Abstract:
A thin-film Light Emitting Diode (LED) and methods of manufacturing the same are disclosed. Specifically, the thin-film LED is provided with an epitaxial layer having a proton implantation that controls the size of the active volume. Controlling the size of the active volume enables the thin-film LED to enjoy decreased rise and fall times, thereby achieving a thin-film LED that is useable for transmission in high transmission rate communication systems.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The present disclosure is generally directed toward Light Emitting Diodes (LEDs) and specifically directed toward thin-film LEDs. 
       BACKGROUND 
       [0002]    Up to now, the only fast Light Emitting Diodes (LEDs) available are volume emitters. The output power of these volume-emitting LEDs is increased by a Bragg reflector at the rear side or at both sides (e.g., resonant cavity LED). Volume emitters are somewhat limited in that they will always have a larger form factor than their thin-film counterparts. 
         [0003]    In the meantime, the progress at High Brightness LEDs (HB-LEDs) is enormously high. These HB-LEDs are designed for use in illumination, specifically in fields of use such as: light bulb replacement; automotive bulbs; and backlighting for flat screen televisions and projectors. All of these high output power LEDs are based on the thin-film manufacturing process. A significant disadvantage to using thin-film LEDs is that they are extremely slow in time behavior. The red thin-film LEDs (e.g., approximately 650 nm) are especially slow. Accordingly, the thin-film LEDs are severely limited in that they can only be used in plastic optical fiber data-rate transmission systems where transmission speeds are no more than 5-10 Mbit/s. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The present disclosure is described in conjunction with the appended figures, which are not necessarily drawn to scale: 
           [0005]      FIG. 1  is a chart depicting coupled power as a function of forward current for 650 nm thin-film LEDs with temperature as an adjusted parameter; 
           [0006]      FIG. 2  is a chart depicting a 650 nm thin-film LEDs stability of coupled power in dBm over a temperature range from −40° C. up to 125° C.; 
           [0007]      FIG. 3  is a chart depicting a thin-film LEDs rise and fall time in nanoseconds as a function of switched current in milliamps; 
           [0008]      FIG. 4  is a chart depicting the impact of the decreased emitting area on the rise and fall time along with a 300 μm×300 μm LED volume emitter&#39;s rise and fall time; 
           [0009]      FIG. 5A  is a cross-sectional view showing a first thin-film LED structure in accordance with embodiments of the present disclosure; 
           [0010]      FIG. 5B  is a cross-sectional view of the thin-film LED in  FIG. 5   a  further showing current flow through the structure in accordance with embodiments of the present disclosure; and 
           [0011]      FIG. 6  is a cross-sectional view showing a second thin-film LED structure in accordance with embodiments of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    Various aspects of the present disclosure will be described herein with reference to drawings that are schematic illustrations of idealized configurations. As such, variations from the shapes of the illustrations as a result, for example, manufacturing techniques and/or tolerances, are to be expected. Thus, the various aspects of the present disclosure presented throughout this document should not be construed as limited to the particular shapes of elements (e.g., regions, layers, sections, substrates, etc.) illustrated and described herein but are to include deviations in shapes that result, for example, from manufacturing. By way of example, an element illustrated or described as a rectangle may have rounded or curved features and/or a gradient concentration at its edges rather than a discrete change from one element to another. Thus, the elements illustrated in the drawings are schematic in nature and their shapes are not intended to illustrate the precise shape of an element and are not intended to limit the scope of the present disclosure. 
         [0013]    It will be understood that when an element such as a region, layer, section, substrate, or the like, is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. It will be further understood that when an element is referred to as being “formed” or “established” on another element, it can be grown, deposited, etched, attached, connected, coupled, or otherwise prepared or fabricated on the other element or an intervening element. 
