Abstract:
A method of manufacturing a vertical light emitting diode includes: providing a first substrate; forming a lapping stop layer on the first substrate, the lapping stop layer being harder than the first substrate; depositing an epitaxial layer on the lapping stop layer; bonding a second substrate on the epitaxial layer; and removing the first substrate from the lapping stop layer.

Description:
BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    The present disclosure relates generally to light emitting devices, and more particularly to a method of manufacturing a vertical light emitting diode (LED). 
         [0003]    2. Description of Related Art 
         [0004]    Generally, a nitride-based semiconductor LED is grown on a sapphire substrate, but the sapphire substrate is a rigid nonconductor and has poor thermal conductivity. Therefore, there is a limitation in reducing the manufacturing costs by reducing the size of a nitride-based semiconductor LED, or improving the optical power and chip characteristic. Particularly, because the application of a high current is essential for achieving high power LED, it is important to solve a heat dissipation problem of the LED. To solve this problem, there has been proposed a vertical LED in which a sapphire substrate is removed by using a laser lift off (LLO) technique or a lapping process. 
         [0005]    However, the LLO technique may be inadequate and inefficient for manufacturing large size LED due to a high cost thereof. In addition, cracks may occur at the edge of a light emitting structure of the LED, which reduces the reliability of the LED. Although the lapping process has the advantage of low cost and high efficiency compared with the LLO technique, it is difficult to differentiate the interface between different layers of the LED, resulting in a high risk of damage of the light emitting structure of the LED. 
         [0006]    What is needed therefore is a method of manufacturing a vertical light emitting diode which can overcome the above mentioned limitations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    Many aspects of the present embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the views. 
           [0008]      FIGS. 1-7  are cross sectional views of a vertical light emitting diode in different manufacturing steps of a method in accordance with an embodiment of the present disclosure. 
           [0009]      FIG. 8  is a cross sectional view of a light emitting diode obtained by a method in accordance with an alternative embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0010]    The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. It is understood that when an element such as a layer, region or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. It is understood that if part of an element, such as a surface, is referred to as “outer”, it is near from the outside of the device than other parts of the element. Furthermore, the term “directly” means that there are no intervening elements. 
         [0011]    Referring to  FIG. 1 , a first substrate  11  is provided. The first substrate  11  may be one of sapphire, Si, GaAs, InP, SiC, or other suitable materials. 
         [0012]    Referring to  FIG. 2 , a lapping stop layer  12  is formed on or directly formed on the first substrate  11 . A hardness of the lapping stop layer  12  is larger than that of the first substrate  11 . The lapping stop layer  12  is preferred to transparent, whereby it is not needed to be removed in the following procedure. It is understood that the lapping stop layer  12  may also be opaque which should be removed in the following procedure to increase a light emitting efficiency of the light emitting diode. The lapping stop layer  12  may be one of diamond, diamond like carbon (DLC), SiC, Al 2 O 3 , quartz, Si 3 N 4 , SiO 2 , GaN, AlN, InN or other suitable materials, or a mixture of two or more of diamond, DLC, SiC, Al 2 O 3 , quartz, Si 3 N 4 , SiO 2 , GaN, AlN, InN. The lapping stop layer  12  may be formed on the first substrate  11  by a process of metal organic chemical vapor deposition (MOCVD), plasma-enhanced chemical vapor deposition (PECVD), evaporating, sputtering, or other chemical or physical processes. The lapping stop layer  12  may be configured as dots, islands, plates or other suitable shapes. The lapping stop layer  12  is evenly distributed on a surface of the first substrate  11 . Voids defined in the lapping stop layer  12  may be a path of circuit, and also a place for deposition of an epitaxial layer  13  ( FIG. 3 ) with high quality. The lapping stop layer  12  is 0.7-2 μm thick, which is a benefit for growing the epitaxial layer  13 . 
         [0013]    As shown in  FIG. 3 , the epitaxial layer  13  is grown on the lapping stop layer  12 . The epitaxial layer  13  is a multi-layered structure composed of semiconductor compounds. The semiconductor compounds include semiconductors of Group III-V or Group II-VI, and a typical one is a GaN-based semiconductor. 
         [0014]    Referring to  FIG. 4 , a second substrate  14  is bonded to the epitaxial layer  13 . The second substrate  14  may be one of Si, Al, Cu or other suitable conductive materials. Bonding the second substrate  14  on the epitaxial layer  13  may be accomplished with metallic bonding, adhesion, electronic plating, chemical plating or spin-coating, etc. 
         [0015]    As shown in  FIG. 5 , the first substrate  11  is removed by grinding, lapping or polishing. Since the lapping stop layer  12  is harder than the first substrate  11 , lapping speeds of the two are quite different, and the lapping can be stopped precisely as soon as the lapping tool touches the lapping stop layer  12 . Thereby, the epitaxial layer  13  is avoided to be lapped away by the lapping tool. 
         [0016]    As shown in  FIG. 6 , the lapping stop layer  12  is still remained in the epitaxial layer  13 . An exposed bottom portion of the epitaxial layer  13  and an exposed bottom portion of the lapping stop layer  12  cooperatively form a compound surface  16 . When the lapping stop layer  12  is transparent, there is no need to remove the lapping stop layer  12 , and an electrode  15  can be directly formed on the compound surface  16  to form a vertical light emitting diode  10 . 
         [0017]    In addition, the present embodiment comprises roughening the compound surface  16  by wet or dry etching for increasing a light output efficiency of the light emitting diode  10 , as illustrated in  FIG. 7 . 
         [0018]    Referring to  FIG. 8 , in an alternative embodiment, the lapping stop layer  12  can be removed by etching (such as inductively coupled plasma etching) to expose the epitaxial layer  13 . The electrode  15  can be plated on the epitaxial layer  13 . Accordingly, an outer surface of the epitaxial layer  13  can also be roughened to increase the light output efficiency of the light emitting diode  10 . 
         [0019]    The method of the present disclosure utilizing the characteristic of the different lapping speeds between the first substrate  11  and the lapping stop layer  12 , to precisely control a lapping value and prevent from destroying the epitaxial layer  13 . The method of the present disclosure is more suitable for manufacturing larger wafer and may save time and cost. 
         [0020]    It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the disclosure or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the disclosure.