TWI396297B - Light emitting diode structure and manufacturing method of the same - Google Patents
Light emitting diode structure and manufacturing method of the same Download PDFInfo
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本發明有關於一種發光二極體(LED),特別是有關於一種具有光子晶體結構之高發光效率發光二極體結構及其製造方法。 The invention relates to a light-emitting diode (LED), in particular to a high luminous efficiency light-emitting diode structure having a photonic crystal structure and a manufacturing method thereof.
近來世界能源的短缺導致油價不斷的飆漲,全球各個國家莫不積極地投入節能產品的開發,例如省電燈泡便是此一趨勢下的產物。隨著發光二極體(LED)技術的進步,白光或其它顏色(例如:藍光)發光二極體的應用也逐漸開展,其應用包括:液晶顯示器(LCD)背光板、印表機、用於電腦之光學連接構件(optical interconnects in computers)、指示燈、地面燈、逃生燈、醫療設備光源、汽車儀錶及內裝燈、輔助照明、主照明…等等。簡而言之,發光二極體係以背光源與照明功能為當前的主要應用。在下一世代的照明市場中,將是發光二極體的天下。由於發光二極體具有輕巧、省電及壽命長等優點,因此,符合了世界的趨勢潮流。歐、美、日等國皆以舉國之力投入開發的行列,而我國的發光二極體產業,在全球市場上,無論研發以及製造均佔有舉足輕重的角色與地位。所以,在發光二極體領域的下一世代發展中,台灣勢將不會缺席。 Recently, the shortage of energy in the world has led to the continuous rise of oil prices. Countries around the world are not actively investing in the development of energy-saving products. For example, energy-saving bulbs are the product of this trend. With the advancement of light-emitting diode (LED) technology, the application of white light or other color (for example, blue light) light-emitting diodes has gradually developed, including: liquid crystal display (LCD) backlight, printer, for Computer optical connectors (indicators), indicator lights, ground lights, emergency lights, medical equipment light sources, automotive instrumentation and interior lights, auxiliary lighting, main lighting, etc. In short, the light-emitting diode system is currently the main application with backlight and illumination functions. In the lighting market of the next generation, it will be the world of light-emitting diodes. Because the light-emitting diode has the advantages of light weight, power saving and long life, it conforms to the trend of the world. Europe, the United States, Japan and other countries are all invested in the development of the country, and China's LED industry, in the global market, both in research and development and manufacturing have a pivotal role and status. Therefore, in the next generation of development in the field of light-emitting diodes, Taiwan will not be absent.
目前,發光二極體在白光市場的應用,已將小型照明市場,帶入另外一個境界。其中,手機的背光源已經被發光二極體所取代。從早期的黃、綠光發光二極體到現在的白光或藍光發光二極體,已經將手機點綴的五彩繽紛。至於個人數位助理(personal digital assistant:PDA)乃至液晶顯示面板(TFT-LCD)的背光源,也都將成為發光二極體的天下。其具有輕薄省電的優點將使其具有不可取代的地位。 At present, the application of light-emitting diodes in the white light market has brought the small lighting market to another level. Among them, the backlight of the mobile phone has been replaced by the light-emitting diode. From the early yellow and green light-emitting diodes to the current white or blue light-emitting diodes, the mobile phone has been decorated with colorful colors. As for the personal digital assistant (PDA) and even the backlight of the liquid crystal display panel (TFT-LCD), it will also become the world of light-emitting diodes. Its advantages of light and power saving will make it irreplaceable.
就現階段而言,距離實際進入白光發光二極體照明時代,尚有一段距離。若白光發光二極體要取代現階段照明市場,發光效率至少要 達到80 lm/W以上,這個目標也將成為各國努力的目標之一。 At this stage, there is still a long way to go from the era of white light-emitting diode lighting. If the white light emitting diode is to replace the current lighting market, the luminous efficiency must be at least Achieving above 80 lm / W, this goal will also become one of the goals of national efforts.
在發光二極體的發光機制中,其發光效率取決於內部的量子效率以及外部的取光效率,其中內部的量子發光效率主要係由發光二極體的組成材料及其結晶性來控制。換言之,發光二極體的發光效率主要係由磊晶的結構以及品質來決定,當磊晶層中有缺陷存在時,由於結構中的缺陷係造成光子被吸收的主要因素,因此,發光二極體的發光效率將會大幅度地降低。 In the luminescence mechanism of the light-emitting diode, the luminous efficiency depends on the internal quantum efficiency and the external light extraction efficiency, and the internal quantum luminescence efficiency is mainly controlled by the constituent materials of the light-emitting diode and its crystallinity. In other words, the luminous efficiency of the light-emitting diode is mainly determined by the structure and quality of the epitaxial layer. When a defect exists in the epitaxial layer, the photodiode is absorbed due to defects in the structure. The luminous efficiency of the body will be greatly reduced.
傳統之發光二極體之發光層所形成之光,在經由P型半導體層與透明導電層之界面時會產生反射,使得該發光二極體之光取出效率(light extraction efficiency)受到影響。此外,在發光二極體之發光表面增加粗糙化表面的圖樣或是形成光子晶體結構,均是於半導體層上直接加工,此種方法容易使得發光層被破壞或是造成元件損傷。此外,由於藍寶石基板硬度高、耐腐蝕性強,因此加工上有一定的困難度,一般的加工方式主要係利用微影蝕刻製程、電子束或雷射加工等方式於藍寶石基板製作特定的圖案。受限於上述製程之限制,較難得到奈米級的圖樣及進行大面積元件的製作,並且上述技術之製造過程較繁複且設備及製作成本相對的較昂貴。 The light formed by the light-emitting layer of the conventional light-emitting diode is reflected by the interface between the P-type semiconductor layer and the transparent conductive layer, so that the light extraction efficiency of the light-emitting diode is affected. In addition, the pattern of increasing the roughened surface or the formation of the photonic crystal structure on the light-emitting surface of the light-emitting diode is directly processed on the semiconductor layer, and the method is easy to cause the light-emitting layer to be damaged or cause damage to the element. In addition, since the sapphire substrate has high hardness and high corrosion resistance, it has a certain degree of difficulty in processing. The general processing method mainly uses a lithography etching process, electron beam or laser processing to form a specific pattern on the sapphire substrate. Limited by the above-mentioned process limitations, it is difficult to obtain a nano-scale pattern and to manufacture a large-area component, and the manufacturing process of the above technology is complicated and the equipment and manufacturing cost are relatively expensive.
