Patent Publication Number: US-2006001055-A1

Title: Led and fabrication method of same

Description:
This application claims the priority benefit under 35 U.S.C. §119 of Japanese Patent Application No. 2004-338624 filed on Nov. 24, 2004 and Japanese Patent Application No. 2004-046173 filed on Feb. 23, 2004, which are both hereby incorporated in their entirety by reference.  
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to an LED and a fabrication method of the LED.  
      2. Description of the Related Art  
      Conventionally, an LED such as a power white LED is configured as shown in  FIG. 34 . Namely, as shown in  FIG. 34 , an LED  1  is configured by forming a horn  2   a,  which results from a concave recessed portion, on a conductive substrate  2  including a metal such as copper that has a high thermal conductivity, directly mounting an LED chip  3  on the bottom surface of the horn  2   a,  thereafter disposing phosphors (not shown) inside the horn  2   a,  and covering the periphery and surface of the conductive substrate  2  with an insulator  4  such as a resin or ceramic.  
      According to the LED  1  of this configuration, the LED chip  3  is supplied with electricity from the outside, whereby the LED chip  3  is driven and emits light, the light emitted from the LED chip  3  is directly reflected or reflected by the inner walls of the horn  2   a,  thereafter strikes the phosphors, excites the phosphors, and the light becomes white due to the mixing of the colors of the excitation light and the light from the LED chip  3  and is emitted to the outside.  
      As shown in  FIG. 35 , an LED  1 ′ of a configuration where a sub-mount substrate  5 , which comprises a ceramic or silicon in which an electrode is formed by patterning, is disposed on the bottom surface of the horn  2   a  and the LED chip  3  is mounted on the sub-mount substrate  5  is also known.  
      An LED  6  of a configuration as shown in  FIG. 36  is also known. As shown in  FIG. 36 , the LED  6  is configured by forming a horn  7   a,  which results from a concave recessed portion, on an insulator substrate  7  such as a ceramic or resin, patterning an electrode  7   b  by printing, plating or depositing the electrode inside the horn  7   a,  thereafter mounting the LED chip  3  on the electrode  7   b,  and then disposing phosphors (not shown) inside the horn  7   a.    
      It should be noted that, as shown in  FIG. 37 , the horn  7   a  may also be configured by laminating a thin insulator substrate. According to the LED  6  of this configuration, the LED chip  3  is similarly supplied with electricity from the outside, whereby the LED chip  3  is driven and emits light, the light emitted from the LED chip  3  is directly reflected or reflected by the inner walls of the horn  7   a,  thereafter strikes the phosphors, excites the phosphors, and the light becomes white due to the mixing of the colors of the excitation light and the light from the LED chip  3  and is emitted to the outside.  
      An LED  8  of a configuration as shown in  FIG. 38  is also known. As shown in  FIG. 38 , the LED  8  has substantially the same configuration as that of the LED  6  shown in  FIG. 36 , and has the different configuration of a plural of LED chips  3  (two LED chips in the drawings) mounted in the horn  7   a.    
      With respect to the LED  1 , it may be necessary to mutually connect the LED chips  3  in parallel when fabricating a multichip LED, because a metal with a high thermal conductivity is used for the mount portions of the LED chips  3 , and the current is supplied to the LED chips via the mount portion. For this reason, the current ends up being concentrated at the LED chips  3 , whose Vf resulting from variation is low, and sometimes the lifespan ends up becoming short.  
      In contrast, with respect to the LED  1 ′, it is possible to mutually connect the LED chips  3  in series when fabricating a multichip LED because the sub-mount substrate  5  is used, but the number of parts increases, the cost of the parts and assembly costs become high, and the number of joint portions increases. Thus, there is the problem that thermal resistance at the time of operation ends up increasing.  
      Also, with respect to the LED  6 , it is possible to mutually connect the LED chips  3  in series when fabricating a multichip LED because the electrode is patterned with respect to the insulator substrate  7 , but the light emission efficiency drops, the emitted light beams are reduced, and the lifespan drops because the insulator configuring the insulator substrate  7  has a low thermal conductivity.  
      With respect thereto, ceramic materials such as an AlN ceramic have come to be developed as insulators with a high thermal conductivity, but there are the problems that the cost of the materials themselves is high and the processability is poor.  
      Moreover, with respect to the LED  1 , the LED  1 ′ and the LED  6 , there is a limit on the extent to which the chips can be made compact because it is necessary to form the horns  2   a  and  7   a  in both, and incorporating other elements and circuits inside the package has been substantially difficult.  
      Furthermore, with respect of the LED  8 , the total power of light, namely the power of light taken out upward falls down less than the sum of the individual powers of each LED chip  3 , because the light absorption among the LED  6  depends on the distance of the LED chips  3 , and because the light that emitted from each LED chips  3  is reflected by the inclined side surface of the horn  7   a  and returned to the LED chips  3  is absorbed by the LED chips  3 .  
      With respect of the brightness distribution of the light taken out upward, the variation is produced accordance with the distances among each LED chip  3  and the above mentioned light absorption of the LED chips  3 .  
      With respect thereto, by providing a partition made of the non-transparent material, the light absorption among each LED chip  3  can be excluded. But, in the case the partition is provided by machine-working or resin molding, the distance between each LED chip  3  is widened, so that the characteristic of the light distribution become worse and the uneven brightness occurs.  
      Moreover, with respect to the LED  1 , the LED  1 ′, the LED  6  and the LED  8 , as shown in the  FIG. 39 , for example in the case that the LED  6  is mounted on the mounting board  9  such as the printed board, the flexible board etc. (or lead frame), for electrically connecting the LED chip to the connecting portion  9 a of the conductive pattern on the mounting board  9 , the bonding wire  9   b  (or lead wire) is necessary, because the so-called reflow-soldering for improving the efficiency of the mounting process cannot be carried out.  
      Accordingly, since a joining strength or an insulation of the above mentioned bonding wire or lead wire are insufficient, it is necessary to cover these by a resin molding or a package for protecting these bonding wire or lead wire. So, the advantages of a small- or thin-size of the LED package cannot be utilized.  
      With respect of fixing the LED  1  on the mounting board  9 , an adhesive is needed, and in the case that the LED is mounted adjacent to other parts such as a lens-module etc., the above mentioned bonding wire can be interfered, and it is difficult to the LED on the mounting board with maintaining the heat-radiation.  
     SUMMARY OF THE INVENTION  
      In light of the above, in accordance with an aspect of the invention, an LED and a fabrication method thereof can be provided where a rise in temperature resulting from heat emission can be excellently suppressed, where the fabrication of a multichip LED is easily possible, and which can be easily and compactly configured, where, in the case of a plural of LED chips are provided, a light power is raised as high as possible, and where the LED can be mounted easily without a bonding wire.  
      The conventional art has several drawbacks. In accordance with an aspect of the invention, the following exemplary advantages and features can be provided;  
      (1) in the working process of the silicon substrate, a dry process is not needed,  
      (2) in the process of electrode patterning, a contact is formed by a spray method or an electro-forming method, not by a laser trimming process,  
      (3) an electrode pattern can be formed only on a LED-mounted surface of the silicon substrate, and is not necessarily formed on a back surface of the silicon substrate,  
      (4) it is possible to provide a dummy pattern for heat-radiation on a back surface of the silicon substrate.  
      In accordance with another aspect of the invention there can be provided an LED including a silicon substrate; a pair of electrodes can be formed inside a horn formed on the silicon substrate by anisotropic etching; an LED chip can be mounted inside the horn, the LED chip being electrically connected to the pair of electrodes; and a resin mold can be made of a resin material that is filled in the horn.  
      The horn can be formed by etching the silicon substrate from an upper surface of the silicon substrate to an intermediate height and that each electrode be formed so as to extend along the surface of the silicon substrate from a bottom surface of the horn via side surfaces of the horn. The silicon substrate may include a flat first substrate having a surface on which the electrodes are formed and a second substrate laminated on the first substrate, the second substrate being provided with the horn that vertically penetrates the second substrate. The LED chip can be die-bonded to one of the pair of electrodes inside the horn and is wire-bonded to the other of the pair of electrodes inside the horn. The LED chip can be mounted so as to straddle the pair of electrodes inside the horn, with electrodes formed at both lower side edges of the LED chip being electrically connected respectively to the pair of electrodes inside the horn. The silicon substrate may be formed with a (100) surface serving as the surface, and the side surfaces of the horn may be formed as (111) surfaces. The side surfaces of the horn can be provided with a mirror surface on the surfaces. An actuator and an IC circuit may be formed adjacent to the horn on the silicon substrate. Granular phosphors may be mixed in with the resin material forming the resin mold.  
      In accordance with another aspect of the invention there can be provided a method of fabricating an LED that can include providing a silicon substrate having a surface in which a horn is formed by anisotropic etching, the horn having a pair of electrodes formed therein; mounting an LED chip inside the horn such that the LED chip is electrically connected to the pair of electrodes; and filling the interior of the horn with a resin material to form a resin mold.  
      The LED chip can be supplied with electricity from the outside via the electrodes, whereby the LED chip is driven. Then, the light emitted from the LED chip can be directly reflected or reflected by the bottom surface or the side surfaces of the horn of the silicon substrate and emitted upward via the resin mold.  
      In this case, the substrate on which the LED chip is mounted is configured by a silicon substrate with a high thermal conductivity (about 150 W/m·k), and it becomes possible to thin the thickness of the substrate. Thus, as will be understood from the following equation, thermal resistance is reduced and the heat generated by the LED at the time the LED is driven is efficiently dissipated via the substrate. 
 
Thermal Resistance=Thickness of Substrate ( m )/ 
 
Thermal Conductivity (W/m·K)×Electrothermal Cross-Sectional Area (m 2 ) 
 
      Thus, a rise in the temperature of the LED chip is suppressed, and there is no drop in the light emission efficiency of the LED chip due to heat. Thus, the emitted light beams are not reduced by the generated heat of the LED chip and the lifespan does not drop.  
      Additionally, because the electrodes for electrical connection to the LED chip are formed by patterning, it is possible to mutually connect the LED chips in series when fabricating a multichip LED.  
      Moreover, the horn  11   a  is microfabricated on the silicon substrate by a semiconductor fabrication technique, it is possible to integrally configure, with the LED chip, other semiconductor devices such as an IC. Thus, it becomes possible to incorporate an LED chip drive circuit and the LED can be compactly configured including the drive circuit.  
      In a case where the horn is formed by etching the silicon substrate from the upper surface of the silicon substrate to an intermediate height and each electrode is formed so as to extend along the surface of the silicon substrate from a bottom surface of the horn via side surfaces of the horn, the silicon substrate disposed with the horn can be configured in an integrated structure and can be fabricated by an easy process.  
      In this case, because the thickness of the silicon substrate inside the horn can be controlled by time management when the horn is etched, the thermal resistance of the silicon substrate with respect to the LED chip can be reduced.  
      It should be noted that the specific thickness of the substrate in this case can be 0.1 to 0.5 mm in view of the rigid balance with thermal resistance.  
      In a case where the silicon substrate is configured from a flat first substrate including a surface on which the electrodes are formed and a second substrate laminated on the first substrate, and the second substrate is disposed with the horn that vertically penetrates the second substrate, electrodes and a wiring pattern of complex shapes can be formed on the first substrate, whereby it is possible to easily incorporate a drive circuit for the LED chip.  
      In a case where the LED chip is die-bonded to one electrode inside the horn and wire-bonded to the other electrode, an LED chip disposed with electrodes at the top and bottom can be easily mounted inside the horn.  
      In a case where the LED chip is mounted so as to straddle the electrodes inside the horn and electrodes formed at both lower side edges of the LED chip are electrically connected to both of the electrodes inside the horn, a so-called flip chip type LED chip disposed with electrode portions at both side edges of the lower surface can be easily mounted inside the horn.  
      In a case where the silicon substrate is formed with a (100) surface serving as the surface and the side surfaces of the horn are formed as (111) surfaces, side surfaces with a predetermined inclination angle can be easily formed by anisotropic etching. In this case, the (111) surfaces are processed to 54.7°.  
