CN103107247A - Manufacturing method and structure of LED chip - Google Patents
Manufacturing method and structure of LED chip Download PDFInfo
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Abstract
本发明是有关于一种LED芯片的制造方法及其结构。其中该方法包括下列步骤:提供一导电块材;提供一磊晶块材;进行结合;移除磊晶层基材;制作独立发光二极管;形成一第二绝缘层;以及进行电性连接。导电块材上形成有第一、第二及第三发光二极管,其中第一与第二发光二极管相互并联,第二与第三发光二极管相互串联。因此借由本发明可以形成具有可弹性设计的发光二极管串并联的基本单元结构,从而可以大幅的提升发光二极管芯片衍生设计的多样性及应用。
The present invention relates to a method for manufacturing an LED chip and its structure. The method includes the following steps: providing a conductive block; providing an epitaxial block; combining; removing the epitaxial layer substrate; making an independent light-emitting diode; forming a second insulating layer; and electrically connecting. A first, second, and third light-emitting diode are formed on the conductive block, wherein the first and second light-emitting diodes are connected in parallel, and the second and third light-emitting diodes are connected in series. Therefore, the present invention can form a basic unit structure of light-emitting diode series-parallel connection with flexible design, thereby greatly improving the diversity and application of the derivative design of the light-emitting diode chip.
Description
技术领域 technical field
本发明涉及一种LED芯片的制造方法及其结构,特别是涉及一种应用于照明的LED芯片的制造方法及其结构。The invention relates to a method for manufacturing an LED chip and its structure, in particular to a method for manufacturing an LED chip used in lighting and its structure.
背景技术 Background technique
图1是一种现有习知水平架构的发光二极管的剖视图。现有习知水平架构的并联发光二极管101,其是在一砷化镓(GaAs)的绝缘基材10上形成一N型半导体层111;然后在N型半导体层111上又形成一P型半导体层112;接着以蚀刻方式形成多颗发光二极管11;最后借由第一绝缘材料12及导电层13使不同的发光二极管11间形成并联结构。以TD工艺制作的发光二极管11,只能将不同的发光二极管11彼此形成并联结构而无法形成串联结构。FIG. 1 is a cross-sectional view of a conventional LED with a horizontal structure. The conventional parallel light-emitting diode 101 with a horizontal structure is to form an N-
图2是一种现有习知晶圆结合(Wafer Bonding,WB)工艺下的发光二极管水平架构的剖视图。现有习知以WB工艺技术制作的并联发光二极管102,其是在一金属或硅基材14上形成一第二绝缘材料15;接着在第二绝缘材料15上形成P型半导体层112;然后在P型半导体层112上又形成一N型半导体层111;接着以蚀刻方式形成多颗发光二极管11;最后借由第一绝缘材料12及导电层13使不同的发光二极管11间形成并联结构。以WB工艺制作的垂直型发光二极管11,只能将不同的发光二极管11彼此形成并联结构而无法形成串联结构。FIG. 2 is a cross-sectional view of a light-emitting diode horizontal structure under a conventional wafer bonding (Wafer Bonding, WB) process. Existing conventional parallel light-
图3是一种现有习知WB工艺下的串联式发光二极管的剖视图。现有习知WB工艺下的水平架构发光二极管可以形成一串联发光二极管103,其是在一金属或硅基材14上形成一第二绝缘材料15;接着在第二绝缘材料15上形成一P型半导体层112;然后在P型半导体层112上又形成一N型半导体层111;接着以蚀刻方式形成多颗发光二极管11;最后借由第一绝缘材料12及导电层13使不同的发光二极管11间形成串联结构。FIG. 3 is a cross-sectional view of a serial LED in a conventional WB process. The horizontal structure light-emitting diode under the existing conventional WB process can form a series light-
现有习知水平架构的发光二极管只能形成一并联发光二极管101结构,现有习知WB工艺下的水平架构发光二极管同样的也只能形成一并联发光二极管102结构或者只能形成一串联发光二极管103结构,无法在单一工艺中同时形成一串并联结构,因此现有习知技术在使用上因此受到很大的限制。The existing conventional horizontal light-emitting diodes can only form a parallel light-emitting diode 101 structure, and the existing horizontal light-emitting diodes under the conventional WB process can only form a parallel light-
由此可见,上述现有的LED芯片的制造方法及其结构在方法、产品结构及使用上,显然仍存在有不便与缺陷,而亟待加以进一步改进。为了解决上述存在的问题,相关厂商莫不费尽心思来谋求解决之道,但长久以来一直未见适用的设计被发展完成,而一般方法及产品又没有适切的方法及结构能够解决上述问题,此显然是相关业者急欲解决的问题。因此如何能创设一种新的LED芯片的制造方法及其结构,实属当前重要研发课题之一,亦成为当前业界极需改进的目标。It can be seen that the above-mentioned existing LED chip manufacturing method and its structure obviously still have inconveniences and defects in terms of method, product structure and use, and need to be further improved urgently. In order to solve the above-mentioned existing problems, relevant manufacturers have tried their best to find a solution, but no suitable design has been developed for a long time, and there is no suitable method and structure for general methods and products to solve the above-mentioned problems. This is obviously a problem that relevant industry players are eager to solve. Therefore, how to create a new manufacturing method and structure of LED chips is one of the current important research and development topics, and has also become a goal that the industry needs to improve.
