Korean Patent Application No. 10-2020-0013017, filed on Feb. 4, 2020, in the Korean Intellectual Property Office, and entitled: “Three Dimensionally Structured Semiconductor Light Emitting Diode and Display Apparatus,” is incorporated by reference herein in its entirety.
Example embodiments relate to a three-dimensionally structured semiconductor light emitting diode and a display apparatus using the same.
A semiconductor light emitting diode (LED) has been used as a light source for a lighting device and also as a light source of various electronic products. For example, a semiconductor LED has been used as a light source for various display devices, e.g., a television (TV), a mobile phone, a personal computer (PC), a laptop PC, a personal digital assistant (PDA), and the like.
For example, a general display device may include a display panel implemented by a liquid crystal display (LCD) and a backlight. Recently, a display device has also been developed to use a LED device as a pixel, such that a backlight may not be required. Such a display device may have a compact size, and may be implemented as a high luminance display device having improved luminous efficiency, e.g., as compared to a general LCD.
According to an example embodiment, a three-dimensionally structured semiconductor light emitting diode includes a first conductivity-type semiconductor rod having first and second portions integral with each other, the first portion defining a first surface, the second portion defining a second surface opposite the first surface, and a side surface extending between the first surface and the second surface, an active layer and a second conductivity-type semiconductor layer sequentially disposed on the side surface of the first conductivity-type semiconductor rod, the active layer and the second conductivity-type semiconductor layer being on the second portion of the first conductivity-type semiconductor rod, an insulating cap layer on the second surface of the first conductivity-type semiconductor rod, a transparent electrode layer on the second conductivity-type semiconductor layer, and a passivation layer on the transparent electrode layer and exposing a portion of the transparent electrode layer, the passivation layer extending to cover a first end of the active layer and a first end of the second conductivity-type semiconductor layer adjacent to the first surface.
According to an example embodiment, a three-dimensionally structured semiconductor light emitting diode includes a first conductivity-type semiconductor rod having a first surface and a second surface opposing each other and a side surface disposed between the first surface and the second surface, and divided into a first portion adjacent to the first surface and a second portion adjacent to the second surface, an active layer and a second conductivity-type semiconductor layer sequentially disposed on a side surface of the second portion of the first conductivity-type semiconductor rod, an insulating cap layer disposed on the second surface of the first conductivity-type semiconductor rod, a transparent electrode layer disposed on the insulating cap layer and extending to a surface of the second conductivity-type semiconductor layer, and a passivation layer disposed on the transparent electrode layer to expose a portion of the transparent electrode layer disposed on the insulating cap layer.
According to an example embodiment, a display device includes a plurality of pixels, a first electrode portion and a second electrode portion disposed in the plurality of pixels, respectively, and spaced apart from each other, and a three-dimensionally structured semiconductor light emitting diode disposed between the first electrode portion and the second electrode portion in a length direction for a first surface of a first conductivity-type semiconductor nano-rod and a transparent electrode layer to be electrically connected to the first electrode portion and the second electrode portion, respectively.
According to an example embodiment, a method of manufacturing a three-dimensionally structured semiconductor light emitting diode includes forming a first conductivity-type semiconductor layer on a substrate, forming a plurality of internal rods using a plurality of nitride cap layers as masks, where the plurality of internal rods are disposed on a remaining first conductivity-type semiconductor layer, forming a plurality of first conductivity-type semiconductor rods by regrowing a first conductivity-type semiconductor on side surfaces of the plurality of internal rods, forming a plurality of three-dimensional light emitting structures by forming an active layer and a second conductivity-type semiconductor layer on side surfaces of the plurality of first conductivity-type semiconductor rods, forming a transparent electrode layer on an upper surface of each of the plurality of insulating cap layers and a surface of the second conductivity-type semiconductor layer, etching the remaining first conductivity-type semiconductor layer disposed between the plurality of three-dimensional light emitting structures, forming a passivation layer on the transparent electrode layer to expose a portion of the transparent electrode layer, and cutting out an etched portion of the plurality of first conductivity-type semiconductor rods.