再者,由於某些發光二極體之半導體層(例如:GaN折射率n>2.4)與空氣(折射率n約略=1.0)之間的折射係數差異很大,其全反射臨界角約只有20~30度,造成大部分發光層所產生的光只能在元件內部全反射,無法有效地出光,所以即使內部的發光效率提高,外部的取光效率若無法改善也是枉然。 Furthermore, since the refractive index between the semiconductor layers of some light-emitting diodes (for example, GaN refractive index n>2.4) and air (refractive index n is approximately 1.0) is large, the critical angle of total reflection is only about 20 ~30 degrees, the light generated by most of the luminescent layer can only be totally reflected inside the component, and can not effectively emit light, so even if the internal luminous efficiency is improved, the external light extraction efficiency can not be improved.
因此,基於上述之問題,以及因應趨勢之需求,從製程技術來改善發光二極體之取光效率已成為重要的發展方向。是故,本發明將提出一種具有高發光效率之發光二極體結構與其製造方法,其可以提高發光二極體的光取出效率(light extraction efficiency),並可降低發光二極體磊晶層之晶體缺陷,提高發光效率。 Therefore, based on the above problems, and in response to the trend of demand, it has become an important development direction to improve the light extraction efficiency of the light-emitting diode from the process technology. Therefore, the present invention will provide a light-emitting diode structure having high luminous efficiency and a manufacturing method thereof, which can improve the light extraction efficiency of the light-emitting diode and reduce the epitaxial layer of the light-emitting diode. Crystal defects improve luminous efficiency.
本發明之目的在於提供一種新穎的具有多孔性光子晶體結構之發光二極體結構與其製造方法。 It is an object of the present invention to provide a novel light-emitting diode structure having a porous photonic crystal structure and a method of fabricating the same.
本發明之再一目的在於提供一種具有(週期性)微米級孔洞的光子晶體結構之發光二極體。 It is still another object of the present invention to provide a light-emitting diode of a photonic crystal structure having (periodic) micron-scale pores.
本發明之目的在於提供一種具有(週期性)奈米級孔洞的光子晶體結構之發光二極體。 It is an object of the present invention to provide a light-emitting diode of a photonic crystal structure having (periodic) nano-scale pores.
本發明之另一目的在於將微米級週期性孔洞的光子晶體結構建構於基板本身,使呈現規則性週期性排列,此種方式可以改善磊晶品質以及增加外部取光效率以有效地提高發光二極體的發光效率。 Another object of the present invention is to construct a photonic crystal structure of micron-order periodic holes on the substrate itself so as to exhibit regular periodic arrangement, which can improve the epitaxial quality and increase the external light extraction efficiency to effectively improve the light emission. The luminous efficiency of the polar body.
本發明之另一目的在於將奈米級週期性孔洞的光子晶體結構建構於微米級光子晶體結構之上,使呈現規則且週期性排列,此種方式可以改善磊晶品質並降低磊晶時所產生之缺陷,使發光二極體之電性較佳。 Another object of the present invention is to construct a photonic crystal structure of a nano-scale periodic hole on a micron-scale photonic crystal structure so as to exhibit a regular and periodic arrangement, which can improve the epitaxial quality and reduce the epitaxial structure. The defects generated make the electrical properties of the light-emitting diodes better.
本發明之又一目的在於提供一種可以簡化製程以適用於大面積元件製造之發光二極體。 It is still another object of the present invention to provide a light-emitting diode that can simplify the process for use in the manufacture of large-area components.
一種發光二極體,包括:基板,具有第一孔洞於其中;光子晶體結構(作為緩衝層),形成於基板之上,該光子晶體結構具有第二孔洞位於至少基板之上與第一孔洞之中;第一型磊晶層,形成於光子晶體結構之上;發光層,形成於上述第一型磊晶層之上;第二型磊晶層,形成於上述發光層之上;第一接觸電極,形成於上述該第一型磊晶層之上;以及,第二接觸電極,形成於上述第二型磊晶層之上。 A light emitting diode comprising: a substrate having a first hole therein; a photonic crystal structure (as a buffer layer) formed on the substrate, the photonic crystal structure having a second hole located on at least the substrate and the first hole a first type epitaxial layer formed on the photonic crystal structure; a light emitting layer formed on the first type epitaxial layer; and a second type epitaxial layer formed on the light emitting layer; the first contact An electrode is formed on the first type epitaxial layer; and a second contact electrode is formed on the second type epitaxial layer.
一種發光二極體之製造方法,包括:首先,提供一基板;接著,移除部份基板以形成第一孔洞於基板之中;接著,形成一多孔性光子晶體結構於基板之上,其中光子晶體結構具有第二孔洞位於至少基板之上與第一孔洞之中;隨後,形成一第一型磊晶層於上述多孔性光子晶體結構之上;之後,形成一發光層於上述第一型磊晶層之上;然後,形成一第二型磊晶層於上述發光層之上;接著,形成一第一接觸電極於上述第一型磊晶層之上;之後,形成一第二接觸電極於上述第二型 磊晶層上。 A method of manufacturing a light emitting diode, comprising: firstly, providing a substrate; then, removing a portion of the substrate to form a first hole in the substrate; and then forming a porous photonic crystal structure on the substrate, wherein The photonic crystal structure has a second hole located on at least the substrate and the first hole; subsequently, forming a first type epitaxial layer on the porous photonic crystal structure; and then forming a light emitting layer on the first type Forming a second type of epitaxial layer on the light-emitting layer; then forming a first contact electrode on the first type of epitaxial layer; and then forming a second contact electrode In the second type above On the epitaxial layer.
