the height h is suitably set to be approximately equal to or smaller than a half of the thickness of the substrate. Then, even after the striped structure has been formed, the substrate can maintain its rigidity and can be handled with no problem at all.
b) generally illustrates a cross-sectional structure 56 of a single projection 50a of the striped structure 50 as viewed perpendicularly to the longitudinal direction (i.e., perpendicularly to the direction in which the projection 50a runs). As shown in
c) is a schematic top view of the striped structure 50. As described above, the angle β defined by the direction in which the projections 50a of the striped structure 50 run with respect to the a-axis (which will be simply referred to herein as an “angle β”) falls suitably within the range of 5 degrees≦|β|≦80 degrees, more suitably within the range of 30 degrees≦|β|≦60 degrees, and even more suitably within the range of 40 degrees≦|β|≦50 degrees. In this case, the angle β is supposed to be the angle defined by the line of intersection 55 between the shadowed plane 54 shown in
The plane 54 is parallel to a plane defined by the a- and c-axes (which will be referred to herein as an “ac plane”) and is present where the plane 54 intersects with the slope 52.
Also, as shown in
Hereinafter, the relationship between the striped structure 50 and the polarization property of the light emitted from this semiconductor light-emitting element 101, the relationship between the striped structure 50 and the light extraction efficiency and the relationship between the striped structure 50 and the light distribution characteristic will be explained.
As shown in
Next, it will be considered on what condition the polarization property of the light that has been incident on a plane can be maintained in the transmitted light, too.
As can be seen from
However, if either the p-wave component or the s-wave component of the incident light is equal to zero, such a zero wave component cannot be included in the transmitted light, and therefore, the ratio of the scalar quantities does not change and the electric field vector direction can be maintained. In other words, in order to lessen the polarization property, the light incident on the surface of the striped structure 50 that contacts with the outside may not consist of only the p-wave component or only the s-wave component.
The semiconductor light-emitting element 101 made of a nitride-based semiconductor that uses an m plane as its principal surface produces light polarized in the a-axis direction.
As shown in
If the angle β is greater than 0 degrees (i.e., if the direction in which the stripes run becomes not parallel to the a-axis), then the slope 52 becomes not parallel to the a-axis. As a result, the light incident on the slope 52 comes to have a p-wave component, and the polarization property is lessened for the reasons described above. The same can be said if the angle β has a negative value.
The polarization property can also be lessened even if the angle β is 90 degrees. When the angle β is 90 degrees, the stripes run in the c-axis direction as shown in
However, in most of the light polarized in the a-axis direction, which has been produced at the point q, the angle defined by the propagation vector with respect to the c-axis becomes different from 90 degrees as in the propagation vector k2. The incident plane of the propagation vector k2 is not parallel to the ma plane. In that case, the polarized light k2 with the propagation vector k2 is incident as a composite wave of s- and p-waves on the slope 52 of the striped structure 50. That is why when the polarized light k2 is transmitted through the slope 52 to leave this light-emitting element, the ratio of the scalar quantities of the p- and s-waves changes and the electric field vector direction changes, too. As a result, every light polarized in the a-axis direction, which has been produced at the point q, has its electric field vector direction disturbed at the slope 52 except the polarized light k1. Consequently, if β=90 degrees, the degree of polarization can be reduced. In this description, the “degree of polarization” is a value calculated by the following Equation (6):
(degree of polarization)=(Imax−Imin)/(Imax+Imin) (6)
Imax and Imin are values to be obtained when measurement is carried out in the following manner. Specifically, a polarizer is arranged parallel to the light-emitting face and the intensity of the light that has been transmitted through the polarizer is measured with the polarizer rotated. The intensity of the light measured becomes a maximum value at a certain angle and becomes a minimum value at another angle. The maximum and minimum values in such a situation are identified herein by Imax and Imin, respectively. If the intensity of the light remains the same at every angle, then Imax and Imin are equal to each other and the degree of polarization becomes zero.