Features will become apparent to those of skill in the art by describing in detail exemplary embodiments with reference to the attached drawings, in which:
Referring to
In detail, referring to
Referring to
An active layer forming area may be sufficiently secured using the side surface 122C of the first conductivity-type semiconductor rod 122, e.g., without the portion 122E. For example, an aspect ratio of the first conductivity-type semiconductor rod 122 may be equal to or greater than 4. As the active layer 125 is formed on a single crystal plane, i.e., on the side surface 122C of the first conductivity-type semiconductor rod 122, color uniformity may be implemented.
The first conductivity-type semiconductor rod 122 in the example embodiment may include an internal rod 122N and a regrowth layer 122R disposed on a side surface of the internal rod 122N. For example, as illustrated in
Referring to
In example embodiments, even when a cross-sectional surface of the internal rod 122N has a rounded shape, rather than a hexagonal shape, the first conductivity-type semiconductor rod 122 may have a hexagonal columnar shape having a hexagonal cross-sectional surface.
Referring to
The light emitting structure 120 in the example embodiment, including the first conductivity-type semiconductor rod 122, the active layer 125, and the second conductivity-type semiconductor layer 127, may be nitride semiconductor single crystal.
The first conductivity-type semiconductor rod 122 may include nitride semiconductor satisfying N-type InxAlyGa1-x-yN (0≤x<1, 0≤y<1, 0≤x+y<1), and an N-type impurity may be Si. For example, the first conductivity-type semiconductor rod 122 may include an N-type GaN layer. The second conductivity-type semiconductor layer 127 may be a nitride semiconductor layer satisfying a P-type InxAlyGa1-x-yN (0≤x<1, 0≤y<1, 0≤x+y<1), and a P-type impurity may be Mg. In an example embodiment, the second conductivity-type semiconductor layer 127 may be implemented to have a single layer structure, but an example embodiment thereof is not limited thereto. In another example embodiment, the second conductivity-type semiconductor layer 127 may have a multiple layer structure, layers of which may have different compositions. The active layer 125 may have a multiple quantum well (MQW) structure in which a quantum well layer and a quantum barrier layer are alternately stacked. For example, the quantum well layer and the quantum barrier layer may be InxAlyGa1-x-yN (0≤x≤1, 0≤y≤1, 0≤x+y≤1) having different compositions. In an example embodiment, the quantum well layer may be InxGa1-xN (0<x≤1), and the quantum barrier layer may be GaN or AlGaN. A thickness of each of the quantum well layer and the quantum barrier layer may be within a range of about 1 nm to about 50 nm. The active layer 125 may not be limited to the multiple quantum well structure, and may also have a single quantum well structure.
The three-dimensionally structured semiconductor light emitting diode 100 may further include an insulating cap layer 132 disposed on the second surface 122B of the first conductivity-type semiconductor rod 122. A transparent electrode layer 135 may be on the insulating cap layer 132 and on the light emitting structure 120, e.g., on the second conductivity-type semiconductor layer 127, to be connected to the second conductivity-type semiconductor layer 127.
Referring to
The insulating cap layer 132 may have an area greater than an area of the second surface 122B of the first conductivity-type semiconductor rod 122. The insulating cap layer 132 may have a portion extending further than the second surface 122B of the first conductivity-type semiconductor rod 122 along an entire circumference of the insulating cap layer 132. The insulating cap layer 132 may be configured as a mask pattern used in a process of forming the first conductivity-type semiconductor rod 122 (see
The insulating cap layer 132 may be provided such that the transparent electrode layer 135 may not be connected to the first conductivity-type semiconductor rod 122 and the active layer 125. In an example embodiment, the active layer 125 and the second conductivity-type semiconductor layer 127 may have ends, e.g., top surfaces (
The transparent electrode layer 135 may be disposed on the insulating cap layer 132, and may extend to a surface of the second conductivity-type semiconductor layer 127. In an example embodiment, the extended portion of the transparent electrode layer 135 may be disposed on an entire surface of the second conductivity-type semiconductor layer 127. However, an example embodiment thereof is not limited thereto, and the extended portion of the transparent electrode layer 135 may be formed on only a partial region of the surface of the second conductivity-type semiconductor layer 127.
