Abstract:
An integrated lighting apparatus includes at least a lighting device, a control device comprising an integrated circuit, and a connector that is used to electrically connect the lighting device and the control device. With the combination, the integrated circuit drives the lighting device in accordance with its various designed functionality, thus expands applications of the integrated lighting apparatus.

Description:
BACKGROUND 
     1. Technical Field 
     The application relates to the field of lighting apparatus, and more specifically, to integrated lighting apparatus and the manufacturing method thereof. 
     2. Related Application Data 
     As the developing of the technology to integrate the light emitting devices and other components, how to adopt the light emitting diodes (LEDs) in various apparatus becomes an interesting topic because of LED&#39;s small size and low power consumption which are suitable for many applications. At present, the packaged light-emitting diodes are integrated with an external control component such as PCB circuit board for the main body, and then illuminates when the LED is controlled and driven by the external control. However, the integration device is too large to meet the current requirement for the electronic products which is light, thin, short, small, and have the extendable module applications. 
     SUMMARY 
     The present disclosure provides a novel structure and the manufacturing method thereof for reducing the volume of the integrated light emitting apparatus. 
     An integrated lighting apparatus comprises a control device including a semiconductor substrate, an integrated circuit block formed on the semiconductor substrate, a plurality of power pad formed on the integrated circuit block, a light emitting device including an active layer, a first electrode, a second electrode, a connector including a first conductive region and a second conductive region, wherein the first electrode is electrically connected to the control device through the first conductive region, and the second electrode is electrically connected to the control device through the second conductive region 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an integrated lighting apparatus according to one embodiment of the present disclosure. 
         FIGS. 2A to 2D  illustrate the corresponding structures fabricated by the manufacturing method according to one embodiment of the present disclosure. 
         FIG. 3  is a schematic view showing a light emitting diode. 
         FIGS. 4A to 4C  illustrate the corresponding structures of a connector fabricated by the manufacturing method according to one embodiment of the present disclosure. 
         FIGS. 5A to 5C  illustrates an integrated lighting apparatus according to one embodiment of the present disclosure. 
         FIG. 6  illustrates an integrated lighting apparatus according to one embodiment of the present disclosure. 
         FIG. 7  illustrates an integrated lighting apparatus according to another embodiment of the present disclosure. 
         FIGS. 8A to 8B  illustrate the corresponding structures fabricated by the manufacturing method according to one embodiment of the present disclosure 
         FIGS. 9A to 9B  illustrate the corresponding equivalent circuit of one embodiment of the present disclosure 
         FIGS. 10A to 10D  illustrate the corresponding structures fabricated by the manufacturing method according to one embodiment of the present disclosure 
         FIG. 11  illustrates an integrated lighting apparatus according to another embodiment of the present disclosure. 
         FIGS. 12A to 12B  illustrate the corresponding structures fabricated by the manufacturing method according to another embodiment of the present disclosure. 
         FIG. 13  illustrates an integrated lighting apparatus according to another embodiment of the present disclosure. 
         FIG. 14  illustrates an integrated lighting apparatus according to another embodiment of the present disclosure. 
         FIG. 15  illustrates an integrated lighting apparatus according to another embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIG. 1  shows a schematic view of a control device  100  including a semiconductor substrate  101 , an integrated circuit block  102  and a plurality of power pads  103 , wherein the integrated circuit block  102  is formed on the semiconductor substrate  101  and the power pads  103  are formed on the integrated circuit block  102 . The integrated circuit block  102  includes a plurality of plugs  1021  and a dielectric block  1022 . The material of the semiconductor substrate  101  can be semiconductor whose band gap is between the insulator and conductor, for example, silicon (Si), germanium (Ge), GaN, GaAs, and so on. The method for forming the integrated circuit block  102  can be semiconductor manufacturing technology such as photolithography process, etching process, thin film process, diffusion process, and ion implantation process, and so on. 
