TWI553912B - 發光裝置晶片級封裝 - Google Patents
發光裝置晶片級封裝 Download PDFInfo
- Publication number
- TWI553912B TWI553912B TW101102646A TW101102646A TWI553912B TW I553912 B TWI553912 B TW I553912B TW 101102646 A TW101102646 A TW 101102646A TW 101102646 A TW101102646 A TW 101102646A TW I553912 B TWI553912 B TW I553912B
- Authority
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- Taiwan
- Prior art keywords
- conductive material
- light emitting
- insulating layer
- insulating
- openings
- Prior art date
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- 239000000758 substrate Substances 0.000 claims description 27
- 239000002184 metal Substances 0.000 claims description 22
- 229910052751 metal Inorganic materials 0.000 claims description 22
- 239000004020 conductor Substances 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 18
- 238000005286 illumination Methods 0.000 claims description 11
- 238000009413 insulation Methods 0.000 claims description 8
- 239000011810 insulating material Substances 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims 1
- 238000000576 coating method Methods 0.000 claims 1
- 239000004065 semiconductor Substances 0.000 description 9
- 125000006850 spacer group Chemical group 0.000 description 9
- 239000000463 material Substances 0.000 description 8
- 229910000679 solder Inorganic materials 0.000 description 7
- 230000017525 heat dissipation Effects 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 238000001459 lithography Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Classifications
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- H01L33/02—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies
- H01L33/08—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a plurality of light emitting regions, e.g. laterally discontinuous light emitting layer or photoluminescent region integrated within the semiconductor body
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Description
本發明係關於固態發光裝置領域,且特定言之,本發明係關於一種晶片級封裝中之發光裝置及一種製造此一裝置之方法。
發光裝置(LED)且尤其是以大於約四分之一瓦操作之發光裝置一般包含提供光之一半導體元件及提供機械支撐、電連接、熱消散、波長轉換等等之一或多個非半導體元件。
隨著固態LED之普及性及使用領域不斷擴大,來自大量銷售之潛在收益增加,製造商之間之銷售競爭亦增加。在此一環境中,每單位成本之均衡少量節省對收益性會有重大影響。因此,LED之製造商致力於降低材料成本及製造成本。