上述基板係藉由微影與蝕刻製程,以形成第一孔洞於基板之中。上述第二孔洞多孔性光子晶體結構係利用純鋁薄膜進行陽極處理製程所形成之多孔性氧化鋁薄膜。 The substrate is formed by a lithography and etching process to form a first hole in the substrate. The second porous porous photonic crystal structure is a porous aluminum oxide film formed by an anodizing process using a pure aluminum film.
本發明的一些實施例會詳細描述如下。然而,除了詳細描述的實施例外,本發明可以廣泛地在其它的實施例中施行,並且本發明之保護範圍並不受限於下述之實施例,其係以後述的申請專利範圍為準。 Some embodiments of the invention are described in detail below. However, the present invention may be widely practiced in other embodiments, and the scope of the present invention is not limited to the embodiments described below, which are subject to the scope of the following claims.
再者,為提供更清楚的描述及更易理解本發明,圖示中各部分並沒有依照其相對尺寸繪圖,不相關之細節部分也未完全繪出,以求圖示的簡潔。 Further, in order to provide a clearer description and a better understanding of the present invention, the various parts of the drawings are not drawn according to their relative dimensions, and the irrelevant details are not fully drawn for simplicity of illustration.
請參考圖示,其中所顯示僅僅是為了說明本發明之較佳實施例,並非用以限制本發明。一般降低磊晶層之晶格缺陷的方式係對(藍寶石)基板直接作表面的加工處理,以形成微米級或奈米級的凹凸結構。 The drawings are only intended to illustrate the preferred embodiments of the invention and are not intended to limit the invention. Generally, the lattice defect of the epitaxial layer is reduced by directly processing the surface of the (sapphire) substrate to form a micron- or nano-scale uneven structure.
本發明先利用濕蝕刻處理技術(或乾蝕刻、拋光、電子束、離子束等技術)在基板之中形成具有週期性晶格係數之微米級二維光子晶體結構,此光子晶體結構可以便利於後續製程之進行。此種結構不僅可以有效改善磊晶品質,更可以增加內部量子發光效率,並解決基板與磊晶層之間的光全反射之問題以及減少沿著界面產生的側向漏光情形,結果有效地提昇了發光二極體的外部取光效率。 The invention firstly forms a micro-scale two-dimensional photonic crystal structure having a periodic lattice coefficient in a substrate by using a wet etching process (or dry etching, polishing, electron beam, ion beam, etc.), and the photonic crystal structure can be facilitated. The subsequent process is carried out. Such a structure can not only effectively improve the epitaxial quality, but also increase the internal quantum luminescence efficiency, solve the problem of total light reflection between the substrate and the epitaxial layer, and reduce the lateral light leakage generated along the interface, and the result is effectively improved. The external light extraction efficiency of the light emitting diode.
本發明另外利用陽極處理技術(或電子束轟擊)在第一層結構(例如AlN、SiO2、Al2O3)表面製造一層具有(週期性)奈米級晶格係數之二維光子晶體結構,此光子晶體結構可以有效的改善磊晶品質,增加內部量子發光效率。再者,奈米級晶格係數可以大幅降低磊晶生長時所產生之缺陷,並控制與降低基板與磊晶層之間所產生之漏電流,使發光二極體之電性大幅提昇。 The invention additionally utilizes anodizing techniques (or electron beam bombardment) to fabricate a two-dimensional photonic crystal structure having a (periodic) nanoscale lattice coefficient on the surface of the first layer structure (eg, AlN, SiO 2 , Al 2 O 3 ). The photonic crystal structure can effectively improve the epitaxial quality and increase the internal quantum luminous efficiency. Furthermore, the nano-scale lattice coefficient can greatly reduce the defects generated during epitaxial growth, and control and reduce the leakage current generated between the substrate and the epitaxial layer, so that the electrical properties of the light-emitting diode are greatly improved.
在一實施例中,藉由調整發光層材料,使其發光介於藍光範圍,利用本發明之多孔性氧化鋁光子晶體結構所產生光激發現象,以增加發光二極體之發光強度。 In one embodiment, the light-emitting phenomenon generated by the porous alumina photonic crystal structure of the present invention is used to increase the light-emitting intensity of the light-emitting diode by adjusting the material of the light-emitting layer such that the light is in the blue light range.
請參閱第六圖,其係根據本發明之發光二極體結構之截面圖。上述發光二極體結構,包括:一基板10具有微米級多孔性光子晶體結構於其中、奈米級多孔性光子晶體結構14、第一型磊晶層15、發光層17、第二型磊晶層18、第一接觸電極16以及第二接觸電極19。舉一實施例而言,上述基板10之材質可以為藍寶石(sapphire)、氮化鎵(GaN)、氮化鋁(AlN)、碳化矽(SiC)或氮化鎵鋁(GaAlN)。上述基板10經過一粗糙化的製程而將基板10之表面粗糙化而形成粗糙表面。舉一實施例而言,上述表面粗糙化製程係在基板10之中形成一具有週期性晶格係數之微米級二維光子晶體結構。 Please refer to the sixth drawing, which is a cross-sectional view of the structure of the light emitting diode according to the present invention. The light emitting diode structure comprises: a substrate 10 having a micron-sized porous photonic crystal structure therein, a nano-scale porous photonic crystal structure 14, a first-type epitaxial layer 15, a light-emitting layer 17, and a second-type epitaxial crystal. Layer 18, first contact electrode 16, and second contact electrode 19. In one embodiment, the material of the substrate 10 may be sapphire, gallium nitride (GaN), aluminum nitride (AlN), tantalum carbide (SiC) or gallium aluminum nitride (GaAlN). The substrate 10 is subjected to a roughening process to roughen the surface of the substrate 10 to form a rough surface. In one embodiment, the surface roughening process forms a micro-scale two-dimensional photonic crystal structure having a periodic lattice coefficient in the substrate 10.
