TWI419362B - High luminous efficiency solid state light emitting element and its manufacturing method - Google Patents
High luminous efficiency solid state light emitting element and its manufacturing method Download PDFInfo
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本發明是有關於一種固態發光元件及其製造方法,特別是指一種高發光效率固態發光元件及其製造方法。The present invention relates to a solid state light emitting device and a method of fabricating the same, and more particularly to a high luminous efficiency solid state light emitting device and a method of fabricating the same.
發光二極體(Light Emitting Diode;LED)屬半導體元件之一種,由於LED具有體積小、壽命長、耗電量小等特性,已普遍應用於3C產品指示器與顯示裝置之上,然而不論是作為顯示器或背光源,發光二極體的發光效率一直以來都是非常重要的研究課題。Light Emitting Diode (LED) is a kind of semiconductor component. Due to its small size, long life and low power consumption, LED has been widely used in 3C product indicators and display devices. As a display or a backlight, the luminous efficiency of a light-emitting diode has been a very important research topic.
一般而言,發光二極體元件的發光效率可分為內部量子效率和外部量子效率。內部量子效率是指電子與電洞在發光層中結合放出光子的效率,因此與磊晶層本身所使用的有機或無機發光材料有直接密切的關係,外部量子效率則是指光子從元件發射到被取出的總效率,它是內部量子效率和光子取出率的總乘積,而光子取出率則為光子由發光二極體元件內部發射至外界的效率,其深受發光二極體元件本身結構設計與物理特性的影響,例如,為提昇光子取出率有效的將磊晶層產生的光反射到所需發射的光發射面,因此會選擇不同具有高反射率的反射層來提昇光自發射面發出的效率。In general, the luminous efficiency of a light-emitting diode element can be classified into internal quantum efficiency and external quantum efficiency. Internal quantum efficiency refers to the efficiency with which electrons and holes combine to emit photons in the luminescent layer. Therefore, it has a direct and close relationship with the organic or inorganic luminescent materials used in the epitaxial layer itself. The external quantum efficiency refers to the photon emitted from the component to the photo. The total efficiency of the extraction, which is the total product of the internal quantum efficiency and the photon extraction rate, and the photon extraction rate is the efficiency of the photon emitted from the inside of the LED component to the outside, which is deeply designed by the structure of the LED component itself. And the influence of physical characteristics, for example, effective to enhance the photon extraction rate to reflect the light generated by the epitaxial layer to the light emitting surface of the desired emission, so different reflective layers with high reflectivity are selected to enhance the light emitted from the emitting surface. s efficiency.
而為提昇發光二極體元件的發光效率,元件的設計除了需考量光子取出率之外,如何確保磊晶層在電致發光的過程當中達到最佳的發光效率亦是另一個考量的重點。例 如,可於接著單元與磊晶層間增加一將電流均勻的分散到發光層的電流分散層,以確保於磊晶層內的電子與電洞對得到最佳的結合效率,或是將發光二極體元件間的歐姆接觸電阻降到最低,以提昇電流進入發光層的效率。In order to improve the luminous efficiency of the LED component, in addition to considering the photon extraction rate, how to ensure the best luminous efficiency of the epitaxial layer in the electroluminescence process is another important consideration. example For example, a current dispersion layer that uniformly distributes the current to the light-emitting layer may be added between the subsequent unit and the epitaxial layer to ensure optimal bonding efficiency of electrons and holes in the epitaxial layer, or to emit light. The ohmic contact resistance between the polar body elements is minimized to increase the efficiency of current flow into the luminescent layer.
另外,散熱問題也是發光二極體發展的另一個重要關鍵。由於目前發光二極體(LED)元件的光電轉換效率約只有10~30%,大部分的電能在光電轉換的過程中均被浪費轉換成廢熱而累積在發光二極體元件內,特別是在高功率及大尺寸的發光二極體元件所產生的廢熱會更多,因此若無法將累積在發光二極體元件內的廢熱排出,就會造成發光二極體元件的劣化,降低發光二極體元件的使用壽命,則此新一代的人工光源無法有更大的突破。In addition, the heat dissipation problem is another important key to the development of light-emitting diodes. Since the photoelectric conversion efficiency of the current LED (LED) component is only about 10 to 30%, most of the electrical energy is wasted into waste heat during the photoelectric conversion process and accumulated in the LED component, especially in High-power and large-sized LED components generate more waste heat. Therefore, if the waste heat accumulated in the LED components cannot be discharged, the LED components will be degraded and the LEDs will be lowered. The lifetime of the body components, this new generation of artificial light sources can not make a greater breakthrough.