圖1繪示包括半導體元件110及至少兩個非半導體元件(一陶瓷基板120及一對電極122)之一習知中高功率LED。如圖可見,在此一實施例中,陶瓷基板120超過發光半導體結構110面積之兩倍;額外面積主要用以促進經由電極122而至半導體結構110之外部連接。因此,基板120占裝置之材料成本之一相當大部分。另外,將半導體結構110放置在基板120上需要一精確拾取及放置處理,此會增加裝置之製造成本。
Ibbetson等人於2008年2月12日發表之USP 7,329,905
「CHIP-SCALE METHODS FOR PACKAGING LIGHT EMITTING DEVICES AND CHIP-SCALE PACKAGED LIGHT EMITTING DEVICES」揭示一種使用晶圓接合來消除拾取及放置處理且減小支撐基板大小之技術。如圖2A中所繪示,一第一晶圓包含一基板212,多個LED結構216係形成於該基板上且接點218在該等結構頂部。一第二晶圓包含一載體基板220,其包含貫穿導通孔222且接點228、238分別在載體基板之頂部及底部。如圖2B所繪示,第一晶圓係經倒置且接合至第二晶圓,LED結構之接點218係耦合至載體基板頂部處之對應接點228。為減少對自LED結構頂部輸出之光之干擾,可視情況薄化或移除第一晶圓之生長基板212。隨後,所得晶圓接合結構被切割/單粒化(虛線)成個別發光裝置,且載體基板底部處之接點238用於外部連接至LED結構。接著,此等裝置可被放置在一印刷電路板上且耦合至該板上之對應電極(一般使用焊料回流技術)。
雖然USP 7,329,905之技術無需拾取及放置個別LED結構且減小LED結構上之基板面積(相較於圖1之習知結構),但材料及/或製造之進一步成本降低或簡化將為有利。
有利的是無需提供晶片級封裝發光裝置中之貫穿導通孔。亦為有利的是提供與用於基板之材料相關及與通過基板而耦合至該發光裝置相關之更多選擇。
在本發明之一實施例中,用以支撐LED結構之生長之基
板係用以支撐一上部結構在LED結構上之建立。較佳地,該上部結構係建立為一系列層,其包含形成自LED結構至該上部結構之頂部之一導電路徑之一導電元件。該結構隨後經倒置使得該上部結構變為LED結構之載體基板,且薄化或移除原基板。使用促進電傳導及絕緣以及熱傳導及消散之材料來建立該結構。
參考附圖,以舉例方式進一步詳細解釋本發明。
在全部圖式中,相同元件符號指示類似或對應特徵或功能。為說明之目的而包含該等圖式且其等非意欲限制本發明之範圍。
在以下描述中,為解釋而非限制之目的,闡述具體細節(諸如特定架構、介面、技術等等)以提供本發明之概念之一完全理解。然而,熟習此項技術者將明白可在背離此等具體細節之其他實施例中實踐本發明。同樣地,本描述之正文係關於如圖中所繪示之例示性實施例且非意欲限制超出明確包含在申請專利範圍內之限制之本發明。為簡單及清楚之目的,省略熟知裝置、電路及方法之詳細描述以免不必要細節使本發明之描述不清楚。
可參考圖3之例示性流程圖及圖4之對應發光裝置結構而最佳理解本發明之處理及裝置。雖然本發明尤其適合於在一晶圓或其他載體上建立多個發光裝置,但圖4及隨附描述將解決一單一例示性發光裝置之建立。熟習此項技術者將認識到載體上所建立裝置之數量與本發明之原理無關。
在310中,將發光元件416及相關聯電極接點418A、418B建立在一基板412上,通常為促進半導體裝置及互連層之建立之一生長基板。發光元件416係繪示為一層堆疊以對應於一陽極與陰極之間之一發光物質之典型夾層結構。任何數量之已知技術可用以建立圖4A及4B之結構,圖4A係一側視圖且圖4B係一俯視圖。
在此例示性實施例中,裝置係經組態以提供用於與發光元件416之電極之一者(例如陽極)耦合之一組四個接觸區418A及用於與另一電極(例如陰極)耦合之一較大周圍區418B。一間隙415使此等電極418A、418B隔離。四個接觸區418A及較大區418B之使用促進裝置內之一更均勻電流密度分佈;在一些實施例中,接觸區418A可耦合至提供不同光輸出波長(色彩)之個別發光裝置。為易於參考,本文中假定此等電極418A意欲耦合至電力之一共用源極。
在320中,可測試已建立之發光元件416,但可在完成以下詳述之上部結構之建立後替代地執行測試。在330(圖4C)中,將一絕緣材料420(諸如一介電質)施加至結構以使電極與隨後導電層隔離(選擇位置428A、428B處除外)。習知微影技術可用以提供絕緣材料420之此圖案化層。如下進一步所詳述,光輸出意欲沿遠離電極418A至418B及絕緣材料420之一方向自裝置射出;因此,電極418A至418B及絕緣層420具較佳反射性以減少光在裝置內之損失或吸收量。替代地,電極418A至418B或絕緣層420可為透明,其依賴提供此等反射之隨後層。亦如下進一步所詳述,絕
緣材料420較佳地導熱且不導電。