The transparent electrode layer 135 may be a transparent electrode including, e.g., transparent conductive oxide or transparent conductive nitride, and may also include graphene. For example, the transparent electrode layer 135 may include at least one of indium tin oxide (ITO), zinc-doped indium tin oxide (ZITO), zinc indium oxide (ZIO), gallium indium oxide (GIO), zinc tin oxide (ZTO), fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (AZO), gallium-doped zinc oxide (GZO), In4Sn3O12, and Zn(1-x)MgxO (zinc magnesium oxide, 0≤x≤1).
In an example embodiment, the three-dimensionally structured semiconductor light emitting diode 100 may include a passivation layer 140 disposed on the transparent electrode layer 135 to expose a portion of the transparent electrode layer 135 disposed on the insulating cap layer 132. The passivation layer 140 in the example embodiment may include a first insulating film 141 and a second insulating film 142.
As illustrated in
The three-dimensionally structured semiconductor light emitting diode 100 may include a first connection electrode 210 connected to the first surface 122A of the first conductivity-type semiconductor rod 122, and a second connection electrode 220 connected to the contact region 135E of the transparent electrode layer 135. The first and second connection electrodes 210 and 220 may extend to a portion adjacent to the passivation layer 140. For example, the first connection electrode 210 may extend to a side surface of the portion 122E adjacent to the first surface 122A.
Referring to
By configuring each pixel using the three-dimensionally structured semiconductor light emitting diode illustrated in
Referring to
Each of the three-dimensionally structured semiconductor light emitting diodes 100 may have a predetermined length, e.g., sufficient length, such that the three-dimensionally structured semiconductor light emitting diodes 100 may be disposed, e.g., directly, on first and second electrode portions 310 and 320, respectively. In an example embodiment, the three-dimensionally structured semiconductor light emitting diodes 100 may be self-aligned between the first and second electrode portions 310 and 320 using electrical bias, and the aligned three-dimensionally structured semiconductor light emitting diodes 100 may be fastened by an insulating support body 330. Driving circuit devices, e.g., transistors 370 and capacitors 380, and an insulating film 360 covering the driving circuit devices may be disposed between a substrate 410 and the three-dimensionally structured semiconductor light emitting diodes 100.
Referring to
Referring to
In an example embodiment, the substrate 101 may be of nitride single crystal growth, and the first conductivity-type semiconductor layer 122′ may be an N-type nitride semiconductor layer, e.g., N-type GaN. For example, the substrate 101 may include at least one of an insulating, conductive, and semiconducting material, e.g., Si, SiC, MgAl2O4, MgO, LiAlO2, LiGaO2, GaN, or the like.
A buffer layer may be formed on the substrate 101 in advance, i.e., before the first conductivity-type semiconductor layer 122′ is formed. The buffer layer may be provided to alleviate a lattice defect of the first conductivity-type semiconductor layer 122′ grown on the substrate 101, and may include an undoped nitride semiconductor, e.g., undoped GaN, undoped AlN, or undoped InGaN.
The first conductivity-type semiconductor layer 122′ may be grown by a metal organic chemical vapor deposition (MOCVD) process. After an insulating layer is formed on the first conductivity-type semiconductor layer 122′, the plurality of insulating cap layers 132 for a rod structure (also referred to as “internal rod 122N”) may be formed using a patterning process. For example, the plurality of insulating cap layers 132 may include silicon nitride or silicon oxynitride.