      In a case where the side surfaces of the horn are disposed with a mirror surface on the surface, the light emitted from the LED chip is reflected by the mirror surface disposed at the surface when the light is made incident at the side surfaces of the horn, whereby the reflectivity at the side surfaces of the horn becomes higher and reflection efficiency is improved. Thus, the emission efficiency of the light from the LED is improved. In this case, as the mirror material, Au and Al can be used for a red LED and Ag and Al can be used for a blue LED.  
      In a case where an actuator and an IC circuit are formed adjacent to the horn on the silicon substrate, the optical axis of the light emitted from the LED is swung by the actuation of the actuator or part of the light-emitting portion is blocked off, whereby the light distribution characteristics and the shape of the light-emitting portion can be changed. Thus, for example, when the LED is used as the light source of an automobile headlight, it becomes possible to switch the high beam and the low beam and to realize a so-called AFS function.  
      In a case where granular phosphors are mixed in with the resin material forming the resin mold, the light emitted from the LED chip strikes these phosphors and excites the phosphors, whereby the color of the excitation light from the phosphors and the color of the light from the LED chip become mixed, and the mixed color light is emitted to the outside. Thus, white light can be obtained.  
      According to the second configuration, in the completed LED, the LED chip is supplied with electricity from the outside via the electrodes, whereby the LED chip is driven. Then, the light emitted from the LED chip is directly reflected or reflected by the bottom surface or the side surfaces of the horn of the silicon substrate and is emitted upward via the resin mold.  
      Additionally, because the substrate on which the LED chip is mounted is configured by a silicon substrate with a high thermal conductivity, the heat generated by the LED chip at the time the LED chip is driven is efficiently dissipated via the substrate. Thus, a rise in the temperature of the LED chip is suppressed, and there is no drop in the emission efficiency of the LED chip due to heat. Thus, the emitted light beams are not reduced by the generated heat of the LED chip and the lifespan does not drop.  
      In this case, because the silicon substrate disposed with the horn can be easily fabricated using an existing semiconductor fabrication device, the LED can be fabricated relatively easily and at a relatively low cost.  
      In accordance with another aspect of the invention, an LED can include a silicon substrate; a horn formed on the silicon substrate by liquid phase etching; at least two electrodes formed inside the horn; at least one LED chip mounted inside the horn, the LED chip being electrically connected to the electrodes; and a resin mold made of a resin material that is filled in the horn.  
      The electrodes can be drawn out from the horn, and electrically contact with lead frames. The horn can be formed by etching the silicon substrate from an upper surface of the silicon substrate to a height above a lower surface so as not to pass through completely the substrate and that each electrode is formed so as to extend along the surface of the silicon substrate from a bottom surface of the horn via side surfaces of the horn. The silicon substrate may include a flat first substrate having a surface on which the electrodes are formed and a second substrate laminated on the first substrate, the second substrate being provided with the horn that vertically penetrates the second substrate. Each LED chip can be die-bonded to one of the electrodes inside the horn and is wire-bonded to another electrode inside the horn. Each LED chip can be mounted so as to straddle two of electrodes inside the horn, with electrodes formed at both lower side edges of the LED chip being electrically connected respectively to the two electrodes inside the horn. The side surfaces of the horn may be formed as any of (111), (110) or (100) surfaces. The side surfaces of the horn can be provided with a mirror surface on the surfaces. An actuator may be formed on the silicon substrate. An electronic circuit may be formed on the silicon substrate. The electronic circuit can be any of a photo-diode, a transistor, an IC, or the like.  
      A resin can be filled in the horn. Phosphors may be mixed in with the resin. The horn may have a partition wall that surrounds respectively each LED chip. The upper end of the partition wall may be flat in height as same as a height of an upper surface of the silicon substrate. The upper end of the partition wall may have a crest line in height as same an upper surface of the silicon substrate. The upper end of the partition wall may have a crest line in height lower than an upper surface of the silicon substrate. The side surface of the partition wall may have a flat, convex or concave form. The side surfaces of the partition wall may be formed as any of(111), (110) or (100) surfaces.  
      In accordance with another aspect of the invention, an LED can include a silicon substrate; a horn formed on the silicon substrate by liquid phase etching; at least two contact-holes formed on the silicon substrate by liquid phase etching; at least two electrodes extended respectively from inside of the horn to the lower end of each contact-hole; and at least one LED chip mounted inside the horn, the LED chip being electrically connected to the electrodes.  
      In accordance with another aspect of the invention, an LED can include a silicon substrate; a horn formed on the silicon substrate by liquid phase etching; at least two contact-edges formed on the silicon substrate by liquid phase etching; at least two electrodes extended respectively from inside of the horn to the lower end of each contact-edge; and at least one LED chip mounted inside the horn, the LED chip being electrically connected to the electrodes.  
      The silicon substrate has a rectangular form in a view from LED-chip-mounted side, and the contact-edges is formed at least on one of the four corner of the rectangular form. A metal thin film is provided on the lower surface of the silicon substrate at least in the region of the horn. The silicon substrate may be arranged via the metal thin film to the heat-radiating member. A lens may be arranged on the horn. The lens may be a convex lens. The lens may be a spherical lens. A recess for positioning the lens may be formed around the horn on the silicon substrate.  
      In accordance with another aspect of the invention, a method of fabricating an LED can include a process of forming a horn on a silicon substrate by liquid phase etching; a process of forming at least two electrodes inside the horn; a process of mounting at least one LED chip inside the horn such that the LED chip is electrically connected to the electrodes.  
      The method can include a process of filling the interior of the horn with a resin material to form a resin mold. In the process of forming a horn on the silicon substrate by liquid phase etching, a plural of horns may be formed adjacent each other, and a partition wall may be formed between the horns. The upper end of the partition wall may be in height as same as, or lower than, a height of an upper surface of the silicon substrate. The surface of the partition wall may have a convex or concave form.  
      In accordance with another aspect of the invention, a method of fabricating an LED can include a process of forming an oxidized film on a surface of a silicon substrate; a process of patterning the oxidized film so as to expose each portion to be a contact-hole; a process of forming a shallow recess in each portion to be a contact-hole by liquid phase etching; a process of patterning the oxidized film so as to expose each portion to be a horn; a process of forming horns and contact-holes on the silicon substrate by liquid phase etching; a process of an insulating film on the surface of the silicon substrate; a process of forming electrode-patterns on the silicon substrate; a process of mounting at least one LED chip inside each horn such that the LED chip is electrically connected to the electrodes; and a process of cutting out the silicon substrate.  
      In accordance with another aspect of the invention, a method of fabricating an LED can include a process of forming an oxidized film on a silicon substrate; a process of patterning the oxidized film so as to expose each portion to be a through-bore; a process of forming a shallow recess in each portion to be a through-bore by liquid phase etching; a process of patterning the oxidized film so as to expose each portion to be a horn; a process of forming horns and through-bores on the silicon substrate by liquid phase etching; a process of an insulating film on the surface of the silicon substrate; a process of forming electrode-patterns on the silicon substrate; a process of mounting at least one LED chip inside each horn such that the LED chip is electrically connected to the electrodes; and a process of cutting out the silicon substrate so as to cross each through-bore to form a contact edge.  
      In accordance with another aspect of the invention, a method of fabricating an LED can include a process of forming at least two electrodes on a first silicon substrate; a process of forming through-bores on a second silicon substrate by liquid phase etching and forming a horn on the side wall of each through-bore; a process of bonding the first and second silicon substrates each other so as to expose the electrodes in each through-bore; and a process of mounting at least one LED chip inside the horn such that the LED chip is electrically connected to the electrodes.  
      The method can include a process of forming a mirror surface in an inner surface of each through-bore; and/or a process of filling the interior of the horn with a resin material to form a resin mold; and/or a process of insulating the surfaces of silicon substrates by oxidized film.  
      According to the third configuration, each of the LED chips is supplied with electricity from the outside via the electrodes, whereby each LED chip is driven. Then, the light emitted from each LED chip is directly reflected or reflected by the bottom surface or the side surfaces of the horn of the silicon substrate and is emitted upward via the resin mold.  
      In this case, the substrate on which the LED chips are mounted is configured by a silicon substrate with a high thermal conductivity (about 150 W/m·k), and it becomes possible to thin the thickness of the substrate. Thus, as will be understood from the following equation, thermal resistance is reduced and the heat generated by each LED at the time each LED is driven is efficiently dissipated via the substrate. 
 
Thermal Resistance=Thickness of Substrate ( m )/Thermal Conductivity (W/m·K)×Electrothermal Cross-Sectional Area (m 2 ) 
 
      Thus, a rise in the temperature of each LED chip is suppressed, and there is no drop in the light emission efficiency of each LED chip due to heat. Thus, the emitted light beams are not reduced by the generated heat of each LED chip and the lifespan does not drop. Additionally, because the electrodes for electrical connection to each LED chip are formed by patterning, it is possible to mutually connect the LED chips in series when fabricating a multichip LED.  
      Moreover, the horn  11   a  is microfabricated on the silicon substrate by a semiconductor fabrication technique, it is possible to integrally configure, with the LED chips, other semiconductor devices such as an IC. Thus, it becomes possible to incorporate an LED chip drive circuit and the LED can be compactly configured including the drive circuit.  
      In a case where the horn is formed by etching the silicon substrate from the upper surface of the silicon substrate to a height above a lower surface so as not to pass through completely the substrate and where each electrode is formed so as to extend along the surface of the silicon substrate from a bottom surface of the horn via side surfaces of the horn, the silicon substrate disposed with the horn can be configured in an integrated structure and can be fabricated by an easy process.  
      In this case, because the thickness of the silicon substrate inside the horn can be controlled by time management when the horn is etched, the thermal resistance of the silicon substrate with respect to each LED chip can be reduced.  
      It should be noted that the specific thickness of the substrate in this case can be 0.1 to 0.5 mm in view of the rigid balance with thermal resistance.  
      In a case where the silicon substrate is configured from a flat first substrate including a surface on which the electrodes are formed and a second substrate laminated on the first substrate, and the second substrate is disposed with the horn that vertically penetrates the second substrate, electrodes and a wiring pattern of complex shapes can be formed on the first substrate, whereby it is possible to easily incorporate a drive circuit for the LED chips.  
      In a case where the LED chips are die-bonded to one electrode inside the horn and wire-bonded to another electrode, an LED chip disposed with electrodes at the top and bottom can be easily mounted inside the horn.  
      In a case where each of the LED chips is mounted so as to straddle the electrodes inside the horn and electrodes formed at both lower side edges of each LED chip are electrically connected to both of the electrodes inside the horn, a so-called flip chip type LED chip disposed with electrode portions at both side edges of the lower surface can be easily mounted inside the horn.  
      In a case where the silicon substrate is formed with a (100) surface serving as the surface and the side surfaces of the horn are formed as (111) surfaces, side surfaces with a predetermined inclination angle can be easily formed by anisotropic etching. In this case, the (111) surfaces are processed to 54.7°.  
      Although in the above description the silicon substrate with a (100) surface and the horn with a (111) side surface are adopted, but a silicon substrate with a (110) surface or an off-axised substrate can be used, and an inclined angle of the horn must not be 54.7°. For example, in the case that a horn is formed on a substrate with a (110) surface, by etching with enchant of TMAH and a mask-pattern, a straight part of which is parallel to a orientation-flat corresponding to (100) surface, an side surface of the formed horn is vertical. Here, the horn with the vertical side surface is useful to construct a light source which positively reduces a light emitting area and raises a brightness, for example, a head-lamp for vehicle etc.  
      With respect of the substrate with a (100) surface, in the case that a horn is formed on a substrate with a (110) surface, by etching with etchant of EDP and a mask-pattern, a straight part of which is 45° to a orientation-flat corresponding to (100) surface, an inclined angle of the formed horn is 45°. And under the same condition, by etching with etchant of KOH, an inclined angle of the formed horn is 90° (vertical). Therefore, in the above embodiment, a substrate with a (100) surface is described, but by changing suitably a crystal orientation of a substrate, a form of a mask-pattern and an etchant depending on a purpose of use, any device with a required horn-form can be produces.  