         [0014]    Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top” may be used herein to describe one element&#39;s relationship to another element as illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of an apparatus in addition to the orientation depicted in the drawings. By way of example, if an apparatus in the drawings is turned over, elements described as being on the “lower” side of other elements would then be oriented on the “upper” side of the other elements. The term “lower” can, therefore, encompass both an orientation of “lower” and “upper” depending of the particular orientation of the apparatus. Similarly, if an apparatus in the drawing is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The terms “below” or “beneath” can therefore encompass both an orientation of above and below. 
         [0015]    Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and this disclosure. 
         [0016]    As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0017]    Various aspects of a thin-film LED may be illustrated with reference to one or more example configurations. A thin-film LED is an LED that is deposited onto a substrate in thin material layers. Thin-film refers to a technology and is not restricted to any particular thickness for each layer. 
         [0018]    Furthermore, various descriptive terms used herein, such as “transparent” should be given the broadest meaning possible within the context of the present disclosure. For example, something that is described as being “transparent” should be understood as having a property allowing no significant obstruction or absorption of electromagnetic radiation in the particular wavelength (or wavelengths) of interest, unless a particular transmittance is provided. 
         [0019]    It is with respect to the above-noted shortcomings that embodiments of the present disclosure were envisioned. In particular, embodiments of the present disclosure contemplate combing red thin-film technologies with proton implantation technologies to yield extremely fast data communication LEDs (e.g., red LEDs) with a very high output power level. The data transmission speed and output power level can be optimized by selectively adjusting the diameter of the active volume of the LED. Considering the number of the Quantum Wells (QW) in the active volume of the LED, the optimization can be expended to the temperature dependency of the output power. With a higher number of the QWs, the temperature degradation gets smaller, but the speed gets slower. 
         [0020]    It should be appreciated that while certain examples discussed herein will be related to a particular type of LED (e.g., red LEDs), the increase in the speed of the LEDs by proton implantation is not restricted to red LEDs. Instead, it should be appreciated that any type of thin-film LED (e.g., blue, green, infrared, etc.) can benefit from the proton implantation mechanisms described herein. 
         [0021]    Due to the fact that the optical output power of such thin-film LEDs is much higher in comparison to the volume emitters, new thin-film LED-based data communication transmitters can be realized with a much lower current consumption. Accordingly, the wall plug efficiency (e.g., ratio of optical output power to electrical input power) is drastically improved, yielding much lower electrical energy consumption in relation to current state-of-the-art plastic optical fiber transmitter products. 
         [0022]      FIG. 1  depicts the coupled power versus the LED current with temperature as a parameter. A state-of-the-art fast volume-emitting LED is also shown. As can be seen in  FIG. 1 , more than 1 mW coupled CW power into a standard 1 mm plastic optical fiber is possible for low current levels using a traditional red thin-film LED. It can also be seen that the slope of the P-I curve is nearly independent of the temperature. 
         [0023]    The stability of the coupled power over a temperature range from −40° C. up to 125° C. is given in  FIG. 2 . Here a multicore glass fiber has been used, as the plastic optical fiber is limited in the temperature range up to 110° C. Only 1 dB output power degradation is measured for the red thin-film LED. 
         [0024]    While traditional thin-film LEDs exhibit fantastic power efficiencies and operating temperatures, traditional thin-film LEDs have a relatively high rise and fall time as compared to their volume emitter counterparts. This phenomenon is depicted in  FIG. 3 , where it is shown that the 20% to 80% rise time is 28 ns when switching the current from 0 to 10 mA and down to 15 ns by switching up to 50 mA. Therefore, such a traditional thin-film LED might be used as source in plastic optical fiber data communication transmission systems as long as the transmission rates are no larger than 10 Mbit/s. 
         [0025]    As is known in the LED arts, the rate equation of the carrier density of an LED is as follows: 
         [0000]    
       
