JP2010067984A - 発光素子の製造方法、発光装置の製造方法、発光素子、および発光装置 - Google Patents
発光素子の製造方法、発光装置の製造方法、発光素子、および発光装置 Download PDFInfo
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- JP2010067984A JP2010067984A JP2009209589A JP2009209589A JP2010067984A JP 2010067984 A JP2010067984 A JP 2010067984A JP 2009209589 A JP2009209589 A JP 2009209589A JP 2009209589 A JP2009209589 A JP 2009209589A JP 2010067984 A JP2010067984 A JP 2010067984A
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Abstract
【解決手段】発光素子の製造方法は、基板100上にバッファ層108を形成し、バッファ層108上に光結晶パターン106(photonic crystal pattern)とパッドパターン107を形成し、光結晶パターン106とパッドパターン107は、各々金属物質を含み互いに物理的に接続され、光結晶パターン106とパッドパターン107が形成されたバッファ層108上に順次に積層された第1導電型の第1導電パターン112、発光パターン114、第2導電型の第2導電パターン116を含む発光構造体110を形成し、第1導電パターン112と電気的に接続された第1電極140と、第2導電パターン116と電気的に接続された第2電極150を形成することを含む。
【選択図】図7
Description
また、発光素子のデザインによって発光パターンの全領域がもれなく使用されるのではなく、発光パターンの一部領域のみが使用され得る。すなわち、発光パターンの一部領域にのみ電流が流れるようになって電流が流れる一部の領域でのみ光が発散することができる。このような場合、発光量が減るようになる。
本発明が解決しようとする他の課題は、光抽出効率が向上して欠陥が少なく、発光量が増加した発光素子および発光装置を提供するものである。
本発明の技術的課題は、以上で言及した技術的課題に制限されず、言及されていないまた他の技術的課題は、次の記載から当業者に明確に理解されるであろう。
本発明の請求項1に対応する解決手段1によると、発光素子の製造方法は、基板上にバッファ層を形成し、バッファ層上に光結晶パターン(photonic crystal pattern)とパッドパターンを形成し、光結晶パターンと前記パッドパターンは、各々金属物質を含み互いに物理的に接続され、光結晶パターンと前記パッドパターンが形成されたバッファ層上に順次に積層された第1導電型の第1導電パターン、発光パターン、第2導電型の第2導電パターンを含む発光構造体を形成し、第1導電パターンと電気的に接続された第1電極と、第2導電パターンと電気的に接続された第2電極を形成することを含む。
その他解決手段の具体的な内容は詳細な説明および図面に記載されている。
図1〜図9は、本発明の第1実施形態による発光素子の製造方法を説明するための中間段階図である。この中、図2、図3は、図1に示す光結晶パターン(photonic crystal pattern)の例示的形態を示す図である。図8および図9は、本発明の第1実施形態の発光素子の動作を説明するための図である。一方、本発明の第1実施形態による発光素子としては、ラテラルタイプ(lateral type)またはフリップチップタイプ(flipchip type)を例にあげた。
具体的に、バッファ層108は後述する第1導電層112a、発光層114a、第2発光層116aを作るためのシード層として使用することができる。また、バッファ層108は、基板100と後述する発光構造体(図5の110)の間の格子不整合(lattice mismatch)を防止するために使用される。したがって、バッファ層108は、発光構造体(図5の110)の膜質特性を良くする。
次いで、バッファ層108上に光結晶パターン(photonic crystal pattern)106とパッドパターン107を形成する。
次いで、パッドパターン107上に位置する絶縁層120の一部をエッチングし、絶縁層120を貫通する第1ホール(h1)を形成する。また、パッドパターン107上に位置する第1導電パターン112の一部をエッチングし、第1導電パターン112を貫通する第2ホール(h2)を形成する。