As described above, the degree to which the polarization property is lessened depends on the angle β. It can also be seen that the polarization property is maintained only in a special situation where β=0. As will be described later for specific examples of the present invention, the degree to which the polarization property is lessened can be evaluated by the degree of specific polarization. The present inventors carried out various experiments to evaluate the degree of specific polarization. As a result, the present inventors discovered that the angle β is suitably equal to or greater than 5 degrees, more suitably falls within the range of 30 degrees to 60 degrees. In this description, the “degree of specific polarization” refers herein to a value obtained by normalizing the degree of polarization of a semiconductor light-emitting element with a striped structure that satisfies β=x (where 0<x≦90) with that of a semiconductor light-emitting element with a striped structure that satisfies β=0, and is given by the following Equation (7):
(degree of specific polarization)=degree of polarization of semiconductor light-emitting element with striped structure that satisfies β=x/degree of polarization of semiconductor light-emitting element with striped structure that satisfies β=0 (7)
where 0<x≦90.
Also, as can be seen from
In view of these considerations, it is recommended that the plurality of projections of the striped structure have no upper surface 53 that is parallel to the second principal surface 10b that is the light-emitting face. Specifically, the striped structure suitably has projections with a triangular cross-sectional shape such as the one shown in
Next, the relation between the angle β and the light extraction efficiency will be considered. The light extraction efficiency of a semiconductor light-emitting element with the striped structure 50 on its light-emitting face increases if the light emitted is incident on the slope 52 of the striped structure 50. This is because even light that would be totally reflected at a flat light-emitting face should be incident on the slope 52 at an angle that is equal to or smaller than the angle of total reflection and some of the light should be extracted out of the light-emitting element. Also, even light that has been incident on the slope 52 at an angle that is equal to or greater than the angle of total reflection should be reflected from the slope 52 to have its direction changed. And when the light is incident on the slope 52 next time, its angle of reflection is more likely to be equal to or smaller than the angle of total reflection. For these reasons, in order to increase the light extraction efficiency, it is beneficial that the light emitted is incident on the slope 52 with high probability. Thus, the pitch P of the projections 50a of the striped structure 50 is suitably small.
a) is a top view of the striped structure 50, and
As shown in
Considering the relation between the polarization property and the angle β and the relation between the light extraction efficiency and the angle β described above, to lessen the polarization property sufficiently and increase the light extraction efficiency, the angle β suitably satisfies 5 degrees≦|β|≦80 degrees, and more suitably satisfies 3 degrees≦|β|≦60 degrees.
By making polarized light incident on the striped structure 50 with such conditions satisfied, the semiconductor light-emitting element of this embodiment can also make improvement on the degree of asymmetry of the light distribution characteristic.
Consequently, the propagation vector of the light emitted from the semiconductor light-emitting element 101 satisfies the relation (a-axis component)<(c-axis component). This also means that the relation (intensity of light emitted in a-axis direction)<(intensity of light emitted in c-axis direction) is also satisfied. That is to say, this light distribution characteristic is an asymmetric one.
On the other hand, in the semiconductor light-emitting element 101 of this embodiment, the light incident on the slope 52 of the striped structure 50 is transmitted toward the light-emitting face as shown in
As can be seen, in the semiconductor light-emitting element of the present invention, the light-emitting face, through which the light produced in the active layer region is extracted, has a striped structure that runs to define an angle that satisfies 5 degrees≦|β|, more suitably 30 degrees≦|β|, with respect to the a-axis, and therefore, light polarized in the a-axis direction can be incident as a composite wave of s- and p-wave components on the slope and upper surface of projections that form the striped structure. As a result, the light with a decreased degree of polarization can be extracted with the polarization property lessened. In addition, since the striped structure that runs to define an angle that satisfies |β|≦80 degrees, more suitably, |β|≦60 degrees, is provided, the light produced can be incident on the slope of the striped structure efficiently. As a result, the light extraction efficiency can be increased. Moreover, since the light polarized in the a-axis direction is refracted at the boundary between the slope of the projections and outside so as to go toward the m-axis, the degree of asymmetry of the light distribution characteristic can be improved as well.
According to the present invention, a striped structure is provided for the light-emitting face of a semiconductor light-emitting element in order to make the light incident on the striped structure as much as possible with the condition for lessening the polarization property satisfied, instead of keeping high transmittance or low reflectance. In this respect, it can be said that the semiconductor light-emitting element of Patent Document No. 3, which makes light incident on the light-emitting face at a Brewster angle at which the reflectance becomes zero, is based on a totally different idea from the present invention.
