Substrate with lithium imide layer, LED with lithium imide layer and manufacturing method thereof

A substrate with a lithium imide layer, a LED with a lithium imide layer and a manufacturing method of the LED are provided. The substrate includes a lithium niobate layer and a lithium imide layer. The lithium imide layer is formed on a surface of the lithium niobate layer.

This application claims the benefit of Taiwan Patent Application No. 105127877, filed Aug. 30, 2016, the subject matter of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a semiconductor substrate, a LED and a manufacturing method thereof, and more particularly to a substrate with a lithium imide layer, a LED with a lithium imide layer and a manufacturing method thereof.

BACKGROUND OF THE INVENTION

Generally, a gallium nitride light emitting diode (GaN LED) is grown on a C-plane of a sapphire substrate. However, the lattice constant and the thermal expansion coefficient of the sapphire substrate are obviously distinguished from those of gallium nitride. Consequently, a strain between the gallium nitride epitaxy layer and the sapphire substrate is usually generated.

Moreover, because of the electric insulation property and the thermal insulation property of the sapphire substrate, the efficiency, life and brightness of the GaN LED are adversely affected. Consequently, the technology of growing GaN on sapphire is not satisfied.

Recently, researchers make efforts in the technology of growing gallium nitride on the gallium nitride substrate (i.e., GaN on GaN). Due to the lattice matching effect, it is presumed that the epitaxy layer grown on the GaN substrate has enhanced efficiency for the light emitting diode or the laser diode. However, it is difficult to fabricate the gallium nitride substrate, and the fabricating cost of the gallium nitride substrate is very high. In other words, mass production of the gallium nitride substrate is not feasible so far.

In addition to the sapphire substrate and the gallium nitride substrate, other technologies are researched. For example, the technology of growing gallium nitride on the silicon substrate (GaN on Si) and the technology of growing gallium nitride on the silicon carbide substrate (GaN on SiC) are related technologies.

SUMMARY OF THE INVENTION

The present invention provides a substrate with a lithium imide layer, a LED with a lithium imide layer and a manufacturing method thereof. Due to the lattice match between the lithium imide layer and the gallium nitride (GaN), aluminum gallium nitride (AlGaN) or aluminum nitride (AlN), a metal nitride layer is suitably grown on the lithium imide layer.

An embodiment of the present invention provides a substrate. The substrate includes a lithium niobate layer and a lithium imide layer. The lithium imide layer is formed on a surface of the lithium niobate layer.

Another embodiment of the present invention provides a manufacturing method of a light emitting diode. Firstly, a lithium niobate layer is provided. Then, a chemical reaction is carried out to form a lithium imide layer on a surface of the lithium niobate layer. Then, a stack structure of plural metal nitride layers is formed on a first surface of the lithium imide layer. Then, a lift-off process is performed to separate the lithium niobate layer from the lithium imide layer, so that a second surface of the lithium imide layer is exposed. Then, a metal layer is formed on a second surface of the lithium imide layer. Afterwards, an electrode is formed on the stack structure of the plural metal nitride layers.

A further embodiment of the present invention provides a light emitting diode. The light emitting diode includes a lithium imide layer, a stack structure of plural metal nitride layers, a metal layer and an electrode. The stack structure of plural metal nitride layers is formed on a first surface of the lithium imide layer. The metal layer is formed on a second surface of the lithium imide layer. The electrode is formed on the stack structure of the plural metal nitride layers.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention provides a substrate with a lithium imide (Li2NH) layer. After a lithium niobate (LiNbO3) layer is subjected to a chemical reaction, the lithium imide layer is formed on a surface of the lithium niobate layer. Consequently, the substrate with the lithium imide layer is produced. The lattice constant of the lithium imide layer is close to the lattice constant of the nitrides of the elements of Group III-V. Consequently, the nitrides of the elements of Group III-V are suitably grown on the lithium imide layer. Consequently, the light emitting diode (LED) with the lithium imide layer is produced.

FIG. 1is a substrate with a lithium imide layer according to an embodiment of the present invention. As shown inFIG. 1, the substrate100comprises a lithium niobate layer102and a lithium imide layer104. The lithium imide layer104is formed on a surface of the lithium niobate layer102.

FIG. 2is a flowchart illustrating a manufacturing method of a substrate with a lithium imide layer according to a first embodiment of the present invention. Firstly, a lithium niobate layer is provided (Step S202). Then, a chemical reaction is carried out on the lithium niobate layer, and thus a lithium imide layer is formed on a surface of the lithium niobate layer (Step S204). For example, the chemical reaction is an ammoniation reaction.

In an embodiment, after the lithium niobate layer102is treated with ammonia gas (NH3) at a flow rate of 40 sscm at 700° C. for 1 hour, the lithium imide layer104with a thickness of about 1.64 μm is formed on the surface of the lithium imide layer104. Consequently, the substrate100with the lithium imide layer104is produced.

FIG. 3Aschematically illustrates the X-ray diffraction pattern of the substrate with the lithium imide layer according to an embodiment of the present invention.FIG. 3Bschematically illustrates the X-ray diffraction pattern of a silicon substrate with an aluminum gallium nitride layer Al(1-x)GaxN.FIG. 3Cschematically illustrates the X-ray diffraction pattern of a sapphire substrate with a gallium nitride (GaN) layer, an aluminum gallium nitride (AlGaN) layer and an aluminum nitride (AlN) layer.

