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  • H01L2224/05—Structure, shape, material or disposition of the bonding areas prior to the connecting process of an individual bonding area
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  • H01L2224/04—Structure, shape, material or disposition of the bonding areas prior to the connecting process
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  • H01L2224/16151—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
  • H01L2224/16221—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
  • H01L2224/16225—Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
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  • H01L2224/15—Structure, shape, material or disposition of the bump connectors after the connecting process
  • H01L2224/17—Structure, shape, material or disposition of the bump connectors after the connecting process of a plurality of bump connectors
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  • H01L2924/1204—Optical Diode
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  • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
  • H10H20/01—Manufacture or treatment
  • H10H20/011—Manufacture or treatment of bodies, e.g. forming semiconductor layers
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  • H10H20/80—Constructional details
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  • H10H20/822—Materials of the light-emitting regions
  • H10H20/824—Materials of the light-emitting regions comprising only Group III-V materials, e.g. GaP
  • H10H20/825—Materials of the light-emitting regions comprising only Group III-V materials, e.g. GaP containing nitrogen, e.g. GaN
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  • H10H20/80—Constructional details
  • H10H20/83—Electrodes
  • H10H20/832—Electrodes characterised by their material
  • H10H20/833—Transparent materials

Definitions

• the present disclosure relates to a light emitting diode (LED) structure, and more particularly to a LED structure with a smooth surface for a reflective electrode.
• LED light emitting diode
• LEDs Light emitting diodes
• LEDs have been developed for many years and have been widely used in various light applications.
• LEDs are light-weight, consume less energy, and have a good electrical power to light conversion efficiency, in some application areas, there have been intentions to replace conventional light sources, such as incandescent lamps and fluorescent light sources, with LEDs.
• LEDs produce light in a relatively narrow angular spread direction without side light so that the light cannot be easily collected by optical elements in a package.
• thin-fihn AlInGaN LEDs produce more light per steradian and photons generated therefrom can be efficiently utilized compared to the conventional lateral LEDs with sapphire substrate attached.
• the efficiency (Lumen/W) of the current LEDs is still not high enough to replace the conventional light source for general illumination or other light applications.
• a light emitting diode includes an epitaxial layer structure, a first electrode, and a second electrode.
• the first and second electrodes are separately disposed on the epitaxial layer structure, and the epitaxial layer structure has a RMS (root-mean-square) roughness less than 3 nm on a surface wherein the second electrode is formed.
• a method for manufacturing a light emitting diode includes forming an epitaxial layer structure, and separately depositing a first electrode and a second electrode on the epitaxial layer structure.
• the epitaxial layer structure has a RMS roughness less than about 3nm on a surface whereon the second electrode is formed.
• Fig. 1 A is a cross sectional view of a vertical LED structure.
• Fig. IB is a top view of a vertical LED structure, in which a patterned n contact is shown.
• Fig. 2 A is a cross sectional view of a flip-chipped lateral LED structure with metal joints and a sub-mount.
• Fig. 2B is a top view of a flip-chipped lateral LED structure with both p and n electrodes before flip-chipped to a sub-mount
• Fig. 3 illustrates an exemplary light extraction occurring in a vertical LED structure.
• Fig. 4 is a schematic diagram of a rough interface between a p-GaN layer and a silver (Ag) layer, showing that the rough interface scatters an incident light as well as couples the light into the surface plasmon mode.
• Figs. 5A-5C illustrate a process for manufacturing a vertical LED that has a smooth surface for forming reflective electrode.
• Figs. 6A-6C illustrate a process for manufacturing a flip-chipped lateral LED structure that has a smooth surface for forming reflective electrode.
• Figs. IA and IB illustrate a cross-sectional view and a top view of a vertical LED device, respectively.
• the vertical LED device 100 has a vertical current injection configuration, including a patterned n-type contact (or n-type electrode) 101, an n-type GaN-based layer 102 with a roughened surface, an active region 103, a p-type GaN-based layer 104, a broad area reflective p-type contact (or p-type electrode or reflective p electrode) 105, and a thermally and/or electrically conductive substrate 106 to support the device structure mechanically.