      In a case where the side surfaces of the horn are disposed with a mirror surface on the surface, the light emitted from each LED chip is reflected by the mirror surface disposed at the surface when the light is made incident at the side surfaces of the horn, whereby the reflectivity at the side surfaces of the horn becomes higher and reflection efficiency is improved. Thus, the emission efficiency of the light from the LED is improved. In this case, as the mirror material, Au and Al can be used for a red LED and Ag, Al and an alloy of those can be used for a blue LED.  
      In a case where an actuator are formed adjacent to the horn on the silicon substrate, the optical axis of the light emitted from the LED is swung by the actuation of the actuator or part of the light-emitting portion is blocked off, whereby the light distribution characteristics and the shape of the light-emitting portion can be changed. Thus, for example, when the LED is used as the light source of an automobile headlight, it becomes possible to switch the high beam and the low beam and to realize a so-called AFS function.  
      In a case where granular phosphors are mixed in with the resin material forming the resin mold, the light emitted from each LED chip strikes these phosphors and excites the phosphors, whereby the color of the excitation light from the phosphors and the color of the light from each LED chip become mixed, and the mixed color light is emitted to the outside. Thus, white light can be obtained.  
      In a case where the horn has a partition wall that surrounds respectively each LED chip, the light emitted from each LED chip and oriented to the adjacent LED chip is intercepted by the partition wall, so that an absorption of light among the LED chips is prevented. Thus, the lost of light is reduced and the total power of light taken out upward is raised.  
      In a case where the upper end of the partition wall is flat in height as same as a height of a upper surface of the silicon substrate, or in a case where the upper end of the partition wall has a crest line in height as same a upper surface of the silicon substrate, the light emitted from each LED chip is reflected by the side surfaces of the corresponding horn and the partition wall, and led to upward, so that the total power of light taken out upward is raised, and each distance between the LED chips can be suitably adjusted.  
      In a case where the upper end of the partition wall has a crest line in height lower than a upper surface of the silicon substrate, each distance between the LED chips can be optimally adjusted even if the distance between the LED chips is too long by the upper end of the partition wall being in height as same as a height of a upper surface of the silicon substrate.  
      In a case where the side surface of the partition wall has a flat, convex or concave form, with respect to the light emitted from each LED chip and oriented the side surface of the partition wall, the optimal reflecting characteristic in the reflecting by the side surface can be obtained by selecting the form of the side surface of the partition wall.  
      In a case where the side surfaces of the partition wall may be formed as a (111) surfaces, the side surface with inclined angle 54.7° of the partition wall is obtained at the same time of the horn forming by liquid phase anisotropic etching.  
      In a case where the silicon substrate has at least two contact-holes which pass through the silicon substrate vertically adjacent the horn, each electrodes extending respectively from inside of the horn to the lower end of each corresponding contact-hole via the contact-hole, for the LED is mounted on a mounting-board, the electrodes can be connected directly to a corresponding contact portion on the mounting-board, without using bonding-wire or lead wire, by, for example, reflow-soldering or eutectic junction.  
      In this case, the contact-holes can be formed at the same time of forming a horn on the substrate, so that these can be processed easily and in large quantities by a semiconductor fabrication processes.  
      In a case where the silicon substrate has at least two contact-edges which pass through the silicon substrate vertically at the side surfaces, each electrodes extending respectively from inside of the horn to the lower end of each corresponding contact-edge via the contact-edge, as same as the contact-holes, for the LED is mounted on a mounting-board, the electrodes can be connected directly to a corresponding contact portion on the mounting-board, without using bonding-wire or lead wire, by, for example, reflow-soldering or eutectic junction.  
      In this case, the contact-edges can be formed by that contact-holes are formed at the same time of forming a horn on the substrate, and each of the contact-holes are cut off at the same time of dicing the substrate, so that these can be processed easily and in large quantities by a semiconductor fabrication processes.  
      In a case where the silicon substrate is provided with a metal thin film at least in an area of the horn on lower surface, for the LED is mounted on a mounting-board, the LED can be fixed rigidly to a mounting-board by the metal thin film, so that a heat radiation from the LED to a mounting-board is improved better.  
      According to the fourth configuration, in the completed LED, each of the LED chips is supplied with electricity from the outside via the electrodes, whereby each LED chip is driven. Then, the light emitted from each LED chip is directly reflected or reflected by the bottom surface or the side surfaces of the horn of the silicon substrate and is emitted upward via the resin mold.  
      Additionally, because the substrate on which each LED chip is mounted is configured by a silicon substrate with a high thermal conductivity, the heat generated by each LED chip at the time each LED chip is driven is efficiently dissipated via the substrate. Thus, a rise in the temperature of each LED chip is suppressed, and there is no drop in the emission efficiency of each LED chip due to heat. Thus, the emitted light beams are not reduced by the generated heat of each LED chip and the lifespan does not drop.  
      In this case, because the silicon substrate disposed with the horn can be easily fabricated using an existing semiconductor fabrication device, the LED can be fabricated relatively easily and at a relatively low cost.  
      In this manner, an LED and a fabrication method thereof are provided, where a rise in temperature resulting from heat emission can be excellently suppressed, where the fabrication of a multichip LED is easily possible, and which can be easily and compactly configured, and furthermore where a power of light is raised as high as possible in case of providing with a plural of LED chips, and which can be easily mounted on a mounting-board without using a bonding-wire. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The above and other aspects, features and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:  
       FIG. 1  is a schematic cross-sectional view showing a first embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 2  is a schematic cross-sectional view showing a second embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 3  is a schematic cross-sectional view showing a third embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 4  is a schematic plan diagram showing a fourth embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 5  is a schematic plan diagram showing a state at the time of operation of a thermoelectric actuator in the LED of  FIG. 4 ;  
       FIG. 6  is a schematic perspective diagram showing the configuration of a fifth embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 7  is a schematic cross-sectional view showing a sixth embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 8  is a schematic cross-sectional view showing a seventh embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 9  is a schematic cross-sectional view showing an eighth embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 10  is a schematic plan diagram showing a ninth embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 11  is a schematic plan diagram showing a state at the time of operation of a thermoelectric actuator in the LED of  FIG. 10 ;  
       FIG. 12  is a schematic perspective diagram showing the configuration of a tenth embodiment of an LED made in accordance with the principles of the invention;  
       FIG. 13  is drawings showing the configuration of a eleventh embodiment of an LED made in accordance with the principles of the invention, respectively (A) in a schematic plan view and (B) in a schematic cross-sectional view;  
       FIG. 14  is drawings showing the configuration of a variant embodiment of an LED of  FIG. 13 , respectively (A) in a schematic plan view and (B) in a schematic cross-sectional view;  
       FIG. 15  is drawings showing the manufacturing processes of the LED of  FIG. 13 ;  
       FIG. 16  is drawings showing the configuration of a twelfth embodiment of an LED made in accordance with the principles of the invention, respectively (A) in a schematic plan view and (B) in a schematic cross-sectional view;  
       FIG. 17  is drawings showing the manufacturing processes of the LED of  FIG. 16 ;  
       FIG. 18  is a schematic cross-sectional view showing a variant of an LED of  FIG. 16 ;  
       FIG. 19  is a schematic cross-sectional view showing another variant of an LED of  FIG. 16 ;  
       FIG. 20  is drawings showing the configuration of a thirteenth embodiment of an LED made in accordance with the principles of the invention, respectively (A) in a schematic cross-sectional view and (B) in a schematic plan view;  
       FIG. 21  is drawings showing the manufacturing processes of the LED of  FIG. 20 ;  
       FIG. 22  is drawings showing the configuration of a fourteenth embodiment of an LED made in accordance with the principles of the invention, respectively (A) in a schematic cross-sectional view and (B) in a schematic plan view;  
       FIG. 23  is drawings showing the manufacturing processes of the LED of  FIG. 22 ;  
       FIG. 24  is a schematic cross-sectional view showing a fifteenth embodiment of an LED made in accordance with the principles of the invention in a mounting state;  
       FIG. 25  is drawings showing the configuration of a sixteenth embodiment of an LED made in accordance with the principles of the invention, respectively (A) in a schematic cross-sectional view and (B) in a schematic plan view;  
       FIG. 26  is a schematic cross-sectional diagram showing the LED of  FIG. 25  mounted to a heat sink;  
       FIG. 27  is a schematic perspective view showing a seventeenth embodiment of an LED made in accordance with the principles of the invention in a mounting state;  
       FIG. 28  is a schematic cross-sectional view showing the seventeenth embodiment of an LED made in accordance with the principles of the invention in a mounting state;  
       FIG. 29  is drawings showing the configuration of an eighteenth embodiment of an LED made in accordance with the principles of the invention, respectively (A) in a schematic front view and (B) in a schematic plan view in a mounting state;  
       FIG. 30  is a schematic perspective view showing a nineteenth embodiment of an LED made in accordance with the principles of the invention in a mounting state;  
       FIG. 31  is a schematic perspective view showing a twentieth embodiment of an LED made in accordance with the principles of the invention in a mounting state;  
       FIG. 32  is a schematic perspective view showing a twenty-first embodiment of an LED made in accordance with the principles of the invention in a mounting state;  
       FIG. 33  is a schematic front view showing the twenty-first embodiment of an LED made in accordance with the principles of the invention in a mounting state;  
       FIG. 34  is a schematic cross-sectional view showing an example configuration of a conventional LED;  
       FIG. 35  is a schematic cross-sectional view showing another example configuration of a conventional LED;  
       FIG. 36  is a schematic cross-sectional view showing yet another example configuration of a conventional LED; and  
       FIG. 37  is a schematic cross-sectional view showing a modified example of the conventional LED shown in  FIG. 36 .  
       FIG. 38  is a schematic cross-sectional view showing yet another example configuration of a conventional LED; and  
       FIG. 39  is a schematic cross-sectional view showing a mounting state of the conventional LED shown in  FIG. 38 .  
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
      Exemplary embodiments of the invention will now be described in detail with reference to FIGS.  1  to  33 .  
      It should be noted that, although certain technical features are described with respect to the various embodiments, because the embodiments are specific examples of the invention, the scope of the invention is not limited to these embodiments.  
     First Embodiment  
       FIG. 1  shows the configuration of a first embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 1 , an LED  10  is configured by a silicon substrate  11 , an LED chip  12  mounted inside a horn  11   a  formed as a concave recessed portion in the silicon substrate  11 , and a resin mold  13  including a resin material filling the inside of the horn  11   a.    
      The silicon substrate  11  is flatly formed so that the surface thereof forms a (100) surface.  
      The silicon substrate  11  is disposed with the horn  11   a  formed by the concave recessed portion from the surface to an intermediate height.  
      The horn  11   a  is formed, for example, by anisotropic etching with TMAH so that the side surfaces thereof form (111) surfaces.  
      It should be noted that, because the side surfaces of the horn  1 I a are (111) surfaces, the angle of inclination of the side surfaces with respect to the bottom surface can be set to  54 . 7  degrees.  
      In this case, the horn  11   a  is machined to have an appropriate depth on the basis of time management of the etching process, and the bottom surface of the horn  1 I a can be formed to approach as much as possible the bottom surface of the silicon substrate  11 —i.e., the thickness of the silicon substrate  11  at the bottom surface of the horn  11   a  can be thinned as much as possible—so that it is possible to reduce thermal resistance.  
      Additionally, the silicon substrate  11  is disposed with a pair of electrodes  14  and  15  that extend in  FIG. 1  from the bottom surface of the horn  11   a  to the surface of the silicon substrate  11  via the left and right side surfaces of the horn  11   a.    
      These electrodes  14  and  15  are formed by, for example, forming a thin metal film on the surface of the silicon substrate  11  in which the horn  11   a  is formed, and then pattern-etching the thin metal film.  
      Here, the electrode  14  is disposed with a chip mount portion  14   a  disposed in a center region of the bottom surface of the horn  11   a.  The pattern of the chip mount portion  14   a  has a shape that is identical to the shape of a terminal portion of the LED chip  12  to be attached thereto or a shape that is identical to part of the outer contour line thereof. The chip mount portion  14   a  is also one where self-alignment, in which the pattern and the terminal portion are made to move by the surface tension of the solder melting the floating LED chip  12  so that the pattern and the terminal portion are aligned, can be conducted. The other electrode  15  is disposed with a connection portion  15   a  that is adjacent to the chip mount portion  14   a  at the bottom surface of the horn  11   a.    