Meanwhile, Japanese Laid-Open. Patent Publication No. 2001-201746 discloses a similar technique which is related to the present invention in that a striped structure is provided for the light-emitting face. However, Japanese Laid-Open Patent Publication No. 2001-201746 teaches transforming non-polarized light that has been incident on a light guide member into polarized light and outputting the polarized light by forming a plurality of ribs, each having a predetermined height, on the light guide member for use as a backlight for a liquid crystal display element, and the polarized light is controlled totally inversely to the present invention. This technique just uses the fact that the P- and S-wave components of light incident on a plane have different reflectances and different transmittances as shown in
Hereinafter, an exemplary method for fabricating the semiconductor light-emitting element 101 will be described. As shown in
Specifically, an n-type nitride semiconductor layer 21 is grown epitaxially on a substrate 10 made of n-type GaN, of which the principal surface is an m plane. For example, using silicon as an n-type dopant and Ga(CH3)3 (trimethylgallium (TMG)) and NH3 as source gases, respectively, an n-type nitride semiconductor layer 21 of GaN is deposited to a thickness of about 3 μm at a growing temperature of approximately 900 degrees Celsius to 1100 degrees Celsius.
Next, an active layer region 22 is formed on the n-type nitride semiconductor layer 21. The active layer region 22 may have a GaInN/GaN multiple quantum well (MQW) structure in which Ga1-xInxN well layers, each having a thickness of approximately 9 nm, and GaN barrier layers, each having a thickness of approximately 9 nm, are stacked alternately. In forming the Ga1-xInxN well layers, the growing temperature is suitably decreased to 800 degrees Celsius in order to introduce In. The emission wavelength is selected according to the intended use of the semiconductor light-emitting element 101 and the In mole fraction x is determined by the wavelength. Specifically, if the wavelength is set to be 450 nm (blue), the In mole fraction x is set to fall within the range of 0.18 through 0.2. On the other hand, if the wavelength is 520 nm (green), then x=0.29 to 0.31. And if the wavelength is 630 nm (red), then x=0.43 to 0.44. By controlling the In mole fraction in this manner, a semiconductor light-emitting element 101 which can emit blue, green and red rays and which can be used as an illumination unit is obtained.
Optionally, an undoped GaN layer (not shown) may be deposited to a thickness of about 30 nm on the active layer region 22. Next, a p-type nitride semiconductor layer 23 is formed on the undoped GaN layer. For example, using Cp2Mg (cyclopentadienyl magnesium) as a p-type dopant and TMG, Al(CH3)3 (trimethylaluminum (TMA)) and NH3 as source gases, respectively, a p-type nitride semiconductor layer 23 of p-AlxGa1-xN is deposited to a thickness of about 70 nm at a growing temperature of approximately 900 degrees Celsius to 1100 degrees Celsius. The mole fraction x may be set to be approximately 0.14, for example.
Next, using Cp2Mg as a dopant, a p-GaN contact layer (not shown) is deposited to a thickness of approximately 0.5 μm, for example, on the p-type nitride semiconductor layer 23. After that, the entire substrate is thermally treated at a temperature of approximately 800 degrees Celsius to 900 degrees Celsius for twenty minutes.
Subsequently, a p-type electrode 40 and an n-type electrode 30 are formed. By performing a dry etching process using a chlorine based gas, the p-GaN contact layer, the p-type nitride semiconductor layer 23, the undoped GaN layer, the active layer region 22 and the n-type nitride semiconductor layer 21 are partially removed to make a recess and expose a part of the n-type nitride semiconductor layer 21.
Next, on that part of the n-type nitride semiconductor layer 21, which is exposed at the bottom of the recess 31, a stack of Ti/Pt layers is formed as the n-type electrode 30. Meanwhile, a stack of Pd/Pt layers is formed as the p-type electrode 40 on the p-GaN contact layer. After that, a heat treatment process is carried out to alloy the Ti/Pt layers with the n-type nitride semiconductor layer 21 and the Pd/Pt layers with the p-GaN contact layer and form an n-type electrode 30 and a p-type electrode 40 on the n-type nitride semiconductor layer 21 and on the p-GaN contact layer, respectively.
Thereafter, the second principal surface 10b of the substrate 10 is polished to reduce the thickness of the semiconductor light-emitting element 101 and decrease absorption of light into the semiconductor light-emitting element 101. The semiconductor light-emitting element 101 may have a thickness of 100 μm, for example, because the semiconductor light-emitting element 101 can be handled easily when mounting on a circuit board. In this manner, the structure of the semiconductor light-emitting element 101 with a flat light-emitting face 14 as shown in
Next, a striped structure 50 is formed on the flat light-emitting face 14. The striped structure 50 may be formed by any of various methods including a technique that uses a contact exposure system, a technique that uses an electron beam lithography system, a technique that uses nano imprint, and a technique that uses a stepper. In this embodiment, a method for forming the striped structure 50 using a contact exposure system and an electron beam lithography system will be described in detail. In the following description, the second principal surface 10b, which is the light-emitting face on which the striped structure 50 has not been formed yet, will be referred to herein as a “flat light-emitting face 14”.