• the n-type GaN-based layer 102 is formed on a substrate (not shown), the active region 103 is formed on the n-type GaN-based layer 102, and the p-type GaN-based layer 104 is formed on the active region 103, however, other layers may be included.
• the p-type electrode 105 is directly or indirectly formed on p-type GaN- based layer 104.
• the substrate on which the n-type GaN-based layer 102 is formed is removed so that the patterned n-type electrode 101 can be formed on the surface of the n-type GaN-based layer 102 that was attached to the removed substrate.
• the reflective p-type electrode 105 is mounted on the thermally conductive substrate 106 for mechanical support.
• n-type GaN-based layer 102 and the p-type GaN-based layer 104 are opposite to each other, together they form a pair of carrier injectors relative to the active region 103. Therefore, when a power supply is provided to the LED device 100, electrons and holes will be combined in the active region 103, thereby releasing energy in the form of light,
• arrows inside the LED device 100 show that an electrical path is generally vertically formed from the p-type electrode 105 to the patterned n-type electrode 101.
• Fig. IB shows a top view of the vertical LED of Fig. IA 5 in which an n-type contact with four fingers and a crossbar is shown. It will be recognized by those of ordinary skill in the art that the electrode pattern of the n-type contacts is not limited to the electrode pattern as illustrated.
• Fig. 2A illustrates a cross-sectional view of a flip-chipped lateral LED device 200.
• the flip-chipped lateral LED device 200 is formed as a lateral LED device 200' having a lateral current injection configuration that is flipped over and mounted on a sub- mount substrate 207 with matching metal contact pads 208.
• the sub-mount substrate 207 may be electrically insulated or electrically conductive.
• the metal contact pads 208 are electrically isolated from each other either by forming an electrically insulating sub-mount 207 or an insulating dielectric coating formed over an electrically conducting sub-mount (not shown).
• the lateral LED device 200' includes an n-type GaN-based layer 201 with a roughened surface, an active region 202 formed on the n-type GaN-based layer 201, a p-type GaN-based layer 203, a p-type electrode 204, and an n-type electrode 205.
• Fig. 2B shows a top view of the LED device 200' of Fig. 2 A before being flipped over to mount on the sub-mount substrate 207.
• Fig. 2B shows that the p-type electrode 204 has an area larger than that of the n-type electrode 205.
• the n-type GaN-based layer, the p-type GaN-based layer, and the active layer in the LED devices of Figs. IA-I B and 2A-2B are formed using a GaN-based material.
• injected carriers i.e., holes and electrons
• the reflective index of the GaN-based material is around 2.4 at a wavelength of 460 nm.
• TIR total-internal-reflection
• the LED device 300 in Fig. 3 is a vertical LED device that includes a GaN-based material structure 310, including an n-type GaN-based layer 302, an active region 303, a p-type GaN- based layer 304, an n-type electrode 301, and a p-type electrode 305 mounted on a substrate 306.
• Reference number 320 indicates the direction of travel of light generated inside the LED device 300.
• the light emitting from the active region 303 has about a 50/50 chance of propagating toward the top surface or the bottom surface of the LED device 300.
• the p-type electrode (also referred to interchangeably herein as the reflective electrode) 305 is used to re-direct the light propagating back to the top surface of the LED device 300, as shown in Fig. 3.
• the reflective electrode 305 usually contains a metal, and the reflectivity of the reflective electrode 305 is made to be as high as possible to reduce reflection loss, since the light emission tends to be reflected multiple times before escaping the LED devices, as shown in Fig. 3
• Silver (Ag) is a suitable metal for forming a reflective electrode of an AlInGaN LED device because Ag has a high reflectivity in the wavelength range of interest (i.e., 400- 700 nra), and this material can form ohmic contact with a p-type GaN-based layer. Due to an epitaxial growth process and growth conditions used in manufacturing the GaN-based material structure, there is generally some roughness on the p-type GaN-based layer.