具体的に、第1オーム層131は、例えば、ITO(Indium Tin Oxide)、ジンク(Zn)、ジンクオキサイド(ZnO)、銀(Ag)、チタン(Ti)、アルミニウム(Al)、金(Au)、ニッケル(Ni)、インジウムオキサイド(In2O3)、酸化スズ(SnO2)、銅(Cu)、タングステン(W)、白金(Pt)のうち少なくとも一つを含み得る。
図8を参考にすると、第1導電パターン112がn型であり、第2導電パターン116がp形である場合、第1バイアス(BIAS(−))は、第1電極140、第1オーム層131、パッドパターン107、光結晶パターン106を通して第1導電パターン112に印加されて、第2バイアス(BIAS(+))は、第2電極150、第2オーム層132を通して第2導電パターン116に印加される。第2導電パターン116がn型であり、第1導電パターン112がp形である場合、第2バイアス(BIAS(+))は、第1電極140、第1オーム層131、パッドパターン107、光結晶パターン106を通して第1導電パターン112に印加されて第1バイアス(BIAS(−))は第2電極150、第2オーム層132を通して第2導電パターン116に印加される。
図10〜図14は、本発明の第2実施形態による発光素子の製造方法を説明するための中間段階図である。本発明の第2実施形態による発光素子としてはフリップチップタイプ(flipchip type)を例にあげた。
図12を参照すると、露出された第2導電パターン116上に第2オーム層132を形成する。
第2電極150は、反射率が高い物質を使用することができる。第2電極150は例えば、銀(Ag)、アルミニウム(Al)を使用することができる。発光構造体110で発生した光が第2電極150に反射して光結晶パターン106側に進むようにするためである。
次いで、第1導電パターン112の突出した領域の一部をエッチングしてパッドパターン107上に位置する第1導電パターン112の一部を貫通する第2ホール(h2)を形成する。ここで、第2ホール(h2)の幅は第1ホール(h1)の幅より狭くても良い。前述したように、第1ホール(h1)を形成することには湿式エッチングを利用することができ、第2ホール(h2)を形成することには乾式エッチングを利用することができる。第1ホール(h1)を形成する湿式エッチングと第2ホール(h2)を形成する乾式エッチングは同一のマスク(例えば、フォトレジストパターン)を利用して形成することができる。
ここで、図14を参照して本発明の第2実施形態による発光素子2について詳しく説明する。
図15〜図19は、本発明の第3実施形態による発光素子の製造方法を説明するための中間段階図である。本発明の第3実施形態による発光素子としてはバーチカルタイプ(vertical type)を例にあげた。
具体的に、犠牲層102は後述するように、LLO(Laser Lift Off)方法を用いて基板100を分離するとき、除去される層である。このような犠牲層102は例えば、GaN層を使用することができる。
次いで、第2導電層、発光層、第1導電層をパターニングして第1導電パターン112、発光パターン114、第2導電パターン116を含む発光構造体110を形成する。このとき、発光構造体110は下側の幅が上側の幅より広く、発光構造体110の側壁は傾斜し得る。
次いで、発光構造体110の上面と側面上に絶縁層120を形成する。
次いで、絶縁層120の一部をエッチングして第2導電パターン116の上面一部を露出させる。
次いで、露出された第2導電パターン116上に第2オーム層132を形成する。
次いで、発光構造体110の上面および側面に第2電極150を形成する。すなわち、第2オーム層132および絶縁層120上にコンフォーマルに第2電極150を形成する。したがって、第2電極150は発光構造体110を覆うボウル(bowl)形態であり得る。
例えば、導電基板200と複数の基板100は、接着ボンディング(adhesive bonding)方式によりボンディングすることができるが、具体的に説明すると次のとおりである。
導電基板200と基板100表面に付いている様々な不純物(例えば、パーティクル(particle)、ホコリ(dust)など)は汚染ソース(contamination source)となり得るからである。すなわち、導電基板200と基板100を互いにボンディングしたとき、導電基板200と基板100との間に前述した不純物があれば、ボンディングエネルギ(bonding energy)を弱化させ得る。ボンディングエネルギが弱ければ、導電基板200と基板100が簡単に分離され得る。
次いで、基板100に形成された第2電極150と導電基板200のボンディング面が対向するようにする。
次いで、導電基板200と基板100を熱処理してボンディングする。熱処理をしながら導電基板200と基板100を圧搾してボンディングすることもできる。