第一圖為本發明之發光二極體基板結構之截面圖。上述基板10之表面形成一正光阻層11,如第一圖所示。光阻層11經過一曝光(微影製程)之後,形成一具有曝光區與非曝光區之光阻層12,其中曝光區之光阻層為光阻層12a,請參考第二圖。之後,再透過一顯影製程,將曝光區之光阻層12a移除,結果形成光阻圖案13,請參考第三圖。光阻圖案13形成之後可以透過一硬烤(hard bake)製程以利於後續製程。 The first figure is a cross-sectional view of the structure of the light-emitting diode substrate of the present invention. A surface of the substrate 10 is formed with a positive photoresist layer 11 as shown in the first figure. After the photoresist layer 11 is subjected to an exposure (lithography process), a photoresist layer 12 having exposed regions and non-exposed regions is formed. The photoresist layer of the exposed regions is the photoresist layer 12a. Please refer to the second figure. Thereafter, the photoresist layer 12a of the exposed region is removed through a developing process, and as a result, the photoresist pattern 13 is formed. Please refer to the third figure. After the photoresist pattern 13 is formed, it can be passed through a hard bake process to facilitate subsequent processes.
接下來,以光阻圖案13作為蝕刻罩幕,利用濕式蝕刻(或乾蝕刻、拋光、電子束、離子束等技術)將基板10表面蝕刻形成一具有週期性孔洞10a間距之基板10,如第四圖所示。週期性孔洞10a之結構大小係透過光阻圖案13來定義。舉例而言,上述孔洞10a直徑約0.5-5微米,孔洞與孔洞之間的距離(排列週期)約為1~10微米,孔洞密度約為每平方公分具有108~1012個孔洞。 Next, using the photoresist pattern 13 as an etching mask, the surface of the substrate 10 is etched by wet etching (or dry etching, polishing, electron beam, ion beam, etc.) to form a substrate 10 having a periodic hole 10a pitch, such as The fourth picture shows. The structural size of the periodic holes 10a is defined by the photoresist pattern 13. For example, the hole 10a has a diameter of about 0.5 to 5 μm, a distance between the holes and the holes (arrangement period) is about 1 to 10 μm, and a hole density is about 10 8 to 10 12 holes per square centimeter.
濕式蝕刻之蝕刻溶液例如為草酸(C2H2O4)溶液、磷酸溶液等。舉例而言,酸性蝕刻溶液對於氧化鋁基板有蝕刻的作用,其可產生下列化學反應: Al2O3+3H2SO4 → 2Al(SO4)3+3H2O The etching solution for wet etching is, for example, an oxalic acid (C 2 H 2 O 4 ) solution, a phosphoric acid solution or the like. For example, an acidic etching solution has an effect of etching on an alumina substrate, which can produce the following chemical reaction: Al 2 O 3 +3H 2 SO 4 → 2Al(SO 4 ) 3 +3H 2 O
Al2O3+2H3PO4 → 2AlPO4+3H2O Al 2 O 3 +2H 3 PO 4 → 2AlPO 4 +3H 2 O
在一實施例之中,上述基板蝕刻製程可以在80%的磷酸溶液、5%的硝酸、5%的醋酸以及20%的純水中,加熱至攝氏35~45度的溫度環境之下來進行。隨著加熱處理之浸泡時間的改變,氧化鋁基板孔洞週期 性擴大,其侵蝕速率約為每分鐘1000~3000埃(埃/分)。而在另一實施例之中,上述基版蝕刻製程可以在3:1的酸性溶液中,其溶液組成包括硫酸(H2SO4)溶液(其比例為3)與磷酸(H3PO4)溶液(其比例為1),加熱至攝氏200~400度的溫度環境之下來進行。隨著加熱處理之浸泡時間的改變,氧化鋁基板孔洞週期性擴大,直到一定的大小為止。 In one embodiment, the substrate etching process can be performed by heating in an 80% phosphoric acid solution, 5% nitric acid, 5% acetic acid, and 20% pure water to a temperature of 35 to 45 degrees Celsius. As the immersion time of the heat treatment changes, the pores of the alumina substrate periodically expand, and the erosion rate is about 1000 to 3000 angstroms per liter (A/min). In another embodiment, the above-mentioned base etching process may be in a 3:1 acidic solution, and the solution composition thereof includes a sulfuric acid (H 2 SO 4 ) solution (the ratio of which is 3) and phosphoric acid (H 3 PO 4 ). The solution (in a ratio of 1) is heated to a temperature of 200 to 400 degrees Celsius. As the immersion time of the heat treatment changes, the pores of the alumina substrate periodically expand until a certain size.
接著,於蝕刻基板10之後,沉積一薄層二氧化矽(SiO2)磊晶晶體,其沉積例如係透過蒸鍍(E-GUN)、濺鍍(Sputter)、電漿式化學氣相沉積(PECVD)、化學氣相沉積(CVD)、物理氣相沉積(PVD)、熱浸鍍所形成。沉積二氧化矽(SiO2)磊晶生長完成之後,於基板上便生長一薄層二氧化矽晶體,其可作為後續製成週期性孔洞所必要之緩衝層。 Next, after etching the substrate 10, a thin layer of epitaxial crystal of cerium oxide (SiO 2 ) is deposited, which is deposited, for example, by vapor deposition (E-GUN), sputtering (sputter), and plasma chemical vapor deposition ( PECVD), chemical vapor deposition (CVD), physical vapor deposition (PVD), hot dip plating. After epitaxial growth of deposited cerium oxide (SiO 2 ), a thin layer of cerium oxide crystal is grown on the substrate, which serves as a buffer layer necessary for subsequent periodic holes.
隨後,利用鍍膜沉積技術(例如蒸鍍、濺鍍、電漿式化學氣相沉積、化學氣相沉積、物理氣相沉積、熱浸鍍)形成一金屬薄膜於基板10之上,並填滿孔洞10a。舉一實施例而言,金屬薄膜為鋁金屬薄膜,其薄膜厚度為0.5~2.0微米。 Subsequently, a metal thin film is formed on the substrate 10 by a deposition deposition technique (for example, evaporation, sputtering, plasma chemical vapor deposition, chemical vapor deposition, physical vapor deposition, hot dip plating), and the holes are filled. 10a. In one embodiment, the metal film is an aluminum metal film having a film thickness of 0.5 to 2.0 microns.