Referring to
In this process, a primary rod structure 122N′ (indicated by dashed lines in
A length, e.g., thickness, d to be additionally etched in each of the primary rod structures 122N′ may be configured to be greater than at least a thickness of the active layer 125 (in
As illustrated in the enlarged cross-sectional surface along line A-A′, the primary rod structure 122N′ may have a cross-sectional surface having a shape corresponding to that of a cross-sectional surface of the insulating cap layer 132, and by the additional etching process, the internal rod 122N may have a stable single crystal plane. For example, when nitride semiconductor single crystal is used, the internal rod 122N may have a hexagonal columnar structure. However, an example embodiment thereof is not limited thereto. In an example embodiment, the etching process may not be sufficiently performed such that a cross-sectional surface of the internal rod 122N may have a rounded shape, such as a hexagonal shape without angular portions.
Referring to
The regrowth layer 122R may be regrown on the side surfaces of the plurality of internal rods 122N through the MOCVD process using the same first conductivity-type semiconductor. The side surfaces damaged by the process of etching the plurality of internal rods 122N may have a crystal plane (e.g., a non-polar plane) having improved quality by the regrowth layer 122R. In an example embodiment, even when a cross-sectional surface of the internal rod 122N has a rounded shape, rather than a hexagonal shape, the first conductivity-type semiconductor rod 122 may have a hexagonal columnar structure having a hexagonal cross-sectional surface.
Referring to
For example, the active layer 125 and the second conductivity-type semiconductor layer 127 may be sequentially deposited on the side surfaces of the plurality of first conductivity-type semiconductor rods 122 using the MOCVD process. By this process, a light emitting structure 120 having a core-shell structure may be formed. In an example embodiment, the active layer 125 may have a multiple quantum well structure, e.g., InGaN/GaN, and the second conductivity-type semiconductor layer 127 may be a P-type nitride semiconductor layer. For example, the second conductivity-type semiconductor layer 127 may have a multiple layer structure including p-GaN/p-AlGaN. As discussed previously, the active layer 125 may be formed between each of the first conductivity-type semiconductor rods 122 and a corresponding second conductivity-type semiconductor layer 127, such each of the insulating cap layers 132 overhangs a corresponding first conductivity-type semiconductor rod 122 and a corresponding active layer 125. For example, as illustrated in
Thereafter, referring to
In this process, as the transparent electrode layer 135 is deposited on an overall surface, e.g., on an overall exposed surface of the structure in
In an example embodiment, the transparent electrode layer 135 may be configured as a transparent electrode formed of, e.g., a transparent conductive oxide or a transparent conductive nitride, or may include graphene. For example, the transparent electrode layer 135 may be configured as at least one of ITO, ZITO, ZIO, GIO, ZTO, FTO, AZO, GZO, In4Sn3O12, and Zn(1−x)MgxO(0≤x≤1).
Referring to
In detail, similarly to the process of forming the transparent electrode layer 135 described above, the first insulating film 141 may be formed. The first insulating film 141 may be provided as a passivation layer, and may protect the transparent electrode layer 135 from damages caused by a subsequent etching process. In the case in which damage of the transparent electrode layer 135 disposed on a side surface of the light emitting structure 120 is prevented in a subsequent etching process by other processes, the above-described process may not be performed (see
Thereafter, referring to
In detail, first in this process, the first insulating film 141 having a relatively thin thickness and the transparent electrode layer 135 are completely removed between adjacent ones of the plurality of three-dimensional semiconductor light emitting structures 120. Further, during the same process, the first insulating film 141 may be removed from an upper portion of the insulating cap layer 132 to expose the contact region 135E of the transparent electrode layer 135. Thereafter, the first conductivity-type semiconductor base layer 122U disposed between the plurality of three-dimensional semiconductor light emitting structures 120 may be primarily etched using an anisotropic etching process (e.g., a dry wet etching process).