目前紅光發光二極體常用的基板為砷化鎵(GaAs)基板,藍光發光二極體常用的基板為藍寶石(sapphire)基板,而不論是砷化鎵或藍寶石基板它們共同的缺點就是均具有較差的熱傳導性(砷化鎵的熱傳導性50w/m∘K,藍寶石的熱傳導性40w/m∘K),因此為解決散熱性的問題,金屬基板便成為解決發光二極體散熱的一個重要發展方向,例如已發展的鋁碳化矽複合材料基板(熱傳導性為180w/m∘K)、矽基板(熱傳導性為150w/m∘K),及銅基板(熱傳導性為400w/m∘K),均可藉由其高散熱性而提昇元件的發光效率。At present, the substrate commonly used for the red light emitting diode is a gallium arsenide (GaAs) substrate, and the substrate commonly used for the blue light emitting diode is a sapphire substrate, and the common disadvantage of both the gallium arsenide or the sapphire substrate is that Poor thermal conductivity (thermal conductivity of gallium arsenide 50w/m∘K, thermal conductivity of sapphire 40w/m∘K), so to solve the problem of heat dissipation, metal substrate has become an important development to solve the heat dissipation of light-emitting diodes. Directions, for example, a developed aluminum tantalum carbide composite substrate (thermal conductivity of 180 w/m ∘ K), a ruthenium substrate (thermal conductivity of 150 w/m ∘ K), and a copper substrate (thermal conductivity of 400 w/m ∘ K), The luminous efficiency of the element can be improved by its high heat dissipation.
參閱圖1,為一般發光二極體元件,包含一基板11、一包括多數磊晶層121及配合設置於該多數磊晶層121表 面的頂電極122的二極體單元12,及一連接該基材11與該二極體單元12的接著單元13。該等磊晶層121可在接受電能時以光電效應發光。Referring to FIG. 1 , a general LED component includes a substrate 11 , a plurality of epitaxial layers 121 , and a plurality of epitaxial layers 121 . The diode unit 12 of the top electrode 122 of the surface, and a subsequent unit 13 connecting the substrate 11 and the diode unit 12. The epitaxial layers 121 can emit light with a photoelectric effect when receiving electrical energy.
對發光二極體元件的散熱性而言,除了基板11的散熱性需受到重視外,用來連接該基板11與該二極體單元12的接著單元13所使用的材料也是另一個影響發光二極體元件穩定性的重要原因。In addition to the heat dissipation of the substrate 11 , the material used to connect the substrate 11 and the subsequent unit 13 of the diode unit 12 is another effect on the heat dissipation of the light-emitting diode element. An important reason for the stability of polar components.
目前使用於焊接基板11與二極體單元12的著接單元13的構成材料中,最常使用的材料為以錫(Sn)為主的軟焊(soft solders)材料,及以金-錫(AuSn)或金-鍺(AuGe)合金為主的硬焊(hard solders)材料;錫的優點是便宜但缺點是強度低且熱穩定性差,金-錫(AuSn)或金-鍺(AuGe)的優點是強度高、熱穩定性佳,但是缺點是價格高且熱傳導性能較差。Among the constituent materials currently used for the soldering substrate 11 and the landing unit 13 of the diode unit 12, the most commonly used materials are tin (Sn)-based soft solder materials, and gold-tin ( AuSn) or gold-ruthenium (AuGe) alloy-based hard solders; tin has the advantage of being inexpensive but has the disadvantage of low strength and poor thermal stability, gold-tin (AuSn) or gold-ruthenium (AuGe) The advantages are high strength and good thermal stability, but the disadvantages are high price and poor thermal conductivity.
參閱表一,表一是一般使用於著接單元13的合金材料,由表一可知,以金為主的合金,例如金/20%錫(Au/20%Sn)、金矽(Au/Si)、或金鍺(Au/Ge),都具有良好的機械性質及熱穩定性,但是這些合金材料因為都含有金,因此價格都非常昂貴,且這些合金材料的操作溫度都需要在較高的溫度(280~363℃)條件下進行,都會容易造成二極體元件的損害而破壞發光二極體元件的發光效率。Referring to Table 1, Table 1 is an alloy material generally used for the landing unit 13. As shown in Table 1, gold-based alloys such as gold/20% tin (Au/20% Sn) and gold crucible (Au/Si) ), or Au/Ge, have good mechanical properties and thermal stability, but these alloy materials are very expensive because they all contain gold, and the operating temperatures of these alloy materials need to be higher. When the temperature is (280 to 363 ° C), it is easy to cause damage to the diode element and destroy the luminous efficiency of the light-emitting diode element.
由上述說明可知,對發光二極體元件而言,除了基板的散熱性能外,相關的配合材料也是另一個影響發光二極體元件穩定性及後續發光二極體元件的壽命及工作的表現,因此尋求出一個具有低成本、高熱傳導性能、高強度、高溫穩定性,以及可在較低溫的操作條件下進行基板與二極體單元連接的接著單元構成材料,也一直是在此技術領域者所要積極突破解決的重要課題之一。It can be seen from the above description that, in addition to the heat dissipation performance of the substrate, the related bonding material is another performance that affects the stability of the LED component and the lifetime and operation of the subsequent LED component. Therefore, an illuminating element constituting material having low cost, high heat conduction performance, high strength, high temperature stability, and connection of a substrate and a diode unit under a relatively low temperature operating condition has been sought, and has been in the technical field. One of the important topics to be actively resolved.