First of all, an SiO2 film is deposited as a hard mask material on the flat light-emitting face 14. The SiO2 film may be deposited by plasma chemical vapor deposition (p-CVD) process, for example. Next, a photoresist is applied onto the hard mask. After the photoresist has been applied, an exposure process is carried out using a contact exposure system or an electron beam lithography system and then a development process is performed to define a resist pattern including a plurality of stripes that run in a direction that satisfies 5 degrees≦|β|≦80 degrees, more suitably 30 degrees≦|β|≦60 degrees, with respect to the a-axis.
Thereafter, using the resist pattern as a mask, the hard mask is dry-etched using CF4 gas and O2 gas, for example. Next, using the hard mask as a mask, the flat light-emitting face 14 is dry-etched using a chlorine based gas, for example. Finally, the hard mask is removed by dry etching. In this manner, a semiconductor light-emitting element 101, including the striped structure 50 on the second principal surface 10b of the substrate 10 as shown in
The striped structure 50 may also be formed on the flat light-emitting face 14 in the following manner. First, a photoresist is applied onto the flat light-emitting face 14, an exposure process is performed using a contact exposure system, and then a development process is carried out to define a resist pattern including a plurality of stripes that run in a direction which defines 5 degrees≦|β|≦80 degrees (more suitably, 30 degrees≦|β|≦60 degrees) with respect to the a-axis. By heating the photoresist, dry etch resistance is increased. Thereafter, by using the photoresist as a mask, the flat light-emitting face 14 is dry etched using a chlorine-based gas. As a result, the photoresist is also removed at the same time. In this manner, a semiconductor light-emitting element 101, including the striped structure 50 on the second principal surface 10b of the substrate 10, is completed.
The semiconductor multilayer structure 20 does not have to be formed on an n-type GaN substrate, of which the principal surface is an m plane, but may also be an m-plane GaN layer which has been formed, by crystal growing process, on an SiC substrate, a sapphire substrate, an LiAlO2 substrate, a Ga2O3 substrate, an SiC substrate, or an Si substrate. In that case, before a nitride-based semiconductor is grown epitaxially on any of these substrates, the striped structure 50 may be formed in advance. And after the semiconductor has been grown epitaxially, the substrate is removed by laser lift off process, for example. In this case, the striped structure 50 that has been formed before the semiconductor is epitaxially grown is transferred onto the nitride-based semiconductor. That is why a semiconductor light-emitting element 101 with the striped structure 50 can be eventually obtained by removing the substrate. The semiconductor light-emitting element 101 may be completed in this manner, too. To grow an m-plane nitride-based semiconductor epitaxially on a substrate, the plane orientation of the SiC or sapphire substrate is suitably an m plane, too. However, it was reported that a-plane GaN could grow on an r-plane sapphire substrate. That is why to grow a semiconductor layer, of which the principal surface is an m plane, the principal surface of the substrate 10 does not have to be an m plane but the active layer region 22 needs to be parallel to an m plane and its crystal growing direction needs to be perpendicular to the m plane, to say the least.
The light output member 13 is arranged in contact with the second principal surface 10b of the substrate 10, which is opposite from the other surface with the semiconductor multilayer structure 20. The first principal surface 13a of the light output member 13 is in contact with the substrate 10 and the second principal surface 13b thereof has the striped structure 50. The light output member 13 is made of a material other than a GaN semiconductor such as SiO2, SiN, SiC, TiO2, sapphire, LiAlO2, or Ga2O3 which transmits the polarized light produced in the active layer region 22. More suitably, the light output member 13 is made of a material which can be easily patterned by dry etching, for example.
Generally speaking, a dry etching process to be performed on a nitride-based semiconductor such as the substrate 10 made of n-type GaN has some problems such as a low etch rate and difficulty to control the sidewall shape. However, by providing a light output member 13 made of such a material, the striped structure 50 can be formed more easily. Also, if SiO2 or SiN is used as a material for the light output member 13, the striped structure 50 can be formed by performing a wet etching process using an aqueous solution including hydrofluoric acid.