      Moreover, in this case, both electrodes  14  and  15  are formed so that the surfaces thereof are mirror surfaces at least at regions of the side surfaces. It should be noted that both electrodes  14  and  15  may also be disposed with separate mirror surfaces at the surfaces thereof at least at the regions of the side surfaces.  
      The LED chip  12  can be an LED chip of a publicly known configuration that emits, for example, blue light. The LED chip  12  can be disposed with electrode portions not shown at the upper surface and the lower surface thereof, mounted on the bottom surface of the horn  11   a  of the silicon substrate  11 , and die-bonded to the chip mount portion  14   a  of the electrode  14 , whereby the electrode portion at the lower surface can be electrically connected to the chip mount portion  14   a  and the electrode portion at the upper surface can be electrically connected to the connection portion  15   a  of the other electrode  15  by a bonding wire  12   a  such as a gold wire.  
      The resin mold  13  is configured by a translucent resin material such as epoxy resin, and granular phosphors  13   a  are mixed into the translucent resin material.  
      Thus, after the inside of the horn  11   a  of the silicon substrate  11  is filled with the resin mold  13  and the resin mold  13  is hardened, the granular phosphors  13   a  are dispersed inside.  
      Here, the granular phosphors  13   a  are phosphors that emit, for example, yellow excitation light with respect to the color of the emission light of the LED chip  12 . Thus, the phosphors  13   a  are excited by the blue light from the LED chip  12 , the phosphors  13   a  emit yellow excitation light, the yellow excitation light is mixed with the blue light from the LED chip  12 , and white light is emitted to the outside.  
      The LED  10  according to the embodiment of the invention is configured as described above and can be fabricated as follows on the basis of a fabrication method in accordance with the principles of the invention.  
      Namely, first the horn  11   a  can be formed by anisotropic etching with respect to the surface that is the (100) surface of the flat silicon substrate  11 . In this case, for example, TMAH (tetramethyl ammonium hydride) is used as the etching agent.  
      With TMAH, the undercut resulting from the etching is relatively large and dimensional control is difficult, but there are the advantages that there is little mask damage, an oxidized film mask is usable and the consistency with CMOS is excellent. In contrast, when KOH is used as the etching agent, the undercut is small but the consistency with CMOS is poor.  
      It should be noted that the side surfaces of the horn  11   a  formed by such etching become inclined surfaces with an inclination angle of 54.7 degrees as (111) surfaces.  
      Also, a horn  11   a  with a desired depth can be formed by appropriately managing the etching time.  
      Before the electrodes of the next step are formed, the Si surface is covered and insulated with a thin SiO 2  layer by thermal oxidation.  
      Next, a thin metal film that will serve as the electrodes is formed across the entire surface of the silicon substrate  11  in which the horn  11   a  is formed, and thereafter this thin metal film is pattern-etched, whereby the electrodes  14  and  15  are formed. At this time, the surfaces of the electrodes  14  and  15  are formed as mirror surfaces by forming, by sputtering or deposition, a thin film including a material with a high reflectivity, such as aluminum or silver.  
      Next, the LED chip  12  is mounted on and die-bonded to the chip mount portion  14   a  of the electrode  14 , and the electrode portion of the surface of the LED chip  12  is wire-bonded to the connection portion  15   a  of the other electrode  15  by the bonding wire  12   a.    
      Thereafter, the inside of the horn  11   a  is filled with the resin material in which the granular phosphors  13   a  are mixed in, and the resin material is hardened. Thus, the resin mold  13  is formed inside the horn  11   a.  Thus, the LED  10  is completed.  
      According to the LED  10  fabricated in this manner, electricity is supplied from the outside to the LED chip  12  via the electrodes  14  and  15 , whereby the LED chip  12  is driven.  
      Then, light L emitted from the LED chip  12  is directly reflected or reflected with high reflectivity by the surfaces of the electrodes  14  and  15  formed as mirror surfaces at the bottom surface and the side surfaces of the horn  11   a  of the silicon substrate  11 . The light L strikes the phosphors  13   a  inside the resin mold  13  and excites the phosphors  13   a.  Thus, excitation light is emitted from the phosphors  13   a,  is mixed with the blue light from the LED chip  12 , and is emitted upward via the resin mold  13  as white light.  
      In this case, because the LED chip  12  is mounted on the silicon substrate  11  having a high thermal conductivity of 150 W/m·k, heat generated by the LED chip  12  at the time the LED chip  12  is driven is efficiently dissipated via the silicon substrate  11 .  
      Thus, a rise in the temperature of the LED chip  12  is suppressed and the light emission efficiency of the LED chip  12  does not drop due to the heat, whereby the emitted light beams are not reduced by the heat of the LED chip and the lifespan does not drop.  
      Also, because the electrodes  14  and  15  for electrical connection to the LED chip  12  are formed by patterning, it is possible to mutually connect the LED chips  12  in series when fabricating a multichip LED, and the current does not become concentrated at the LED chip  12  whose Vf is low.  
      Moreover, because the side surfaces of the horn  11   a  are formed as (111) surfaces, the side surfaces of the horn  11   a  are formed as excellent mirror surfaces that cannot be obtained by ordinary machining, such as cutting or punching a metal material or resin molding.  
      Moreover, it is possible to integrally configure another semiconductor device such as an IC by an existing semiconductor fabrication process on the silicon substrate  11 , which can be acquired relatively inexpensively. Thus, it becomes possible to incorporate a drive circuit for conducting lighting and blinking of the LED chip  12 , and the LED  10  can be configured compactly including the drive circuit.  
      In this manner, according to the LED  10 , because the LED  10  uses the silicon substrate  11 , the heat emitted by the LED chip  12  is efficiently dissipated, the LED  10  can be easily fabricated as a multichip LED due to the electrodes  14  and  15  formed by patterning, and it is possible to mutually connect the LED chips  12  in series, whereby current concentration at the LED chip  12  whose Vf is low resulting from variations can be avoided.  
      Also, because the LED  10  can be easily fabricated using an existing semiconductor fabrication device, special capital expenditures are unnecessary, and the LED  10  can be fabricated at a relatively low cost.  
     Second Embodiment  
       FIG. 2  shows the configuration of a second embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 2 , because an LED  20  has substantially the same configuration as that of the LED  10  shown in  FIG. 1 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED  20  is configured by a silicon substrate  21 , the LED chip  12  mounted inside a horn  21   a  formed as a concave recessed portion in the silicon substrate  21 , and the resin mold  13  including a resin material filling the inside of the horn  21   a.    
      Here, the silicon substrate  21  is configured by being laminated in two layers.  
      Namely, the silicon substrate  21  is configured by a lower first substrate  22  and an upper second substrate  23 .  
      The first substrate  22  is configured by a flat silicon substrate, and the electrodes  14  and  15  are formed on the surface thereof by patterning a thin metal film. In this case, the electrodes  14  and  15  extend sideways along the surface of the first substrate  22 , i.e., through the inside of the silicon substrate  21 .  
      In contrast, the second substrate  23  is flatly formed, so that the surface thereof becomes a (100) surface), and is disposed with a horn  21   a  formed so as to vertically penetrate the second substrate  21 .  
      Similar to the horn  11   a  of the LED  10 , the horn  21   a  is formed by, for example, anisotropic etching with TMAH so that the side surfaces thereof become (111) surfaces, and the side surfaces overall are disposed with mirror surfaces. As is publicly known, the mirror surfaces are obtained by forming, by deposition or plating, a thin film of a material with a high reflectivity on the surface of the horn  11   a.    
      The LED  20  of this configuration is fabricated as follows on the basis of a fabrication method in accordance with the principles of the invention.  
      Namely, first the electrodes  14  and  15  are formed by pattern-etching a thin metal film on the surface of the silicon substrate serving as the first substrate  22 .  
      In tandem with this, the horn  21   a  is formed by anisotropic etching of the surface that is the (100) surface of the silicon substrate serving as the second substrate  23 . In this case, because the horn  21   a  vertically penetrates the second substrate  23 , it is not necessary to set with high precision the depth of the horn  21   a,  so that time management of the etching process becomes easy.  
      Next, the mirror surface is formed by deposition or plating on the side surfaces of the horn  21   a  of the second substrate  23 , and thereafter the second substrate  23  is adhered to the first substrate  22 .  
      Next, the LED chip  12  is mounted on and die-bonded to the chip mount portion  14   a  of the electrode  14  exposed to the bottom surface of the horn  21   a,  and the electrode portion of the surface of the LED chip  12  is wire-bonded to the connection portion  15   a  of the other electrode  15  by the bonding wire  12   a.    
      Thereafter, the inside of the horn  21   a  is filled with the resin material in which the granular phosphors  13   a  are mixed in, and the resin material is hardened. Thus, the resin mold  13  is formed inside the horn  21   a.  It should be noted that, before the electrodes are formed, the Si surface is covered and insulated with a thin SiO 2  layer by thermal oxidation resulting from sputtering. Thus, the LED  20  is completed.  
      According to the LED  20  fabricated in this manner, the LED  20  acts in the same manner as the LED  10  shown in  FIG. 1 , and the silicon substrate  21  is configured in two layers, whereby it becomes possible to form a complex wiring pattern on the surface of the first substrate  22 . Also, because the mirror surface is formed across the entire inner surface of the horn  21   a  of the second substrate  23 , the emission efficiency of light to the outside is improved.  
     Third Embodiment  
       FIG. 3  shows the configuration of a third embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 3 , because an LED  30  has substantially the same configuration as that of the LED  20  shown in  FIG. 2 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      The LED  30  is formed so as to be disposed with chip mount portions  14   b  and  15   b,  where the electrodes  14  and  15  mutually face each other with an interval disposed therebetween, in the vicinity of the center of the upper surface of the first substrate  22 .  
      Additionally, a so-called flip chip type LED chip  31  is mounted on and electrically connected to the tops of the chip mount portions  14   b  and  15   b  so as to ride on the electrode portions disposed at both side edges of the undersurface thereof.  
      According to the LED  30  of this configuration, the LED  30  acts in the same manner as the LED  20  shown in  FIG. 2 .  
     Fourth Embodiment  
       FIG. 4  shows the configuration of a fourth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 4 , an LED  40  is one where a thermoelectric bimorph actuator is configured as an actuator adjacent to the horn  11   a  above the silicon substrate  11  with respect to the LED  10  according to  FIG. 1 .  
      The thermoelectric bimorph actuator  41  itself has a publicly known configuration and is configured by etching using the so-called MEMS technique in a semiconductor fabrication process on the silicon substrate  11 .  
      Additionally, the thermoelectric bimorph actuator  41  is supplied with electricity via electrodes not shown, whereby, as shown in  FIG. 5 , it is displaced on the semiconductor substrate  11  and covers part of the upper surface of the horn  11   a.    
      According to the LED  40  of this configuration, light is emitted to the outside from the horn  11   a  of the silicon substrate  11  in a manner similar to the case of the LED  10 . When the thermoelectric bimorph actuator  41  is not operating, light is emitted to the outside from the entire light-emitting portion resulting from the open portion of the upper end of the horn  11   a,  and when the thermoelectric bimorph actuator  41  is operating, part of the light-emitting portion is blocked off by the thermoelectric bimorph actuator  41 , so that it is possible to change the shape of the light-emitting portion. Thus, for example, when the LED  40  is used as the light source of an automobile headlight, switching of the high beam and the low beam becomes possible.  
      It should be noted that changing the shape of the light-emitting portion resulting from the open portion of the upper end of the horn  11   a  can also be realized by another type of actuator that can be configured on the silicon substrate  11 .  
     Fifth Embodiment  
       FIG. 6  shows a fifth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 6 , an LED  50  is one where a vertical comb-type electrostatic actuator  51  is configured as an actuator adjacent to the horn  11   a  on the silicon substrate  11  with respect to the LED  10  according to  FIG. 1 .  