因此,本發明之一目的,即在提供一種不包含金和銀之焊接材料的高發光效率固態發光元件。Accordingly, it is an object of the present invention to provide a high luminous efficiency solid state light-emitting element that does not contain a solder material of gold and silver.
本發明之另一目的,即在一種不包含金和銀之焊接材料的高發光效率固態發光元件的製造方法。Another object of the present invention is a method of manufacturing a high luminous efficiency solid state light-emitting element that does not include a solder material of gold and silver.
於是本發明一種高發光效率固態發光元件包含一基板、一二極體單元,及一接著單元。Thus, a high luminous efficiency solid state light emitting device of the present invention comprises a substrate, a diode unit, and a subsequent unit.
該二極體單元包括多數於該基板表面向上延伸且可在外界供給電能時發光的磊晶層。The diode unit includes an epitaxial layer that extends mostly upwardly on the surface of the substrate and that emits light when externally supplied with electrical energy.
該接著單元,連接該基板及該二極體單元,且該接著單元的構成材料不包含金和銀其中任一項。The bonding unit connects the substrate and the diode unit, and the constituent material of the bonding unit does not include any one of gold and silver.
另外,本發明高發光效率固態發光元件的製造方法包含下列四個步驟。Further, the method for producing a high luminous efficiency solid-state light-emitting element of the present invention comprises the following four steps.
首先在一成長基板上形成一具有多數個半導體磊晶層的二極體單元,該每一磊晶層具有一遠離該成長基板的上表面。First, a diode unit having a plurality of semiconductor epitaxial layers is formed on a growth substrate, and each of the epitaxial layers has an upper surface away from the growth substrate.
接著在一基板表面形成一金屬層,並以該金屬層朝向該等磊晶層的上表面將該基板設置於該二極體單元上。A metal layer is then formed on the surface of the substrate, and the substrate is disposed on the diode unit toward the upper surface of the epitaxial layers.
再將該具有金屬層的基板與該二極體單元加熱到一預定溫度,讓該金屬層轉變成一接著單元後再將該基板與該二極體單元結合。The substrate having the metal layer and the diode unit are heated to a predetermined temperature, and the metal layer is converted into a subsequent unit, and then the substrate is bonded to the diode unit.
然後將該成長基板移除,讓該等磊晶層表面裸露出。The grown substrate is then removed to expose the surface of the epitaxial layers.
最後於該多數裸露出之磊晶層表面形成一可配合提供電能的電極單元,即可得到本發明高發光效率固態發光元件。Finally, an electrode unit capable of supplying electric energy is formed on the surface of the majority of the exposed epitaxial layer to obtain the high luminous efficiency solid-state light-emitting element of the present invention.
本發明之功效在於:藉由一構成材料不包含金和銀的接著單元將該二極體單元與該等磊晶層連接,由於該接著單元具有低成本、高熱傳導性能、高強度,及高溫穩定性,因此可降低成本並提升二極體元件於後續製程時的穩定性及可靠度,進而提高二極體元件的良率及使用壽命。The effect of the invention is that the diode unit is connected to the epitaxial layer by a bonding unit which does not comprise gold and silver, because the bonding unit has low cost, high thermal conductivity, high strength, and high temperature. Stability, therefore, can reduce the cost and improve the stability and reliability of the diode components in the subsequent process, thereby improving the yield and service life of the diode components.
有關本發明之前述及其他技術內容、特點與功效,在以下配合參考圖式之一個較佳實施例的詳細說明中,將可清楚的呈現。The above and other technical contents, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments.
參閱圖2、圖3,本發明高發光效率固態發光元件的 一第一較佳實施例,是由如圖3所示的高發光效率固態發光元件的製造方法所得。Referring to Figures 2 and 3, the high luminous efficiency solid state light-emitting element of the present invention A first preferred embodiment is obtained by a method of fabricating a high luminous efficiency solid state light emitting device as shown in FIG.
該高發光效率固態發光元件包含一基板21、一二極體單元22,及一接著單元23。The high luminous efficiency solid state light emitting device comprises a substrate 21, a diode unit 22, and a subsequent unit 23.
該基板21是選自鋁碳化矽(AlSiC)金屬複合材料、鎢銅合金(CuW)、鉬銅(CuMo)合金其中之一。The substrate 21 is one selected from the group consisting of an aluminum lanthanum carbide (AlSiC) metal composite material, a tungsten copper alloy (CuW), and a molybdenum copper (CuMo) alloy.
該二極體單元22,包括多數分別由半導體材料構成的磊晶層221,及配合設置於該多數磊晶層221頂面的電極單元222,由於此部份構造已為業界所周知,且該二極體單元22的組成及製造方法非為本發明的重點,因此不多加贅述。The diode unit 22 includes a plurality of epitaxial layers 221 each made of a semiconductor material, and an electrode unit 222 disposed on a top surface of the plurality of epitaxial layers 221. Since this portion of the structure is well known in the industry, The composition and manufacturing method of the diode unit 22 are not the focus of the present invention, and therefore will not be further described.
