Patent Abstract:
A light emitting device having a vertical structure and a package thereof, which are capable of damping impact generated in a substrate separation process, and achieving an improvement in mass productivity. The device and package include a sub-mount, a first-type electrode, a second-type electrode, a light emitting device, a zener diode, and a lens on the sub-mount.

Full Description:
[0001]    This application is a continuation of U.S. application Ser. No. 14/018,297, filed Sep. 4, 2013, which is a continuation of Ser. No. 13/080,764, filed Apr. 6, 2011, which is a continuation of U.S. application Ser. No. 11/701,535 filed Feb. 2, 2007, currently allowed now U.S. Pat. No. 7,928,462, issued Apr. 19, 2011, and claims the benefit of Korean Patent Application No. 10-2006-0015039, filed on Feb. 16, 2006 and Korean Patent Application No. 10-2006-0015040, filed on Feb. 16, 2006, which are all hereby incorporated by reference as if fully set forth herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a light emitting device having a vertical structure, a package thereof and a method for manufacturing the same, and more particularly, to a light emitting device having a vertical structure, a package thereof and a method for manufacturing the same which are capable of damping impact generated in a substrate separation process, and achieving an improvement in mass productivity. 
         [0004]    2. Discussion of the Related Art 
         [0005]    Light emitting diodes (LEDs) are well known as a semiconductor light emitting device which converts current to light, to emit light. Since a red LED using GaAsP compound semiconductor was commercially available in 1962, it has been used, together with a GaP:N-based green LED, as a light source in electronic apparatuses, for image display. 
         [0006]    The wavelength of light emitted from such an LED depends on the semiconductor material used to fabricate the LED. This is because the wavelength of the emitted light depends on the band gap of the semiconductor material representing energy difference between valence-band electrons and conduction-band electrons. 
         [0007]    Gallium nitride (GaN) compound semiconductor has been highlighted. One of the reasons why GaN compound semiconductor has been highlighted is that it is possible to fabricate a semiconductor layer capable of emitting green, blue, or white light, using GaN in combination with other elements, for example, indium (In), aluminum (Al), etc. 
         [0008]    Thus, it is possible to adjust the wavelength of light to be emitted, using GaN in combination with other appropriate elements. Accordingly, where GaN is used, it is possible to appropriately determine the materials of a desired LED in accordance with the characteristics of the apparatus to which the LED is applied. For example, it is possible to fabricate a blue LED useful for optical recording or a white LED to replace a glow lamp. 
         [0009]    On the other hand, initially-developed green LEDs were fabricated using GaP. Since GaP is an indirect transition material causing a degradation in efficiency, the green LEDs fabricated using this material cannot practically produce light of pure green. By virtue of the recent success of growth of an InGaN thin film, however, it has been possible to fabricate a high-luminescent green LED. 
         [0010]    By virtue of the above-mentioned advantages and other advantages of GaN-based LEDs, the GaN-based LED market has rapidly grown. Also, techniques associated with GaN-based electro-optic devices have rapidly developed since the GaN-based LEDs became commercially available in 1994. 
         [0011]    GaN-based LEDs have been developed to exhibit light emission efficiency superior over that of glow lamps. Currently, the efficiency of GaN-based LEDs is substantially equal to that of fluorescent lamps. Thus, it is expected that the GaN-based LED market will grow significantly. 
         [0012]    Despite the rapid advancement in technologies of GaN-based semiconductor devices, the fabrication of GaN-based devices suffers from a great disadvantage of high-production costs. This disadvantage is closely related to difficulties associated with growing of a GaN thin film (epitaxial layer) and subsequent cutting of finished GaN-based devices. 
         [0013]    Such a GaN-based device is generally fabricated on a sapphire (Al 2 O 3 ) substrate. This is because a sapphire wafer is commercially available in a size suited for the mass production of GaN-based devices, supports GaN epitaxial growth with a relatively high quality, and exhibits a high processability in a wide range of temperatures. 
         [0014]    Further, sapphire is chemically and thermally stable, and has a high-melting point enabling implementation of a high-temperature manufacturing process. Also, sapphire has a high bonding energy (122.4 Kcal/mole) and a high dielectric constant. In terms of a chemical structure, the sapphire is a crystalline aluminum oxide (Al 2 O 3 ). 