      The vertical comb-type electrostatic actuator  51  itself has a publicly known configuration as a “Vertical Comb” and is configured by etching using the so-called MEMS technique in a semiconductor fabrication process on the silicon substrate  11 .  
      Additionally, the vertical comb-type electrostatic actuator  51  is supplied with electricity via electrodes not shown, whereby, as shown by arrow A in  FIG. 6 , it swings above the semiconductor substrate  11  and some of the light beams emitted from the upper surface of the horn  11   a  are blocked.  
      According to the LED  50  of this configuration, light is emitted to the outside from the horn  11   a  of the silicon substrate  11  in a manner similar to the case of the LED  10 . Due to the vertical comb-type electrostatic actuator  51 , part of the light emitted from the entire light-emitting portion resulting from the open portion of the upper end of the horn  11   a  is selectively blocked off, whereby the light distribution pattern is changed. Thus, for example, when the LED  50  is used as the light source of an automobile headlight, a so-called AFS function can be realized.  
      It should be noted that changing the shape of the light-emitting portion resulting from the open portion of the upper end of the horn  11   a  can also be realized by another type of actuator that can be configured on the silicon substrate  11 .  
     Sixth Embodiment  
       FIG. 7  shows the configuration of a sixth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 7 , an LED  60  is configured by a silicon substrate  61 , an LED chip  62  mounted inside a horn  61   a  formed as a concave recessed portion in the silicon substrate  61 , and a resin mold  63  including a resin material filling the inside of the horn  61   a.    
      The silicon substrate  61  is flatly formed so that the surface thereof forms a (100) surface.  
      The silicon substrate  61  is disposed with the horn  61   a  formed by the concave recessed portion from the surface to a height above a lower surface so as not to pass through completely the substrate  61 .  
      The horn  61   a  is formed, for example, by liquid phase crystal anisotropic etching with TMAH so that the side surfaces thereof form (111) surfaces.  
      It should be noted that, because the side surfaces of the horn  61   a  are (111) surfaces, the angle of inclination of the side surfaces with respect to the bottom surface is set to 54.7 degrees.  
      In this case, the horn  61   a  is machined to have an appropriate depth on the basis of time management of the etching process, and the bottom surface of the horn  61   a  can be formed to approach as much as possible the bottom surface of the silicon substrate  61 —i.e., the thickness of the silicon substrate  61  at the bottom surface of the horn  61   a  can be thinned as much as possible—so that it is possible to reduce thermal resistance.  
      Additionally, the silicon substrate  61  is disposed with a pair of electrodes  64  and  65  that extend in  FIG. 7  from the bottom surface of the horn  61   a  to the surface of the silicon substrate  61  via the left and right side surfaces of the horn  61   a.    
      These electrodes  64  and  65  are formed by, for example, forming a thin metal film on the surface of the silicon substrate  61  in which the horn  61   a  has been formed, and then pattern-etching the thin metal film.  
      Here, the electrode  64  is disposed with a chip mount portion  64   a  disposed in a center region of the bottom surface of the horn  61   a.  The pattern of the chip mount portion  64   a  has a shape that is identical to the shape of a terminal portion of the LED chip  62  to be attached thereto or a shape that is identical to part of the outer contour line thereof. The chip mount portion  64   a  is also one where self-alignment, in which the pattern and the terminal portion are made to move by the surface tension of the solder melting the floating LED chip  62  so that the pattern and the terminal portion are aligned, can be conducted. Another electrode  65  is disposed with a connection portion  65   a  that is adjacent to the chip mount portion  64   a  at the bottom surface of the horn  61   a.    
      Moreover, in this case, both electrodes  64  and  65  are formed so that the surfaces thereof are mirror surfaces at least at regions of the side surfaces. It should be noted that both electrodes  64  and  65  may also be disposed with separate mirror surfaces at the surfaces thereof at least at the regions of the side surfaces.  
      The LED chip  62  is an LED chip of a publicly known configuration that emits, for example, blue light. The LED chip  62  is disposed with electrode portions not shown at the upper surface and the lower surface thereof, is mounted on the bottom surface of the horn  61   a  of the silicon substrate  61 , and is die-bonded to the chip mount portion  64   a  of the electrode  64 , whereby the electrode portion at the lower surface is electrically connected to the chip mount portion  64   a  and the electrode portion at the upper surface is electrically connected to the connection portion  65   a  of the other electrode  65  by a bonding wire  62   a  such as a gold wire.  
      The resin mold  63  is configured by a translucent resin material such as epoxy resin, and granular phosphors  63   a  are mixed into the translucent resin material.  
      Thus, after the inside of the horn  61   a  of the silicon substrate  61  is filled with the resin mold  63  and the resin mold  63  is hardened, the granular phosphors  63   a  are dispersed inside.  
      Here, the granular phosphors  63   a  are phosphors that emit, for example, yellow excitation light with respect to the color of the emission light of the LED chip  62 . Thus, the phosphors  63   a  are excited by the blue light from the LED chip  62 , the phosphors  63   a  emit yellow excitation light, the yellow excitation light is mixed with the blue light from the LED chip  62 , and white light is emitted to the outside.  
      The LED  60  according to the embodiment of the invention is configured as described above and is fabricated as follows on the basis of a fabrication method made in accordance with the principles of the invention.  
      Namely, first the horn  61   a  is formed by liquid phase crystal anisotropic etching with respect to the surface that is the (100) surface of the flat silicon substrate  61 . In this case, for example, TMAH (tetramethyl ammonium hydride) is used as the etching agent.  
      With TMAH, the undercut resulting from the etching is relatively large and dimensional control is difficult, but there are the advantages that there is little mask damage, an oxidized film mask is usable and the consistency with CMOS is excellent. In contrast, when KOH is used as the etching agent, the undercut is small but the consistency with CMOS is poor.  
      It should be noted that the side surfaces of the horn  61   a  formed by such etching become inclined surfaces with an inclination angle of 54.7 degrees as (111) surfaces.  
      Also, a horn  61   a  with a desired depth can be formed by appropriately managing the etching time.  
      Before the electrodes of the next step are formed, the Si surface is covered and insulated with a thin SiO 2  layer or Si 3 N 4  layer by, for example, sputtering method, CVD method or thermal oxidation method.  
      Next, a thin metal film that will serve as the electrodes is formed across the entire surface of the silicon substrate  61  in which the horn  61   a  is formed, and thereafter this thin metal film is pattern-etched, whereby the electrodes  64  and  65  are formed. For the pattern etching method, a method for forming a uniform resist film for a three dimensional form can be used such as a electroformed resist, a sprayed resist, or the like. At this time, the surfaces of the electrodes  64  and  65  are formed as mirror surfaces by forming, by sputtering, vacuum evaporation, or electroplating, a thin film including a material with a high reflectivity, such as aluminum or silver.  
      Next, the LED chip  62  is mounted on and die-bonded to the chip mount portion  64   a  of the electrode  64 , and the electrode portion of the surface of the LED chip  62  is wire-bonded to the connection portion  65   a  of the other electrode  65  by the bonding wire  62   a.    
      Thereafter, the inside of the horn  61   a  is filled with the resin material in which the granular phosphors  63   a  are mixed in, and the resin material is hardened. Thus, the resin mold  63  is formed inside the horn  61   a.  Thus, the LED  60  is completed.  
      According to the LED  60  fabricated in this manner, electricity is supplied from the outside to the LED chip  62  via the electrodes  64  and  65 , whereby the LED chip  62  is driven.  
      Then, light L emitted from the LED chip  62  is directly reflected or reflected with high reflectivity by the surfaces of the electrodes  64  and  65  formed as mirror surfaces at the bottom surface and the side surfaces of the horn  61   a  of the silicon substrate  61 . The light L strikes the phosphors  63   a  inside the resin mold  63  and excites the phosphors  63   a.  Thus, excitation light is emitted from the phosphors  63   a,  is mixed with the blue light from the LED chip  62 , and is emitted upward via the resin mold  63  as white light.  
      In this case, because the LED chip  62  is mounted on the silicon substrate  61  having a high thermal conductivity of 150 W/m·k, heat generated by the LED chip  62  at the time the LED chip  62  is driven is efficiently dissipated via the silicon substrate  61 .  
      Thus, a rise in the temperature of the LED chip  62  is suppressed and the light emission efficiency of the LED chip  62  does not drop due to the heat, whereby the emitted light beams are not reduced by the heat of the LED chip and the lifespan does not drop.  
      Also, because the electrodes  64  and  65  for electrical connection to the LED chip  62  are formed by patterning, it is possible to mutually connect the LED chips  62  in series when fabricating a multichip LED, and the current does not become concentrated at the LED chip  62  whose Vf is low.  
      Moreover, because the side surfaces of the horn  61   a  are formed as (111) surfaces, the side surfaces of the horn  61   a  are formed as excellent mirror surfaces that cannot be obtained by ordinary machining, such as cutting or punching a metal material or resin molding.  
      Moreover, it is possible to integrally configure another semiconductor device such as an IC by an existing semiconductor fabrication process on the silicon substrate  61 , which can be acquired relatively inexpensively. Thus, it becomes possible to incorporate a drive circuit for conducting lighting and blinking of the LED chip  62 , and the LED  60  can be configured compactly including the drive circuit.  
      In this manner, according to the LED  60 , because the LED  60  uses the silicon substrate  61 , the heat emitted by the LED chip  62  is efficiently dissipated, the LED  60  can be easily fabricated as a multichip LED due to the electrodes  64  and  65  formed by patterning, and it is possible to mutually connect the LED chips  62  in series, whereby current concentration at the LED chip  62  whose Vf is low resulting from variations can be avoided.  
      Also, because the LED  60  can be easily fabricated using an existing semiconductor fabrication device, special capital expenditures are unnecessary, and the LED  60  can be fabricated at a relatively low cost.  
     Seventh Embodiment  
       FIG. 8  shows the configuration of a seventh embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 8 , because an LED  70  has substantially the same configuration as that of the LED  60  shown in  FIG. 7 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED  70  is configured by a silicon substrate  71 , the LED chip  62  mounted inside a horn  71   a  formed as a concave recessed portion in the silicon substrate  71 , and the resin mold  63  including a resin material filling the inside of the horn  71   a.    
      Here, the silicon substrate  71  is configured by being laminated in two layers.  
      Namely, the silicon substrate  71  is configured by a lower first substrate  72  and an upper second substrate  73 .  
      The first substrate  72  is configured by a flat silicon substrate, and the electrodes  64  and  65  are formed on the surface thereof by patterning a thin metal film. In this case, the electrodes  64  and  65  extend sideways along the surface of the first substrate  72 , i.e., through the inside of the silicon substrate  71 .  
      In contrast, the second substrate  73  is flatly formed, so that the surface thereof becomes a (100) surface, and is disposed with a horn  71   a  formed so as to vertically penetrate the second substrate  71 .  
      Similar to the horn  61   a  of the LED  60 , the horn  71   a  is formed by, for example, liquid phase crystal anisotropic etching with TMAH so that the side surfaces thereof become (111) surfaces, and the side surfaces overall are disposed with mirror surfaces. As is publicly known, the mirror surfaces are obtained by forming a thin film of a material with a high reflectivity on the surface of the horn  11   a  by deposition or plating.  
      The LED  70  of this configuration is fabricated as follows on the basis of a fabrication method in accordance with the principles of the invention.  
      Namely, first the electrodes  64  and  65  are formed by pattern-etching a thin metal film on the surface of the silicon substrate serving as the first substrate  72 .  
      In tandem with this, the horn  71   a  is formed by liquid phase crystal anisotropic etching of the surface that is the (100) surface of the silicon substrate serving as the second substrate  73 . In this case, because the horn  71   a  vertically penetrates the second substrate  73 , it is not necessary to set with high precision the depth of the horn  71   a,  so that time management of the etching process becomes easy.  
      Next, the mirror surface is formed by deposition or plating on the side surfaces of the horn  71   a  of the second substrate  73 , and thereafter the second substrate  73  is adhered to the first substrate  72 .  