該接著單元23,連接該基板21及該二極體單元22,且該接著單元23的構成材料不包含金和銀其中任一項,於本實施例中該接著單元23為以鎵,以及選自於鋁-鎵固融物(Al-Ga solid solution)、銅-鎵固融物(Cu-Ga solid solution),或其中之一組合為材料所構成。The bonding unit 23 is connected to the substrate 21 and the diode unit 22, and the constituent material of the bonding unit 23 does not include any one of gold and silver. In the embodiment, the bonding unit 23 is gallium, and It is composed of an Al-Ga solid solution, a Cu-Ga solid solution, or a combination thereof.
本發明該接著單元23的構成材料由於不含習知焊接二極體單元與基板之含金的焊料,因此可有效降低材料的成本,且由於該接著單元23具有高熱傳導性能、高強度,及高溫穩定性,因此可提升二極體元件於後續製程時的穩定性及可靠度,進而提高二極體元件的良率及使用壽命。Since the constituent material of the bonding unit 23 of the present invention does not contain the gold-containing solder of the conventional soldering diode unit and the substrate, the cost of the material can be effectively reduced, and the bonding unit 23 has high thermal conductivity and high strength, and The high temperature stability can improve the stability and reliability of the diode components in the subsequent process, thereby improving the yield and service life of the diode components.
上述的高發光效率固態發光元件,在配合以下本發明高發光效率固態發光元件製造方法的說明後,當可更加清楚的明白。The above-described high luminous efficiency solid-state light-emitting element can be more clearly understood after the following description of the manufacturing method of the high luminous efficiency solid-state light-emitting element of the present invention.
首先進行步驟101,準備一以藍寶石為材料構成的成長基板,於該成長基板上形成一個二極體單元,該二極體單元具有複數以氮化鎵半導體為材料經磊晶方式形成的磊晶層,且該每一磊晶層具有一上表面。由於此部份構造已為業界所周知,且該二極體單元的組成及製造方法非為本發明的重點,因此不多加贅述。First, in step 101, a growth substrate made of sapphire is prepared, and a diode unit is formed on the growth substrate, and the diode unit has a plurality of epitaxial crystals formed by using a gallium nitride semiconductor as a material. a layer, and each of the epitaxial layers has an upper surface. Since this part of the structure is well known in the industry, and the composition and manufacturing method of the diode unit are not the focus of the present invention, they will not be described again.
接著進行步驟103,於一基板表面形成一金屬層,該金屬層具有由該基板表面依序向上形成的一由鋁為材料構成的第一金屬膜、一由銅為材料構成的第二金屬膜,及一由鎵為材料構成的第三金屬膜,接著以該金屬層蓋設於該二極體單元表面,得到一中間組合物。Next, in step 103, a metal layer is formed on the surface of a substrate, the metal layer has a first metal film made of aluminum as a material and a second metal film made of copper as a material. And a third metal film made of gallium as a material, and then the metal layer is covered on the surface of the diode unit to obtain an intermediate composition.
再進行步驟105,將該中間組合物加熱至溫度不小於254℃的條件下,讓該金屬層轉變成一焊接該基板與該二極體單元的接著單元後,再將該基板與該二極體單元結合。Step 105 is further performed, the intermediate composition is heated to a temperature of not less than 254 ° C, and the metal layer is transformed into a bonding unit for soldering the substrate and the diode unit, and then the substrate and the diode are further Unit combination.
值得一提的是,該由鎵、銅,及鋁金屬所構成的金屬層,當溫度升到254℃時低溫的鎵(鎵的融點約為30℃)會與銅形成一高溫的介金屬合金(intermetallic phase),CuGax ;以及與鋁形成一鋁-鎵固融物(Al-Ga solid solution)而轉變成為該接著單元。It is worth mentioning that the metal layer composed of gallium, copper, and aluminum metal, when the temperature rises to 254 ° C, the low temperature gallium (the melting point of gallium is about 30 ° C) will form a high temperature dielectric with copper. An intermetallic phase, CuGa x ; and an aluminum-alloy solution formed with aluminum to be converted into the subsequent unit.
參閱圖4、圖5,圖4、圖5分別為銅-鎵及鋁-鎵的二元相圖(binary phase diagram),由圖4中可知在不小於254℃的溫度條件時,銅-鎵合金除了鎵的含量不大於銅-鎵合金重量的66%時為固相以外,其它比例的銅-鎵合金均為液 相或固液相共存;另外由圖5也可得到在溫度不小於254℃時鋁-鎵合金除了在鎵的含量不大於鋁-鎵合金重量的20%時為固相以外,其它比例的鋁-鎵合金均為液相或固液相共存。Referring to FIG. 4 and FIG. 5, FIG. 4 and FIG. 5 are respectively binary phase diagrams of copper-gallium and aluminum-gallium, and it can be seen from FIG. 4 that copper-gallium is not less than 254 ° C. The alloy is a solid phase except that the content of gallium is not more than 66% by weight of the copper-gallium alloy, and other ratios of copper-gallium alloy are liquid. Phase or solid-liquid phase coexist; in addition, as shown in Fig. 5, the aluminum-gallium alloy at a temperature of not less than 254 ° C is a solid phase other than the solid content of gallium content not greater than 20% by weight of the aluminum-gallium alloy. - Gallium alloys are all in the liquid phase or in the solid phase.