       FIGS. 2A˜2D  further describe the method for manufacturing the integrated circuit block  102 . With reference to  FIG. 2A , the semiconductor substrate  101  has a surface  1011 .  FIG. 2B  shows a plurality of solid-state control units  1023  and separation zones  1024  formed on the surface  1011 , wherein any one of the solid-state control units  1023  includes at least one dopant area  1023   a , at least one gate  1023   b  and at least one connection pad  1023   c . The solid-state control unit  1023  can be field-effect transistor (MOSFET), diode, programmable components (FPGA), bipolar junction transistors (BJT), insulated gate bipolar transistor (IGBT), junction FET (JFET) and so on. Then, the dielectric block  1022  and the plugs  1021  are formed on the semiconductor substrate  101  by chemical vapor deposition (CVD) or spin coating technologies as shown in  FIG. 2C . The dielectric block  1022  includes one or more than one dielectric layer, wherein the material of dielectric block  1022  can be silicon oxide (SiO x ), silicon nitride (SiN x ), titanium dioxide (TiO x ), FSG (Fluorosilicate Glass), PSG (Phosphosilicate Glass), BPSG (Borophosphosilicate Glass), aluminum oxide (AlO x ), and so on. The plugs  1021  electrically connect with the solid-state control units  1023 .  FIG. 2D  shows a control device  100  having a plurality of power pads  103  formed on the integrated circuit block  102 . The control device  100  is a logic circuit, and when applying an external power source, such as DC power source, the current flows through the power pads  103  into the solid-state control units  1023  of the integrated circuit block  102 . The control device  100  operates according to the design of circuit. 
       FIG. 3  shows a schematic view of a light emitting device  200 , wherein the light emitting device  200  can be a light-emitting diode, a laser, a SoC (System on Chip) LED, or a combination of the devices mentioned above. In this embodiment, the light emitting device  200  is a light-emitting diode. The light-emitting device  200  includes a first electrode  201 , a second electrode  202 , a first semiconductor layer  203 , a second semiconductor layer  204 , and an active layer  205 . In order to improve the light extraction efficiency, a reflective layer and current spreading layer (not shown) can be optionally formed in the light-emitting diode  200 . The method for manufacturing the light emitting device  200  is well known on a growth substrate (not shown). The material of the semiconductor layers and the active layer can be III-V semiconductor materials, such as the series of AlGaInP like AlGaInP or AlInP; the series of GaN like MN, GaN, AlGaN, InGaN, AlInGaN; II-VI semiconductor materials like ZnSe, ZnSeCr, ZnSeTe, ZnS, CdSe, and so on. 
       FIG. 4  shows a connector  300  fabricated by the manufacturing method according to one embodiment of present disclosure. With reference to  FIG. 4A , a conductive thin film  305  is formed on the integrated circuit block  102  by thin film deposition process. Next, a portion of the conductive thin film  305  are removed by photolithography and etching process to form a connector  300  containing a first conductive region  301  and a second conductive region  302 , as shown in  FIG. 4B . The first conductive region  301  and second conductive region  302  can be optionally formed with different thickness by photolithography and etching process, as shown in the  FIG. 4C . The first conductive region  301  and second conductive region  302  are electrically connected to the plugs  1021  in the control device  100  respectively. 
       FIG. 5A  shows a schematic view of an integrated light-emitting device  10 A, which is the combination of the control device  100 , the light emitting device  200 , and the connector  300 . In this embodiment, the first conductive region  301  is electrically connected to the first electrode  201 , and the second conductive region  302  is electrically connected to the second electrode  202 , wherein the first conductive region  301  and the second conductive region  302  of the connector  300  can be bonded to the first electrode  201  and second electrode  202  of the light emitting device  200 . In this embodiment, the connector  300  further includes an insulating region (not shown in the figure) surrounding the first conductive region  301  and the second conductive region  302  to avoid electrical interference with the environment and to improve mechanical strength of light-emitting device  10 A. The insulating region is formed by CVD or spin coating process, wherein the material of the insulating region can be silicon oxide (SiO x ), silicon nitride (SiN x ), titanium dioxide (TiO x ), FSG, PSG, BPSG, or aluminum oxide (AlO x ), and so on. The insulating region also can be formed by filling aliphatic polyimide, benzocyclobutane, prefluroic cyclobutane, or epoxide resin surrounding the first conductive region  301  and the second conductive region  302 . 