发明内容 Contents of the invention
本发明的目的在于,克服现有的LED芯片的制造方法及其结构存在的缺陷,而提供一种新的LED芯片的制造方法及其结构,所要解决的技术问题是使其能够以晶圆级工艺达成在同一个基材上形成至少一组相互串、并联的发光二极管结构,并借此使发光二极管芯片后续的衍生设计的多样性及应用大幅提升,非常适于实用。The purpose of the present invention is to overcome the defects of the existing LED chip manufacturing method and its structure, and provide a new LED chip manufacturing method and its structure. The technical problem to be solved is to enable it to The process achieves the formation of at least one set of LED structures connected in series and parallel on the same base material, thereby greatly improving the diversity and application of subsequent derivative designs of LED chips, which is very suitable for practical use.
本发明的目的及解决其技术问题是采用以下技术方案来实现的。依据本发明提出的一种LED芯片的制造方法,其包括下列步骤:提供一导电块材,该导电块材包含:一导电基材,其具有一第一区域及一第二区域;一第一绝缘层形成于该第一区域上;及一第一金属层形成于该第二区域及该第一绝缘层上;提供一磊晶块材,该磊晶块材包含:一磊晶层基材;一磊晶层形成于该磊晶层基材上;及一第二金属层形成于该磊晶层相对于该磊晶层基材的另外一侧的一半导体侧;进行结合,是借由结合该第一金属层及该第二金属层将该导电块材与该磊晶块材结合成一体以成为一结合块材;移除该磊晶层基材,是将该磊晶层基材自该结合块材移除以形成一发光二极管块材;制作独立发光二极管,是将该发光二极管块材进行蚀刻,使该第一区域上形成至少一第一发光二极管,使该第二区域上形成至少一第二发光二极管及至少一第三发光二极管;形成一第二绝缘层,其是在该第一发光二极管、该第二发光二极管及该第三发光二极管间形成该第二绝缘层;以及进行电性连接,其是在该第二绝缘层上,借由形成一第一导电层使每一该第一发光二极管及每一该第二发光二极管彼此相互串联,借由形成一第二导电层使每一该第二发光二极管及每一该第三发光二极管彼此相互并联。The purpose of the present invention and the solution to its technical problems are achieved by adopting the following technical solutions. A method for manufacturing an LED chip according to the present invention includes the following steps: providing a conductive bulk material, the conductive bulk material comprising: a conductive substrate having a first region and a second region; a first An insulating layer is formed on the first region; and a first metal layer is formed on the second region and the first insulating layer; an epitaxial bulk material is provided, and the epitaxial bulk material includes: an epitaxial layer substrate ; an epitaxial layer is formed on the epitaxial layer substrate; and a second metal layer is formed on a semiconductor side of the epitaxial layer opposite to the other side of the epitaxial layer substrate; bonding is performed by Combining the first metal layer and the second metal layer to integrate the conductive bulk material and the epitaxial bulk material into a combined bulk material; removing the epitaxial layer substrate is to use the epitaxial layer substrate Remove from the combined block to form a light-emitting diode block; making an independent light-emitting diode is to etch the light-emitting diode block, so that at least one first light-emitting diode is formed on the first region, and at least one first light-emitting diode is formed on the second region. forming at least one second light emitting diode and at least one third light emitting diode; forming a second insulating layer, which is to form the second insulating layer between the first light emitting diode, the second light emitting diode and the third light emitting diode; And for electrical connection, it is on the second insulating layer, by forming a first conductive layer so that each of the first light emitting diodes and each of the second light emitting diodes are connected in series with each other, by forming a second The conductive layer connects each of the second light emitting diodes and each of the third light emitting diodes in parallel with each other.