Referring to
In detail, the portion 122E, i.e., a narrow lower region 122E, may be formed below the plurality of three-dimensional semiconductor light emitting structures 120 by further etching the primarily etched portion using an isotropic etching process. As the portion 122E is formed of a first conductivity-type semiconductor connected to the first conductivity-type semiconductor rod 122, a portion integrated with the first conductivity-type semiconductor rod 122 may be formed. However, the portion 122E may have a cross-sectional shape different from that of the first conductivity-type semiconductor rod 122. Also, the portion 122E may have a width smaller than a width of the first conductivity-type semiconductor rod 122, as discussed previously with reference to
Referring to
The second insulating film 142 may be provided as a passivation layer. The second insulating film 142 may be disposed on the first insulating film 141, and may be formed to cover lower ends of the active layer 125 and the second conductivity-type semiconductor layer 127. When a connection electrode connected to the first conductivity-type semiconductor rod 122 is formed, the second insulating film 142 may prevent unnecessary connection with the transparent electrode layer 135 and also with the second conductivity-type semiconductor layer 127 and the active layer 125. For example, the second insulating film 142 may include oxide, nitride, or oxynitride, similarly to the first insulating film 141.
Referring to
Thereafter, the plurality of three-dimensional semiconductor light emitting structures 120 may be separated from the first conductivity-type semiconductor base layer 122U by cutting out the portion 122E of the plurality of three-dimensional semiconductor light emitting structures 120. For example, the portion 122E may be cut out, e.g., separated from the first conductivity-type semiconductor base layer 122U, along a surface CT (i.e., the inclined dashed line in
Referring to
As illustrated in
The insulating cap layer 132 and the dome-shaped insulating portion 133 may include different insulating materials. For example, the insulating cap layer 132 may include nitride or oxynitride, while the dome-shaped insulating portion 133 may include an oxide, e.g., a spin-on hardmask (SOH).
Referring to
The reflection prevention film 134 may prevent diffuse reflection of light used for the lithography process forming the photoresist pattern PR. For example, the reflection prevention film 134 may include titanium, titanium dioxide, titanium nitride, chrome oxide, carbon, silicon nitride, silicon oxynitride, or amorphous silicon. The hard mask layer 133″ may be formed to a thickness t.
Referring to
In this process, similarly to the process described in
As described above, by performing subsequent processes (processes of
Referring to
As illustrated in
The second insulating film 142 may extend to cover the ends of the active layer 125 and the second conductivity-type semiconductor layer 127 adjacent to the first surface 122A. The second insulating film 142 may prevent a first connection electrode (element 210 in
The transparent electrode layer 135′ in the example embodiment may not remain on the insulating cap layer 132. For example, the transparent electrode layer 135′ disposed on the insulating cap layer 132 may also be removed in the etching process illustrated in
In an example embodiment, the second insulating film 142 may be formed to expose the side surface region 135E′ adjacent to the second surface 122B. As the side surface region 135E′ of the transparent electrode layer 135′ is exposed, a contact area with a second connection electrode (element 220 in
The above-described configurations in the example embodiment may be selectively combined with another example embodiment. For example, the passivation layer 140 of the three-dimensionally structured semiconductor light emitting diode illustrated in
Referring to
As illustrated in
By sufficiently securing a length of the first portion 122_1, a contact area with the first connection electrode (element 210 in
A second insulating film 142′ may be disposed on the transparent electrode layer 135 to expose a portion of the transparent electrode layer 135 disposed on the insulating cap layer 132. In an example embodiment, an insulating portion 153 may be configured as an additional passivation layer, and may be disposed to cover ends of the active layer 125′ and the second conductivity-type semiconductor layer 127′ adjacent to the first surface 122A. The first connection electrode may be connected to the first surface 122A of the first conductivity-type semiconductor rod 122, and a partial region of a side surface of the first portion 122_1 adjacent to the first surface 122A may extend. In an example embodiment, as a length of the first portion 122_1 may be sufficiently secured, it may be unlikely that the first connection electrode is unnecessarily connected to ends of the active layer 125′ and the second conductivity-type semiconductor layer 127′ adjacent to the first surface 122A, and thus, the insulating portion 153 may not be provided.