         [0015]    Meanwhile, since sapphire is an insulating material, available LED devices manufactured using a sapphire substrate (or other insulating substrates) are practically limited to a lateral or vertical structure. 
         [0016]    In the lateral structure, all metal contacts for use in injection of electric current into LEDs are positioned on the top surface of the device structure (or on the same substrate surface). On the other hand, in the vertical structure, one metal contact is positioned on the top surface, and the other contact is positioned on the bottom surface of the device structure after removal of the sapphire (insulating) substrate. 
         [0017]    In addition, a flip chip bonding method has also been widely employed. In accordance with the flip chip bonding method, an LED chip, which has been separately prepared, is attached to a sub-mount of, for example, a silicon wafer or ceramic substrate having an excellent thermal conductivity, under the condition in which the LED chip is inverted. 
         [0018]    However, the lateral structure or the flip chip method suffers from the problems associated with poor heat release efficiency because the sapphire substrate has a heat conductivity of about 27 W/mK, thus leading to a very high heat resistance. Furthermore, the flip chip method has also disadvantages of requiring large numbers of photolithography process steps, thus resulting in complicated manufacturing processes. 
         [0019]    To this end, LED devices having a vertical structure have been highlighted in that the vertical structure involves removal of the sapphire substrate. 
         [0020]    In the fabrication of such a vertical LED structure, a laser lift off (LLO) method is used to remove the sapphire substrate, and thus, to solve the problems caused by the sapphire substrate. 
         [0021]    However, it is impossible to completely remove the sapphire substrate at once, using the LLO method, due to the size and limited uniformity of a laser beam used in the LLO method. For this reason, uniform small-size laser beams are irradiated to respective portions of the sapphire substrate, in order to the entire portion of the sapphire substrate. 
         [0022]    In the LLO method, stress is applied to the GaN thin film upon incidence of a laser beam. In order to separate a sapphire substrate and a GaN thin film from each other, it is necessary to use a laser beam having a high energy density. The laser beam resolves GaN into a metal element, namely, Ga, and nitrogen gas (N 2 ). 
         [0023]    The resolved nitrogen gas exhibits a high expansion force, so that it applies considerable impact not only to the GaN thin film 2, but also to a support layer for the GaN thin film 2 and metal layers required for the fabrication of the device. As a result, a degradation in bondability occurs primarily. In addition, a degradation in electrical characteristics occurs. 
         [0024]    For example, wave patterns exhibited as having irregularities may be formed at the peripheral portion of the GaN thin film after completion of the LLO process. Also, during the LLO process, many poor bonding portions may be observed on the thin film. 
         [0025]    Thus, the nitrogen gas generated during the LLO process damages the semiconductor layer arranged in the vicinity of the nitrogen gas. There may also be a phenomenon that cracks formed at poor-quality portions of the GaN thin film are propagated to other portions of the GaN thin film. 
         [0026]    As apparent from the above description, a prolonged process is required in fabricating a desired device using a GaN thin film to form an LED layer. Furthermore, there are many difficulties in implementing this process. In particular, where separation of a substrate is carried out using a laser, nitrogen gas generated due to the laser may easily damage the thin films of a semiconductor layer arranged in the vicinity of the nitrogen gas. As a result, a degradation in productivity may occur. 
       SUMMARY OF THE INVENTION 
       [0027]    Accordingly, the present invention is directed to a light emitting device having a vertical structure, a package thereof and a method for manufacturing the same that substantially obviate one or more problems due to limitations and disadvantages of the related art. 
         [0028]    An object of the present invention is to provide a light emitting device having a vertical structure, a package thereof and a method for manufacturing the same which are capable of preventing damage of a semiconductor thin film during a laser lift off process, reducing the number of processes and the processing time, enabling the device to have various arrangement and various shapes. 
         [0029]    Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. 
         [0030]    To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a method for manufacturing a package of a light emitting device package having a vertical structure comprises: growing a semiconductor layer having a multilayer structure over a substrate; forming a first electrode on the semiconductor layer; separating the substrate including the grown semiconductor layer into unit devices; bonding each of the separated unit devices on a sub-mount; separating the substrate from the semiconductor layer; and forming a second electrode on a surface of the semiconductor layer exposed in accordance with the separation of the substrate. 