本发明的目的及解决其技术问题还可采用以下技术措施进一步实现。The purpose of the present invention and its technical problems can also be further realized by adopting the following technical measures.
前述的LED芯片的制造方法,其中所述的导电基材为一半导体晶圆基材。In the aforementioned method of manufacturing an LED chip, the conductive base material is a semiconductor wafer base material.
前述的LED芯片的制造方法,其中所述的半导体晶圆基材为IV-IV族、III-IV族、II-VI族、硅、锗、氮化镓或砷化镓的半导体导电基材。The aforementioned method for manufacturing an LED chip, wherein the semiconductor wafer substrate is a semiconductor conductive substrate of Group IV-IV, Group III-IV, Group II-VI, silicon, germanium, gallium nitride or gallium arsenide.
前述的LED芯片的制造方法,其中所述的导电基材为铜钨、钼、铜、钨或锰材质的导电基材。The aforementioned method for manufacturing an LED chip, wherein the conductive substrate is a conductive substrate made of copper tungsten, molybdenum, copper, tungsten or manganese.
前述的LED芯片的制造方法,其中所述的导电基材包括:一非导电基材;及多个第一导电柱穿透该非导电基材且使该些第一导电柱与该第一金属层电性连接。The aforementioned method of manufacturing an LED chip, wherein the conductive base material includes: a non-conductive base material; and a plurality of first conductive posts penetrate the non-conductive base material and make the first conductive posts and the first metal layer electrical connections.
前述的LED芯片的制造方法,其中所述的半导体侧与该第二金属层间形成有一反射层,该反射层内形成有多个第二导电柱以电性连接该半导体侧与该第二金属层。The aforementioned method of manufacturing an LED chip, wherein a reflective layer is formed between the semiconductor side and the second metal layer, and a plurality of second conductive pillars are formed in the reflective layer to electrically connect the semiconductor side and the second metal layer. layer.
本发明的目的及解决其技术问题还采用以下技术方案来实现。依据本发明提出的一种LED芯片结构,其包括:一导电块材,该导电块材包含:一导电基材,其具有一第一区域及一第二区域;一第一绝缘层形成于该第一区域上;及多个第一金属层彼此独立结合于该第二区域及该第一绝缘层上;至少一第一发光二极管,借由多个第二金属层之一与一该第一金属层结合后固设于该第一绝缘层上;至少一第二发光二极管,借由一该第二金属层与一该第一金属层结合后固设于该第二区域上且该第二发光二极管与该第一发光二极管借由多个第二绝缘层之一及一第一导电层相互串联;以及至少一第三发光二极管,借由一该第二金属层与一该第一金属层结合后固设于该第二区域上且借由该些第二绝缘层之一及一第二导电层与该第二发光二极管相互并联。The purpose of the present invention and the solution to its technical problem also adopt the following technical solutions to achieve. According to an LED chip structure proposed by the present invention, it includes: a conductive block material, the conductive block material includes: a conductive base material, which has a first region and a second region; a first insulating layer is formed on the On the first region; and a plurality of first metal layers are independently combined with each other on the second region and the first insulating layer; at least one first light-emitting diode, through one of the plurality of second metal layers and one of the first first metal layers The metal layer is combined and fixed on the first insulating layer; at least one second light-emitting diode is fixed on the second region through the combination of the second metal layer and the first metal layer, and the second The light emitting diode and the first light emitting diode are connected in series through one of a plurality of second insulating layers and a first conductive layer; and at least one third light emitting diode is connected in series through a second metal layer and a first metal layer After being combined, it is fixed on the second region and connected in parallel with the second light emitting diode through one of the second insulating layers and a second conductive layer.
本发明的目的及解决其技术问题还可采用以下技术措施进一步实现。The purpose of the present invention and its technical problems can also be further realized by adopting the following technical measures.
前述的LED芯片结构,其中所述的导电基材为一半导体晶圆基材。In the aforementioned LED chip structure, the conductive base material is a semiconductor wafer base material.
前述的LED芯片结构,其中所述的半导体晶圆基材为IV-IV族、III-IV族、II-VI族、硅、锗、氮化镓或砷化镓的半导体导电基材。The aforementioned LED chip structure, wherein the semiconductor wafer substrate is a semiconductor conductive substrate of Group IV-IV, Group III-IV, Group II-VI, silicon, germanium, gallium nitride or gallium arsenide.
前述的LED芯片结构,其中所述的导电基材为铜钨、钼、铜、钨或锰材质的导电基材。The aforementioned LED chip structure, wherein the conductive substrate is a conductive substrate made of copper tungsten, molybdenum, copper, tungsten or manganese.