しかし、スループット(throughput)を高めるために、図18で示すように、基板100と導電基板200をボンディングするとき、一つの導電基板200に複数の基板100をボンディングすることもできる。具体的に、導電基板200は基板100より大きい。すなわち、導電基板200と基板100を重なっておいたとき、前にある導電基板200に遮られて基板100が見えないことを意味する。例えば、導電基板200と基板100が円形の場合には、導電基板200の直径が基板100の直径より大きい。例えば、導電基板200の直径は6インチ(約150mm)以上であり、基板100の直径は6インチ未満であり得る。導電基板200と基板100が四角形の場合には、導電基板200の対角線の長さが基板100の対角線の長さより大きくてもよい。複数の基板100各々に形成された第2電極150と、導電基板200のボンディング面が対向するようにする。
図19を参照すると、犠牲層102を除去することによって基板100を除去する。
具体的に、基板100を除去することにはLLO(Laser Lift Off)工程またはCLO(Chemical Lift−off)工程を利用することができる。
レーザは基板100側から照射されて、相対的に小さい面積を有しているため、相対的に広い面積の基板100をスキャンする。レーザを利用して犠牲層102を除去する。そうすると、レーザが照射される部分から順次に基板100が分離し始める。
図19を参照すると、基板100が除去された後露出されたバッファ層108の一部をエッチングしてパッドパターン107を露出させる。
次いで、パッドパターン107の少なくとも一部が露出するようにバッファ層108の一部をエッチングする。
次いで、パッドパターン107の露出された領域上に第1オーム層131を形成する。
次いで、第1電極140を第1オーム層131上に形成して本発明の第3実施形態による発光素子3を完成する。
図20は、本発明の第4実施形態による発光素子を説明するための図である。
図20を参照すると、本発明の第4実施形態による発光素子4が第3実施形態と異なる点は、ボウル(bowl)形態の第2電極150に突起151が形成されており、このような突起によって第2電極150内に形成されている発光構造体110内にはフォーム118が形成されるという点である。
図21Aは、本発明の第1実施形態による発光装置を説明するための図である。
図21Aを参照すると、本発明の第1実施形態による発光装置11は回路基板300と、回路基板300上に配置された発光素子1を含む。発光素子1は、サブマウント(submount)250により回路基板300と接続することができる。
サブマウント250も互いに電気的に分離された第3導電領域260、第4導電領域270を含む。第3導電領域260および第4導電領域270はサブマウント250の一面に配置されている。
図21Bは、本発明の第2実施形態による発光装置を説明するための図である。
図21Bを参照すると、本発明の第2実施形態による発光装置12が第1実施形態と異なる点は、回路基板300が貫通ビア(Through Via)316、326を具備するという点である。
図21Cは、本発明の第3実施形態による発光装置を説明するための図である。
図21Cを参照すると、本発明の第3実施形態による発光装置13が第1実施形態と異なる点は、サブマウント250が導電性基板からなっているという点である。
したがって、第3導電領域260とショート(short)しないために第4導電領域270とサブマウント250との間には絶縁膜271が介在している。
図22は、本発明の第4実施形態による発光装置を説明するための図である。
図22を参照すると、本発明の第4実施形態による発光装置14が第1実施形態と異なる点は、発光素子1を囲む蛍光層340と、蛍光層340を囲む第2透明樹脂350を含むという点である。
Ceなどのランタノイド系元素によって主に活力を受ける希土類アルミン酸塩蛍光体にはY3Al5O12:Ce、(Y0.8Gd0.2)3Al5O12:Ce、Y3(Al0.8Ga0.2)5 O12:Ce、 (Y、Gd)3 (Al、Ga)5 O12の助成式で示すYAG系蛍光体などがある。また、Yの一部あるいは全部をTb、Luなどで置換したTb3Al5O12:Ce、Lu3Al5O12:Ceなどもある。
その他の蛍光体にはZnS:Eu、Zn2GeO4:Mn、MGa2S4:Eu(MはSr、Ca、Ba、Mg、Znから選択される少なくとも一つ、XはF、Cl、Br、Iから選択される少なくとも一つ)などがある。
また、前述した蛍光体以外の蛍光体として、同一の性能、効果を有する蛍光体も使用することができる。
図23は、本発明の第5実施形態による発光装置を説明するための図である。図23を参照すると、蛍光体344が発光素子1、回路基板300のプロファイルに沿って形成されている。
別途の第1透明樹脂なしに蛍光体344が塗布された場合であれば、発光素子1を囲む透明樹脂は単一層になる(すなわち、342なしで350が単一層になる)。
