Patent ID: 9653642
Date: 2017-05-16
CPC Classifications: H01L,H01S

Claim:
1. A method for manufacturing a multi-wavelength light-emitting-diode based display panel device, the method comprising: providing at least one carrier wafer; providing a first substrate having a first surface region; forming a first gallium and nitrogen containing epitaxial material overlying the first surface region, the first epitaxial material comprising a first release material overlying the first substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing region configured to emit electromagnetic radiation at a first wavelength, and a p-type gallium and nitrogen containing region overlying the first release material; patterning the first epitaxial material and forming mesas to form a first plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a first pitch between the adjacent die in the array; forming a first interface region overlying the first epitaxial material, the first interface region comprising a metal, a semiconductor, dielectric, oxide, glass, or a polymer; subjecting the first release material to a photo electrochemical (PEC) etch to completely or partially remove the first release material; bonding the first interface region to the at least one carrier wafer to form a bonded structure, while maintaining the first release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of first dice provided on the first substrate member to transfer a first plurality of dice to the at least one carrier wafer; wherein each pair of the transferred dice is configured with a second pitch between each pair of dice on a carrier wafer, the second pitch being equal or greater than the first pitch; providing a second substrate having a second surface region; forming a second gallium and nitrogen containing epitaxial material overlying the second surface region, the second epitaxial material comprising a second release material overlying the second substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing region configured to emit electromagnetic radiation at a second wavelength, and a p-type gallium and nitrogen containing region overlying the second release material; patterning the second epitaxial material and forming mesas to form a second plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a third pitch between the adjacent die in the array; forming a second interface region overlying the second epitaxial material, the second interface region comprising a metal, a semiconductor, dielectric, oxide, glass, or a polymer; subjecting the second release material to an etching process to completely or partially remove the second release material; bonding the second interface region to the at least one carrier wafer to form a bonded structure, while maintaining the second release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of second dice provided on the second substrate member to transfer a second plurality of dice to the at least one carrier wafer wherein each pair of the transferred dice is configured with a fourth pitch between each pair of dice on a carrier wafer, the fourth pitch being equal or greater than the third pitch; and processing the at least one carrier wafer with at least the first plurality of dice and the second plurality of dice to form a multi-color light emitting diode based display panel device operable at least the first wavelength and the second wavelength.