前述的LED芯片结构,其中所述的导电基材包括:一非导电基材;及多个第一导电柱穿透该非导电基材且与该第二区域上的该第一金属层电性连接。The aforementioned LED chip structure, wherein the conductive substrate includes: a non-conductive substrate; and a plurality of first conductive pillars penetrate the non-conductive substrate and are electrically connected to the first metal layer on the second region connect.
前述的LED芯片结构,其中每一该第一发光二极管、每一该第二发光二极管及每一该第三发光二极管分别与其对应的该第二金属层间设有一反射层,并且该第二区域上的该反射层内设置有多个第二导电柱使该第二发光二极管及该第三发光二极管分别与其对应的该第二金属层电性连接。The aforementioned LED chip structure, wherein each of the first light emitting diodes, each of the second light emitting diodes and each of the third light emitting diodes is respectively provided with a reflective layer between the corresponding second metal layer, and the second region A plurality of second conductive pillars are arranged in the reflective layer above to electrically connect the second light-emitting diode and the third light-emitting diode with the corresponding second metal layer respectively.
本发明与现有技术相比具有明显的优点和有益效果。借由上述技术方案,本发明LED芯片的制造方法及其结构至少具有下列优点及有益效果:本发明能够以最简化的工艺,使LED串并联结构同时完成在一导电块材上,从而可以大幅的提升发光二极管芯片衍生设计的多样性及应用。Compared with the prior art, the present invention has obvious advantages and beneficial effects. By virtue of the above-mentioned technical solution, the manufacturing method and the structure of the LED chip of the present invention have at least the following advantages and beneficial effects: The present invention can simultaneously complete the LED series-parallel structure on a conductive block with the most simplified process, so that a large Improve the diversity and application of light-emitting diode chip derivative design.
综上所述,本发明是有关于一种LED芯片的制造方法及其结构。其中该方法包括下列步骤:提供一导电块材;提供一磊晶块材;进行结合;移除磊晶层基材;制作独立发光二极管;形成一第二绝缘层;以及进行电性连接。导电块材上形成有第一、第二及第三发光二极管,其中第一与第二发光二极管相互并联,第二与第三发光二极管相互串联。因此借由本发明可以形成具有可弹性设计的发光二极管串并联的基本单元结构,从而可以大幅的提升发光二极管芯片衍生设计的多样性及应用。本发明在技术上有显著的进步,具有明显的积极效果,诚为一新颖、进步、实用的新设计。To sum up, the present invention relates to a method for manufacturing an LED chip and its structure. Wherein the method comprises the following steps: providing a conductive block; providing an epitaxial block; combining; removing the epitaxial layer substrate; making an independent light emitting diode; forming a second insulating layer; and making electrical connection. First, second and third light emitting diodes are formed on the conductive block, wherein the first and second light emitting diodes are connected in parallel, and the second and third light emitting diodes are connected in series. Therefore, the present invention can form a basic unit structure with a series-parallel connection of light-emitting diodes that can be flexibly designed, thereby greatly improving the diversity and application of derivative designs of light-emitting diode chips. The present invention has significant progress in technology, has obvious positive effects, and is a novel, progressive and practical new design.
上述说明仅是本发明技术方案的概述,为了能够更清楚了解本发明的技术手段,而可依照说明书的内容予以实施,并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂,以下特举较佳实施例,并配合附图,详细说明如下。The above description is only an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention, it can be implemented according to the contents of the description, and in order to make the above and other purposes, features and advantages of the present invention more obvious and understandable , the following preferred embodiments are specifically cited below, and are described in detail as follows in conjunction with the accompanying drawings.
附图说明 Description of drawings
图1是一种现有习知水平架构的发光二极管的剖视图。FIG. 1 is a cross-sectional view of a conventional LED with a horizontal structure.
图2是一种现有习知WB工艺下的发光二极管水平架构的剖视图。FIG. 2 is a cross-sectional view of a horizontal structure of a light-emitting diode under a conventional WB process.
图3是一种现有习知WB工艺下的串联式发光二极管的剖视图。FIG. 3 is a cross-sectional view of a serial LED in a conventional WB process.
图4是本发明实施例的一种LED芯片的制造方法的流程图。Fig. 4 is a flowchart of a method for manufacturing an LED chip according to an embodiment of the present invention.
图5A是本发明实施例的一种导电块材第一结构的剖视图。FIG. 5A is a cross-sectional view of a first structure of a conductive bulk material according to an embodiment of the present invention.