     An external DC power source  50  generates current flowing through the power pad  103  into the light emitting device  10 A.  FIG. 5B  and  FIG. 5C  show the equivalent circuit diagram, which using the control device  100  as a source and the light emitting device  200  as a drain, or the control device  100  as a drain and the light emitting device  200  as a source. The connector  300  is a circuit electrically connected the control device  100  and light-emitting device  200 . The control device  100  can be designed as a chip of the size of several millimeters to several centimeters, then using the control device  100  to control and drive the light emitting device  200 . The integrated light-emitting device  10 A has smaller size and the method for manufacturing the integrated light-emitting device  10 A is easier. 
     The integrated circuit block  102  can be designed as a control device having functions such as rectification, amplification, and other different functions. Taking the wireless device which requires a compact size as an example, an integrated light emitting device  10 A is formed by combining the light emitting device  200  in a backlight source of the display module and the control device  100  through the connector  300 , wherein the control device  100  is the major circuit of the wireless device. In this wireless device, the current of the light emitting device  200  is adjusted by the control device  100  for changing the brightness of the display module. The control device  100  can be designed as a rectifier to convert alternating current to direct current, so the integrated light emitting device  10 A can use AC power directly. 
       FIG. 6  shows a schematic view of a combination of a control device  100 B, a light emitting device  200 B, and a connector  300 B according to a second embodiment of the present disclosure. The structure and the method for manufacturing the control device  100 B are the same with what is disclosed in the first embodiment. The light emitting device  200 B is a vertical type light emitting diode including a first electrode  201 B, a second electrode  202 B, a second semiconductor layer  204 B, and an active layer  205 B. The connector  300 B includes a first conductive region  301 B, a second conductive region  302 B, and a conduction bridge  303 B. The first electrode  201 B of the light emitting device  200 B is electrically connected to the first connective region  301 B of the conductive region  300 B. The second electrode  202 B of the light emitting device  200 B is electrically connected to the second connector  302 B through the conduction bridge  303 B. The conduction bridge  303 B can be a metal wire. In this embodiment, the connector  300 B further includes an insulating region (not shown) surrounding the first conductive region  301 B and the second conductive region  302 B in order to avoid electrical interference with the environment and to improve the mechanical strength of the integrated light emitting device  10 B. The insulating region is formed by CVD or spin coating process, wherein the material of the insulating region can be silicon oxide (SiO x ), silicon nitride (SiN x ), titanium dioxide (TiO x ), FSG, PSG, BPSG, or aluminum oxide (AlO x ), and so on. The insulating region also could be formed by filling aliphatic polyimide, benzocyclobutane, prefluroic cyclobutane or epoxide resin surrounding the first conductive region  301 B and the second conduction region  302 B. 
       FIG. 7  shows a schematic view of a structure of the integrated light emitting device  10 C according to a third embodiment of present disclosure. The integrated light-emitting device  10 C includes a control device  100 C, a connector  300 C, and a light emitting device  200 C, wherein the control device  100 C includes a semiconductor substrate  101 C, an upper surface  110 C, a lower surface  120 C, an integrated circuit block  102 C, a plurality of power pads  103 C, a first connection pad  104 C, a second connection pad  105 C, a first through plug  106 C, and a second through plug  107 C. The integrated circuit block  102 C includes a plurality of plugs  1021 C and a dielectric block  1022 C. The first connection pads  104 C, the second connection pads  105 C, and power pads  103 C are formed on the upper surface  110 C of the control device  100 C. The first through plug  106 C and a second through plug  107 C extend from the upper surface  110 C to the lower surface  120 C of the control device  110 C, the first through plug  106 C and the second through plug  107 C are electrically connected to the first connection pad  104 C and the second connection pad  105 C, respectively. The dielectric block  1022 C can contain one or more dielectric layers, wherein the material of the dielectric block  1022 C could be silicon oxide (SiO x ), silicon nitride (SiN x ), titanium dioxide (TiO x ), FSG, PSG, BPSG, or alumina (AlO x ), and so on. The method for manufacturing includes CVD, spin coating, and so on. The first connection pad  104 C, the second connection pad  105 C, and the power pad  103 C are made in the same steps. The light emitting device  200 C can be a light emitting diode, a laser, or an SOC emitting diodes. In this embodiment, a light emitting diode  200 C comprises a first electrode  201 C, a second electrode  202 C, a first semiconductor layer  203 C, a second semiconductor layer  204 C, and an active layer  205 C. A reflective layer  206 C can be optionally formed in the integrated light-emitting device  10 C to increase the light emitting efficiency. 