Also, the refractive index no of the light output member 13 is suitably equal to or greater than the refractive index nt of an external medium with which the second principal surface 13b with the striped structure 50 contacts (i.e., nt<no). Thus, compared to a situation where the polarized light is transmitted through the substrate 10 and extracted directly, the transmittance of the light through the second principal surface 10b of the substrate 10 can be increased, and eventually, the light extraction efficiency can be further increased.
The degree of polarization of the polarized light extracted through the light output member 13 depends on the refractive index no of the constituent material of the light output member 13, the angle β defined by the direction in which the projections 50a of the striped structure 50 run with respect to the a-axis (see
This semiconductor light-emitting element 102 may be fabricated in the following manner, for example.
First of all, as shown in
Thereafter, a light output member 13 is formed on the second principal surface 10b of the substrate 10. If the light output member 13 needs to be made of SiO2, an SiO2 film is formed by plasma chemical vapor deposition process, for example. In this case, the thicker the SiO2 film, the lower its film quality and its transmittance will be. For that reason, the light output member 13 suitably has a thickness of 10 μm or less.
After that, a resist pattern is defined on the SiO2 film and the SiO2 film is selectively etched using the resist pattern as already described for the first embodiment. For example, by dry-etching the SiO2 film using a mixture of CF4 and O2 gases, the striped structure 50 can be formed more easily and with more controllability than in a situation where the substrate 10 made of a nitride semiconductor is etched. In this manner, the semiconductor light-emitting element 102 shown in
In this semiconductor light-emitting element 103, the semiconductor multilayer structure 20 has no recess 31 and the n-type electrode 30 is arranged on the second principal surface 10b of the substrate 10 with the striped structure 50, which is a major difference from the first embodiment described above. The semiconductor multilayer structure 20, the p-type electrode 40 and the striped structure 50 are the same as their counterparts of the first embodiment.
As shown in
This semiconductor light-emitting element 103 may be fabricated in the following manner. First of all, as already described for the first embodiment, a semiconductor multilayer structure 20 is formed on the first principal surface 10a of the substrate 10. Thereafter, the substrate 10 is polished until the overall thickness thereof becomes approximately 100 μm. Next, a striped structure 50 is formed on the second principal surface 10b of the substrate 10 as already described for the first embodiment.
After the striped structure 50 has been formed, electrodes are formed. First of all, a stack of Ti/Pt layers, for example, is formed as an n-type electrode 30 on a part of the second principal surface 10b with the striped structure 50. Meanwhile, a stack of Pd/Pt layers, for example, is formed as a p-type electrode 40 on the p-type nitride semiconductor layer 23. After that, a heat treatment process is carried out to alloy the Ti/Pt layers with the substrate 10 and the Pd/Pt layers with the p-GaN contact layer and form an n-type electrode 30 and a p-type electrode 40 which are electrically connected to the substrate 10 and the p-GaN contact layer, respectively. In this manner, the semiconductor light-emitting element 103 shown in
In this semiconductor light-emitting element 104, the light output member 13 is arranged to cover the striped structure 50 on the second principal surface 10b of the substrate 10, which is a major difference from the first embodiment, and the substrate 10 does have the striped structure 50, which is a major difference from the second embodiment. The semiconductor multilayer structure 20, the re-type electrode 30, the p-type electrode 40 and the striped structure 50 have the same structures as their counterparts of the first embodiment described above.
The refractive index no of the light output member that covers the striped structure 50 on the second principal surface 10a of the substrate 10 is suitably greater than the refractive index nt of a medium outside of this semiconductor light-emitting element 104 (i.e., nt<no). Also, the light output member 13 suitably has high transmittance with respect to the polarized light produced in the active layer region 22. Thus, compared to a situation where the polarized light is transmitted through the substrate 10 and extracted directly, the transmittance of the light through the second principal surface 10b of the substrate 10 can be increased, and eventually, the light extraction efficiency can be further increased. The light output member 13 is made of a material other than a GaN semiconductor such as SiO2, SiN, SiC, TiO2, sapphire, LiAlO2, or Ga2O3 which transmits the polarized light produced in the active layer region 22.
The light output member 13 may either completely fill the grooves 50b of the striped structure 50 to make the second principal surface 13b, which contacts with the external medium, totally flat or have a striped structure 50′ corresponding to the striped structure 50 of the second principal surface 13b. The refractive index no of the light output member 13 suitably satisfies nt<no<n1, where n1 is the refractive index of the substrate 10. By changing the refractive index stepwise from n1 through nt in this manner, the transmittance to the polarized light produced in the active layer region 22 can be further increased.