图5B是本发明实施例的一种导电块材第二结构的剖视图。FIG. 5B is a cross-sectional view of a second structure of a conductive bulk material according to an embodiment of the present invention.
图6是本发明实施例的一种磊晶块材的剖视图。Fig. 6 is a cross-sectional view of an epitaxial bulk material according to an embodiment of the present invention.
图7是本发明实施例的一种结合块材的剖视图。Fig. 7 is a cross-sectional view of a bonding block according to an embodiment of the present invention.
图8是本发明实施例的一种移除磊晶层基材后的磊晶块材的剖视图。8 is a cross-sectional view of an epitaxial bulk material after removing the epitaxial layer substrate according to an embodiment of the present invention.
图9是本发明实施例的一种蚀刻后的独立发光二极管的示意图。FIG. 9 is a schematic diagram of an etched independent light emitting diode according to an embodiment of the present invention.
图10是本发明实施例的一种在独立发光二极管形成第二绝缘层的示意图。FIG. 10 is a schematic diagram of forming a second insulating layer on an independent light emitting diode according to an embodiment of the present invention.
图11A是本发明实施例的一种在第二绝缘层上以导电层进行串并联电性连接的第一结构的示意图。FIG. 11A is a schematic diagram of a first structure in which a series-parallel electrical connection is performed on a second insulating layer with a conductive layer according to an embodiment of the present invention.
图11B是本发明实施例的一种在第二绝缘层上以导电层进行串并联电性连接的第二结构的示意图。FIG. 11B is a schematic diagram of a second structure in which series-parallel electrical connections are performed on the second insulating layer with a conductive layer according to an embodiment of the present invention.
图12是本发明实施例的一种磊晶块材进一步设有一反射层的剖视图。12 is a cross-sectional view of an epitaxial block further provided with a reflective layer according to an embodiment of the present invention.
图13是本发明实施例的一种使用内设有第一导电柱的非导电基材的LED芯片结构的剖视图。FIG. 13 is a cross-sectional view of an LED chip structure using a non-conductive substrate provided with a first conductive post according to an embodiment of the present invention.
101:并联发光二极管 102:并联发光二极管101: Parallel light-emitting diodes 102: Parallel light-emitting diodes
103:串联发光二极管 10:绝缘基材103: Series light-emitting diodes 10: Insulating substrate
11:发光二极管 111:N型半导体层11: Light-emitting diode 111: N-type semiconductor layer
112:P型半导体层 12:第一绝缘材料112: P-type semiconductor layer 12: The first insulating material
13:导电层 14:金属或硅基材13: Conductive layer 14: Metal or silicon substrate
15:第二绝缘材料 200:LED芯片结构15: Second insulating material 200: LED chip structure
20:导电块材 21:导电基材20: Conductive Block 21: Conductive Substrate
22:第一区域 23:第二区域22: The first area 23: The second area
24:第一绝缘层 25:第一金属层24: The first insulating layer 25: The first metal layer
26:非导电基材 27:第一导电柱26: Non-conductive substrate 27: The first conductive column
30、30’:磊晶块材 31:磊晶层基材30, 30': Epitaxy bulk material 31: Epitaxy layer substrate
32:磊晶层 33:第二金属层32: Epitaxial layer 33: Second metal layer
34:半导体侧 35:反射层34: Semiconductor side 35: Reflective layer
36:第二导电柱 40:结合块材36: The second conductive column 40: Combined blocks
50:发光二极管块材 60:第一发光二极管50: Light-emitting diode block 60: The first light-emitting diode
70:第二发光二极管 80:第三发光二极管70: The second light-emitting diode 80: The third light-emitting diode
90:第二绝缘层 91:第一导电层90: Second insulating layer 91: First conductive layer
92:第二导电层92: Second conductive layer
具体实施方式 Detailed ways
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效,以下结合附图及较佳实施例,对依据本发明提出的LED芯片的制造方法及其结构其具体实施方式、方法、步骤、结构、特征及其功效,详细说明如后。In order to further explain the technical means and effects of the present invention to achieve the intended purpose of the invention, the following in conjunction with the accompanying drawings and preferred embodiments, the specific implementation methods, methods, Steps, structures, features and effects thereof are described in detail below.
有关本发明的前述及其他技术内容、特点及功效,在以下配合参考图式的较佳实施例的详细说明中将可清楚呈现。通过具体实施方式的说明,应当可对本发明为达成预定目的所采取的技术手段及功效获得一更加深入且具体的了解,然而所附图式仅是提供参考与说明之用,并非用来对本发明加以限制。The aforementioned and other technical contents, features and effects of the present invention will be clearly presented in the following detailed description of preferred embodiments with reference to the drawings. Through the description of the specific implementation, it should be possible to obtain a deeper and more specific understanding of the technical means and effects of the present invention to achieve the intended purpose, but the attached drawings are only for reference and description, not for the purpose of the present invention. be restricted.