         [0031]    In another aspect of the present invention, a package of a light emitting device having a vertical structure comprises: a sub-mount having a light emitting device chip mounting portion formed with at least one pair of electrodes; a light emitting device chip bonded to the sub-mount, the light emitting device chip comprising a support layer electrically connected to one side of each electrode of the sub-mount, a first electrode arranged on the support layer, a semiconductor layer arranged on the first electrode and formed with a light extraction pattern, the semiconductor layer having a multilayer structure, and a second electrode arranged on the semiconductor layer and electrically connected to the other side of each electrode of the sub-mount; and zener diodes formed at the sub-mount such that the zener diodes are connected to respective electrodes of the sub-mount. 
         [0032]    In still another aspect of the present invention, a light emitting device having a vertical structure comprises: a support layer made of a metal or semiconductor; an adhesion layer arranged on the support layer, the adhesion layer having a single layer structure or a multilayer structure; a first electrode arranged on the adhesion layer; a semiconductor layer arranged on the first electrode and formed with a light extraction pattern, the semiconductor layer having a multilayer structure; and a second electrode arranged on the semiconductor layer. 
         [0033]    It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0034]    The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings: 
           [0035]      FIGS. 1 to 18  are sectional view illustrating a first embodiment of the present invention, in which: 
           [0036]      FIG. 1  is a sectional view illustrating a process for forming a semiconductor layer; 
           [0037]      FIG. 2  is a sectional view illustrating an example of a process for forming a first electrode and a support layer; 
           [0038]      FIG. 3  is a sectional view illustrating another example of the process for forming the first electrode and support layer; 
           [0039]      FIG. 4  is a sectional view illustrating a laser scribing process; 
           [0040]      FIG. 5  is a sectional view illustrating a first example of a light emitting device chip; 
           [0041]      FIG. 6  is a sectional view illustrating a mesa etching process carried out after the formation of the semiconductor layer; 
           [0042]      FIG. 7  is a sectional view illustrating a process for forming the first electrode and a passivation layer; 
           [0043]      FIG. 8  is a sectional view illustrating a process for forming a metal support layer; 
           [0044]      FIG. 9  is a sectional view illustrating a second example of the light emitting device chip; 
           [0045]      FIG. 10  is a sectional view illustrating a trench etching process carried out after the formation of the semiconductor layer; 
           [0046]      FIG. 11  is a sectional view illustrating a third example of the light emitting device chip; 
           [0047]      FIG. 12  is a sectional view illustrating an example of bonding of the light emitting device chip to a sub-mount in accordance with the present invention; 
           [0048]      FIG. 13  is a schematic view illustrating an example of the sub-mount according to the present invention; 
           [0049]      FIG. 14  is a sectional view illustrating a circuit of the sub-mount according to the present invention; 
           [0050]      FIG. 15  is a sectional view illustrating a state in which a chip is attached to the sub-mount in accordance with the present invention; 
           [0051]      FIG. 16  is a sectional view illustrating a first example of the sub-mount according to the present invention; 
           [0052]      FIG. 17  is a sectional view illustrating a second example of the sub-mount according to the present invention; 
           [0053]      FIG. 18  is a sectional view illustrating a third example of the sub-mount according to the present invention; and 
           [0054]      FIG. 19  is a perspective view illustrating a light emitting device package manufactured in accordance with the present invention; and 
           [0055]      FIGS. 20 to 30  are sectional views illustrating a second embodiment of the present invention, in which: 
           [0056]      FIG. 20  is a sectional view illustrating a process for forming a semiconductor layer; 
           [0057]      FIG. 21  is a sectional view illustrating an example of a process for forming a first electrode; 
           [0058]      FIG. 22  is a sectional view illustrating a laser scribing process; 
           [0059]      FIG. 23  is a sectional view illustrating a fourth example of a light emitting device chip; 
           [0060]      FIG. 24  is a sectional view illustrating a mesa etching process carried out after the formation of the semiconductor layer; 
           [0061]      FIG. 25  is a sectional view illustrating a process for forming the first electrode and a passivation layer; 
           [0062]      FIG. 26  is a sectional view illustrating a process for forming a metal plate; 
           [0063]      FIG. 27  is a sectional view illustrating a fifth example of the light emitting device chip; 
           [0064]      FIG. 28  is a sectional view illustrating a trench etching process carried out after the formation of the semiconductor layer; 
           [0065]      FIG. 29  is a sectional view illustrating a sixth example of the light emitting device chip; and 
           [0066]      FIG. 30  is a sectional view illustrating another example of the bonding of the light emitting device chip to the sub-mount in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0067]    Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. 