• Fig. 4 is an enlarged view of the p-type electrode 305 comprising Ag and the p- type GaN-based layer 304 of Fig. 3, showing light extraction inside the LED device 300.
• the normal incidence of reflectance of Ag measured from the p-type GaN-based layer side is lower than an expected value from a simple optical model calculation because of scattering effects 403 and surface plasmon (SP) absorption 420 resulting from the rough GaN/Ag interface 410, as shown in Fig. 4.
• the rough interface 410 scatters the normal incident light in random directions and reduces the specular reflection at all wavelengths.
• the photons coupled in the surface plasmon (SP) mode 420 typically will not be able to escape and eventually will be lost.
• the SP absorption can have a significant effect on the reflectance measurement.
• the strength of the SP absorption generally correlates to the degree of interface roughness. Even though the SP absorption peak may be below 400 nm, the width of the absorption may still be wide enough to significantly reduce Ag reflectance for wavelengths of around 460 nm.
• the p-type electrode (e.g., Ag electrode) may be deposited on the p-type GaN- based layer by a physical (e.g., electron-beam or thermal) evaporation process, and Ag will conform to the p-type GaN-based layer surface without voids if the deposition is performed properly.
• the roughness of the p-type GaN-based layer/Ag interface is determined by the quality of the p-type GaN-based layer. The presence of voids created during the deposition process or contact annealing process, however, may increase the interface roughness and further enhance the SP absorption.
• an LED device is provided in which the p-type GaN-based layer has a root-mean- square (RMS) roughness less than about 3 ran to ensure appropriate smoothness of the p-type GaN-based layer/Ag electrode interface and to thereby rmnirmze the SP absorption.
• RMS root-mean- square
• a method for manufacturing the p-type GaN-based layer with a smooth surface is provided, such that the SP absorption can be reduced to a maximum extent.
• FIGs. 5A-5C and 6A-6C illustrate manufacturing processes for a vertical LED device 500 and a flip-chipped lateral LED device 600, respectively.
• the processes of Figs. 5 A and 6A basically follow similar manufacturing steps, except with regard to the formation of an n-type electrode and final mounting.
• an n-type GaN-based layer 502 is formed on a substrate, such as a sapphire substrate 501.
• a substrate such as a sapphire substrate 501.
• an active layer 503 and a p- type GaN-based layer 504 are formed, hi an example, the RMS roughness of the surface of the p-type GaN-based layer 504 that will interface with a p-type electrode 505, shown in Fig. 5B, is preferably controlled to be less than about 3 nm.
• the p-type GaN-based layer 504 is formed by MOCVD (Metal-Organic Chemical Vapor Deposition) using metal- organic compound such as trimethyl gallium (TMGa), trimethyl indium (TMIn), trimethyl aluminum (TMAl), and ammonia, hydrogen, nitrogen as well as dopant precursors for silicon and magnesium in a reactor chamber with controlled pressure and temperature.
• MOCVD Metal-Organic Chemical Vapor Deposition
• metal- organic compound such as trimethyl gallium (TMGa), trimethyl indium (TMIn), trimethyl aluminum (TMAl), and ammonia, hydrogen, nitrogen as well as dopant precursors for silicon and magnesium in a reactor chamber with controlled pressure and temperature.
• the growth temperature in the deposition process is preferably greater than about 95O 0 C and the growth rate is preferably less than about 150 A/min.
• the p-type electrode 505 is formed on the p-type GaN-based layer 504, as shown in Fig. 5B.
• a transparent ohmic contact layer (not shown) may be formed on the p-type GaN-based layer 504.
• the transparent ohmic contact layer may be formed by, for example, electron-beam evaporation, sputtering, MOCVD, etc., with doped metal oxides, such as indium tin oxide (TTO) or aluminum doped zinc oxide (AZO).