在340(圖4D)中,在結構上之選擇位置處建立相對較高之絕緣/隔離間隔物430。在一典型實施例中,發光元件416可約為5微米厚,而間隔物430之高度可約為一百微米或更多。微影技術可用以建立此等間隔物430,其使用在選擇位置處固化之一漿液,諸如一環氧樹脂。雖然間隔物430係繪示為具有一矩形橫截面,但熟習此項技術者將認識到此等間隔物430可具有基底大於頂部區之一梯形形狀。
在350(圖4E)中,用金屬438A、438B來填充間隔物430之間之空間。在此等空間內之一晶種層之習知施加之後,可使用金屬(諸如銅)之一上鍍層(overplating)。此上鍍層可在間隔物430上有意延伸,且接著經機械地或化學地或兩者平坦化以暴露間隔物430以使區域438A、438B隔離。金屬438A延伸至絕緣層420之(若干)間隙428A中,藉此接觸發光元件416之(若干)電極接點418A。同樣地,金屬438B延伸至(若干)間隙428B中以接觸(若干)電極接點418B。
在360(圖4F)中,將另一絕緣層442施加在金屬438A、438B上且選擇位置處之間隙448A、448B除外。如同絕緣材料420,絕緣材料442較佳地導熱且不導電。例如,絕緣層442可包含一樹脂或一無機材料,諸如SiO2或Si3N4。
在370(圖4F)中,將一最後金屬層施加在絕緣層442上。在此實例中,形成三個導電接點444、458A、458B。接點458A處之金屬延伸至間隙448A中以通過金屬438A而提供
至電極418A之接觸,接點458B處之金屬延伸至間隙448B中以通過金屬438B而提供至電極418B之接觸。此等接點458A、458B充當外部接點以將一電源耦合至發光元件416。熟習此項技術者將認識到,雖然以上已論述及此等圖中已繪示兩個接點458A、458B,但亦可提供額外接點。例如,發光元件416可包含用於提供不同照明位準、不同色彩及色彩組合等等之多個分段。
金屬墊444未耦合至下層金屬結構438A、438B且用來提供用於散熱之一外部接點。即,假定經由絕緣層420、442而絕緣之熱極少,金屬結構438A、438B將用來將由發光元件416產生之熱傳導至金屬墊444,且自金屬墊444傳導至下層基板,諸如一印刷電路板。
在380(圖4G至圖4H)中,結構係經倒置使得芯金屬結構438A、438B提供發光裝置之結構支撐以允許原生長基板412被移除或厚度減小,藉此減少光沿與芯金屬結構438A、438B相反之一方向自發光元件416之「頂部」射出時之光學損失。如圖4H之仰視圖中所繪示,接點444、458A、458B可橫跨裝置之寬度而延伸以促進至裝置之外部連接。
尤其應注意,使用本發明之原理所建立之一發光裝置無需晶圓接合,且外部接點458A、458B之定位及定向實質上無關於內部電極418A、418B之定位及定向,藉此提供實質設計靈活性(相較於貫穿導通孔(圖2A至圖2B中之222)之使用)。
可根據需要而進一步處理圖4G之結構。例如,可施加一層波長轉換材料(例如磷光體)以產生不同於由發光元件416產生之色彩之(若干)色彩,以便產生(例如)產生一白色發光裝置之一色彩組合。同樣地,可將一透鏡建立在結構頂上以提供特定光學品質及/或保護裝置之上層。
熟習此項技術者將認識到圖4A至圖4H中所繪示之特定結構僅為一例示性結構。圖5至圖8繪示可使用以上所論述技術來建立之若干替代結構。為易於參考,在此等圖中,用淡陰影覆蓋陽極元件,用適中陰影蓋覆陰極元件且用深陰影覆蓋熱元件。以無陰影繪示絕緣截面。
圖5繪示本身不具有一單獨熱元件之一例示性結構。在此實例中,一壁520圍繞裝置之周邊延伸且耦合至陰極結構528B。此壁520係經組態以通過裝置之外周邊而散熱。
一外部散熱器或散熱片結構(圖中未繪示)可貼附至外周邊以進一步促進散熱。熟習此項技術者將認識到壁520可替代地與結構528A、528B絕緣,藉此形成未電耦合至發光元件416之一單獨散熱元件。
圖6繪示一例示性結構,其提供經由裝置之邊緣而至陽極結構628A及陰極結構628B之外部連接。在此實例中,一熱元件644橫跨裝置之底部而延伸。
圖7繪示附接至一印刷電路板710之一邊緣連接裝置之另一實例。在此實例中,僅陰極結構728B延伸至邊緣,陽極結構728A延伸至裝置底部處之一接點758A。陰極728B可經由焊料接頭730而耦合至印刷電極板710上之導體712B,
且陽極接點758A可經由焊料球740而耦合至印刷電極板710上之導體712A。可使用將結構耦合至印刷電路板之各種方法,其包含使用焊料球或一連續焊料膜。
圖8繪示多陽極裝置之一仰視圖。如上所註釋,發光裝置可包含複數個發光元件。當提供單獨接點858A1至858A4時,可藉由選擇性啟動電極858A1至858A4之一或多個組合而變動強度或色彩。在此實例中,繪示一共用陰極接點858B,但熟習此項技術者將認識到可提供多個陰極接點以促進各種不同組態。在此實例中,將熱元件844放置在陽極接點與陰極接點之間。
雖然圖式及先前描述中已詳細繪示及描述本發明,但此繪示及描述應被視為說明性或例示性而非限制性;本發明不受限於所揭示之實施例。
