CN110429099B - Manufacturing method of high-brightness composite substrate - Google Patents

Manufacturing method of high-brightness composite substrate Download PDF

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CN110429099B
CN110429099B CN201910742941.5A CN201910742941A CN110429099B CN 110429099 B CN110429099 B CN 110429099B CN 201910742941 A CN201910742941 A CN 201910742941A CN 110429099 B CN110429099 B CN 110429099B
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coating
metal
sapphire
composite substrate
sio
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CN110429099A (en
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徐良
李昌勋
史伟言
刘建哲
夏建白
张磊
彭艳亮
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Huangshan Bolante Semiconductor Technology Co ltd
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    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10HINORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80Constructional details
    • H10H20/85Packages
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10HINORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80Constructional details
    • H10H20/85Packages
    • H10H20/855Optical field-shaping means, e.g. lenses
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10HINORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H29/00Integrated devices, or assemblies of multiple devices, comprising at least one light-emitting semiconductor element covered by group H10H20/00
    • H10H29/10Integrated devices comprising at least one light-emitting semiconductor component covered by group H10H20/00
    • H10H29/14Integrated devices comprising at least one light-emitting semiconductor component covered by group H10H20/00 comprising multiple light-emitting semiconductor components
    • H10H29/142Two-dimensional arrangements, e.g. asymmetric LED layout
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10HINORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/01Manufacture or treatment
    • H10H20/036Manufacture or treatment of packages
    • H10H20/0363Manufacture or treatment of packages of optical field-shaping means

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Abstract

本发明公开了一种高亮度复合衬底的制作方法,主要包括以下步骤:在蓝宝石平片上沉积一层金属涂层;在金属涂层上涂覆一层正性光刻胶涂层,并曝光、显影选择性的去除不需要的部分在金属涂层上形成一组正性光刻胶柱;以正性光刻胶柱作为阻挡层进行ICP刻蚀,在蓝宝石平片上形成一组相互独立的金属凸台;利用化学气相沉积方法在蓝宝石平片有金属凸台的一面沉积一层SiO2涂层;在SiO2涂层上涂覆一层负性光刻胶涂层,并曝光、显影选择性的去除不需要的部分,从而在SiO2涂层上形成一组负性光刻胶柱;以负性光刻胶柱和SiO2涂层作为阻挡层进行ICP刻蚀,从而得到一种高亮度复合衬底。本发明通过蓝宝石、金属涂层和SiO2形成复合衬底,能够显著提高LED芯片的亮度。

Figure 201910742941

The invention discloses a manufacturing method of a high-brightness composite substrate, which mainly comprises the following steps: depositing a layer of metal coating on a sapphire flat plate; coating a layer of positive photoresist coating on the metal coating, and exposing , The development selectively removes the unwanted parts and forms a group of positive photoresist columns on the metal coating; uses the positive photoresist columns as the blocking layer to carry out ICP etching, and forms a set of mutually independent on the sapphire flat wafer. Metal boss; use chemical vapor deposition method to deposit a layer of SiO 2 coating on the side of the sapphire flat plate with metal boss; apply a layer of negative photoresist coating on the SiO 2 coating, and choose exposure and development The undesired parts are removed effectively, thereby forming a set of negative photoresist pillars on the SiO coating ; ICP etching is performed with the negative photoresist pillars and the SiO coating as barrier layers, resulting in a high Brightness composite substrate. The present invention forms a composite substrate through sapphire, metal coating and SiO 2 , which can significantly improve the brightness of the LED chip.