As shown inFIGS. 3A and 3B, the 2-theta angle (2θ) of the lithium imide layer on the (200) plane is about 35.6°, the 2-theta angle (2θ) of the aluminum nitride (AlN) layer on the (0002) plane is about 36°, and the 2-theta angle (2θ) of the gallium nitride (GaN) layer on the (0002) is about 34.5°. In other words, the lattice of the lithium imide layer on the (200) plane matches the lattice of the aluminum nitride (AlN) layer on the (0002) plane or the lattice of the gallium nitride (GaN) layer on the (0002).

Similarly, the lattice of the lithium imide layer on the (400) plane matches the lattice of the aluminum nitride (AlN) layer on the (0004) plane or the lattice of the gallium nitride (GaN) layer on the (0004).

As shown inFIGS. 3A and 3C, the 2-theta angle (2θ) of the lithium imide layer on the (311) plane is about 60.42°, and the 2-theta angle (2θ) of the aluminum nitride (AlN) layer on the (11-20) plane is about 60.5°. In other words, the lattice of the lithium imide layer on the (311) plane matches the lattice of the aluminum nitride (AlN) layer on the (11-20) plane.

Since the lattice of the lithium imide layer matches the lattice of the aluminum nitride (AlN) layer or the lattice of the gallium nitride (GaN) layer, a light emitting diode can be produced by forming metal nitride layers on the lithium imide layer.

FIGS. 4A, 4B and 4Care schematic cross-sectional views illustrating a process of manufacturing a LED with a lithium imide layer according to an embodiment of the present invention.

Firstly, a substrate400with a lithium niobate layer402and a lithium imide layer404is provided. Then, a stack structure410of plural metal nitride layers are formed on the lithium imide layer404. In an embodiment, the plural metal nitride layers comprise a P-type metal nitride layer416, a metal nitride active layer417and an N-type metal nitride layer418. For example, the P-type metal nitride layer416is a P-type aluminum nitride (AlN) layer, a P-type aluminum gallium nitride (AlGaN) layer or a P-type gallium nitride (GaN) layer. The metal nitride active layer417is an aluminum nitride (AlN) active layer, an aluminum gallium nitride (AlGaN) active layer or a gallium nitride (GaN) active layer. The N-type metal nitride layer418is an N-type aluminum nitride (AlN) layer, an N-type aluminum gallium nitride (AlGaN) layer or an N-type gallium nitride (GaN) layer. In some embodiments, the stack structure410comprises more than three metal nitride layers.

Then, as shown inFIG. 4B, a lift-off process is performed to separate the lithium niobate layer402from the lithium imide layer404. After the lift-off process is completed, the plural meal nitride layers are stacked on a first surface of the lithium imide layer404. Since the lithium niobate layer402is detached from the lithium imide layer404, a second surface of the lithium imide layer404is exposed. The lift-off process is a laser lift-off process or any other appropriate lift-off process.

Then, as shown inFIG. 4C, a bonding process is performed. By the bonding process, a metal layer422is attached on the second surface of the lithium imide layer404. The metal layer422is used as a reflective layer of the LED or an electrode of the LED. Afterwards, another electrode420is formed on the stack structure410of plural metal nitride layers. Consequently, the LED with the lithium imide layer is manufactured.

FIG. 5is a flowchart illustrating a manufacturing method of a substrate with a lithium imide layer according to a second embodiment of the present invention. Firstly, a lithium niobate layer is provided (Step S402). Then, at least one metal oxide layer is formed on the lithium niobate layer (Step S404). Then, a chemical reaction is carried out to form a lithium imide layer on a surface of the lithium niobate layer (Step S406).

In the step S404, the at least one metal oxide layer is formed on the lithium niobate layer by an atomic layer deposition process. For example, the metal oxide layer is a hafnium oxide (HfO) layer or a zinc oxide (ZnO) layer. Alternatively, the at least one metal oxide layer is a stack structure of plural metal oxide layers, e.g., a three-layered stack structure of a hafnium oxide (HfO) layer, a zinc oxide (ZnO) layer and another hafnium oxide (HfO) layer. In the step S406, the chemical reaction is an ammoniation reaction.

The deposition of the metal oxide layer can accelerate the formation of the lithium imide layer. After a stack structure with a hafnium oxide (HfO) layer, a zinc oxide (ZnO) layer and another hafnium oxide (HfO) layer is deposited on the lithium niobate layer, the lithium niobate layer is treated with ammonia gas (NH3) at a flow rate of 40 sscm at 700° C. for 1 hour. Then, a lithium imide layer with a thickness of about 2.532 μm is formed on the surface of the lithium imide layer. Consequently, the substrate with the lithium imide layer is produced.

From the above descriptions, the present invention provides a substrate with a lithium imide layer and a manufacturing method of the substrate. After a lithium niobate layer is subjected to a chemical reaction, the lithium imide layer is formed on a surface of the lithium niobate layer. Consequently, the substrate with the lithium imide layer is produced. The lattice constant of the lithium imide layer is close to the lattice constant of the nitrides of the elements of Group III-V. Consequently, the nitrides of the elements of Group III-V are suitably grown on the lithium imide layer. Consequently, the light emitting diode (LED) with the lithium imide layer is produced.

During the ammoniation reaction of the lithium niobate layer, dehydrogenation of the nitrogen-hydrogen bond leads to the increase of positively charged holes. Consequently, the lithium imide layer is a P-type layer. That is, the substrate with the lithium imide layer is a P-type substrate.