因此,為了得到一可用以連接該基板及該二極體單元的固相接著單元,較佳地,該銅-鎵形成的介金屬合金(intermetallic phase),CuGax ,鎵的含量為不大於銅-鎵合金重量的66%(即x不大於2),且鋁-鎵合金中鎵的含量不大於鋁-鎵合金重量的20%。另外,該金屬層也可只由鋁及鎵兩金屬層組成,得到的接著單元則為鋁-鎵固融物(Al-Ga solid solution)所構成,且鋁-鎵合金中鎵的含量不大於鋁-鎵合金重量的20%。該由鎵、鋁-鎵及/或銅-鎵為材料所構成的接著單元不僅比習知使用以金為主的焊料具有較低的操作溫度,並由於不含金因此成本較低,且該由鎵、鋁-鎵固融物及/或銅-鎵介金屬合金所構成的接著單元具有高熱傳導性能、高強度,及高溫穩定性,因此可提升二極體元件於後續製程時的穩定性及可靠度,進而提高二極體元件的良率及使用壽命。Therefore, in order to obtain a solid phase connecting unit that can be used to connect the substrate and the diode unit, preferably, the copper-gallium forming intermetallic phase, CuGa x , gallium content is not more than copper. - 66% by weight of the gallium alloy (i.e., x is not greater than 2), and the content of gallium in the aluminum-gallium alloy is not more than 20% by weight of the aluminum-gallium alloy. In addition, the metal layer may be composed only of two metal layers of aluminum and gallium, and the obtained subsequent unit is composed of an Al-Ga solid solution, and the content of gallium in the aluminum-gallium alloy is not more than 20% by weight of the aluminum-gallium alloy. The bonding unit composed of gallium, aluminum-gallium and/or copper-gallium is not only lower in operating temperature than conventionally used gold-based solder, but also low in cost due to the absence of gold, and The bonding unit composed of gallium, aluminum-gallium solid solution and/or copper-gallium intermetallic alloy has high thermal conductivity, high strength, and high temperature stability, thereby improving the stability of the diode component in subsequent processes. And reliability, thereby improving the yield and service life of the diode components.
參閱圖6,又,值得一提的是,該步驟105也可使用一接著裝置3,將該金屬層轉變成一焊接該基板與該二極體單元的接著單元,將該基板與該二極體單元結合。Referring to FIG. 6, further, it is worth mentioning that the step 105 can also use a bonding device 3 to convert the metal layer into a bonding unit for soldering the substrate and the diode unit, and the substrate and the diode. Unit combination.
該接著裝置3包括一壓力腔31、一抽氣腔32,及一由該壓力腔31及該抽氣腔32相互配合界定出之密閉的容置空間33。該壓力腔31具有一入氣孔311及一出氣孔312 可供氣體進出,該抽氣腔32具有一加熱單元321及一管狀的抽氣件322。實施步驟105時,可將該經步驟103得到的中間組合物置入該抽氣腔32中,藉由該加熱單元321加熱將該金屬層轉變成一焊接該基板與該二極體單元的接著單元後再將該基板與該二極體單元結合,另外,也可將該中間組合物置於該容置空間33中,再將一箔片,例如鋁箔、銅箔、聚亞醯胺,或石墨置於該基板上,然後由該壓力腔31調整壓力到約15~200psi,同時將加熱單元321的溫度調整到預定溫度並經由抽氣件322的抽氣配合後,經由該箔片對該基板施加一非等向性壓力,使該基板與該等磊晶層可達到一更均勻的密著性。The squeezing device 3 includes a pressure chamber 31, an air venting chamber 32, and a sealed accommodating space 33 defined by the pressure chamber 31 and the air venting chamber 32. The pressure chamber 31 has an air inlet 311 and an air outlet 312. The gas is taken in and out, and the suction chamber 32 has a heating unit 321 and a tubular suction member 322. When the step 105 is performed, the intermediate composition obtained in the step 103 can be placed in the suction chamber 32, and the heating layer 321 is heated to convert the metal layer into a subsequent unit that solders the substrate and the diode unit. The substrate is then combined with the diode unit. Alternatively, the intermediate composition may be placed in the accommodating space 33, and a foil such as aluminum foil, copper foil, polyamine, or graphite may be placed. The substrate is then adjusted to a pressure of about 15 to 200 psi by the pressure chamber 31, and while the temperature of the heating unit 321 is adjusted to a predetermined temperature and the air is drawn through the suction member 322, the substrate is applied through the foil. The non-isotropic pressure allows the substrate to achieve a more uniform adhesion to the epitaxial layers.