Figure 201910742941

Description

Manufacturing method of high-brightness composite substrate
Technical Field
The invention relates to the field of manufacturing of LED substrates, in particular to a manufacturing method of a high-brightness composite substrate.
Background
As is well known, a PSS (patterned sapphire substrate) is located in an upstream process in the LED display industry, plays a crucial role, and can effectively reduce the dislocation density of a GaN epitaxial material, thereby reducing non-radiative recombination in an active region, reducing reverse leakage current, improving the service life of an LED, and other advantages. At present, micro-nano patterned sapphire substrate technology is generally adopted, conical patterns which are arranged periodically are manufactured on the surface of an epitaxial sapphire substrate, and epitaxial growth parameters are controlled to grow GaN with higher quality by utilizing the characteristic of high potential energy of conical inclined planes on the sapphire patterned substrate. However, with the rapid development of the LED display industry, the consumer market has higher and higher requirements for product quality and brightness, and the brightness of the conventional micro-nano patterned sapphire substrate LED chip is a bottleneck in the prior art, which is a revolutionary breakthrough if the brightness can be improved by more than about 2%.
Along with high requirements of the consumer market, the conventional micro-nano patterned sapphire substrate is difficult to meet the requirements, so that a new sapphire substrate preparation method must be adopted to meet the requirements of people from the aspects of materials and structures.
Disclosure of Invention
The invention aims to provide a manufacturing method of a high-brightness composite substrate, which is used for further improving the brightness of a sapphire substrate.
The technical scheme adopted by the invention for solving the technical problems is as follows: a method for manufacturing a high-brightness composite substrate comprises the following steps:
(1) firstly, selecting a flat sapphire sheet with a smooth surface and two polished surfaces, and cleaning to remove impurities on the surface;
(2) a layer of metal coating is vapor-plated on the sapphire flat sheet;
(3) coating a positive photoresist coating on the metal coating, and selectively removing unnecessary parts by exposure and development to form a group of positive photoresist columns on the metal coating;
(4) carrying out ICP etching by taking the positive photoresist column as a barrier layer, and forming a group of mutually independent metal bosses on the sapphire flat sheet;
(5) depositing a layer of SiO on the surface of the sapphire flat sheet with the metal boss by using a chemical vapor deposition method2Coating;
(6) in SiO2Coating a negative photoresist layer on the coating layer, exposing and developing to selectively remove the undesired portions, thereby forming a SiO layer2Forming a group of negative photoresist columns on the coating;
(7) with negative photoresist posts and SiO2The coating is used as a barrier layer to carry out ICP etching, thereby obtaining the high-brightness composite liningAnd (4) bottom.
In order to ensure clean cleaning, the sapphire plain film in the step (1) is firstly scrubbed by acetone for 5-10 minutes and then subjected to concentrated H at 90 DEG C2SO4And H2O2Cleaning for 10-15 minutes in a mixed solution with a volume ratio of 3:1 or 5:2, cleaning for 8-10 minutes by using 80 ℃ deionized water, finally cleaning for 5-10 minutes by using 25 ℃ deionized water, and then spin-drying for 3-10 minutes at a high speed.
Preferably, the thickness of the metal coating in the step (2) is 5-1000 nm, and the metal is one or a mixture of Au, Ag, Ni, Co, Fe, Cu, Pt, Pd and Al.
Preferably, the film thickness of the positive photoresist coating in the step (3) is 0.5-3.0 μm, and the exposure time is 50-400 ms.
Specifically, in the step (4), ICP etching is to send the developed sapphire flat sheet into an etching machine for plasma dry etching, the power of an upper electrode of the etching machine is set to be 100-2000W, the power of a lower electrode of the etching machine is set to be 100-1500W, and BCL (bulk continuous plasma etching) is set3Flow rate of 50-200 sccm, CHF3The flow is 0-20 sccm, the etching temperature is 10-50 ℃, the helium pressure is 1-10 mTorr, and the time is 100-1000 s.
Preferably, SiO in the step (5)2The thickness is 0.5-2.0 μm, and the temperature of the chemical vapor deposition chamber is 100-500 ℃.
Preferably, in the step (6), the thickness of the negative photoresist coating is 0.5-3.0 μm, the sapphire plain film is exposed from the other surface of the sapphire plain film opposite to the surface with the metal boss, the metal boss replaces a photoetching plate to be used as a shield for exposure, the exposure time is 3-20 s, and the photoresist at the position where the metal boss is not shielded is removed during development.
Specifically, in the step (7), ICP etching is to send the developed sapphire flat sheet into an etching machine for plasma dry etching, the power of an upper electrode of the etching machine is set to be 100-2000W, the power of a lower electrode of the etching machine is set to be 100-1500W, and BCL (bulk continuous plasma etching) is set3Flow rate of 50-200 sccm, CHF3The flow is 0-20 sccm, the etching temperature is 10-50 ℃, the helium pressure is 1-10 mTorr, and the time is 100-3000 s.
The invention has the beneficial effects that: the invention adopts sapphire, metal coating and SiO2The composite substrate is formed, and the brightness of the chip can be remarkably improved. Because the chemical property stability of the metal is relatively poor, a layer of SiO is wrapped on the metal2The coating can effectively avoid the defect that metal is easy to oxidize. The bottom metal coating effectively reduces light refraction and increases light reflection efficiency, and SiO2The refractive index of 1.45 is less than that of 1.76 of sapphire, so that the scattering effect of the substrate on light can be effectively improved, and the luminous efficiency of the LED chip is further improved. Compared with the LED chip using the traditional patterned sapphire substrate, the brightness of the LED chip is improved by more than 5 percent.
The invention will be explained in more detail below with reference to the drawings and examples.
Drawings
FIG. 1 is a process flow diagram of the present invention.
FIG. 2 is a schematic cross-sectional view of a sapphire flat sheet after deposition of a metal coating in accordance with the present invention.