图4是本发明实施例的一种LED芯片的制造方法的流程图。图5A是本发明实施例的一种导电块材第一结构的剖视图。图5B是本发明实施例的一种导电块材第二结构的剖视图。图6是本发明实施例的一种磊晶块材的剖视图。图7是本发明实施例的一种结合块材的剖视图。图8是本发明实施例的一种移除磊晶层基材后的磊晶块材的剖视图。图9是本发明实施例的一种蚀刻后的独立发光二极管的示意图。图10是本发明实施例的一种在独立发光二极管形成第二绝缘层的示意图。图11A是本发明实施例的一种在第二绝缘层上以导电层进行串并联电性连接的第一结构的示意图。图11b是本发明实施例的一种在第二绝缘层上以导电层进行串并联电性连接的第二结构的示意图。图12是本发明实施例的一种磊晶块材进一步设有一反射层的剖视图。图13是本发明实施例的一种使用内设有第一导电柱的非导电基材的LED芯片结构的剖视图。Fig. 4 is a flowchart of a method for manufacturing an LED chip according to an embodiment of the present invention. FIG. 5A is a cross-sectional view of a first structure of a conductive bulk material according to an embodiment of the present invention. FIG. 5B is a cross-sectional view of a second structure of a conductive bulk material according to an embodiment of the present invention. Fig. 6 is a cross-sectional view of an epitaxial bulk material according to an embodiment of the present invention. Fig. 7 is a cross-sectional view of a bonding block according to an embodiment of the present invention. 8 is a cross-sectional view of an epitaxial bulk material after removing the epitaxial layer substrate according to an embodiment of the present invention. FIG. 9 is a schematic diagram of an etched independent light emitting diode according to an embodiment of the present invention. FIG. 10 is a schematic diagram of forming a second insulating layer on an independent light emitting diode according to an embodiment of the present invention. FIG. 11A is a schematic diagram of a first structure in which a series-parallel electrical connection is performed on a second insulating layer with a conductive layer according to an embodiment of the present invention. FIG. 11 b is a schematic diagram of a second structure in which series and parallel electrical connections are performed on the second insulating layer with a conductive layer according to an embodiment of the present invention. 12 is a cross-sectional view of an epitaxial block further provided with a reflective layer according to an embodiment of the present invention. FIG. 13 is a cross-sectional view of an LED chip structure using a non-conductive substrate provided with a first conductive post according to an embodiment of the present invention.
如图4所示,本实施例的一种LED芯片的制造方法S200包括下列步骤:提供一导电块材(步骤S10);提供一磊晶块材(步骤S20);进行结合(步骤S30);移除磊晶层基材(步骤S40);制作独立发光二极管(步骤S50);形成一第二绝缘层(步骤S60);以及进行电性连接(步骤S70)。As shown in FIG. 4 , a manufacturing method S200 of an LED chip in this embodiment includes the following steps: providing a conductive bulk (step S10); providing an epitaxial bulk (step S20); performing bonding (step S30); Removing the epitaxial layer substrate (step S40); fabricating an independent light emitting diode (step S50); forming a second insulating layer (step S60); and performing electrical connection (step S70).