The semiconductor light-emitting element 104 may be fabricated in the following manner, for example. First of all, the semiconductor multilayer structure 20, the n-type electrode 30 and the p-type electrode 40 are formed on the substrate 10 as already described for the first embodiment. Meanwhile, the striped structure 50 is formed on the second principal surface 10b of the substrate 10.
After that, the output member 13 is deposited. If an SiO2 film is deposited as the output member 13, a plasma chemical vapor deposition process may be used. Thereafter, if necessary, the striped structure 50′ is formed on the light output member 13 by the method that has already been described for the second embodiment.
In this semiconductor light-emitting element 105, the light output member 13 is arranged on the p-type nitride semiconductor layer 23 and the polarized light produced in the active layer region 22 is transmitted through the p-type nitride semiconductor layer 23 and extracted through the light output member 13, which is a major difference from the first embodiment described above.
As shown in
The n-type electrode 30 is arranged on, and electrically connected to, the second principal surface 10b of the substrate 10. The semiconductor multilayer structure 20 and the striped structure 50 have the same structures as their counterparts of the first embodiment described above.
The light output member 13 is made of a material other than a GaN semiconductor such as SiO2, SiN, SiC, TiO2, sapphire, LiAlO2, or Ga2O3 which transmits the polarized light produced in the active layer region 22. More suitably, the light output member 13 is made of a material which can be easily patterned by dry etching, for example. Also, the refractive index no of the light output member 13 is suitably equal to or greater than the refractive index nt of an external medium with which the first principal surface 13a with the striped structure 50 contacts (i.e., nt<no). Thus, compared to a situation where the polarized light is transmitted through the p-type nitride semiconductor layer 23 and extracted directly, the transmittance of the light through the first principal surface 23a of the p-type nitride semiconductor layer 23 can be increased.
On top of that, compared to the second embodiment, the interval between the light output member 13 and the active layer region 22 can be shortened and absorption of the polarized light produced in the active layer region 22 into the semiconductor layer can be reduced. As a result, the light extraction efficiency can be further increased. Furthermore, as already described for the second embodiment, the striped structure 50 can also be formed easily.
This semiconductor light-emitting element 105 may be fabricated in the following manner. First of all, as already described for the first embodiment, a semiconductor multilayer structure 20 is formed on the substrate 10 as shown in
Next, electrodes are formed. First of all, a stack of Ti/Pt layers, for example, is formed as an n-type electrode 30 on the second principal surface 10b of the substrate 10. Meanwhile, a stack of Pd/Pt layers, for example, is formed as a p-type electrode 40 on a part of the p-type nitride semiconductor layer 23. After that, a heat treatment process is carried out to alloy the Ti/Pt layers with the substrate 10 and the Pd/Pt layers with the p-GaN contact layer and form an n-type electrode 30 and a p-type electrode 40 which are coupled to the substrate 10 and the p-GaN contact layer, respectively.
After the electrodes have been formed, a light output member 13 is formed on the first principal surface 23a of the p-type nitride semiconductor layer 23. If the light output member 13 needs to be made of SiO2, an SiO2 film is deposited by plasma chemical vapor deposition process, for example. In this case, the thicker the SiO2 film, the lower its film quality and its transmittance will be. For that reason, the light output member 13 suitably has a thickness of 10 μm or less.
Thereafter, a resist pattern is defined on the SiO2 film and the SiO2 film is selectively etched using the resist pattern as already described for the first embodiment. For example, by dry-etching the SiO2 film using a mixture of CF4 and O2 gases, the striped structure 50 can be formed easily and with good controllability.
Finally, a resist pattern is defined on the striped structure 50 and the SiO2 film is selectively etched using the resist pattern (e.g., wet-etched with hydrofluoric acid) to expose the p-type electrode 40. In this manner, the semiconductor light-emitting element 105 shown in
In this semiconductor light-emitting element 106, the striped structure 50 has been formed on the first principal surface 23a of the p-type nitride semiconductor layer 23 and the p-type electrode 40 has been formed over the entire surface of the striped structure 50, which are major differences from the fifth embodiment.