再,更值得一提的是,於磊晶的過程中由於該成長基板與該磊晶層間膨脹係數的差異所導致的應力通常會使磊晶層的表面通常有不平整的情形。Further, it is worth mentioning that the stress caused by the difference in the expansion coefficient between the growth substrate and the epitaxial layer in the process of epitaxy generally causes the surface of the epitaxial layer to have an unevenness.
參閱圖7,為氮化鎵系半導體磊晶層形成於藍寶石基板後產生的變形,由圖7可知該形成有氮化鎵半導體磊晶層的藍寶石基板從中央到邊緣有約30μm的偏移率,因此會造成該等磊晶層表面的不平整,一般硬質平板型的基板不易與該有微變形的二極體單元密合,而不好的密合則容易導致後續進行藍寶石基板剝離製程的良率降低,且會影響二極體元件的可靠度。因此為了提昇基板與該二極體單元的密合程度,該基板為薄型且具有可撓性,可隨著該等磊晶層的高低起伏而貼合,因此,較佳地,該基板的厚度為不大於500μm,更佳地,該基板的厚度為不大於200μm, 以得到一可以與該二極體單元密著性較佳的基板。Referring to FIG. 7, the deformation of the gallium nitride-based semiconductor epitaxial layer formed on the sapphire substrate is as shown in FIG. 7. The sapphire substrate on which the epitaxial layer of the gallium nitride semiconductor is formed has an offset ratio of about 30 μm from the center to the edge. Therefore, the surface of the epitaxial layer is not flat. Generally, the rigid flat substrate is not easily adhered to the micro-deformed diode unit, and the poor adhesion is likely to cause subsequent sapphire substrate peeling process. The yield is reduced and the reliability of the diode components is affected. Therefore, in order to improve the adhesion between the substrate and the diode unit, the substrate is thin and flexible, and can be attached with the undulation of the epitaxial layers. Therefore, preferably, the thickness of the substrate For no more than 500 μm, more preferably, the thickness of the substrate is not more than 200 μm. A substrate having better adhesion to the diode unit is obtained.
再進行步驟107,以電射剝離(laser lift off)或濕式蝕刻方式將該成長基板與該磊晶層剝離,將該磊晶層表面露出。Further, in step 107, the grown substrate is peeled off from the epitaxial layer by laser lift off or wet etching, and the surface of the epitaxial layer is exposed.
最後進行步驟109,於該多數磊晶層表面形成一可配合提供電能的電極單元,即可得到如圖2所示的該高發光效率固態發光元件的較佳實施例。Finally, in step 109, an electrode unit capable of supplying electric energy is formed on the surface of the plurality of epitaxial layers, thereby obtaining a preferred embodiment of the high luminous efficiency solid-state light-emitting element as shown in FIG. 2.
以步驟107利用電射剝離該成長基板的製程而言,由於所選擇的雷射波長會穿過該藍寶石成長基板而達到該半導體材料構成的磊晶層,而該雷射的能量被該磊晶層吸收後會導致高溫而容易破壞該磊晶層,因此值得一提的是,進行步驟101時使用的藍寶石成長基板也可形成具有如步驟103所提的金屬層於該成長基板表面,由於該以鎵為材料構成的金屬層的熔點只有約30℃,因此僅需較小的能量即可將該成長基板以鎵金屬層為剝離膜與該二極體單元脫離,而可避免目前因雷射剝離製程產生的高溫而對磊晶層產生的破壞。In the process of stripping the grown substrate by electro-radiation in step 107, the selected laser wavelength passes through the sapphire growth substrate to reach an epitaxial layer composed of the semiconductor material, and the energy of the laser is epitaxial. After the layer is absorbed, high temperature is generated and the epitaxial layer is easily destroyed. Therefore, it is worth mentioning that the sapphire growth substrate used in step 101 can also form a metal layer as described in step 103 on the surface of the growth substrate. The melting point of the metal layer made of gallium is only about 30 ° C, so that only a small amount of energy is required to separate the grown substrate from the gallium metal layer as a release film, thereby avoiding the current laser The high temperature generated by the stripping process causes damage to the epitaxial layer.
另外,磊晶層於磊晶形成的過程中,由於藍寶石的熱膨脹係數(約等於6ppm/∘K)略大於例如以氮化鎵為材料構成的磊晶層,所以於該等磊晶層內會產生抗壓內應力(compressive stress),為了避免進行步驟107將該成長基板與該磊晶層剝離時因為內應力急速釋放造成磊晶層的破壞,因此該實施步驟103時選用的基板為選自熱膨脹係數等於或略大於該藍寶石成長基板的熱膨脹係數,以保持磊 晶層於磊晶形成過程中的內應力,不會因後續製程而導致內應力急速釋放造成磊晶層的破壞。In addition, in the process of epitaxial layer formation, since the thermal expansion coefficient of sapphire (about 6 ppm/∘K) is slightly larger than the epitaxial layer made of, for example, gallium nitride, it will be in the epitaxial layer. Compressive stress is generated. In order to avoid the destruction of the epitaxial layer caused by the rapid release of the internal stress when the growth substrate and the epitaxial layer are peeled off in step 107, the substrate selected in the step 103 is selected from the group consisting of The coefficient of thermal expansion is equal to or slightly larger than the coefficient of thermal expansion of the sapphire growth substrate to maintain the thermal expansion The internal stress of the crystal layer during the epitaxial formation process does not cause the destruction of the epitaxial layer caused by the rapid release of the internal stress due to the subsequent process.