FIG. 3 is a schematic cross-sectional view of a positive photoresist coating applied over a metal coating in accordance with the present invention.
FIG. 4 is a schematic cross-sectional view of a positive photoresist column formed on a metal coating according to the present invention.
FIG. 5 is a schematic cross-sectional view of a metal mesa formed by ICP etching according to the present invention.
FIG. 6 shows the deposition of a layer of SiO on a metal bump according to the present invention2Schematic cross-sectional view of the coating.
FIG. 7 shows the present invention on SiO2A cross-sectional view of a negative photoresist coating applied over the coating.
Figure 8 is a schematic cross-sectional view of the present invention exposing and developing a negative photoresist coating.
FIG. 9 shows the present invention on SiO2A cross-sectional view of a set of negative photoresist pillars formed on the coating.
Fig. 10 is a schematic cross-sectional view of a high-brightness composite substrate of the present invention.
Detailed Description
An embodiment is a manufacturing method of a high-brightness composite substrate, a process flow is shown in fig. 1, and the specific manufacturing method comprises the following steps:
(1) firstly, a flat sapphire sheet 1 with a flat surface is provided, and the back surface of the flat sapphire sheet is light-permeable after double-sided polishing treatment. The sapphire plain film 1 is firstly scrubbed by acetone for 5-10 minutes and then subjected to concentrated H at 90 DEG C2SO4And H2O2Cleaning for 10-15 minutes in a mixed solution with a volume ratio of 3:1 or 5:2, cleaning for 8-10 minutes by using 80 ℃ deionized water, finally cleaning for 5-10 minutes by using 25 ℃ deionized water, and then spin-drying for 3-10 minutes at a high speed.
(2) The cleaned sapphire flat sheet 1 is placed in a cavity of an electron gun evaporation plating machine, a metal material used for film plating is bombarded by accelerated electrons, kinetic energy of the electrons is converted into heat energy to heat the metal material to 2000-6000 ℃ to evaporate the metal material, and then the metal material is plated on the surface of the sapphire flat sheet to prepare a layer of metal coating 2 with the thickness of 5-2000 nm, as shown in figure 2, wherein the metal coating 2 is made of one or a mixture of several metals of Au, Ag, Ni, Co, Fe, Cu, Pt, Pd and Al. The metal coating 2 may be formed by a plating process such as atomic layer deposition or sputtering.
(3) A positive photoresist coating 3 with the film thickness of 0.5-3.0 mu m is coated on the metal coating 2, as shown in figure 3, and then exposure treatment is carried out for 50-400 ms, the part which does not need to be exposed is shielded by a photoetching plate during exposure, and the positive photoresist coating is exposed from the upper part of the positive photoresist coating. The unwanted portions are then selectively removed by a developing process to form a set of positive photoresist pillars 4 on the metal coating, as shown in fig. 4.
(4) Feeding the developed sapphire flat sheet 1 into an etching machine to carry out plasma dry etching by taking the positive photoresist column 4 as a barrier layer, setting the power of an upper electrode of the etching machine to be 100-2000W, the power of a lower electrode of the etching machine to be 100-1500W, and carrying out BCL (bulk continuous plasma etching)3Flow rate of 50-200 sccm, CHF3The flow is 0-20 sccm, the etching temperature is 10-50 ℃, the helium pressure is 1-10 mTorr, the time is 100-1000 s, and the residual product is purged by argon after etching2、Ar、N2、C2H4And the main etching gas is not fixed as the same gas, and the corresponding main etching gas is used according to different metals, so that a group of mutually independent metal bosses 5 are formed on the sapphire flat sheet, as shown in fig. 5.
(5) Depositing a layer of SiO on the surface of the sapphire flat sheet with the metal boss 5 by using a plasma enhanced chemical vapor deposition method2Coating 6, shown in FIG. 6, SiO in the direction of the arrow2The direction of deposition of the coating 6. The temperature of the chamber used for PECVD (plasma enhanced chemical vapor deposition) is 100-500 ℃, and SiO is2The thickness is 0.5-2.0 μm, and the fluidity is changed according to the size of the metal pattern, and the thickness is changed by SiO2The coating can provide a protective film for the oxidation of metal and is also due to SiO2The refractive index of 1.45 is less than that of 1.76 of sapphire, so that the scattering effect of the substrate on light can be effectively improved, and the luminous efficiency of the LED chip is further improved.
(6) In SiO2A coating 7 of negative photoresist is applied over the coating 6 as shown in figure 7. The thickness of the negative photoresist coating is 0.5-3.0 μm, and the sapphire flat sheet is exposed from the other side of the sapphire flat sheet opposite to the side with the metal boss, as shown in fig. 8, and the direction of the arrow is the exposure direction. Exposing by replacing a photoetching plate with a metal boss as a shield for 3-20 s in a short time, taking the metal coating shielding part with gaps as an unexposed part, then developing, removing the unexposed part by reacting with a developing solution during developing according to the characteristics of the negative photoresist, and removing the unexposed part by reacting with the developing solution in SiO2A negative photoresist column 8 is formed on the coating as shown in fig. 9. The method reduces the cost of designing a mask or a photoetching plate with patterns and saves the cost.
(7) Sending the developed sapphire flat sheet into an etching machine to make the sapphire flat sheet have negative photoresist columns 8 and SiO2The coating 6 is used as a barrier layer to carry out plasma dry etching, the power of an upper electrode of an etching machine is set to be 100-2000W, the power of a lower electrode is set to be 100-1500W, and BCL (binary coded decimal) is adopted3Flow rate of 50-200 sccm, CHF3The flow is 0-20 sccm, the etching temperature is 10-50 ℃, the helium pressure is 1-10 mTorr, and the time is 100-3000 s, and the high-brightness patterned composite substrate is obtained after etching. As shown in fig. 10.
The invention is described above with reference to the accompanying drawings. It is to be understood that the specific implementations of the invention are not limited in this respect. Various insubstantial improvements are made by adopting the method conception and the technical scheme of the invention; the present invention is not limited to the above embodiments, and can be modified in various ways.