The p-type electrode 40 is a transparent electrode made of ITO in this embodiment. Optionally, a sufficiently thin metal layer which makes ohmic contact with the p-type nitride semiconductor layer 23 may be interposed between the transparent electrode and the p-type nitride semiconductor layer 23. In this semiconductor light-emitting element 106, the p-type electrode 40 can cover the entire first principal surface 23a of the p-type nitride semiconductor layer 23, and therefore, low-resistance p-type ohmic contact is realized.
This semiconductor light-emitting element 106 may be fabricated in the following manner. First of all, as already described for the first embodiment, a semiconductor multilayer structure 20 is formed on the substrate 10 as shown in
In this semiconductor light-emitting element 107, the p-type electrode 40 covers only a part of the striped structure 50 on the first principal surface 23a of the p-type nitride semiconductor layer 23, which is a major difference from the sixth embodiment described above. By providing such a small p-type electrode 40, absorption of light into the p-type electrode 40 can be reduced, and the light extraction efficiency can be increased, compared to the sixth embodiment.
This semiconductor light-emitting element 107 may be fabricated in the following manner. First of all, as already described for the first embodiment, a semiconductor multilayer structure 20 is formed on the substrate 10 as shown in
To confirm the effects of the present invention, various semiconductor light-emitting elements were fabricated by the manufacturing process of the first embodiment and had their performance evaluated.
First of all, as shown in
Next, an active layer region 22 was formed on the n-type nitride semiconductor layer 21. The active layer region 22 had a GaInN/GaN multiple quantum well (MQW) structure in which Ga1-xInxN well layers (where x=0.19), each having a thickness of 9 nm, and GaN barrier layers, each having a thickness of 9 nm, were stacked alternately. When the Ga1-xInxN well layers were formed, the growing temperature was lowered to 800 degrees Celsius in order to introduce In.
Next, an undoped GaN layer (not shown) was deposited to a thickness of 30 nm on the active layer region 22. Subsequently, a p-type nitride semiconductor layer 23 was formed on the undoped GaN layer. Using Cp2Mg (cyclopentadienyl magnesium) as a p-type dopant and supplying TMG, TMA and NH3 as source gases to a reaction chamber, a p-type nitride semiconductor layer 23 of p-Al0.14Ga0.86N was deposited to a thickness of about 70 nm at a growing temperature of 1050 degrees Celsius.
Next, using Cp2Mg as a dopant, a p-GaN contact layer (not shown) was deposited to a thickness of 0.5 μm on the p-type nitride semiconductor layer 23.
Subsequently, by performing a dry etching process using a chlorine based gas, the p-GaN contact layer, the p-type nitride semiconductor layer 23, the undoped GaN layer, the active layer region 22 and the n-type nitride semiconductor layer 21 were partially removed to make a recess 31 and expose a part of the n-type nitride semiconductor layer 21.
Next, on that part of the n-type nitride semiconductor layer 21, which was exposed at the bottom of the recess 31, a stack of Ti/Pt layers was formed as the n-type electrode 30. Meanwhile, a stack of Pd/Pt layers was formed as the p-type electrode 40 on the p-GaN contact layer. After that, a heat treatment process was carried out to alloy the Ti/Pt layers with the n-type nitride semiconductor layer 21 and the Pd/Pt layers with the p-GaN contact layer and form an n-type electrode 30 and a p-type electrode 40 on the n-type nitride semiconductor layer 21 and on the p-GaN contact layer, respectively.
Thereafter, the substrate 10 was polished to reduce the overall thickness to 100 μm. In this manner, a portion functioning as a semiconductor light-emitting element was completed.
Next, a striped structure 50 was formed. First of all, an SiO2 film was deposited as a hard mask material on the second principal surface 10b of the substrate 10. The SiO2 film was deposited by plasma chemical vapor deposition process. Next, a photoresist for electron beam lithography was applied onto the hard mask and was patterned using an electron beam lithography system. Thereafter, using the electron beam lithography photoresist as a mask, the hard mask was dry-etched with CF4 gas and O2 gas. Next, using the hard mask as a mask, the second principal surface 10b of the substrate 10 was dry-etched using a chlorine based gas. Finally, the hard mask was removed by dry etching. In this manner, a semiconductor light-emitting element was completed.
The striped structure had a pitch p of 300 nm and its height h was set to be 300 nm. Its cross-sectional shape was a roughly trapezoidal one.