      Next, the LED chip  62  is mounted on and die-bonded to the chip mount portion  64   a  of the electrode  64  exposed to the bottom surface of the horn  71   a,  and the electrode portion of the surface of the LED chip  62  is wire-bonded to the connection portion  65   a  of the other electrode  65  by the bonding wire  62   a.    
      Thereafter, the inside of the horn  71   a  is filled with the resin material in which the granular phosphors  63   a  are mixed in, and the resin material is hardened. Thus, the resin mold  63  is formed inside the horn  71   a.  It should be noted that, before the electrodes are formed, the Si surface is covered and insulated with a thin SiO 2  layer or Si 3 N 4  layer by, for example, sputtering method, CVD method or thermal oxidation method. Thus, the LED  70  is completed.  
      According to the LED  70  fabricated in this manner, the LED  70  acts in the same manner as the LED  60  shown in  FIG. 7 , and the silicon substrate  71  is configured in two layers, whereby it becomes possible to form a complex wiring pattern on the surface of the first substrate  72 . Also, because the mirror surface is formed across the entire inner surface of the horn  71   a  of the second substrate  73 , the emission efficiency of light to the outside is improved.  
     Eighth Embodiment  
       FIG. 9  shows the configuration of an eighth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 9 , because an LED  80  has substantially the same configuration as that of the LED  70  shown in  FIG. 8 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      The LED  80  is formed so as to be disposed with chip mount portions  64   b  and  65   b,  where the electrodes  64  and  65  mutually face each other with an interval disposed therebetween, in the vicinity of the center of the upper surface of the first substrate  72 .  
      Additionally, a so-called flip chip type LED chip  81  is mounted on and electrically connected to the tops of the chip mount portions  64   b  and  65   b  so as to ride on the electrode portions disposed at both side edges of the undersurface thereof.  
      According to the LED  80  of this configuration, the LED  80  acts in the same manner as the LED  70  shown in  FIG. 8 .  
     Ninth Embodiment  
       FIG. 10  shows the configuration of a ninth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 10 , an LED  90  is one where a thermoelectric bimorph actuator is configured as an actuator adjacent to the horn  61   a  above the silicon substrate  61  with respect to the LED  60  according to  FIG. 7 .  
      The thermoelectric bimorph actuator  91  itself has a publicly known configuration and is configured by etching using the so-called MEMS technique in a semiconductor fabrication process on the silicon substrate  61 .  
      Additionally, the thermoelectric bimorph actuator  91  is supplied with electricity via electrodes not shown, whereby, as shown in  FIG. 11 , it is displaced on the semiconductor substrate  61  and covers part of the upper surface of the horn  61   a.    
      According to the LED  90  of this configuration, light is emitted to the outside from the horn  61   a  of the silicon substrate  61  in a manner similar to the case of the LED  60 . When the thermoelectric bimorph actuator  91  is not operating, light is emitted to the outside from the entire light-emitting portion resulting from the open portion of the upper end of the horn  61   a,  and when the thermoelectric bimorph actuator  91  is operating, part of the light-emitting portion is blocked off by the thermoelectric bimorph actuator  91 , so that it is possible to change the shape of the light-emitting portion. Thus, for example, when the LED  90  is used as the light source of an automobile headlight, switching of the high beam and the low beam becomes possible.  
      It should be noted that changing the shape of the light-emitting portion resulting from the open portion of the upper end of the horn  61   a  can also be realized by another type of actuator that can be configured on the silicon substrate  61 .  
     Tenth Embodiment  
       FIG. 12  shows the configuration of a tenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 12 , an LED  100  is one where a vertical comb-type electrostatic actuator  101  is configured as an actuator adjacent to the horn  61   a  on the silicon substrate  61  with respect to the LED  60  according to  FIG. 7 .  
      The vertical comb-type electrostatic actuator  101  itself has a publicly known configuration as a “Vertical Comb” and is configured by etching using the so-called MEMS technique in a semiconductor fabrication process on the silicon substrate  61 .  
      Additionally, the vertical comb-type electrostatic actuator  101  is supplied with electricity via electrodes not shown, whereby, as shown by arrow A in  FIG. 12 , it swings above the semiconductor substrate  61  and some of the light beams emitted from the upper surface of the horn  61   a  are blocked.  
      According to the LED  100  of this configuration, light is emitted to the outside from the horn  61   a  of the silicon substrate  61  in a manner similar to the case of the LED  60 . Due to the vertical comb-type electrostatic actuator  101 , part of the light emitted from the entire light-emitting portion resulting from the open portion of the upper end of the horn  61   a  is selectively blocked off, whereby the light distribution pattern is changed. Thus, for example, when the LED  100  is used as the light source of an automobile headlight, a so-called AFS function can be realized.  
      It should be noted that changing the shape of the light-emitting portion resulting from the open portion of the upper end of the horn  11   a  can also be realized by another type of actuator that can be configured on the silicon substrate  61 .  
     Eleventh Embodiment  
       FIG. 13  shows the configuration of an eleventh embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 13 , because an LED  110  has substantially the same configuration as that of the LED  60  shown in  FIG. 7 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED  110  is configured by a silicon substrate  61 , two LED chip  62  mounted inside a horn  61   a,    61   b  formed side by side respectively as a concave recessed portion in the silicon substrate  61 , and the resin mold  63  including a resin material filling the inside of the horn  61   a,    61   b.    
      Here, the silicon substrate  61  is flatly formed so that the surface thereof forms a (100) surface, and is disposed with the two horn  61   a,    61   b  formed by the concave recessed portion from the surface to an intermediate height.  
      Similar to the horn  61   a  of the LED  60 , these horns  61   a,    61   b  are formed, for example, by liquid phase crystal anisotropic etching with TMAH so that the side surfaces thereof form (111) surfaces.  
      Moreover, these horns  61   a,    61   b  are arranged apart from each other, and form a partition wall  61   c  between those.  
      This partition wall  61   c  has a height as same as the upper surface of the silicon substrate  61 , and its upper surface is flatly formed. A width of the upper surface is so selected as several μm to several 10 μm.  
      This partition wall  61   c  may be formed, as shown in  FIG. 14 , as peaked to provide a crest line at the upper end. Thus, without changing the height of the partition wall  61   c,  a distance of the LED chips  62  can be reduced.  
      Additionally, the silicon substrate  61  is disposed with a pair of electrodes (not shown) serving as reflecting mirrors in the bottom surface and side surface of the horn  61   a  and in the side surface of the partition wall  61   c,  and these electrodes supply electricity to the LED chips  62 , by connecting both of the LED chips  62  in series or in parallel.  
      These electrodes are formed by, for example, forming a thin metal film such as silver on the surface of the silicon substrate  61  in which the horn  61   a  is formed, and then pattern-etching the thin metal film.  
      Moreover, these electrodes extend via the side surfaces of the horn  61   a,    61   b  to the upper surface of the silicon substrate  61 , and the upper surface area can be connected electrically to a connecting portion on a mounting board by using a bonding wire, lead wire, soldering or silver-paste.  
      The LED  110  of this configuration is fabricated as follows on the basis of a fabrication method in accordance with the principles of the invention as shown in  FIG. 15 .  
      Namely, a silicon substrate  61  of a single crystal silicon wafer with 525 μm thickness is prepared, a (100) surface of which has been flattened by optical polishing process, and on the surface of the silicon substrate  61  is formed a thermal oxidation silicon film  61   d  with 500 nm thickness by diffusion furnace, as shown in  FIG. 15 (A).  
      And, as shown in  FIG. 15 (B), on the flat surface of the silicon substrate  61  is formed a resist pattern by photolithography method, then the thermal oxidation silicon film  61   d  is removed selectively by etching of buffered hydrofluoric acid (BHF) so that a pattern of the thermal oxidation silicon film  61   d  is formed.  
      Thereafter, as shown in  FIG. 15 (C), the horn  61   a,    61   b  are formed at the same time by, for example, liquid phase crystal anisotropic etching with TMAH solution, then all of the remaining thermal oxidation silicon film  61   d  is removed by BHF solution.  
      Next, shown in  FIG. 15 (D), on the entire surface of the silicon substrate  61 , that including the horn  61   a  and  61   b,  is formed again a thermal oxidation silicon film  61   e  with 500 nm thickness by diffusion furnace so that the entire surface of the silicon substrate  61  is insulated, then on that a electrode film  61   f  is formed by sputtering method. This electrode film  61   f  can be formed of Ti with 20 nm thickness and Cu with 200 nm thickness.  
      Then, as shown in  FIG. 15 (E), by a electroformed resist or a sprayed resist coating, on the entire surface of the silicon substrate  61 , that including the horn  61   a  and  61   b,  is applied a resist  61   g,  then a patterning of the resist  61   g  is carried out by photolithography method.  
      Thereafter, as shown in  FIG. 15 (F), by using the resist pattern  61   g  as a mask, the electrode film  61   f  is wet-etched, then a electrode pattern  61   h  is formed. In this case, the electrode pattern  61   h  is formed so as to both of the LED chips  12  in series.  
      Next, as shown in  FIG. 15 (G), on that are formed a reflecting mirror film  61   i  that consist of Ni with 5 μm thickness and Ag with 3 μm thickness formed by electro-plating method.  
      Thereafter, as shown in  FIG. 15 (H), to the electrode film pattern  61   f  constructing one electrode formed at the bottom portion of each horn  61   a  and  61   b,  the LED chip  62  is mounted on respectively, and die-bonded by solder or eutectic bonding, and the electrode portion of the surface of each LED chip  62  is wire-bonded to the electrode film pattern  61   f  constructing another electrode by the bonding wire  62   a.    
      Then, the inside of each horn  61   a  and  61   b  is filled with the resin material in which the granular phosphors  63   a  are mixed in, and the resin material is hardened. Thus, the resin mold  63  is formed inside the horn  61   a.  Thus, the LED  110  is completed.  
      According to the LED  110  fabricated in this manner, the LED  110  acts in the same manner as the LED  60  shown in  FIG. 7 , and between the two LED chip  62  is arranged the partition wall  61   c,  whereby a light absorption among the LED chips  62  is suppressed so that a lost of power of light is reduced.  
      For example, in the LED using two LED chip  62  respectively of 120 mW power with a bias 3V and 350 mA, supplying the LED with the bias 6V and 350 mA, a twice power, that is, 240 mW power was obtained. It is conjectured that the light absorption among the LED chips  62  is suppressed by the partition wall  61   c.    
     Twelfth Embodiment  
       FIG. 16  shows the configuration of a twelfth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 16 , because an LED  120  has substantially the same configuration as that of the LED  110  shown in  FIG. 13 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED  120  is configured by a silicon substrate  61 , two LED chip  62  mounted inside a horn  61   a,    61   b  formed side by side as a concave recessed portion in the silicon substrate  61 , and the resin mold  63  including a resin material filling the inside of the horn  61   a,    61   b.    
      In this case, the LED  120  is different from the LED  110  only by that the partition wall  61   c  has a crest line that is lower than the upper surface of the silicon substrate  61 .  
      The LED  120  of this configuration is fabricated as follows on the basis of a fabrication method in accordance with the principles of the invention as shown in  FIG. 17 .  
      Namely, as shown in  FIG. 17 (A), on a surface of a silicon substrate  61  is formed a thermal oxidation silicon film  61   d  with 500 nm thickness by diffusion furnace.  
      And, as shown in  FIG. 17 (B), on the flat surface of the silicon substrate  61  is formed a resist pattern by photolithography method, then the thermal oxidation silicon film  61   d  is removed selectively by etching of BHF solution so that a pattern of the thermal oxidation silicon film  61   d  is formed.  
      Then, as shown in  FIG. 17 (C), on the entire surface of the silicon substrate  61  is formed a silicon nitride film  61   j  with 200 nm thickness by plasma CVD method.  
      Next, as shown in  FIG. 17 (D), using a resist mask(not shown) formed by photolithography method, by thermal phosphoric acid process or plasma etching process, the silicon nitride film  61   j  is patterned.  