然後,再利用陽極處理(anodization)技術在基板10與孔洞10a表面形成週期性奈米級多孔性氧化金屬薄膜圖案14,請參考第五圖。舉例而言,上述多孔性氧化金屬薄膜圖案14包括複數個孔洞形成於基板10之上。舉例而言,形成於孔洞10a區之上的孔洞14b的深度比形成於非孔洞區之上的14a孔洞的深度還大。 Then, a periodic nano-sized porous oxidized metal thin film pattern 14 is formed on the surface of the substrate 10 and the hole 10a by an anodization technique, please refer to the fifth drawing. For example, the porous oxidized metal thin film pattern 14 includes a plurality of holes formed on the substrate 10. For example, the depth of the hole 14b formed over the area of the hole 10a is greater than the depth of the hole 14a formed above the non-hole area.
舉例而言,對於上述純鋁薄膜之陽極處理係在0.2~0.5莫耳濃度(M)的草酸(C2H2O4)溶液,外加20~50伏特之直流電壓之環境下進行。隨著陽極處理之時間的改變,多孔性氧化鋁薄膜厚度逐漸增加,舉例而言,氧化鋁薄膜孔洞直徑約為5~400奈米(較佳為30~80奈米),孔洞與孔洞之間的距離(排列週期)約為80~120奈米,孔洞密度約為每平方公分具有108~1012個孔洞。 For example, the anode treatment of the above pure aluminum film is carried out in an environment of 0.2 to 0.5 molar concentration (M) of oxalic acid (C 2 H 2 O 4 ), plus a direct current voltage of 20 to 50 volts. As the time of the anode treatment changes, the thickness of the porous alumina film gradually increases. For example, the pore diameter of the alumina film is about 5 to 400 nm (preferably 30 to 80 nm), between the pores and the pores. The distance (arrangement period) is about 80 to 120 nm, and the hole density is about 10 8 to 10 12 holes per square centimeter.
一般而言,陽極處理金屬薄膜後呈現細胞管狀(cellular tube)結構。形成此種結構型態的過程詳述如下:開始通電時,鋁陽極表面的某些部位開始溶解,隨著時間增長,鋁溶解量增加,而陽極表面開始呈現凹凸不平的粗糙度,時間續增,由於凹凸不平造成溶解速率不一, 溶解較快的部位逐漸凹陷,而溶解的鋁離子逐漸形成氫氧化鋁與氧化鋁沉積在表面,但是仍留有孔隙以供溶解反應繼續進行,一段時間之後,堆積的沉澱即形成管壁,管壁的主要成份包含水氧化鋁或膠狀氫氧化鋁,其中愈接近管壁中央含水量愈少,愈接近純氧化鋁,而接近電解液區域即為鋁溶解沉積的區域,沉積愈久則愈緻密。 In general, an anodized metal film exhibits a cellular tube structure. The process of forming such a structure is detailed as follows: at the beginning of energization, some parts of the surface of the aluminum anode start to dissolve, and as time increases, the amount of aluminum dissolved increases, and the surface of the anode begins to exhibit uneven roughness, and the time continues to increase. Due to unevenness, the dissolution rate varies. The faster dissolved portion gradually sag, and the dissolved aluminum ions gradually form aluminum hydroxide and alumina deposited on the surface, but there are still pores for the dissolution reaction to continue, and after a period of time, the deposited precipitate forms the tube wall, and the tube The main component of the wall contains water-alumina or colloidal aluminum hydroxide. The closer the water content is to the center of the tube wall, the closer it is to pure alumina, and the area close to the electrolyte is the area where aluminum is dissolved and deposited. The longer the deposition, the denser it is. .
利用酸性溶液進行陽極處理時,酸性電解質會分解純鋁金屬表面,並且開始成長氧化層。純鋁金屬表面分解造成細小孔洞的產生,同時孔洞底部會形成阻障層使得氧化層與金屬鋁隔離,當孔洞形成趨於穩定時,則將以一定速率開始成長,形成類似蜂巢結構的氧化鋁層。 When anodizing with an acidic solution, the acidic electrolyte decomposes the surface of the pure aluminum metal and begins to grow the oxide layer. Decomposition of pure aluminum metal surface causes the formation of fine pores. At the same time, a barrier layer is formed at the bottom of the hole to isolate the oxide layer from the metal aluminum. When the pore formation tends to be stable, it will start to grow at a certain rate to form a honeycomb structure similar to honeycomb structure. Floor.
陽極處理時操作電壓會影響孔洞、孔距與細胞的大小,它們之間的關係是成正比的。換言之,施加的電壓越大,其孔洞、孔距與細胞也相對的較大。 The operating voltage during anode processing affects the pores, pore spacing and cell size, and the relationship between them is directly proportional. In other words, the larger the applied voltage, the larger the hole, the hole pitch and the cell.
理論上,陽極氧化鋁膜的孔洞可以規則性的排列,但是通常其範圍不會超過幾微米。在孔洞形成之初,無次序的孔洞生成將造成陽極氧化鋁膜正面孔洞不規則,而孔洞生成穩定時,模板背面才可以看到規則的孔洞排列。為了得到大範圍的規則孔洞,可以利用二次陽極處理(two-step anodization)或在鋁金屬層表面預置圖案(pre-pattern)等兩種方法。 Theoretically, the pores of the anodized aluminum film can be regularly arranged, but usually the range does not exceed a few microns. At the beginning of the formation of the voids, the disordered pore formation will cause the pores on the front side of the anodized aluminum film to be irregular, and when the pore formation is stable, the regular pore arrangement can be seen on the back side of the template. In order to obtain a wide range of regular holes, two methods such as two-step anodization or pre-pattern on the surface of the aluminum metal layer may be used.