         
           
             
               
                  
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                 t 
               
             
             = 
             
               
                 I 
                 eV 
               
               - 
               
                 n 
                 
                   τ 
                   sp 
                 
               
             
           
         
       
       
         
           and 
         
       
       
         
           
             
               τ 
               sp 
             
             = 
             
               1 
                
               
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                
               
                 ( 
                 
                   B 
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                     n 
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         [0000]    where I is the pump current, I/(eV) is the pumpterm, 
         [0000]    
       
         
           
             n 
             
               τ 
               sp 
             
           
         
       
     
         [0000]    is the spontaneous recombination, B is the radiative recombination coefficient, and  n  is the Quasi stationary carrier density. 
         [0026]    As can be appreciated from the above, some ways to speed up an LED (e.g., increase the 
         [0000]    
       
         
           
             
               
                  
                 n 
               
               
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         [0000]    include increasing the current, I, or decreasing the volume/area of the LED&#39;s active zone. 
         [0027]    The impact of the decreased area on the rise and fall time is shown in  FIG. 4 . For a comparison, the rise and fall time for a 300 μm×300 μm LED (volume emitter) is also given. By decreasing the active volume/area of the LED, the rise and fall time is decreased from 20 ns down to roughly 5 ns for an LED having an active area diameter of approximately 80 μm. 
         [0028]    It is, therefore, one aspect of the present disclosure to utilize this technology for a thin-film LED wafer. By reducing the active area of a thin-film LED, the overall rise and fall time of the thin-film LED can also be reduced. More specifically, the lowest switching time constants will be obtained for thin-film LED wafers with approximately 2 to 5 Quantum Wells in the active zone. 
         [0029]    In particular, it is an aspect of the present disclosure to provide a thin-film LED wafer that is capable of operating in Gigabit data transmission systems. 
         [0030]      FIG. 5A  depicts a first thin-film LED structure  500  in accordance with embodiments of the present disclosure. The LED structure  500  is shown to include a bottom contact  504 , a substrate  508 , a mirror layer  512 , the whole epitaxial layer  516  (e.g., the epitaxial layer  516  may include a heterostructure and cladding layer outside of an active layer or volume  532 ), proton implantation  520 , a passivation layer  524 , and a top contact  528 . It should be appreciated that some or all of the layers or components of the LED structure  500  may be deposited using any type of known deposition technique. Examples of such techniques include, without limitation, Chemical Vapor Deposition (CVD) processes (e.g., metal organic chemical vapor deposition), Atomic Layer Deposition (ALD), plasma-enhanced ALD, and/or photo-enhanced CVD. 
         [0031]    In some embodiments, the bottom contact  504  may correspond to a sintered material and may correspond to an anode of the LED structure  500 . The bottom contact  504  can be constructed of any electrically-conductive material. Examples of suitable materials that can be used for the bottom contact  504  include, without limitation, gold, titanium, nickel, platinum, palladium, chromium, and combinations thereof. In some embodiments, the bottom contact  504  may correspond to an n- or p-metal contact constructed of a high-conductivity metal. 
         [0032]    The substrate  508  may correspond to any type of material suitable to physically and/or mechanically support the other layers of the structure  500 . In some embodiments, the substrate  508  is sapphire, Silicon Carbide, Silicon, or the like. Other types of materials may also be used to construct the substrate  508  including, without limitation, GaAs or Ge, and combinations thereof. 
         [0033]    The mirror layer  512  may correspond to any type of metal or reflective material that helps to direct light generated in the active volume  532  generally upward (e.g., toward the top contact  528 ). Examples of materials that may be used to construct the mirror layer  512  include, without limitation, gold, silver, alumina, etc. 
         [0034]    The epitaxial layer  516  may include an active volume having a plurality of Quantum Wells (e.g., between 2 and 7) that enable the active volume  532  to emit photons in response to having current pass therethrough. Specifically, when an electrical potential is applied across the bottom contact  504  and top contact  528 , electrons may pass through the active volume  532 , thereby causing the active volume  532  to emit photons as a result. As a non-limiting example, the active volume  532  may be constructed of Aluminum-Indium-Gallium-Phosphide (AlInGaP) or a functional equivalent. 
         [0035]    In accordance with at least some embodiments of the present disclosure, the proton implantation  520  is used to constrict or control a size of the active volume  532  within the total planar epitaxial layer  516 . As can be seen in  FIG. 5B , the proton implantation  520  may be used to destroy the crystal structure outside of the active volume  532 , thereby forcing the forward current  536  to flow thru the active volume  532 , yielding an increased carrier density in the active volume  532 . In other words, the proton implantation  520  reduces the cross section of the active volume  532  and eliminates the electrical conductivity outside the active volume  532 . Such a feature can be achieved without having to provide the proton implantation  520  completely through the total epitaxial layer  516 . Rather, the thickness of the proton implantation  520  may be less than the thickness of the epitaxial layer  516  without departing from the scope of the present disclosure. 