      Thereafter, as shown in  FIG. 17 (E), the shallow horn  61   a,    61   b  are formed at the same time by, for example, anisotropic etching with TMAH solution, then, as shown in  FIG. 17 (F), after washing all of the remaining silicon nitride film  61   j  is removed by thermal phosphoric acid process or plasma etching process. Then, again by liquid phase crystal anisotropic etching with TMAH solution, a big horn including the horn  61   a,    61   b  separated by the partition wall  61   c.    
      Next, after removing the thermal oxidation silicon film  61   d,  as shown in  FIG. 17 (G), on the entire surface of the silicon substrate  61 , that including the horn  61   a  and  61   b,  is formed again a thermal oxidation silicon film  61   e  with 500 nm thickness by diffusion furnace so that the entire surface of the silicon substrate  61  is insulated.  
      Thereafter, similar as in FIGS.  15 (D) to (H), on that a electrode film  61   f  is formed by sputtering, a electrode pattern  61   h  is formed by pattern etching, and on the electrode pattern  61   h  is formed a reflecting mirror  61   i,  then on each electrode pattern  61   h  in the horn  61   a  and  61   b,  the LED chip  62  is respectively die-bonded. And, the surface of each LED chip  62  is wire-bonded to the adjacent electrode pattern  61   h,  and then the inside of the horn  61   a  and  61   b  are filled with the resin material in which the granular phosphors  63   a  are mixed in, and the resin material is hardened. Thus, the resin mold  63  is formed inside the horn  61   a.  Thus, the LED  120  is completed.  
      According to the LED  120  of this configuration, the LED  120  acts in the same manner as the LED  60  shown in  FIG. 7 , and between the two LED chip  62  is arranged the relatively shallow partition wall  61   c,  whereby a light absorption among the LED chips  62  is suppressed so that a lost of power of light is reduced.  
      For this LED  120 , by a evaluation as same as that in the LED  110 , a twice power of light was obtained, and a light radiation characteristic like a dot light source was obtained by reducing the distance between the LED chips  62 .  
      In the above mentioned LED  120 , the side surfaces of the partition wall  61   c  was configured as inclined flat surfaces with an angle of inclination as same as the angle of inclination of the side surfaces of the horn  61   a,    61   b;  however, the silicon substrate  61  may be configured by being laminated in two layers similar to the LED  70  in  FIG. 18 , a partition wall formed on a lower first substrate  72 , and a big horn  121  formed on an upper second substrate  73 . In this case, the horn  121  and the partition wall can be separately formed by liquid phase crystal anisotropic etching, so that these are formed with different angles of inclination by controlling the etching suitably.  
      Also, in the above mentioned LED  110  and  120 , the side surfaces of the partition wall  61   c  was configured as inclined flat surfaces; however, the side surfaces of the partition wall  61   c  may be formed as concave as shown in  FIG. 19 (A) or as convex as shown in  FIG. 19 (B), by changing conditions of the anisotropic etching or by exchanging the anisotropic etching for an isotropic etching on the way.  
      In the case of  FIG. 19 (B), it is able to set up the height of the partition wall  61   c  suitably by controlling the etching process.  
      By various forms of the partition wall  61   c,  the reflection of light emitted from the LED chip  62  by the side surfaces of the partition wall  61   c  can be controlled, so that, it is able to realize a desired distribution of brightness and a desired distribution of light by this control of reflection.  
      In this manner, according to the LED  110  and  120 , because the partition wall  61   c  is arranged between the LED chips  62 , the absorption of light among the LED chips  62  can be suppressed, whereby a power of light can be increased.  
      Also, because the distance between the LED chips  62  can be adjusted suitably by the form of the partition wall  61   c,  the distance between the LED chips  62  can be reduced more, particularly in the case of the partition wall  61   c  formed lower than the upper surface of the silicon substrate  61 , the distribution characteristic substantially similar a dot light source is obtained, and a mixing effect of the light bundle emitted form each LED chip  62  is raised in the case of mixing the light bundle emitted from each LED chip  62 .  
      And, in the above mentioned LED  110  and  120 , two LED chips  62  were mounted; however, three or more LED chips  62  can be mounted, and particularly in the case of LED chips emitting light of primaries, for example, red, green and blue light are mounted, by that a mixing effect of the light bundle emitted form each LED chip  62  is raised, a white light with good color rendering will be obtained.  
     Thirteenth Embodiment  
       FIG. 20  shows the configuration of a thirteenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 20 , because an LED  130  has substantially the same configuration as that of the LED  60  shown in  FIG. 7 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED  130  is configured by a silicon substrate  131 , a LED chip  132  mounted inside a horn  131   a  formed as a concave recessed portion in the silicon substrate  131 , and the resin mold  133  including a resin material filling the inside of the horn  131   a.    
      Here, the silicon substrate  131  is flatly formed so that the surface thereof forms a (100) surface, and is disposed with the two horn  131   a  formed by the concave recessed portion from the surface to an intermediate height, and furthermore has two contact-hole  131   b,    131   c  formed adjacent this horn  131   a,  namely adjacent the both side of the horn  131   a  in a cross-sectional view of  FIG. 20 (A).  
      Similar to the horn  131   a,  these contact-holes  131   b,    131   c  are formed, for example, by liquid phase crystal anisotropic etching with TMAH so that the side surfaces thereof form (111) surfaces.  
      Additionally, the silicon substrate  131  is disposed with a pair of electrodes  132  and  133  that extend in  FIG. 20 (A) from the bottom surface of the horn  131   a  to the surface of the silicon substrate  131  via the left and right side surfaces of the horn  131   a  and to the ends via respectively left and right contact-holes  131   b,    131   c.    
      These electrodes  132  and  133  are formed by, for example, forming a thin metal film on the surface of the silicon substrate  131  in which the horn  131   a  and contact-holes  131   b,    131   c  have been formed, and then pattern-etching the thin metal film.  
      Similar to the horn  61   a  of the LED  60 , these horns  131   a,    131   b  are formed, for example, by liquid phase crystal anisotropic etching with TMAH so that the side surfaces thereof form (111) surfaces.  
      Here, the electrode  132  is disposed with a chip mount portion  132   a  disposed in a center region of the bottom surface of the horn  131   a,  and another electrode  133  is disposed with a connection portion  133   a  that is adjacent to the chip mount portion  132   a  at the bottom surface of the horn  131   a.    
      Moreover, in this case, both electrodes  132  and  133  are formed so that the surfaces thereof are mirror surfaces at least at regions of the side surfaces of the horn  131   a.  It should be noted that both electrodes  132  and  133  may also be disposed with separate mirror surfaces at the surfaces thereof at least at the regions of the side surfaces.  
      The contact-holes  131   b,    131   c  respectively extend to the lower surface of the silicon substrate  131 , and the portion of the electrode  132 ,  133  formed in the contact-holes  131   b  and  131   c  are exposed under the lower ends of the contact-holes  131   b,    131   c.    
      The LED  130  of this configuration is fabricated as follows on the basis of a fabrication method in accordance with the principles of the invention as shown in  FIG. 21 .  
      Namely, a silicon substrate  131  of a single crystal silicon wafer with 525 μm thickness is prepared, a (100) surface of which has been flattened by optical polishing process, and on the surface of the silicon substrate  131  is formed a thermal oxidation silicon film  131   d  with 500 nm thickness by diffusion furnace, as shown in  FIG. 21 (A).  
      And, as shown in  FIG. 21 (B), on the flat surface of the silicon substrate  131  is formed a resist pattern by photolithography method, then the thermal oxidation silicon film  131   d  is removed selectively by etching of BHF solution so that a pattern of the thermal oxidation silicon film  131   d  (for forming the contact-holes) is formed.  
      Thereafter, as shown in  FIG. 21 (C), the shallow recessed portion  131   e,    131   f  surrounded by an inclined surfaces of (111) surface are formed by liquid phase crystal anisotropic etching with TMAH solution heated at 85° C., then the silicon substrate  131  is drawn up from TMAH solution, and, as shown in  FIG. 21 (D), again using a resist pattern formed by photolithography method, a pattern of the thermal oxidation silicon film  131   d  (for forming the horn) is formed.  
      Next, as shown in  FIG. 21 (E), the horn  131   a  and the contact-holes  131   b,    131   c  are formed again by anisotropic etching with TMAH, then the silicon substrate  131  is drawn up from TMHA solution.  
      And, as shown in  FIG. 21 (F), the remaining thermal oxidation silicon film  131   d  can be removed by BHF solution, then on the entire surface of the silicon substrate  131  is formed again a thermal oxidation silicon film  131   g  with 500 nm thickness by diffusion furnace so that the entire surface of the silicon substrate  131  is insulated.  
      Next, as shown in  FIG. 21 (G), an electrode film and a reflecting film  131   h ′ can be sequentially formed, for example, of Ti and Cu by sputtering method.  
      Then, by a electroformed resist or a sprayed resist coating, on the entire surface of the silicon substrate  131  is applied a resist, then a patterning of the resist is carried out by photolithography method, and thereafter, by using this resist pattern as a mask, the electrode film and the reflecting film are wet-etched, then, as shown in  FIG. 21 (H), the electrode pattern  131   h  (the electrode  132  and  133 ) are formed. Thereafter, on these electrode pattern, films of Ni with 2 μm thickness and Ag with 3 μm thickness can be formed by, for example, electroplating, thereby the electrode/reflecting film can be formed.  
      Next, as shown in  FIG. 21 (I), to the electrode pattern  131   h  constructing one electrode formed at the bottom portion of the horn  131   a,  the LED chip  62  is mounted, and die-bonded by reflow-soldering method, eutectic bonding or silver-paste, and the electrode portion of the surface of the LED chip  62  is wire-bonded to the electrode pattern  131   h  constructing another electrode by the bonding wire  62   a.    
      Then, the inside of the horn  131   a  is filled with the resin material in which the granular phosphors  63   a  are mixed in, and the resin material is hardened. Thus, as shown in  FIG. 21 (J), the resin mold  63  is formed inside the horn  131   a.  Thus, the LED  130  is completed.  
      And, in the case of mounting the LED  130  on the mounting board  134 , as shown in  FIG. 21 (K), the package of the LED  130  is put on the determined place of the mounting board  134 , the electrodes  132 ,  133  extending to the lower ends of the contact-holes  131   b  and  131   c  is connected to the connecting portion  134   a,    134   b  consist of conductive patterns on the mounting board  134  by reflow-soldering. Thus, the LED  130  is mounted.  
      According to the LED  130  constructed in this manner, the LED  130  acts in the same manner as the LED  60  shown in  FIG. 7 , and, when mounting on the mounting boars  134 , the electrodes  132 ,  133  extending to the lower ends of the contact-holes  131   b  and  131   c  is directly contacted, and connected by soldering, to the connecting portions  134   a,    134   b  on the mounting board  134 , thereby bonding-wire and lead wire are unnecessary, and other parts can be mounted adjacent the LED  130  on the mounting boars  134 .  
      For this LED  130 , by a evaluation of light emitting as same as that in the LED  110  with bias of 3V, 350 mA, a white light with 110 mW power was obtained.  
     Fourteenth Embodiment  
       FIG. 22  shows the configuration of a fourteenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 22 , because an LED  140  has substantially the same configuration as that of the LED  130  shown in  FIG. 20 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED  140  is different from the  130  only at the point that the LED  140  is provided with contact-edges  131   i,    131   j  instead of the contact-holes  131   b,    131   c.    
      Here, each of the contact-edges  131   i,    131   j  has a form of cutting in half the above mentioned contact-hole  131   b  or  131   c  in along centerline at the both end of the silicon substrate  131 .  
      Similar to the horn  131   a,  these contact-edges  131   i,    131   j  are formed, for example, by liquid phase crystal anisotropic etching with TMAH so that the side surfaces thereof form (111) surfaces.  
      And, a pair of electrodes  132  and  133  formed on the surface of the silicon substrate  131  extend in  FIG. 22 (A) from the bottom surface of the horn  131   a  to the surface of the silicon substrate  131  via the left and right side surfaces of the horn  131   a  and respectively to the lower ends of the left and right contact-edges  131   i,    131   j.    
      The LED  140  of this configuration is fabricated as follows on the basis of a fabrication method in accordance with the principles of the invention as shown in  FIG. 23 .  