鋁金屬陽極處理所使用的電解液可以包括很多種,其中每一種電解液的主要化學成份不同,經其處理後的薄膜組織不同,孔洞性質也因之有所差異。舉例而言,上述電解液包括:(1)硫酸液,例如15~20%硫酸,操作電壓為14~22伏特、電流密度為1~2A/dm2、環境溫度18~25℃、處理時間10~60分鐘,其可以形成薄膜厚度為3~35微米。硫酸溶液製程所得到的薄膜抗蝕性良好,而且抗磨耗性佳,此製程若將操作溫度降至5℃以下,硫酸濃度降至7%左右,處理電壓提高至23~120伏特,可以長時間處理以獲得厚度200微米以上的相對硬質陽極薄膜;(2)鉻酸液,例如包括5~10%鉻酸,操作電壓為40伏特、電流密度為0.15~0.30A/dm2、環境溫度35℃、處理時間30分鐘,其可以形成薄膜厚度約為2~3微米,鉻酸溶液製程所得到的薄膜亦具有良好抗蝕性; (3)草酸液,例如包含0.3莫耳或3~5wt%草酸(C2H2O4),電壓為40~60伏特、電流密度為1~2A/dm2、環境溫度18~20℃、處理時間40~60分鐘,其可以形成薄膜厚度約為10~65微米,此外,當環境溫度降至3~5℃,經長時間處理可以獲得厚度625微米的薄膜;(4)磷酸液,例如含10%磷酸,電壓為10~12伏特、環境溫度23~25℃、處理時間20~30分鐘,其可以形成薄膜厚度約為1~2微米,磷酸液處理之薄膜孔隙較大。 The electrolyte used for the anodizing of the aluminum metal may include a plurality of kinds of electrolytes, each of which has a different main chemical composition, and the pore structure is different depending on the structure of the film after the treatment. For example, the electrolyte includes: (1) sulfuric acid liquid, for example, 15 to 20% sulfuric acid, operating voltage is 14 to 22 volts, current density is 1 to 2 A/dm 2 , ambient temperature is 18 to 25 ° C, and processing time is 10 ~60 minutes, it can form a film thickness of 3 ~ 35 microns. The film obtained by the sulfuric acid solution process has good corrosion resistance and good anti-wear property. If the operating temperature is lowered to below 5 ° C, the sulfuric acid concentration is reduced to about 7%, and the treatment voltage is increased to 23 to 120 volts, which can be used for a long time. Processing to obtain a relatively hard anode film having a thickness of 200 μm or more; (2) chromic acid solution, for example, including 5 to 10% chromic acid, operating voltage of 40 volts, current density of 0.15 to 0.30 A/dm 2 , ambient temperature of 35 ° C The treatment time is 30 minutes, which can form a film thickness of about 2 to 3 microns, and the film obtained by the chromic acid solution process also has good corrosion resistance; (3) the oxalic acid solution, for example, contains 0.3 mole or 3 to 5 wt% of oxalic acid. (C 2 H 2 O 4 ), voltage is 40~60 volts, current density is 1~2A/dm 2 , ambient temperature is 18~20°C, processing time is 40~60 minutes, and it can form a film thickness of about 10~65 Micron, in addition, when the ambient temperature drops to 3~5 °C, a film with a thickness of 625 microns can be obtained after long-term treatment; (4) Phosphoric acid solution, for example, containing 10% phosphoric acid, voltage of 10-12 volts, ambient temperature 23~25 °C, treatment time 20~30 minutes, it can form a film thickness of about 1~2 microns, phosphoric acid solution Larger pores of the film.
上述四種電解液之成分組成以及其操作條件僅係本發明舉出之實施例,並非用以限定本發明。這四種電解液中形成薄膜時,實際上有一定的孔隙,允許鋁金屬持續溶出以形成薄膜,同時其薄膜具有一定的溶解度,因此薄膜可以持續成長至其溶解速度與成長速度相等為止。此外,它種電解液如硼酸液、酒石酸液等,其生成的薄膜較緻密,不容易允許鋁金屬經由電解溶出,因此適合使用於形成較薄的薄膜。 The composition of the above four electrolytes and the operating conditions thereof are merely examples of the invention, and are not intended to limit the invention. When the film is formed in the four electrolytes, there is actually a certain pore, which allows the aluminum metal to be continuously eluted to form a film, and the film has a certain solubility, so that the film can continue to grow until the dissolution rate and the growth rate are equal. Further, it is an electrolyte such as boric acid solution, tartaric acid solution, etc., which produces a film which is denser and does not easily allow the aluminum metal to be dissolved by electrolysis, and is therefore suitable for use in forming a thin film.
舉一實施例而言,多孔性氧化金屬薄膜例如為多孔性氧化鋁薄膜。然後,再透過一熱處理製程,其可以利用氧化矽爐管執行,爐管內抽真空使其真空度達1~10-3 torr,處理溫度於攝氏500~1100度底下進行,時間為4小時。經由熱處理製程完成後,二氧化鋁(Al2O3)晶體生長完成之後,其於氧化鋁薄膜圖案14之上形成二氧化鋁多晶狀態磊晶體,可以作為週期性孔洞之緩衝層。 In one embodiment, the porous oxidized metal film is, for example, a porous alumina film. Then, through a heat treatment process, it can be performed by using a cerium oxide furnace tube, the vacuum is increased in the furnace tube to a vacuum of 1 to 10-3 torr, and the treatment temperature is performed at 500 to 1100 degrees Celsius for 4 hours. After the completion of the heat treatment process, after the growth of the alumina (Al 2 O 3 ) crystal is completed, the aluminum oxide polycrystalline state epitaxial crystal is formed on the aluminum oxide thin film pattern 14 and can serve as a buffer layer for the periodic pores.