         [0068]    The present invention may, however, be embodied in many alternate forms and should not be construed as limited to the embodiments set forth herein. Accordingly, while the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims. 
         [0069]    Like numbers refer to like elements throughout the description of the figures. In the drawings, the thickness of layers and regions are exaggerated for clarity. 
         [0070]    It will be understood that when an element such as a layer, region or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. It will also be understood that if part of an element, such as a surface, is referred to as “inner,” it is farther to the outside of the device than other parts of the element. 
         [0071]    In addition, relative terms, such as “beneath” and “overlies”, may be used herein to describe one layer&#39;s or region&#39;s relationship to another layer or region as illustrated in the figures. 
         [0072]    It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures. Finally, the term “directly” means that there are no intervening elements. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0073]    It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. 
         [0074]    These terms are only used to distinguish one region, layer or section from another region, layer or section. Thus, a first region, layer or section discussed below could be termed a second region, layer or section, and similarly, a second region, layer or section may be termed a first region, layer or section without departing from the teachings of the present invention. 
       First Embodiment 
       [0075]    Hereinafter, a first embodiment of the present invention will be described with reference to the accompanying drawings. 
         [0076]    First, a method for manufacturing individual semiconductor light emitting device chips will be described. 
         [0077]    As shown in  FIG. 1 , in order to manufacture a light emitting device chip according to this embodiment, a semiconductor layer  20  having a multilayer structure is formed over a sapphire substrate  10 , using a thin film growing method such as a hydride vapor phase epitaxy (HVPE) or a metal organic chemical vapor deposition (MOCVD) method. The HVPE method is advantageous in that it is possible to grow a thin film having a low impurity concentration, namely, a high purity, at a high growth rate of 50 to 100 μm per hour. 
         [0078]    The growth of the semiconductor layer  20 , which has a multilayer structure, can be achieved by first forming an n type GaN semiconductor layer over the substrate  10 , forming an active layer over the n type GaN semiconductor layer, and forming a p type GaN semiconductor layer over the active layer. 
         [0079]    A first electrode  30  is then formed on the semiconductor layer  20 , as shown in  FIG. 2 . The first electrode  30  is a p type electrode or an ohmic electrode. In this case, a transparent electrode may be used for the first electrode  30 . The transparent electrode may be made of a transparent conductive oxide such as indium tin oxide (ITO). 
         [0080]    A separate support layer  40  may be formed over the first electrode  30 , in order to achieve an enhancement in light emission efficiency and an improvement in bonding structure, and to provide a function for protecting or supporting the semiconductor layer  20 . The support layer  40  may be made of a metal or a semiconductor containing silicon. 
         [0081]    The support layer  40  may include a reflection layer adapted to reflect light emerging from the active layer of the semiconductor layer  20 , and thus, to achieve an enhancement in light emission efficiency, and an anti-diffusion layer formed over the reflection layer. 
         [0082]    The anti-diffusion layer is also called a “under bump metallization (UBM) layer”. Where plating is carried out over a reflection electrode, or a metal support layer is attached to the reflection electrode, a solder is mainly used. In this case, the solder may be diffused into the semiconductor layer  20  in a melted state, so that it may adversely affect light emission characteristics. The anti-diffusion layer functions to avoid such a phenomenon. 
         [0083]    In order to enable a chip to be bonded to a sub-mount, which will be described later, a plate made of a metal such as Cu, Ni, or Au may be subsequently formed on the anti-diffusion layer. For the same purpose, a semiconductor wafer or substrate made of, for example, Si, may be attached to the anti-diffusion layer. 
         [0084]    On the other hand, after the formation of the first electrode  30  over the semiconductor layer  20  formed over the substrate  10 , an adhesion layer  41  having a single layer structure or a multilayer structure may be formed over the first electrode  30 , for formation of the support layer  40 , as shown in  FIG. 3 . 
         [0085]    In this case, the first electrode  30  may include a reflection film, or may be made of a material having a high reflectivity, to function as a reflection electrode. 