図24は、本発明の第6実施形態による発光装置を説明するための図である。
図24を参照すると、本発明の第6実施形態による発光装置16が第3実施形態と異なる点は、発光素子1を囲む第1透明樹脂342、第1透明樹脂342上に形成された蛍光体344、蛍光体344上に形成された第2透明樹脂350を含むという点である。
すなわち、第1透明樹脂342と蛍光体344を混ぜて塗布せず、別々に塗布したため、蛍光体344は第1透明樹脂342の表面に沿ってコンフォーマルに薄く形成することができる。
図25は、本発明の第7実施形態による発光装置を説明するための図である。本発明の第7実施形態による発光装置は、トップビュータイプ発光パッケージを図示しているが、これに限定されるものではない。
図25を参照すると、発光素子1がマウントされたサブマウント250がパッケージ本体210上に配置されている。具体的に、パッケージ本体210内部にスロット(slot)212が形成されており、発光素子1がマウントされたサブマウント250がスロット212内に配置され得る。特に、スロット(slot)212は側壁が傾斜し得る。発光素子1で発生した光は側壁に反射して前に進むことができる。発光素子1で発生した光がスロット212の側壁に反射する程度、反射角度、スロット212を満たす透明樹脂層の種類、蛍光体の種類などを考慮してスロット212のサイズを決定した方がよい。また、サブマウント250がスロット212の中に置かれた方がよい。発光素子1と側壁までの距離が同一になれば、色度の不均一を容易防止することができる。
例えば、白色を作るために蛍光体を使用する場合は次のとおりにすることができる。発光素子1がブルー(blue)波長の光を放出する場合、蛍光体264は黄色(yellow)蛍光体を含み得、演色評価数(Color Rendering Index、CRI)特性を高めるために赤(red)蛍光体も含み得る。または、発光素子1がUV波長の光を放出する場合、蛍光体はRGB(Red、Green、Blue)すべてを含み得る。
図26〜図28は、本発明の第8実施形態による発光装置を説明するための図である。具体的に、図26〜図28は、複数の発光素子が回路基板に配列された発光素子アレイを説明するための図である。特に、図27および図28は、発光素子アレイ上に蛍光層340と第2透明樹脂350が形成された形態を例示的に示すものである。
第1導電領域310および第2導電領域320に適切なバイアスが印加されれば、発光素子1内部の発光構造体(図示せず)に順方向バイアスがかかると、発光素子1は光を発散する。
図29は、本発明の第9実施形態による発光装置を説明するための図である。
本発明の第9実施形態による発光装置は最終製品(end product)であることを図29に示す。図29の発光装置は、照明装置、表示装置、モバイル装置(携帯電話、MP3プレーヤ、ナビゲーション(Navigation)など)のような様々な装置に適用され得る。図29に示す例示的装置は、液晶表示装置(LCD)で使用するエッジ型(edge type)バックライトユニット(Back Light Unit:BLU)である。液晶表示装置は、自体光源がないため、バックライトユニットが光源として使用され、バックライトユニットは主に液晶パネルの後方から照明する。
発光素子1は光を提供する役割を果たす。ここで、使用される発光素子1はサイドビュータイプであり得る。
プリズムシート416上部面に三角柱形状のプリズムが一定の配列を有して形成されており、通常2枚のシートで構成されて各々のプリズム配列が互いに所定の角度で交錯するように配置されて拡散シート414で拡散された光を液晶パネル450に垂直方向に進むようにする。
図30〜図33は、本発明の第10〜13の実施形態による発光装置を説明するための図である。
図30〜図33では、前述した発光装置が適用された例示的な装置(最終製品、end product)を示す。図30は、プロジェクタを、図31は、自動車のヘッドライトを、図32は、街灯を、図33は、照明灯を図示した。図30〜図33で使用される発光素子1はトップビュータイプであり得る。
Claims (12)
- 基板上にバッファ層を形成するステップと、
前記バッファ層上に光結晶パターンとパッドパターンを形成し、前記光結晶パターンと前記パッドパターンは、各々金属物質を含み、互いに物理的に接続されるステップと、
前記光結晶パターンと前記パッドパターンが形成されたバッファ層上に順次に積層された第1導電型の第1導電パターン、発光パターン、第2導電型の第2導電パターンを含む発光構造体を形成するステップと、
前記第1導電パターンと電気的に接続された第1電極と、前記第2導電パターンと電気的に接続された第2電極を形成するステップと、
を含む発光素子の製造方法。 - 前記光結晶パターンと前記パッドパターンは、実質的に同一のレベルに形成される請求項1に記載の発光素子の製造方法。