Claims (8)

1. A method for manufacturing a high-brightness composite substrate comprises the following steps:
(1) firstly, selecting a flat sapphire sheet with a smooth surface and two polished surfaces, and cleaning to remove impurities on the surface;
(2) a layer of metal coating is vapor-plated on the sapphire flat sheet;
(3) coating a positive photoresist coating on the metal coating, and selectively removing unnecessary parts by exposure and development to form a group of positive photoresist columns on the metal coating;
(4) carrying out ICP etching by taking the positive photoresist column as a barrier layer, and forming a group of mutually independent metal bosses on the sapphire flat sheet;
(5) depositing a layer of SiO on the surface of the sapphire flat sheet with the metal boss by using a chemical vapor deposition method2Coating;
(6) in SiO2Coating a negative photoresist layer on the coating layer, exposing and developing to selectively remove the undesired portions, thereby forming a SiO layer2Forming a group of negative photoresist columns on the coating; exposing the sapphire plain film from the other surface of the sapphire plain film with the metal boss, replacing a photoetching plate with the metal boss as a shield for exposure, wherein the exposure time is 3-20 s, and removing photoresist at the position where the metal boss is not shielded during development;
(7) with negative photoresist posts and SiO2And performing ICP etching by using the coating as a barrier layer, thereby obtaining the high-brightness composite substrate.
2. The method for manufacturing a high-luminance composite substrate according to claim 1, wherein: the blue diamond in the step (1)Washing the stone flat sheet with acetone for 5-10 min, and then carrying out concentrated H at 90 DEG C2SO4And H2O2Cleaning for 10-15 minutes in a mixed solution with a volume ratio of 3:1 or 5:2, cleaning for 8-10 minutes by using 80 ℃ deionized water, finally cleaning for 5-10 minutes by using 25 ℃ deionized water, and then spin-drying for 3-10 minutes at a high speed.
3. The method for manufacturing a high-luminance composite substrate according to claim 1, wherein: the thickness of the metal coating in the step (2) is 5-1000 nm, and the metal is one or a mixture of more of Au, Ag, Ni, Co, Fe, Cu, Pt, Pd and Al.
4. The method for manufacturing a high-luminance composite substrate according to claim 1, wherein: the film thickness of the positive photoresist coating in the step (3) is 0.5-3.0 μm, and the exposure time is 50-400 ms.
5. The method for manufacturing a high-luminance composite substrate according to claim 1, wherein: and (4) ICP etching, namely feeding the developed sapphire flat sheet into an etching machine for plasma dry etching, setting the power of an upper electrode of the etching machine to be 100-2000W, the power of a lower electrode of the etching machine to be 100-1500W, and setting BCL3Flow rate of 50-200 sccm, CHF3The flow is 0-20 sccm, the etching temperature is 10-50 ℃, the helium pressure is 1-10 mTorr, and the time is 100-1000 s.
6. The method for manufacturing a high-luminance composite substrate according to claim 1, wherein: SiO in the step (5)2The thickness is 0.5-2.0 μm, and the temperature of the chemical vapor deposition chamber is 100-500 ℃.
7. The method for manufacturing a high-luminance composite substrate according to claim 1, wherein: and (4) in the step (6), the thickness of the negative photoresist coating is 0.5-3.0 μm.
8. Fabrication of the high brightness composite substrate of claim 1The method is characterized in that: and (7) ICP etching, namely feeding the developed sapphire flat sheet into an etching machine for plasma dry etching, setting the power of an upper electrode of the etching machine to be 100-2000W, the power of a lower electrode of the etching machine to be 100-1500W, and setting BCL3Flow rate of 50-200 sccm, CHF3The flow is 0-20 sccm, the etching temperature is 10-50 ℃, the helium pressure is 1-10 mTorr, and the time is 100-3000 s.
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