熟習此項技術者在實踐本發明時,可自圖式、揭示內容及隨附請求項之一研究而理解及實現所揭示實施例之其他變動。在請求項中,用語「包括」不排除其他元件或步驟,且不定冠詞「一」不排除複數個。在互不相同之附屬請求項中列舉某些措施之純事實並不指示不能有利使用此等措施之一組合。請求項中之任何元件符號不應被解釋為限制範圍。
110‧‧‧半導體元件
120‧‧‧基板
122‧‧‧電極
212‧‧‧基板
216‧‧‧發光裝置結構
218‧‧‧接點
220‧‧‧載體基板
222‧‧‧貫穿導通孔
228‧‧‧接點
238‧‧‧接點
412‧‧‧基板
415‧‧‧間隙
416‧‧‧發光元件
418A‧‧‧接觸區/電極
418B‧‧‧較大周圍區/電極
420‧‧‧絕緣材料
428A‧‧‧選擇位置/間隙
428B‧‧‧選擇位置/間隙
430‧‧‧間隔物
438A‧‧‧金屬結構
438B‧‧‧金屬結構
442‧‧‧絕緣層/絕緣材料
444‧‧‧接點/金屬墊
448A‧‧‧間隙
448B‧‧‧間隙
458A‧‧‧接點
458B‧‧‧接點
520‧‧‧壁
528A‧‧‧陽極結構
528B‧‧‧陰極結構
628A‧‧‧陽極結構
628B‧‧‧陰極結構
644‧‧‧熱元件
710‧‧‧印刷電極板
712A‧‧‧導體
712B‧‧‧導體
728A‧‧‧陽極結構
728B‧‧‧陰極結構
730‧‧‧焊料接頭
740‧‧‧焊料球
758A‧‧‧接點
844‧‧‧熱元件
858A1‧‧‧陽極/接點
858A2‧‧‧陽極/接點
858A3‧‧‧陽極/接點
858A4‧‧‧陽極/接點
858B‧‧‧共用陰極接點
圖1繪示一例示性先前技術發光裝置。
圖2A至圖2B繪示另一例示性先前技術發光裝置。
圖3繪示利用適合於支撐一發光裝置且提供外部接點以
將該發光裝置耦合至一電源之一上部結構來建立該發光裝置之一例示性流程圖。
圖4A至圖4H繪示發光裝置在製造期間之例示圖。
圖5至圖8繪示形成一發光裝置之例示性替代結構。
416‧‧‧發光元件
458A‧‧‧接點
458B‧‧‧接點
520‧‧‧壁
528A‧‧‧陽極結構
528B‧‧‧陰極結構
Claims (15)
- 一種製造一發光裝置之方法,其包括:在一基板上形成一發光結構,該發光結構具有與該基板相對之一頂面且包含可在該頂面處接達(accessible)之至少第一及第二電極;在該等電極上形成一第一絕緣層,且該第一絕緣層中之至少第一及第二開口用於分別接觸該等至少第一及第二電極;在該第一絕緣層上形成絕緣壁,該等絕緣壁經組態以提供該等至少第一與第二開口之間之絕緣;用導電材料填充該等絕緣壁之間之空間之至少一部分,該導電材料延伸至該等至少第一及第二開口中以接觸該等至少第一及第二電極;其中該等絕緣壁及導電材料係經組態以提供該發光結構之結構支撐;及在該導電材料上形成一第二絕緣層,該第二絕緣層具有至少另二開口以用於接觸延伸至該等至少第一及第二開口中之該導電材料之至少一部分;在該第二絕緣層及該至少另二開口上塗覆一金屬層;及形成通過該第二絕緣層之該至少另二開口而耦合至該導電材料之該至少一部分之至少二導電接點。
- 如請求項1之方法,其包含移除該基板之部分或全部。
- 如請求項1之方法,其包含: 於在該第二絕緣層及該至少另二開口上塗覆一金屬層之步驟之後在該第二絕緣層上形成至少一熱接點,該熱接點係與該導電材料電絕緣。
- 如請求項1之方法,其中該導電材料之至少一部分延伸至該發光裝置之至少一外部邊緣。
- 如請求項1之方法,其中該等絕緣壁為至少100微米高。
- 如請求項1之方法,其中該發光結構包含複數個發光元件。
- 如請求項1之方法,其包含沿與該第一絕緣層相反之一方向於該發光結構上形成一波長轉換層。
- 如請求項1之方法,其包含於該發光結構上形成一透鏡元件。
- 一種發光裝置,其包括:一發光結構,其包含至少第一及第二電極;一第一絕緣層,其沿與一意欲光輸出方向相反之一方向定位在該等至少第一及第二電極上,且該第一絕緣層中之至少第一及第二開口用於分別接觸該等至少第一及第二電極;一或多個絕緣壁,其等在該第一絕緣層上,該等絕緣壁提供該等至少第一與第二開口之間之絕緣;及導電材料,其位於該一或多個絕緣壁之各者之任一側上,該導電材料延伸至該等至少第一及第二開口中以接觸該等至少第一及第二電極,其中該等絕緣壁及導電材料係經組態以提供該發光元 件之結構支撐,一第二絕緣層,其在該導電材料上,該第二絕緣層具有至少另二開口以用於接觸延伸至該等至少第一及第二開口中之該導電材料之至少一部分;一金屬層,其係在該第二絕緣層及該至少另二開口上;及至少二導電接點,其係通過該第二絕緣層之該至少另二開口而耦合至該導電材料之該至少一部分。
- 如請求項9之發光裝置,其包含:至少一熱接點,其在該第二絕緣層上,該熱接點係與該導電材料電絕緣。
- 如請求項9之發光裝置,其中該絕緣材料之至少一部分延伸至該發光裝置之至少一外部邊緣。
- 如請求項9之發光裝置,其中該等絕緣壁為至少100微米高。
- 如請求項9之發光裝置,其中該發光結構包含複數個發光元件。
- 如請求項9之發光裝置,其進一步包含一波長轉換層。
- 如請求項9之發光裝置,其進一步包含一透鏡元件。
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