      Namely, similar to the LED  120  shown in  FIG. 20 , as shown in FIGS.  21 (A) to (H), on the upper surface of the silicon substrate  131 , the horn  131   a,  the contact-hole  131   b  and  131   c  and the electrode pattern  131   h.    
      Here, the electrode pattern  131   h  (the electrodes  132 ,  133 ) extends from the horn  131   a  to the lower end of the contact-holes  131   b,    131   c  in those via the surface of the silicon substrate  131 .  
      Then, as shown in  FIG. 23 (A), the silicon substrate  131  is cut off by dicing along a section through the center of each contact-hole  131   b,    131   c.  Thereby, each contact-hole  131   b,    131   c  are cut in half respectively to be the contact-edge  131   i,    131   j.    
      Thereafter, as shown in  FIG. 23 (B), to the electrode pattern  131   h  constructing one electrode  132  formed at the bottom portion of the horn  131   a,  the LED chip  62  is mounted, and die-bonded by reflow-soldering method, eutectic bonding or silver-paste, and the electrode portion of the surface of the LED chip  62  is wire-bonded to the electrode pattern  131   h  constructing another electrode  133  by the bonding wire  62   a.    
      Then, the inside of the horn  131   a  is filled with the resin material in which the granular phosphors  63   a  are mixed in, and the resin material is hardened. Thus, as shown in  FIG. 23 (C), the resin mold  63  is formed inside the horn  131   a.  Thus, the LED  140  is completed.  
      And, in the case of mounting the LED  130  on the mounting board  134 , as shown in  FIG. 23 (D), the package of the LED  140  is put on the determined place of the mounting board  134 , the electrodes  132 ,  133  extending to the lower ends of the contact-edges  131   i  and  131   j  is connected to the connecting portion  134   a,    134   b  consist of conductive patterns on the mounting board  134  by reflow-soldering. Thus, the LED  140  is mounted.  
      In this case, because the contact-edges  131   i  and  131   j  are provided instead of the contact-holes  131   b  and  131   c,  when mounting, a potting of cream solder to the contact-edges  131   i,    131   j  is easily carried out, so that an operativity is improved.  
     Fifteenth Embodiment  
       FIG. 24  shows the configuration of a fifteenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 24 , because an LED  150  has substantially the same configuration as that of the LED  130  shown in  FIG. 20 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED  150  is different from the  130  only at the point that a metal thin film  151  is provided in the region corresponding the horn  131   a  on the backside surface of the silicon substrate  131 .  
      Here, the metal thin film  151  is consist of metal such as Au or Ag, and formed by sputtering, and patterned by lift-off method or wet-etching.  
      And, in the case of mounting the LED  150  on the mounting board  134 , as shown in  FIG. 24 , the package of the LED  150  is put on the determined place of the mounting board  134 , the electrodes  132 ,  133  extending to the lower ends of the contact-holes  131   b  and  131   c  is connected to the connecting portion  134   a,    134   b  consist of conductive patterns on the mounting board  134  by reflow-soldering. Thus, the LED  150  is mounted.  
      In this case, because the metal thin film  151  provided on the backside surface of the silicon substrate  131  contacts to the conductive pattern portion  134   c  for heat-radiation on the mounting board  134 , the heat generated from the LED chip  62  is transmitted from the silicon substrate  131  to the conductive pattern portion  134   c  for heat-radiation via the metal thin film  151 , thereby the heat generated from the LED chip  62  can be radiated efficiently.  
     Sixteenth Embodiment  
       FIG. 25  shows the configuration of a sixteenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 25 , an LED  160  is a variant of the LED  150  shown in  FIG. 24 .  
      Namely, the LED  160  is different from the  150  only at the point that the thermal oxidation silicon film  131   g  is removed in a region, that the metal thin film  151  is formed in, on the lower surface of the silicon substrate  131 .  
      According to the LED  160  of this configuration, in the case of mounting the LED  160  on the heat sink  161 , as shown in  FIG. 26 , the package of the LED  160  is put on the surface of the heat sink  161  by inserting a thermal conductive sheet  162 , and the contact-holes  131   b,    131   c  is put on the lead frame  163 ,  164 , then the electrodes  132 ,  133  extending to the lower ends of the contact-holes  131   b  and  131   c  is connected respectively to the lead frames  163 ,  164  by reflow-soldering. Thus, the LED  160  is mounted.  
      In this case, because the metal thin film  151  provided on the lower surface of the silicon substrate  131  contacts directly to the lower surface of the silicon substrate  131  and via the thermal conductive sheet  162  to the heat sink  161 , the heat from the LED chip  62  is transmitted from the silicon substrate  131  to the heat sink  161  via the thermal conductive sheet  162 , thereby the heat resistance is reduced extremely, for example, as 2° C./W, so that an effect of heat radiation is raised.  
     Seventeenth Embodiment  
       FIG. 27  shows the configuration of a seventeenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 27 , because an LED has substantially the same configuration as that of the LED  60  shown in  FIG. 7 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED is configured by a silicon substrate  61 , a horn  61   a  formed as a concave recessed portion in the silicon substrate  61 , a LED chip  62  mounted center of the horn  61   a,  the resin mold  63  including a resin material filling the inside of the horn  61   a,  and a lens  200 .  
      This lens  200  is arranged above the horn  61   a  before the resin mold  63  filled in the horn  61   a  is hardened, then fixed by hardening of the resin mold  63 . Particularly a recess  201  for positioning the lens  200  is adjacent the horn  61   a,  thereby the lens can be mounted precisely and easily. This recess  201  can be formed at the same time by liquid phase etching for forming the horn, thereby the accuracy of mask for etching can be brought to the positioning accuracy of the lens  200  substantially.  
      Additionally, in  FIG. 27 , two rectangular recesses  201  are formed; however three or more recesses  201  can be formed, or substantially circular or polygonal recesses surrounding the horn can be formed. Also, as shown in  FIG. 28 , the horn is formed with two steps, thereby the upper step can be used as a recess for positioning the lens  200 .  
     Eighteenth Embodiment  
       FIG. 29  shows the configuration of an eighteenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 29 , because an LED has substantially the same configuration as that of the LED  60  shown in  FIG. 7 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED is configured by a silicon substrate  61 , a horn  61   a  formed as a concave recessed portion in the silicon substrate  61 , a LED chip  62  mounted center of the horn  61   a,  the resin mold  63  including a resin material filling the inside of the horn  61   a,  and a spherical lens  200 .  
      This spherical lens  200  is arranged above the horn  61   a  before the resin mold  63  filled in the horn  61   a  is hardened, then fixed by hardening of the resin mold  63 . Particularly, in the case of the horn formed in a square shape, by fixing the spherical lens  200  against the edge of the horn  61   a,  the spherical lens  200  can be positioned uniquely, thereby advantageously an offset of the optical axis is hard to occur material of the lens itself can be light-transparent material such as glass, resin material, and can have a good adhesion to the mold resin since the lens is adhered and fixed to the mold resin.  
     Nineteenth Embodiment  
       FIG. 30  shows the configuration of a nineteenth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 30 , because an LED has substantially the same configuration as that of the LED  140  shown in  FIG. 22 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED is configured by a silicon substrate  131 , a horn  131   a  formed as a concave recessed portion in the silicon substrate  131 , a plural of LED chips  62  mounted center of the horn  131   a,  the resin mold  63  including a resin material filling the inside of the horn  131   a,  and contact-edges  131   i,    131   j.    
      Here, the contact-edges are formed respectively at four corners of the rectangular bottom surface of the horn  131   a,  and the electricity can be supplied via each contact-edge to corresponding LED chip. Thereby, when, for example, a red LED chip and a green LED chip are mounted in the same horn, light emitting of each LED chip can be controlled individually through an external circuit. Additionally, in  FIG. 30 , by using four electrodes, two LED chips are electrically connected and driven individually; however by forming other contact-edge in a vicinity of the silicon substrate  131 , each of tree or more LED chips can be electrically connected independently.  
     Twentieth Embodiment  
       FIG. 31  shows the configuration of a twentieth embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 31 , because an LED has substantially the same configuration as that of the LED  140  shown in  FIG. 22 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED is configured by a silicon substrate  131 , a horn  131   a  formed as a concave recessed portion in the silicon substrate  131 , a plural of LED chips  62  mounted center of the horn  131   a,  the resin mold  63  including a resin material filling the inside of the horn  131   a,  and contact-edges  131   i,    131   j.    
      Here, the contact-edges are formed respectively at two positioned adjacent each other of four corners of the bottom surface of the horn  131   a,  and, the LED will be mounted on the mounting board so that the horn, in which the LED chips are mounted, opens to the direction parallel to the substrate. Namely, the LED of this embodiment is configured as a side-view type surface-mounting type LED.  
     Twenty-first Embodiment  
       FIG. 32  shows the configuration of a twenty-first embodiment of an LED made in accordance with the principles of the invention.  
      As shown in  FIG. 32 , because an LED has substantially the same configuration as that of the LED  60  shown in  FIG. 7 , the same reference numerals will be given to the same constituent elements and description of those same constituent elements will be omitted.  
      Namely, the LED is configured by a silicon substrate  61 , a horn  61   a  formed as a concave recessed portion in the silicon substrate  61 , a plural of LED chips  62  mounted center of the horn  61   a,  the resin mold  63  including a resin material filling the inside of the horn  61   a,  and lead frames  67   a,    67   b.    
      Here, the LED is different from the LED  60  in  FIG. 7  at the point that the lead frames  67   a,    67   b  are mounted at the left and right side of the silicon substrate  61  respectively so as to be electrically connected to the electrodes. Thereby, a thin surface-mounting type device can be produced to be suited for mounting.  
      In fabricating the LED, shallow recesses  66   a,    66   b  for positioning the lead frames can be formed in the silicon substrate  61 . Since these recesses  66   a,    66   b  can be formed at the same time that the horn is formed by liquid phase etching, additional process is not necessary.  
      For the lead frames are certainly connected to the electrode contact portions on the silicon substrate, electric connection are carried out using a conductive paste. Electric connection can be carried out using eutectic bonding or laser beam welding. In this case, mechanical rigidity in each bonding of the lead frames and the silicon substrate is highly, thereby the LED is easily treated when mounting.  
      Also, in  FIG. 33 , a LED is shown that the silicon substrate with the lead frames is molded integratedly with the resin mold. In the case, the resin penetrates between the lead frames and the silicon substrate, thereby a short-circuit can be prevented, so that a reliability is raised. Also, the lead frames are fixed by the resin, thereby the mechanical rigidity is increased more, so that the LED can be treated.  
      Furthermore, a metal thin film can be formed in a region corresponding to the LED chips in the lower surface of the silicon substrate, so that the lead frames and the metal thin film will be fixed to a mounting board by reflow-soldering process. Thereby, the region of the backside of silicon substrate that corresponds to the bottom surface of the LED chip is directly contacted to the mounting board via solder, so that the heat-radiation is improved.  
      In the preceding embodiments, the LED was configured so that the phosphors mixed inside the resin mold were excited by the blue light from the LED chip and so that white light was emitted due to the mixing of the colors of the excitation light and the blue light from the LED chip; however, it will be apparent that the LED may also be one where the light from the LED chip is emitted as is to the outside by a resin mold in which the phosphors are not mixed in.  
      Also, in the preceding embodiments, only the LED chip was mounted on the silicon substrate, but the invention is not limited thereto. It will be apparent that other semiconductor devices may also be integrally configured on the silicon substrate by a semiconductor fabrication process.  
      Moreover, in the preceding embodiments, the mirror surface was disposed on the side walls of the horn on the silicon substrate, but the invention is not limited thereto. It will be apparent that the mirror surface does not have to be disposed.  
      According to an embodiment of an LED made in accordance with the principles of the invention, an LED chip can be mounted inside a horn formed on a silicon substrate, whereby the LED can be compactly configured at a relatively low cost. Also, because the LED can easily accommodate multichip LED fabrication, it is possible to use the LED as a light source for various devices.  
      While illustrative and exemplary embodiments of the invention 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 insofar as limited by the prior art.