• TTO indium tin oxide
• AZO aluminum doped zinc oxide
• the transparent ohmic contact layer is presented, the RMS roughness of the transparent ohmic contact layer may be controlled to be less than about 3 nm regardless of the RMS roughness of the p-GaN surface.
• the p-type electrode 505 of Figs. 5B and 5C is a reflective layer for reflecting light emitted downwardly back to the top surface of the LED device, as shown in figs. 5B and 5C.
• Exemplary metals used in forming the p-1ype electrode 505 include Ag 9 Pt, Ni, Cr, Ti, Al, Pd, Ru, Rh, Mo, and their alloys.
• the substrate 501 is removed from the n-type GaN-based layer 502 to allow an n-type electrode 506 to be formed on the surface of the n-type GaN-based layer 502 that was attached to the substrate 501, as shown in Fig. 5C.
• the surface of the n-type GaN-based layer 502 on which the n-type electrode 506 is formed is roughened according to a conventional roughening method to minimize the total internal reflection (TIR) effect and enhance light extraction efficiency.
• the p-type electrode 505 may be mounted on a sub-mount substrate 508 for a mechanical support.
• the sub-mount substrate 508 may include similar materials to those used in the substrate 501. That is, the sub-mount substrate 508 may be selected from one or more of the followings: metals, such as Cu, Mo, W, and Al, or their alloys; semiconductor materials, such as Si, GaAs, GaP, InP, and Ge; and/or ceramics, such as Al 2 O 3 and AlN.
• metals such as Cu, Mo, W, and Al, or their alloys
• semiconductor materials such as Si, GaAs, GaP, InP, and Ge
• ceramics such as Al 2 O 3 and AlN.
• Figs. 6A-6C will now be described in further detail. Similar to Fig. 5A 5 in Fig, 6A, an n-type GaN-based layer 602, an active layer 603, and a p-type GaN-based layer 604 are formed on a substrate, such as a sapphire substrate 601. As described above with reference to Fig.
• the p-type GaN-based layer 503 may be formed by a MOCVD (Metal- Organic Chemical Vapor Deposition) using metal-organic compound such as trimethyl gallium (TMGa), trimethyl indium (TMIn), trimethyl aluminum (TMAl) 5 and ammonia, hydrogen, nitrogen as well as dopant precursors for silicon and magnesium in a reactor chamber with controlled pressure and temperature.
• MOCVD Metal- Organic Chemical Vapor Deposition
• metal-organic compound such as trimethyl gallium (TMGa), trimethyl indium (TMIn), trimethyl aluminum (TMAl) 5 and ammonia, hydrogen, nitrogen as well as dopant precursors for silicon and magnesium in a reactor chamber with controlled pressure and temperature.
• the growth temperature in the deposition process is preferably greater man about 95O 0 C and the growth rate is preferably less than about 150 A/min.
• the RMS roughness of the p-type GaN-based layer may be, for example, less than about 3 nm.
• a transparent ohmic contact layer 609 and a reflective p-type electrode 605 are formed on the p-type GaN-based layer 604.
• the transparent ohmic contact layer 609 is optional and does not limit the scope of the invention.
• the RMS roughness of the surface in direct contact with reflective electrode 605, for example, the p-GaN surface or the transparent ohmic contact layer surface, may be less than 3 nm.
• Fig. 6C shows that parts of the reflective p-type electrode 605, the transparent ohmic contact layer 609, and the p-type GaN- based layer 604 are etched away to allow an n-type electrode 606 to be formed on top of the n-type GaN-based layer 602, as shown in Fig. 6C.
• the LED structure made by this process is then flipped over and mounted on a sub-mount substrate 608 with matching metal contact pads 611 via solder joints or metal interconnects 610.
• the metal contact pads 611 are electrically isolated from each other either by an electrically insulating sub-mount 608 or an insulating dielectric coating formed over an electrically conducting sub-mount (not shown).

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