     The connector  300 C includes a first conductive region  301 C, a second conductive region  302 C, an insulating region  400 C, and a first connection surface  320 C. The method for manufacturing the connection region  300 C comprises the steps of forming the first conductive region  301 C, the second conductive region  302 C, and the insulating region  400 C on the lower surface  120 C of control device  100 C by processes like photolithography, etching, and thin film deposition. The material of the first conductive region  301 C and the second conductive region  302 C can be metal, metal compounds and a combination thereof. The material of insulating region  400 C can be silicon oxide (SiO x ), silicon nitride (SiN x ), titanium dioxide (TiO x ), FSG, PSG, BPSG, or aluminum oxide (AlO x ), and so on. The method for manufacturing insulating region  400 C comprises CVD, spin coating, filling techniques, and so on. The first conductive region  301 C is electrically connected to the first through plug  106 C, and the second conductive region  302 C is electrically connected to the second through plug  107 C. 
       FIGS. 8A to 8B  show a schematic view of the process for manufacturing the first through plug  106 C and the second through plug  107 C according to this embodiment. With reference to  FIG. 8A , forming a first through hole  1061 C and a second through hole  1071 C by etching the control device  100 C from the lower surface  120 C to the upper surface  110 C. Then, a single or multi-layers of metals, metal compounds, or combinations thereof can be filled into the first through hole  1061 C and the second through hole  1071 C to form the first through plug  106 C and the second through plug  107 C by CVD, sputter, electro plating or physical vapor deposition (PVD) thin film process, as shown in  FIG. 8B . The manufacturing process of the power pad, the first connection pad, and the second connection pad and the manufacturing process of the first through plug and the second through plug can be exchanged, which means that the first and second power pad, first through plug, and second through plug can be completed firstly. In addition, the first through plug and second through plug in order to reduce the interference of integrated circuit block  102 C, an insulating region can be firstly formed on the inner wall of the first through hole  1061 C and the second through hole  1071 C. Then, the single or multi-layers metal of metals, metal compounds, or the combinations thereof are filled into the first through hole  1061 C and second through hole  1071 C to form the first through plug  106 C and the second through plug  107 C. 
     An external DC power source generates current and through the power pad  103 C into the light emitting device  10 C.  FIGS. 9A and 9B  show the equivalent circuit diagram of  FIGS. 8A and 8B . The control device  100 C as a source and light emitting diode  200 C as a drain, or the control device  100 C as a drain and light emitting diodes as a source  200 C. The connector  300 C is a circuit electrically connected the control device  100 C and the light emitting device  200 C. 
     Forming the first through plug  106 C and the second through plug  107 C in the control device  100 C, and placing the light emitting device  200 C near the lower surface of the control device  100 C. The first through plug  106 C and the second through plug  107 C are formed in the non-integrated circuits  102 C to avoid the internal complex integrated circuits of control device  100 C and to increase the tolerance of the process. Another advantage of this embodiment is that the light emitting device  200 C is near the lower surface of the control device  200 C so the upper surface of control device  100 C have the space to integrate the second control device into a multi-functions system. 
     As shown in  FIG. 10  A, the control device  100 D includes a first surface  110 D, a second surface  120 D, a semiconductor substrate  101 D, an integrated circuit block  102 D, a plurality of power pads  103 D, a first connection pad  104 D, and a first through plug  106 D. The integrated circuit block  102 D includes a plurality of plugs  1021 D and a dielectric block  1022 D. The first connection pad  104 D and the power pads  103 D are formed on the first surface  110 D, and the first connection pad  104 D is electrically connected to the integrated circuit block  102 D and the first through plug  106 D. The power pad  103 D can be electrically connected to an external power supply to import the current into the control device  100 D. The first through plug  104 D extends from the first surface  110 D to the second surface  120 D and electrically connected to the first connection pad  104 D. The first connection pad  104 D and the power pad  103 C can be produced in the same steps. The semiconductor substrate  101 D includes an extension component  1011 D protruding outside of the control device  100 D. The dielectric block  1022  contains one or more dielectric layers, wherein the material of dielectric layer  1022  can be silicon oxide (SiO x ), silicon nitride (SiN x ), titanium dioxide (TiO x ), FSG, PSG, BPSG, or alumina (AlO x ). Manufacturing methods includes CVD, spin coating, and so on. The method for manufacturing the first through plug  106 D and the first through plug  106 C of the third embodiment are the same process. 