         [0036]    Accordingly, the active volume  532  corresponds to the remaining active area of the whole active volume of the LED structure  500 . Positioning of the proton implantation  520  substantially acts as a mask to limit/control the active size of the active volume  532  to diameter D, thereby enabling the LED structure  500  to operate at substantially higher rates (e.g., reducing the overall rise and fall time of the thin-film LED structure  500 ). Thus, incorporating the proton implantation  520  enables the thin-film LED structure  500  to operate as a transmitter in plastic optical data communication systems where transmission rates may exceed 1 Gigabit/sec. According to embodiments of the present disclosure, the thin-film LED structure  500  can be designed for specific bitrate ranges (e.g., anywhere between 10 Mbit/sec and 10 Gigabit/sec) by adjusting the number of Quantum Wells in the active volume  532  as well as controlling the diameter D of the active volume  532 . An illustrative diameter D of the active volume  532  may vary anywhere from 60 um up to 180 um and the specific diameter D of any particular thin-film LED structure  500  can vary depending upon the transmission rate in the optical transmission system, which has to be fulfilled by the LED transmitter. 
         [0037]    In some embodiments, the thin-film LED structure  500  is generally configured to emit light from the active volume  532  toward the passivation layer  524  and top contact  528 . Thus, the depicted thin-film LED structure  500  is configured as a top-emitting LED structure. Furthermore, while embodiments of the present disclosure have discussed using a proton implantation  520  to constrict the active volume  532  to have a diameter D, it should be appreciated that the proton implantation  520  does not necessarily have to constrict the active volume  532  to a circular shape. Instead, the active volume  532 , when viewed from above, may have a square, rectangular, elliptical, polygonal, triangular, or any other type of shape without departing from the scope of the present disclosure. The discussion of a circular active volume  532  is for illustrative purposes only and should not be construed as limiting in any way. 
         [0038]    Completing the discussion of the structure  500 , the passivation layer  524  and top electrode  528  are formed on top of the epitaxial layer  516  and proton implantations  520 . The top electrode  528  may correspond to a cathode of the structure  500  and may include similar or identical materials used for the bottom electrode  504 . The layout, in some embodiments, is an open metal ring with conductive lines inside for an uniform current density in the active zone  532 . The passivation layer  524  may be constructed using any type of deposition technique known in the art. As some non-limiting examples, the passivation layer  524  may correspond to a quarter wavelength (or odd multiple) Si x N y  layer formed on exposed surfaces of the top contact  528 . The establishment of the passivation layer  524  may be done in order to reduce the reflection at the LED-air interface (e.g., refractive index step) and secondly shield the LED material from the environment (e.g., humidity, aggressive atmosphere, etc.). Alternatively, the passivation layer  524  could be formed by sputtering, electron beam evaporation, or by coating with a suitable protective material, such as epoxy or flowable SiO 2 . As another example, spin-coating may prove to be a particularly useful coating technique. In  FIG. 5A , it is shown that the top contact layer  528  comprises an area larger than the active volume  532  by less than the overall area of the total epitaxial  516 . In other words, the top contact  528  is at least partially formed on the proton implantations  520  that establish the active volume  532 , but the current flow is limited thru the active volume  532 . One major difference between thin-film LEDs and volume emitters, is that thin-film LEDs produce substantially more power (e.g., the light produced by thin-film LEDs is more intense), as the metal layer reflectivity is very high. Accordingly, simple substitution of old low-power LEDs with the thin-film LEDs described herein may not be possible. Instead, one may be required to adapt the power output of the thin-film LED so as to avoid saturating the optical receiver in the data communication system. 
         [0039]      FIG. 6  depicts a second thin-film LED structure  600  having a controlled output power. Specifically, the thin-film LED structure  600  may be similar or identical to the thin-film LED structure  500  except that the thin-film LED structure  600  is provided with an attenuation layer  604  that substantially covers the active volume  532 . As a non-limiting example, the attenuation layer  604  may be provided to reduce the output power of the LED structure  600 . In some embodiments, the attenuation layer  604  may be established by evaporating or sputtering a layer of alumina on top of the active passivation layer, outside the bonding area and then oxidizing the alumina. The oxidized alumina is relatively stable and is a very efficient attenuator of light emitted from the active volume  532 . In some embodiments, the thickness of the attenuation layer  604  may be controlled to control the output power level of the LED structure  600 . Of course, different thicknesses of attenuation layers  604  may be selected depending upon the desired output power for the LED structure  600  and the application later on. 
         [0040]    Advantageously, the attenuation layer  604  is constructed so as to directly contact the passivation layer  524  as well as the top contact  528 . In other words, the overall area of the attenuation layer  604  may be larger than the active volume  532  since some light emitted by the active volume  532  may be initially emitted toward the mirror layer  512  and reflected back toward the attenuation layer  604  at an area larger than the active volume  532 . As with the thickness of the attenuation layer  604 , the area of the attenuation layer  604  may also be controlled to accommodate a desired output power for the LED structure  600 . 
         [0041]    Specific details were given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments. 
         [0042]    While illustrative embodiments of the disclosure have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art.