此外,本發明之發光二極體包括一N型半導體層15,形成於基板10與多孔性氧化金屬薄膜14之上。N型半導體磊晶層15可以透過化學氣相沉積(CVD)、有機金屬化學氣相沉積(MOCVD)方式形成。另外,一發光層17,形成於上述N型半導體層15之上。上述發光層17為一主動層(active layer),其可以由複數個井層(well layer)與複數個阻障層(barrier layer)交互堆疊而形成。一P型半導體磊晶層18,形成於上述發光層17之上,同樣地,P型半導體層18可以透過化學氣相沉積、有機金屬化學氣相沉積(MOCVD)方式形成。上述P型半導體層18或N型半導體層15之材質可以選自氮化鎵(GaN)、氮化銦鎵(IrGaN)、氮化鎵系或氮基(nitride-based)半導體磊晶之一。 Further, the light-emitting diode of the present invention comprises an N-type semiconductor layer 15 formed on the substrate 10 and the porous oxidized metal film 14. The N-type semiconductor epitaxial layer 15 can be formed by chemical vapor deposition (CVD) or organometallic chemical vapor deposition (MOCVD). Further, a light-emitting layer 17 is formed on the N-type semiconductor layer 15. The light-emitting layer 17 is an active layer, which may be formed by stacking a plurality of well layers and a plurality of barrier layers. A P-type semiconductor epitaxial layer 18 is formed on the light-emitting layer 17, and similarly, the P-type semiconductor layer 18 can be formed by chemical vapor deposition or metalorganic chemical vapor deposition (MOCVD). The material of the P-type semiconductor layer 18 or the N-type semiconductor layer 15 may be selected from one of gallium nitride (GaN), indium gallium nitride (IrGaN), gallium nitride-based or nitride-based semiconductor epitaxial.
第二接觸電極19,形成於上述P型半導體層18之表面,其係用以 作為P型接點或N型接點。另外,一第一接觸電極16,形成於上述N型半導體層15之上,其係用以作為N型接點或P型接點。上述二接觸電極,其材質可以選自鈦/鋁(TiAl)、鈦/鋁/鈦/金(Ti/Al/Ti/Au)及鈦/鋁/鎳/金(Ti/Al/Ni/Au)合金之一。 The second contact electrode 19 is formed on the surface of the P-type semiconductor layer 18, and is used for As a P-type contact or N-type contact. Further, a first contact electrode 16 is formed on the N-type semiconductor layer 15 for use as an N-type contact or a P-type contact. The above two contact electrodes may be made of titanium/aluminum (TiAl), titanium/aluminum/titanium/gold (Ti/Al/Ti/Au), and titanium/aluminum/nickel/gold (Ti/Al/Ni/Au). One of the alloys.
此外,本發明亦提供發光二極體之製造方法,其主要步驟包括:首先,提供一基板10。接著,形成一光阻層12於基板10之上,藉由微影與蝕刻製程以圖案化基板10以得到孔洞圖案10a。隨後,形成金屬薄膜於基板10之上並填入孔洞10a。接著,針對金屬薄膜進行陽極處理製程而形成奈米級多孔性氧化金屬薄膜孔洞結構14,此即為本發明之多孔性光子晶體結構。舉一實施例而言,上述基板10之材質包括藍寶石(sapphire)、氮化鎵(GaN)、氮化鋁(AlN)、碳化矽(SiC)或氮化鎵鋁(GaAlN)。 In addition, the present invention also provides a method of manufacturing a light-emitting diode, the main steps of which include: first, providing a substrate 10. Next, a photoresist layer 12 is formed on the substrate 10, and the substrate 10 is patterned by a lithography and etching process to obtain a hole pattern 10a. Subsequently, a metal thin film is formed on the substrate 10 and filled in the hole 10a. Next, an anode treatment process is performed on the metal thin film to form a nanoporous porous metal oxide film pore structure 14, which is the porous photonic crystal structure of the present invention. In one embodiment, the material of the substrate 10 includes sapphire, gallium nitride (GaN), aluminum nitride (AlN), tantalum carbide (SiC) or aluminum gallium nitride (GaAlN).
然後,形成一N型半導體層15於多孔性光子晶體結構14之上。之後,形成發光層17於上述N型半導體層15之上。上述發光層17為一主動層(active layer),其可以由複數個井層(well layer)與複數個阻障層(barrier layer)交互堆疊而形成。接著,形成一P型半導體層18於發光層17之上。 Then, an N-type semiconductor layer 15 is formed over the porous photonic crystal structure 14. Thereafter, the light-emitting layer 17 is formed on the above-described N-type semiconductor layer 15. The light-emitting layer 17 is an active layer, which may be formed by stacking a plurality of well layers and a plurality of barrier layers. Next, a P-type semiconductor layer 18 is formed over the light-emitting layer 17.
然後,形成一第一接觸電極16於N型半導體層15之表面,其係用來作為N型接觸電極。之後,形成一第二接觸電極19於P型半導體層18上,其係用來作為P型接觸電極。上述二電極,其材質可以選自氮化鈦、鈦/鋁(TiAl)、鈦/鋁/鈦/金(Ti/Al/Ti/Au)及鈦/鋁/鎳/金(Ti/Al/Ni/Au)合金之一。 Then, a first contact electrode 16 is formed on the surface of the N-type semiconductor layer 15, which is used as an N-type contact electrode. Thereafter, a second contact electrode 19 is formed on the P-type semiconductor layer 18, which serves as a P-type contact electrode. The above two electrodes may be made of titanium nitride, titanium/aluminum (TiAl), titanium/aluminum/titanium/gold (Ti/Al/Ti/Au), and titanium/aluminum/nickel/gold (Ti/Al/Ni). /Au) One of the alloys.
利用上述多孔性氧化鋁薄膜之特性,使得上述發光層17所形成之發光路徑在N型半導體層15與基板10之界面之間降低反射率,使得大部分激發之光可以輻射至元件之外部。結果使得本發明之發光二極體之取光效率(light extraction efficiency)提高。另外,此光子晶體結構也能有效的改善磊晶品質,增加內部量子發光效率。 By utilizing the characteristics of the above porous alumina film, the light-emitting path formed by the light-emitting layer 17 reduces the reflectance between the interface of the N-type semiconductor layer 15 and the substrate 10, so that most of the excited light can be radiated to the outside of the element. As a result, the light extraction efficiency of the light-emitting diode of the present invention is improved. In addition, the photonic crystal structure can also effectively improve the epitaxial quality and increase the internal quantum luminous efficiency.