       FIGS. 10B-10D  show a schematic view of the process for manufacturing the connector  300 D. Firstly, forming two connection holes  303 D in the extension component  1011 D in the semiconductor substrate by photolithography and etching processes, and then forming a conduction layer  304 D onto the second surface  120 D of control device  100 D and filling the connection holes  303 D by CVD, sputtering, electro plating, PVD process and their combination, as shown in  FIG. 10C . The material of the conduction layer  304 D can be single or multi-layer of metals, metal compounds, or combinations thereof. After that, forming the first conductive region  301 D and the second conductive region  302 D, wherein the first conductive region  301 D is electrically connected to the first through plug  106 D. In this embodiment, the extension component  1011 D of the semiconductor substrate in the control device  100 D can be used to form the connector  300 D, and without additional insulating region to cover the first and second conductive regions. 
       FIG. 11  shows a combination of the light emitting device  200 D and the control device  100 D by the connector  300 D to form an integrated light emitting device  10 D. The second conductive region  302 D of the connector  300 D is electrically connected to a second light emitting device after completing of the integrated light emitting devices  10 D. Also, the light emitting device  200 D is electrically connected to the control device  100 D in an extension component  1011 D of semiconductor substrate so the first surface  110 D of the control device  100 D can be connected to other components such as a second control element or a second light emitting device. 
     As shown in  FIGS. 12A˜12B , a plurality of control devices  100 E and connectors  300 E are formed on a semiconductor wafer  500 . The manufacturing methods of the control devices  100 E and the connectors  300 E are similar, such as photolithography, etching, thin film, diffusion, and ion implantation processes. In this embodiment, the manufacturing process is at wafer-level such that a large number of control devices  100 E and a plurality of connectors  300 E can be completed quickly and at the same time. In this embodiment, further includes a carrier  600  that contains a plurality of light emitting device  200 E. As shown in  FIG. 12B , the light emitting devices  200 E are attached to the connectors  300 E by bonding. Finally, the carrier  600  is removed to form a plurality of integrated light emitting devices  10 E, as shown in  FIG. 13 . The plurality of integrated light emitting devices  10 E can be cut into a single integrated light-emitting device  10 E, or also to cut into a light-emitting system includes more than one integrated light emitting devices  10 E. 
       FIG. 14  shows a backlight module  700 , wherein the backlight module  700  includes a light source device  710  comprising the light-emitting device  711  described in above embodiments of the present disclosure, and an optical device  720  placed on the light path of light source device  710  to process the light appropriately. A power supply system  730  provides the required power to the light source device  710 . 
       FIG. 15  shows a schematic view of a lighting device  800 , which can be the lamps of car, street lights, flashlights, an indicator lights, and so on. The light device  800  includes a light source device  811  comprising the light emitting device  810  mentioned above, a power supply system  820  to provide the required power, and a control elements  830  to control the current input. 
     It will be apparent to those having ordinary skill in the art that various modifications and variations can be made to the devices in accordance with the present disclosure without departing from the scope or spirit of the disclosure. In view of the foregoing, it is intended that the present disclosure covers modifications and variations of this disclosure provided they fall within the scope of the following claims and their equivalents. 
     Although the drawings and the illustrations above are corresponding to the specific embodiments individually, the element, the practicing method, the designing principle, and the technical theory can be referred, exchanged, incorporated, collocated, coordinated except they are conflicted, incompatible, or hard to be put into practice together. 
     Although the present application has been explained above, it is not the limitation of the range, the sequence in practice, the material in practice, or the method in practice. Any modification or decoration for present application is not detached from the spirit and the range of such.