參閱表二,表二是不同材料的熱膨脹係數及熱傳導性能。因此,於本實施例中該基板是選自鋁碳化矽(AlSiC)金屬複合材料、鎢銅合金(CuW)、鉬銅(CuMo)合金等熱膨脹係數約等於或略大於藍寶石的熱膨脹係數的材料構成。Refer to Table 2, Table 2 for the thermal expansion coefficient and thermal conductivity of different materials. Therefore, in the embodiment, the substrate is made of a material selected from the group consisting of aluminum lanthanum carbide (AlSiC) metal composite material, tungsten copper alloy (CuW), and molybdenum copper (CuMo) alloy, and the thermal expansion coefficient is approximately equal to or slightly larger than the thermal expansion coefficient of sapphire. .
參閱圖8,更值得一提的是,該步驟103的基板21可為具有一基層211,及一由該基層211表面依序向上形成的一反射層212、一緩衝層213,及一電流分散層214,而製得如圖7所示的該高發光效率固態發光元件。Referring to FIG. 8, it is more worth mentioning that the substrate 21 of the step 103 may have a base layer 211, and a reflective layer 212, a buffer layer 213, and a current dispersion formed by sequentially forming the surface of the base layer 211. Layer 214, which produces the high luminous efficiency solid state light emitting element as shown in FIG.
該反射層212為由高反射性的金屬材料所構成,可選自金、鋁、銀、銅、鉑及鈀其中任一或此等材料之組合。The reflective layer 212 is made of a highly reflective metal material and may be selected from any one of gold, aluminum, silver, copper, platinum, and palladium or a combination thereof.
該緩衝層213可由一或多種折射率不大於該電流分散層214的介電常數材料堆疊而成,具有一表面215及多數個由該表面215向下貫通的穿孔216。The buffer layer 213 may be formed by stacking one or more dielectric constant materials having a refractive index no greater than the current dispersion layer 214, having a surface 215 and a plurality of through holes 216 extending downwardly from the surface 215.
該電流分散層214可選自氧化銦錫、鎳金合金,及二氧化釕其中任一或此等材料之組合,具有高導電性、透明 性,及高折射率,可供電流水平擴散流通且可讓該磊晶層221產生的光透射出,且該反射層212具有一沉積於該緩衝層213表面的表面部217,及多數沉積於該等穿孔216的導通部218。The current dispersion layer 214 may be selected from the group consisting of indium tin oxide, nickel gold alloy, and cerium oxide, or a combination of these materials, having high conductivity and transparency. And a high refractive index, the current level is diffused and the light generated by the epitaxial layer 221 is transmitted, and the reflective layer 212 has a surface portion 217 deposited on the surface of the buffer layer 213, and most of the deposited The conductive portion 218 of the through holes 216.
該反射層212可經由該等導通部218與該電流分散層214電導通。The reflective layer 212 can be electrically connected to the current dispersion layer 214 via the conductive portions 218 .
當光線由該磊晶層221發出接觸到該表面部217及該等導通部218時,可將光線反射後實質轉向外界射出,而經由該等穿孔216的形狀、孔徑,及分布密度可調整得到最佳的光取出效率,因此,較佳地,該電流分散層214的膜厚為10~500nm、該每一穿孔216的直徑為2~20μm且任兩穿孔216的距離為5~100μm。When light is emitted from the epitaxial layer 221 to the surface portion 217 and the conductive portions 218, the light can be reflected and then substantially turned to the outside, and the shape, the aperture, and the distribution density of the through holes 216 can be adjusted. Preferably, the current dispersion layer 214 has a film thickness of 10 to 500 nm, the diameter of each of the through holes 216 is 2 to 20 μm, and the distance between any two of the holes 216 is 5 to 100 μm.
參閱圖9、圖10,圖9為具有不同穿孔216排列的高發光效率固態發光元件示意圖,圖10則為圖9的局部放大,表示光線經由該表面部217及該等導通部218反射後的光線分布示意圖。9 and FIG. 10, FIG. 9 is a schematic diagram of a high luminous efficiency solid-state light-emitting element having different perforations 216, and FIG. 10 is a partial enlarged view of FIG. 9 and showing light reflected by the surface portion 217 and the conductive portions 218. Schematic diagram of light distribution.
由上述說明可知,藉由一構成材料不包含金和銀的接著單元將該二極體單元與該磊晶層連接,由於該接著單元具有低成本、高熱傳導性能、高強度,及高溫穩定性,因此可降低成本並提升二極體元件於後續製程時的穩定性及可靠度,進而提高二極體元件的良率及使用壽命,故確實能達成本發明之目的。It can be seen from the above description that the diode unit is connected to the epitaxial layer by a bonding unit which does not contain gold and silver, because the bonding unit has low cost, high thermal conductivity, high strength, and high temperature stability. Therefore, the cost and the stability and reliability of the diode component in the subsequent process can be improved, thereby improving the yield and the service life of the diode component, so that the object of the present invention can be achieved.