Referring to
The etched internal rod 122N may be the same as or similar to the internal rod 122N obtained in the process illustrated in
In this process, the insulating layer 153′ may be formed to cover the etched internal rod 122N and the insulating cap layer 132, and an upper region 122N_2 of the internal rod 122N may be exposed through an etch back process. The insulating layer 153′ may include an insulating material having an etch selectivity different from that of the insulating cap layer 132. For example, the insulating layer 153′ may be silicon oxide, and the insulating cap layer 132 may be silicon nitride.
Referring to
This process may be performed through a process similar to a partial process (the processes of
The first conductivity-type semiconductor rod 122 may be formed by forming the regrowth layer 122R on a surface of the upper region 122N_2 of the internal rod 122N (see the process illustrated in
Thereafter, the transparent electrode layer 135 may be formed on an upper surface of the insulating cap layer 132 and a surface of the second conductivity-type semiconductor layer 127′ (see the process illustrated in
Referring to
The portions of the transparent electrode layer 135 and the second insulating film 142′ removed in the anisotropic etching process may be the portions disposed on an upper surface of the light emitting structure 120 and the portions disposed between the light emitting structures 120. The transparent electrode layer 135 disposed on the insulating cap layer 132 may be exposed through this process.
Referring to
The lower region 122N_1 of the internal rod 122N may be “a second portion” in view of the first conductivity-type semiconductor rod 122. The second portion 122_2 of the first conductivity-type semiconductor rod 122 may be exposed by removing the insulating layer 153′. Even after this process, the insulating layer 153′ may include an insulating material having an etch selectivity, different from a material of the second insulating film 142′, such that the second insulating film 142′ may remain. For example, the insulating layer 153′ may be silicon oxide, and the second insulating film 142′ may be silicon nitride.
In an example embodiment, the insulating layer 153′ may not be completely removed, and the insulating portion 153 may remain. The remaining insulating portion 153 may cover ends of the active layer 125 and the second conductivity-type semiconductor layer 127 adjacent to the first portion 122_1.
The plurality of three-dimensional semiconductor light emitting structures 120 may be separated, and each three-dimensional semiconductor light emitting structure 120 may not be used as an independent light source, but may be implemented as a single semiconductor light emitting diode as illustrated in
Referring to
The plurality of three-dimensional semiconductor light emitting structures 120 in the example embodiment may be a structure in which a second electrode 170 is formed instead of the second insulating film 142′ in the process illustrated in
Also, an etching process may be applied to expose a partial region of the first conductivity-type semiconductor base layer 122U. The first electrode 160 may be formed in the exposed region of the first conductivity-type semiconductor base layer 122U.
By way of summation and review, an example embodiment provides a three-dimensionally structured semiconductor light emitting diode having high efficiency. An example embodiment also provides a display apparatus including a three-dimensionally structured semiconductor light emitting diode.
That is, as described above, a semiconductor light emitting diode including the plurality of three-dimensional semiconductor light emitting structures 120 may be provided. According to the aforementioned example embodiments, by forming the active layer on a crystal plane (e.g., a side surface of the first conductivity-type semiconductor rod) without a defect, a three-dimensionally structured semiconductor light emitting diode having improved efficiency may be provided. By configuring each pixel using the three-dimensionally structured semiconductor light emitting diode, a high resolution display device may be implemented.
Example embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. In some instances, as would be apparent to one of ordinary skill in the art as of the filing of the present application, features, characteristics, and/or elements described in connection with a particular embodiment may be used singly or in combination with features, characteristics, and/or elements described in connection with other embodiments unless otherwise specifically indicated. Accordingly, it will be understood by those of skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims.
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