本發明的主要優點如下: The main advantages of the invention are as follows:
1.利用濕式蝕刻製程於(藍寶石)基板上達到形成週期性規則排列 孔洞的效果,能大幅提昇外部取光效率,更可以提昇發光二極體內部發光效率,同時亦可以簡化製程,避免因製程加工所造成的損害。 1. Using a wet etching process on a (sapphire) substrate to form a periodic regular arrangement The effect of the hole can greatly improve the external light extraction efficiency, and can improve the internal luminous efficiency of the light-emitting diode, and at the same time, the process can be simplified and the damage caused by the processing can be avoided.
2.利用陽極處理製程於(藍寶石)基板上達到表面粗化的效果,除了能有效提昇內部發光效率之外,也可以降低磊晶生長時所產生的缺陷,避免因界面與磊晶層所產生的漏電流對發光二極體所造成的損害。 2. Using the anodizing process to achieve the surface roughening effect on the (sapphire) substrate, in addition to effectively improving the internal luminous efficiency, it can also reduce the defects generated during epitaxial growth and avoid the interface and the epitaxial layer. The leakage current causes damage to the light-emitting diode.
3.利用光子晶體效應,可以有效的改善磊晶品質以及側向漏光問題,而結構本身週期性的凹凸型態亦可以減少基板與磊晶層之間的全反射情形,增加光的取出效率。 3. Using the photonic crystal effect, the epitaxial quality and the lateral light leakage problem can be effectively improved, and the periodic irregular shape of the structure itself can also reduce the total reflection between the substrate and the epitaxial layer, and increase the light extraction efficiency.
4.利用光子晶體本身具有光激發特性,可以增加發光二極體之發光強度。 4. The photon crystal itself has photoexcitation characteristics, which can increase the luminous intensity of the light-emitting diode.
5.本發明之製程簡易且適合用於大面積元件的製造。 5. The process of the present invention is simple and suitable for use in the manufacture of large area components.
本發明以較佳實施例說明如上,然其並非用以限定本發明所主張之專利權利範圍。其專利保護範圍當視後附之申請專利範圍及其等同領域而定。凡熟悉此領域之技藝者,在不脫離本專利精神或範圍內,所作之更動或潤飾,均屬於本發明所揭示精神下所完成之等效改變或設計,且應包含在下述之申請專利範圍內。 The present invention has been described above by way of a preferred embodiment, and is not intended to limit the scope of the claimed invention. The scope of patent protection is subject to the scope of the patent application and its equivalent fields. Any modification or refinement made by those skilled in the art without departing from the spirit or scope of the present invention is equivalent to the equivalent change or design made in the spirit of the present disclosure, and should be included in the following patent application scope. Inside.
10‧‧‧基板 10‧‧‧Substrate
10a‧‧‧孔洞 10a‧‧‧ hole
11‧‧‧光阻層 11‧‧‧Photoresist layer
12‧‧‧曝光後之光阻層 12‧‧‧Photoreceptor layer after exposure
12a‧‧‧曝光區之光阻層 12a‧‧‧Photoresist layer in the exposed area
13‧‧‧光阻圖案 13‧‧‧resist pattern
14‧‧‧多孔性氧化金屬薄膜 14‧‧‧Porous oxidized metal film
14a、14b‧‧‧孔洞 14a, 14b‧‧‧ holes
15‧‧‧N型半導體層 15‧‧‧N type semiconductor layer
16‧‧‧第一接觸電極 16‧‧‧First contact electrode
17‧‧‧發光層 17‧‧‧Lighting layer
18‧‧‧P型半導體層 18‧‧‧P type semiconductor layer
19‧‧‧第二接觸電極 19‧‧‧Second contact electrode
藉由以下詳細之描述結合所附圖示,將可輕易的了解上述內容及此項發明之諸多優點,其中:第一圖為根據本發明之形成光阻層於基板上之截面圖。 The above and many advantages of the invention will be readily apparent from the following detailed description in conjunction with the accompanying drawings in which: FIG. 1 is a cross-sectional view of a photoresist layer formed on a substrate in accordance with the present invention.
第二圖為根據本發明之曝光於光阻上之截面圖。 The second figure is a cross-sectional view of the exposure to the photoresist in accordance with the present invention.
第三圖為根據本發明之形成光阻圖案於基板上之截面圖。 The third figure is a cross-sectional view of a photoresist pattern formed on a substrate in accordance with the present invention.
第四圖為根據本發明之形成圖案化基板之截面圖。 The fourth figure is a cross-sectional view of a patterned substrate in accordance with the present invention.
第五圖為根據本發明之形成奈米級多孔性光子晶體結構於圖案化基板上之截面圖。 Figure 5 is a cross-sectional view of a nanoscale porous photonic crystal structure formed on a patterned substrate in accordance with the present invention.
第六圖為根據本發明之具有奈米級多孔性光子晶體結構之發光二極體之截面圖。 Figure 6 is a cross-sectional view of a light-emitting diode having a nano-scale porous photonic crystal structure according to the present invention.
10‧‧‧基板 10‧‧‧Substrate
14‧‧‧多孔性氧化金屬薄膜 14‧‧‧Porous oxidized metal film
15‧‧‧N型半導體層 15‧‧‧N type semiconductor layer
16‧‧‧第一接觸電極 16‧‧‧First contact electrode
17‧‧‧發光層 17‧‧‧Lighting layer
18‧‧‧P型半導體層 18‧‧‧P type semiconductor layer
19‧‧‧第二接觸電極 19‧‧‧Second contact electrode
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TWI459593B (en) * | 2009-06-19 | 2014-11-01 | Fu Der Lai | Structure of light emitting diodes for increase of light emitting efficiency |
TWI407592B (en) * | 2009-11-20 | 2013-09-01 | Advanced Optoelectronic Tech | Light emitting diode and method for manufacturing the same |
CN102646766B (en) * | 2011-02-18 | 2014-08-27 | 展晶科技(深圳)有限公司 | Light emitting diode (LED) epitaxial structure and processing procedure |
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CN102361053B (en) * | 2011-11-01 | 2013-05-01 | 东南大学 | Light-emitting diode with photonic crystal structure |
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