惟以上所述者,僅為本發明之較佳實施例而已,當不能以此限定本發明實施之範圍,即大凡依本發明申請專利 範圍及發明說明內容所作之簡單的等效變化與修飾,皆仍屬本發明專利涵蓋之範圍內。However, the above is only the preferred embodiment of the present invention, and the scope of the present invention cannot be limited thereto, that is, the patent application according to the present invention The scope of the invention and the equivalent equivalents and modifications of the invention are still within the scope of the invention.
101‧‧‧步驟101‧‧‧Steps
103‧‧‧步驟103‧‧‧Steps
105‧‧‧步驟105‧‧‧Steps
107‧‧‧步驟107‧‧‧Steps
109‧‧‧步驟109‧‧‧Steps
21‧‧‧基板21‧‧‧Substrate
211‧‧‧基層211‧‧‧ grassroots
212‧‧‧反射層212‧‧‧reflective layer
213‧‧‧緩衝層213‧‧‧buffer layer
214‧‧‧電流分散層214‧‧‧current dispersion layer
215‧‧‧表面215‧‧‧ surface
216‧‧‧穿孔216‧‧‧Perforation
217‧‧‧表面部217‧‧‧ Surface
218‧‧‧導通部218‧‧‧Training Department
22‧‧‧二極體單元22‧‧‧diode unit
221‧‧‧磊晶層221‧‧‧Elevation layer
222‧‧‧電極單元222‧‧‧electrode unit
23‧‧‧接著單元23‧‧‧Next unit
3‧‧‧接著裝置3‧‧‧Next device
31‧‧‧壓力腔31‧‧‧ Pressure chamber
311‧‧‧入氣孔311‧‧‧Intake holes
312‧‧‧出氣孔312‧‧‧ Vents
32‧‧‧抽氣腔32‧‧‧Exhaust chamber
321‧‧‧加熱單元321‧‧‧heating unit
322‧‧‧抽氣件322‧‧‧Exhaust parts
33‧‧‧容置空間33‧‧‧ accommodating space
圖1是一示意圖,說明習知發光二極體元件的結構圖2是一示意圖,說明本發明高發光效率固態發光元件的第一較佳實施例;圖3是一流程圖,說明本發明高發光效率固態發光元件的第一較佳實施例的製造方法圖4是一張二元相圖,說明銅-鎵雙成分合金的相圖;圖5是一張二元相圖,說明鋁-鎵雙成分合金的相圖;圖6是一示意圖,說明實施步驟105時的接著裝置;圖7是一曲率圖,說明磊晶後的藍寶石基板的偏斜變形曲線;圖8是一示意圖,說明具有反射層、緩衝層,及電流分散層的高發光效率固態發光元件;圖9是一俯視示意圖,說明本發明高發光效率固態發光元件,具有不同穿孔之緩衝層的穿孔分布示意圖;及圖10是一示意圖,說明本發明高發光效率固態發光元件,光線經反射層反射後的光線分布示意圖。1 is a schematic view showing the structure of a conventional light-emitting diode element. FIG. 2 is a schematic view showing a first preferred embodiment of the high luminous efficiency solid-state light-emitting element of the present invention; FIG. 3 is a flow chart illustrating the present invention. FIG. 4 is a binary phase diagram illustrating a phase diagram of a copper-gallium two-component alloy; and FIG. 5 is a binary phase diagram illustrating an aluminum-gallium two-component alloy FIG. 6 is a schematic view showing the following device when the step 105 is performed; FIG. 7 is a curvature diagram illustrating the skew deformation curve of the sapphire substrate after epitaxial; FIG. 8 is a schematic view showing the reflective layer and the buffer Layer, and a high luminous efficiency solid-state light-emitting element of the current dispersion layer; FIG. 9 is a top plan view showing a schematic diagram of a perforation distribution of a buffer layer having different perforations of the high luminous efficiency solid-state light-emitting element of the present invention; and FIG. 10 is a schematic view illustrating The high luminous efficiency solid-state light-emitting element of the invention has a light distribution diagram of light reflected by the reflective layer.
21‧‧‧基板21‧‧‧Substrate
22‧‧‧二極體單元22‧‧‧diode unit
221‧‧‧磊晶層221‧‧‧Elevation layer
222‧‧‧電極單元222‧‧‧electrode unit
23‧‧‧接著單元23‧‧‧Next unit
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TWI688136B (en) * | 2014-07-17 | 2020-03-11 | 日商新力股份有限公司 | Photoelectric conversion element, imaging device, light sensor and method of manufacturing photoelectric conversion element |
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TWI688136B (en) * | 2014-07-17 | 2020-03-11 | 日商新力股份有限公司 | Photoelectric conversion element, imaging device, light sensor and method of manufacturing photoelectric conversion element |
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