A portion functioning as a semiconductor light-emitting element was made in the same procedure as in Example 1, Reference Example 1 and Comparative Example 1. After that, a striped structure was made in a different procedure from in Example 1, Reference Example 1 and Comparative Example 1. Specifically, an SiO2 film was deposited as a hard mask material on the second principal surface 10b of the substrate 10. The SiO2 film was deposited by plasma chemical vapor deposition process. Next, a photoresist was applied onto the hard mask and was patterned using a contact exposure system. Thereafter, using the photoresist as a mask, the hard mask was dry-etched with CF4 gas and O2 gas. Next, using the hard mask as a mask, the second principal surface 10b of the substrate 10 was dry-etched using a chlorine based gas. Finally, the hard mask was removed by dry etching. In this manner, a semiconductor light-emitting element was fabricated.
The striped structure had a pitch p of 8 μm and its height h was set to be 4 μm. Its cross-sectional shape was a roughly trapezoidal one.
Semiconductor light-emitting elements, of which the striped structure defined angles β of 0, 5, 30, 45 and 90 degrees, respectively, with respect to the a-axis, were fabricated. First of all, a portion functioning as a semiconductor light-emitting element was made in the same procedure as in Example 1, Reference Example 1 and Comparative Example 1. After that, a striped structure was made in a different procedure from in Example 1, Reference Example 1 and Comparative Example 1. Specifically, a photoresist was applied onto the second principal surface 10b of the substrate 10 and was patterned using a contact exposure system and then heated to 230 degrees Celsius. Thereafter, using the photoresist as a mask, the second principal surface 10b of the substrate 10 was dry-etched using a chlorine based gas. In this process step, the photoresist was also removed at the same time as a result of the dry etching process. In this manner, a semiconductor light-emitting element was fabricated.
The striped structure had a pitch p of 8 μm and its height h was set to be 2.5 μm. By making the striped structure by the manufacturing process described above, a different cross-sectional shape from that of Example 2, Reference Example 2 and Comparative Example 2 could be obtained. Specifically, its cross-sectional shape was a roughly isosceles triangular one.
A semiconductor light-emitting element, including every member of Example 1 but the striped structure 50, was fabricated as Comparative Example 4 in the same procedure as in Example 1.
(Evaluating the Performances of Examples 1 to 3, Reference Examples 1 to 3 and Comparative Examples 1 to 4)
The performances of the semiconductor light-emitting elements thus fabricated were evaluated. To confirm that most of the propagation vectors k were present within a plane parallel to the mc plane (see
As can be seen from
Next, the light distribution characteristics of the semiconductor light-emitting elements of Example 1, Reference Example 1 and Comparative Example 1 were measured. The system used for measurement also has the arrangement shown in
Next, the present inventors confirmed how much degree of polarization was lessened in the polarized light emitted.
(percentage of degree of polarization maintained)=(degree of polarization of semiconductor light-emitting element S)/(degree of polarization of comparative example) (9)
As shown in
To inspect the relation between the angle β and the degree of polarization more closely, the degrees of polarization of the semiconductor light-emitting elements of Example 3, Reference Example 3 and Comparative Example 3 were measured.
(degree of specific polarization)(degree of polarization of Example 3 or Comparative Example 3)/(degree of polarization of reference Example 3) (10)
As shown in
According to the results of measurement shown in
More specifically, in the semiconductor light-emitting element from which the results of measurement shown in
As can be seen, the percentage of the degree of polarization maintained varies according to the cross-sectional shape of each projection of the striped structure. However, the dependence of the effect of lessening the polarization property by the slope on the angle β would be no different irrespective of the cross-sectional shape. That is why no matter what cross-sectional shape each projection of the striped structure has, the angle β would suitably fall within the range of 5 degrees to 80 degrees, more suitably within the range of 30 degrees to 60 degrees, and most suitably should be around 45 degrees.
Next, the light extraction efficiencies were checked out.
As can be seen, the semiconductor light-emitting element according to Example 1, 2 or 3 can reduce the degree of asymmetry of the light distribution characteristic as shown in
The semiconductor light-emitting element of the present invention has high light extraction efficiency, a sufficiently small degree of polarization, and good enough light distribution characteristic, and can be used as any of various light sources. The semiconductor light-emitting element of the present invention can be used particularly effectively as an ordinary illumination unit that is not required to have polarization property.
Number | Date | Country | Kind |
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2010-177915 | Aug 2010 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/JP2011/004466 | 8/5/2011 | WO | 00 | 2/1/2013 |