如图5A所示,提供一导电块材(步骤S10),导电块材20包含一导电基材21,为了同时形成水平及垂直架构的发光二极管,因此将导电基材21区分为具有一第一区域22和一第二区域23。接着在第一区域22上形成有一第一绝缘层24,借此可以提供后续制作水平架构的发光二极管的条件。然后又在第二区域23及第一绝缘层24上形成有一第一金属层25,第一金属层25除了提供后续结合步骤使用之外,第二区域23上的第一金属层25同时也提供后续制作垂直架构的发光二极管的条件。As shown in FIG. 5A, a conductive block material is provided (step S10). The
如图5B所示,在选择导电基材21时,导电基材21可以为一半导体晶圆基材,例如半导体晶圆基材可以为IV-IV族、III-IV族、II-VI族、硅、锗、氮化镓或砷化镓的半导体导电基材21;或者导电基材21可以为例如铜钨、钼、铜、钨或锰材质...等具有良好导电性的导电基材21。此外,导电基材也可以使用非导电基材26且经过加工后成为导电基材,例如导电基材包括一非导电基材26且在非导电基材26内具有多个第一导电柱27,每一个第一导电柱27都穿透非导电基材26并且与第一金属层25电性连接,同时第一导电柱27也提供了导热的功能。As shown in Figure 5B, when selecting the
如图6所示,提供一磊晶块材(步骤S20),磊晶块材30为一发光二极管磊晶块材,磊晶块材30包含有一磊晶层基材31;一磊晶层32及一第二金属层33。磊晶层基材31是用以支撑及成长LED的基材,磊晶层基材31上形成有LED的磊晶层32。为了后续的结合,磊晶层32的半导体侧34也就是磊晶层32相对于磊晶层基材31的另外一侧,形成了有第二金属层33。As shown in Figure 6, an epitaxial block is provided (step S20), the
如图7所示,进行结合(步骤S30),由于在导电块材20上具有第一金属层25而在磊晶块材30具有一第二金属层33,因此可以在同材料特性的基础上,借由结合第一金属层25及第二金属层33进而将导电块材20与磊晶块材30结合成一体,这样的结合又可以使导电块材20与磊晶块材30成为一结合块材40。As shown in FIG. 7, the bonding (step S30) is carried out. Since there is a
如图8所示,移除磊晶层基材(步骤S40),导电块材20与磊晶块材30成为一结合块材40后,导电块材20将可取代磊晶层基材31而提供磊晶层32在结构上的支撑。此时必须将磊晶层基材31自结合块材40移除,以使发光二极管能有效的出光,此外磊晶层基材31移除后也能方便后续每一发光二极管电极的制作。将磊晶层32转移到导电块材20上且移除磊晶层基材31后结合块材40便形成了一发光二极管块材50。As shown in FIG. 8 , the epitaxial layer substrate is removed (step S40 ), and after the
如图9所示,制作独立发光二极管(步骤S50),发光二极管块材50形成后,接着对发光二极管块材50进行蚀刻。为了后续能制作出串、并联的发光二极管结构,首先要借由蚀刻使发光二极管块材50形成多个独立的发光二极管,因此蚀刻时必须蚀刻至第一绝缘层24前停止,使第一金属层25成为多个彼此不电性连接的独立区块。As shown in FIG. 9 , independent LEDs are manufactured (step S50 ). After the
在蚀刻的规划上,由于第一区域22上的第一绝缘层24可以提供制作水平架构的条件,因此在第一区域22上必须形成至少一第一发光二极管60;又由于第二区域23上的第一金属层25与第二金属层33可以与导电基材21电性连接,因此提供了制作垂直架构的条件,因此第二区域23上必须形成至少一第二发光二极管70及至少一第三发光二极管80的并联结构;最后进而使第一发光二极管60与相互并联的第二发光二极管70及第三发光二极管80再次形成串联结构。In the planning of etching, since the first insulating
如图10所示,形成一第二绝缘层(步骤S60),在制作独立发光二极管(步骤S50)后,为了后续串、并联电路的形成,因此在第一发光二极管60、第二发光二极管70及第三发光二极管80间被蚀刻的部位必须形成一第二绝缘层90以达到必要的电性隔离。As shown in Figure 10, a second insulating layer is formed (step S60). After making the independent light emitting diode (step S50), in order to form the subsequent series and parallel circuits, the first
如图11A及图11B所示,进行电性连接(步骤S70),第二绝缘层90制作完成后,在第二绝缘层90上接着借由形成一第一导电层91使每一第一发光二极管60及每一第二发光二极管70彼此相互串联,又借由在第二绝缘层90上形成一第二导电层92使每一第二发光二极管70及每一第三发光二极管80彼此相互并联,如此即可在同一导电块材20上形成具有串、并联电路的发光二极管电路。As shown in Fig. 11A and Fig. 11B, carry out electrical connection (step S70), after the second insulating
如图12所示,为了增加发光二极管的出光效率,磊晶块材30’在制作时,磊晶层32的半导体侧34与第二金属层33间可以形成有一反射层35,借由反射层35的反射可以达到增加发光二极管的出光效率的功效。反射层35一般是使用一电介质(dielectric)材料加以制作,由于第二发光二极管70及第三发光二极管80必须是垂直架构,因此至少在第二发光二极管70及第三发光二极管80的半导体侧34必须与第二金属层33电性连接,所以至少对应于第二发光二极管70及第三发光二极管80部位的反射层35内,必须形成有多个第二导电柱36,以使第二发光二极管70及第三发光二极管80的半导体侧34与第二金属层33电性连接,同时第二导电柱36也具有导热的功效。As shown in FIG. 12 , in order to increase the light extraction efficiency of the light-emitting diode, a