- 前記光結晶パターンは、複数の反復的なパターンを含み、
前記発光構造体で発生する光の波長がλであるとき、前記複数の反復的なパターンのうち互いに隣接したパターンの間の間隔はλ/4である請求項1に記載の発光素子の製造方法。 - 前記光結晶パターンは、ライン形態またはメッシュ形態である請求項1に記載の発光素子の製造方法。
- 前記パッドパターンの幅は、約40≡以下である請求項1に記載の発光素子の製造方法。
- 前記第2電極は、前記発光構造体の上部または側壁に形成される請求項1に記載の発光素子の製造方法。
- 前記発光構造体を形成するステップは、
前記光結晶パターンと前記パッドパターンが形成されたバッファ層上に順次に第1導電型の第1導電層、発光層、第2導電型の第2導電層を形成し、
前記第2導電層、発光層、第1導電層をパターニングし、前記第2導電パターン、前記発光パターン、前記第1導電パターンを含む発光構造体を完成し、前記第1導電パターンの幅が前記第2導電パターンの幅および前記発光パターンの幅より広いため、前記第1導電パターンが側方向に突出され、前記第1導電パターンの突出された領域の下には前記パッドパターンが位置することを特徴とする請求項1に記載の発光素子の製造方法。 - 前記第1電極と前記第2電極を形成するステップは、
前記発光構造体を形成した後、前記発光構造体上に第2電極を形成するステップと、
前記基板と導電基板をボンディングし、前記第2電極が前記基板と前記導電基板の間に配置されるようにボンディングするステップと、
前記基板を除去するステップと、
前記バッファ層上に第1電極を形成するステップと、
を含む請求項1に記載の発光素子の製造方法。 - 請求項1ないし請求項8のうち何れか一項の発光素子の製造方法を利用する発光装置の製造方法。
- 基板上に形成されたバッファ層と、
前記バッファ層上に形成され、各々金属物質を含み互いに物理的に接続された光結晶パターンとパッドパターンと、
前記光結晶パターンおよびパッドパターンが形成されたバッファ層上に順次に形成された第1導電型の第1導電パターン、発光パターン、第2導電型の第2導電パターンを含む発光構造体と、
前記第1導電パターンと電気的に接続された第1電極と、
前記第2導電パターンと電気的に接続された第2電極とを含む発光素子。 - 導電基板と、
前記導電基板上に形成された第2電極と、
前記第2電極上に順次に形成されて第2導電型の第2導電パターン、発光パターン、第1導電型の第1導電パターンを含む発光構造体と、
前記第1導電パターン上に形成されて各々金属物質を含み互いに物理的に接続される光結晶パターンとパッドパターンと、
前記光結晶パターンとパッドパターンが形成された第1導電パターン上に形成されて前記パッドパターンの少なくとも一部を露出させるバッファ層と、
前記露出したパッドパターン上に形成された第1電極とを含む発光素子。 - 請求項10または請求項11の発光素子を含む発光装置。
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CN113711370A (zh) * | 2019-04-22 | 2021-11-26 | 亮锐有限责任公司 | 具有设置在由嵌入式纳米结构层和反射器限定的光学腔内的有源区的led |
JP2022526801A (ja) * | 2019-04-22 | 2022-05-26 | ルミレッズ リミテッド ライアビリティ カンパニー | 埋設ナノ構造化層および反射器により定められた光キャビティ内に配置された活性領域を有するled |
US11942571B2 (en) | 2019-04-22 | 2024-03-26 | Lumileds Llc | LED with active region disposed within an optical cavity defined by an embedded nanostructured layer and a reflector |
Also Published As
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US8288755B2 (en) | 2012-10-16 |
US7960196B2 (en) | 2011-06-14 |
US20100062554A1 (en) | 2010-03-11 |
KR20100030472A (ko) | 2010-03-18 |
TW201017936A (en) | 2010-05-01 |
TWI460884B (zh) | 2014-11-11 |
US20110204325A1 (en) | 2011-08-25 |
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