为了避免工艺上的对位而增加制造的复杂度,多个第二导电柱36不局限于形成在第一区域22或第二区域23上的反射层35内,使每一第一发光二极管60、第二发光二极管70及第三发光二极管80的半导体侧34皆与第二金属层33电性连接。由于第一发光二极管60对应的第二金属层33已经被蚀刻成为独立且不互相电性连接,因此这样的作法并不会影响串联电路的制作。In order to avoid process alignment and increase manufacturing complexity, the plurality of second
请再次参阅图11A所示,以上述的制造方法,本发明又提供一种LED芯片结构200的实施例,其包括:一导电块材20;至少一第一发光二极管60;至少一第二发光二极管70;至少一第三发光二极管80。Please refer to FIG. 11A again. With the above manufacturing method, the present invention provides an embodiment of an
导电块材20,其包含一导电基材21。导电基材21具有一第一区域22及一第二区域23,第一区域22上具有一第一绝缘层24,第二区域23及第一绝缘层24上具有多个彼此独立的第一金属层25。在制作工艺中,第一金属层25经过蚀刻后会成为多个彼此独立且不互相电性连接的区块,也就是多个第一金属层25,但这些第一金属层25具有提供在工艺上进行结合的功效。The
同样的在选择导电基材21时,导电基材21可以为一半导体晶圆基材,例如半导体晶圆基材可以是IV-IV族、III-IV族、II-VI族、硅、锗、氮化镓或砷化镓的半导体导电基材21;或者导电基材21可以为铜钨、钼、铜、钨或锰材质...等具有良好导电性的导电基材21。Similarly, when selecting the
如图11B所示,导电基材也可以使用非导电基材26且经过加工后成为导电基材,例如导电基材包括一非导电基材26且在非导电基材26内具有多个第一导电柱27,每一个第一导电柱27都穿透非导电基材26并且与第一金属层25电性连接,同时第一导电柱27也提供了导热的功能。As shown in FIG. 11B, the conductive base material can also use a
第一发光二极管60,借由多个第二金属层33其中之一与多个第一金属层25其中之一结合后,可以使第一发光二极管60固设于第一区域22的第一绝缘层24上。The first
第二发光二极管70,借由一第二金属层33与一第一金属层25结合后,同样的可以使第二发光二极管70固设于第二区域23上。此外,第二发光二极管70与第一发光二极管60可借由多个第二绝缘层90之一及一第一导电层91使彼此相互串联。After the second
第三发光二极管80,借由另一组一第二金属层33与一第一金属层25结合后,使第三发光二极管80固设于第二区域23上。第三发光二极管80与第二发光二极管70也可借由多个第二绝缘层90之一及一第二导电层92使彼此相互并联。The third
如图13所示,同样为了增加发光二极管的出光效率,每一第一发光二极管60、第二发光二极管70及第三发光二极管80分别与每一第二金属层33间可以设有一反射层35,又由于第二发光二极管70及第三发光二极管80要成为一垂直架构,因此至少第二区域23上的反射层35内必须具有多个第二导电柱36,如此才能使第二发光二极管70及第三发光二极管80分别与其对应的第二金属层33电性连接,同样的第二导电柱36也具有导热的功能。As shown in FIG. 13 , in order to increase the light extraction efficiency of the LEDs, a
以上有关LED芯片结构200的实施例,因为是依照LED芯片的制造方法S200实施例所制造出来的产品,因此详细或相同内容的部分将不再重复一一赘述。The above-mentioned embodiment of the
以上所述,仅是本发明的较佳实施例而已,并非对本发明作任何形式上的限制,虽然本发明已以较佳实施例揭露如上,然而并非用以限定本发明,任何熟悉本专业的技术人员,在不脱离本发明技术方案范围内,当可利用上述揭示的技术内容作出些许更动或修饰为等同变化的等效实施例,但凡是未脱离本发明技术方案内容,依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰,均仍属于本发明技术方案的范围内。The above description is only a preferred embodiment of the present invention, and does not limit the present invention in any form. Although the present invention has been disclosed as above with preferred embodiments, it is not intended to limit the present invention. Anyone familiar with this field Those skilled in the art, without departing from the scope of the technical solution of the present invention, may use the technical content disclosed above to make some changes or modify them into equivalent embodiments with equivalent changes, but as long as they do not depart from the technical solution of the present invention, the Technical Essence Any simple modifications, equivalent changes and modifications made to the above embodiments still fall within the scope of the technical solution of the present invention.
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Application publication date: 20130515 |