         [0086]    The adhesion layer  41  arranged on the first electrode  30  is a metal layer for bonding the support layer  40  to the first electrode  30 . The adhesion layer  41  may have a single layer structure or a multilayer structure including two or more layers. 
         [0087]    The adhesion layer  41  may have a thickness corresponding to 2 to 10 times the thickness of the first electrode  30 , in order to provide a sufficient bonding strength. 
         [0088]    The support layer  40  is bonded to the adhesion layer  41 . The support layer  40  may be made of a semiconductor wafer or substrate containing Si. 
         [0089]    For the support layer  40 , a metal plate may be used. The metal plate may be formed over the adhesion layer  41  in accordance with a plating process. 
         [0090]    Thereafter, a process for separating the chip structure fabricated as described above into individual unit device chips is carried out. As shown in  FIG. 4 , the substrate  10  is first thinned. Scribing is then carried out using a laser, to define regions corresponding to respective unit device chips. Thereafter, a cutting force is applied to the scribed portions of the chip structure in accordance with a mechanical method, thereby causing the chip structure to be separated into individual chips  100 . 
         [0091]    On the other hand, in accordance with another method for manufacturing individual light emitting device chips, individual device chips may be fabricated using a mesa etching process carried out after the growth of the semiconductor layer  20  which has a multilayer structure, as shown in  FIG. 6 . 
         [0092]    In the mesa etching process, the semiconductor layer  20  grown over the substrate  10  is etched until the n type semiconductor layer is exposed in each device chip region. 
         [0093]    In this case, as shown in  FIG. 7 , a first electrode  30  is then formed. Subsequently, a passivation layer  50  is formed to protect the first electrode  30  and surfaces exposed in accordance with the etching process. 
         [0094]    Thereafter, a support layer  40  is formed, as shown in  FIG. 8 . The support layer  40  may include a reflection electrode, an anti-diffusion layer, and a metal plate made of a metal such as Cu, Ni, or Au. 
         [0095]    Subsequently, a process for thinning the substrate  10 , performing laser scribing, and separating chips is carried out in the same manner as described above. Each separated chip  100  has a structure as shown in  FIG. 9 . 
         [0096]    Alternatively, device chips may be fabricated by performing, in place of the mesa etching process, a trench etching process in which the semiconductor layer  20  is etched until the substrate  10  is exposed, as shown in  FIG. 10 . 
         [0097]    The remaining processes are identical to those in the above-described case. Each chip  100 , which is finally obtained, has a structure as shown in  FIG. 11 . 
         [0098]    As shown in  FIG. 12 , each chip  100  is bonded to a sub-mount  60  which is separately prepared. The bonding of the chip  100  is carried out such that the first electrode  30  or support layer  40  of the chip  100  is attached to a mounting portion  61  of the sub-mount  60 . The first electrode  30  or support layer  40  is electrically connected to electrodes  62  and  63  formed at the mounting portion  61  of the sub-mount  60 . 
         [0099]    A reflection plate  65  may be formed on a portion of each of the electrodes  62  and  63 . 
         [0100]    For the sub-mount  60 , a substrate made of Si, MN ceramic, AlO x , Al 2 O 3 , or BeO, or a PCB substrate may be used. Zener diodes  64  may be formed at the sub-mount  60 , to achieve an improvement in electrostatic discharge (ESD) property. 
         [0101]    When static electricity is generated in a device, a high voltage may be applied to the device. In this case, an electrostatic breakdown occurs, so that the characteristics of the device disappear. This phenomenon is called an “ESD phenomenon”. Such an ESD phenomenon occurs frequently in a procedure of assembling or handling the device in a manual manner or using equipment. Accordingly, it is important to enhance the characteristics of the device by optimizing the structure of the device for eliminating an internal current concentration phenomenon, and thus, achieving an improvement in ESD property (namely, an increase in the electrostatic resistance of the device at a higher voltage). 
         [0102]    In detail, such static electricity may be generated during a process for manufacturing a semiconductor, or during a process for mounting the manufactured semiconductor on a PCB. 
         [0103]    Static electricity is not always generated. Furthermore, although static electricity is generated, its quantity (voltage and current) is not constant. For this reason, for a quantitative test for static electricity, it is necessary to produce static electricity having constant voltage and current waveforms. For an international standard (for complete products) for standardized static electricity, there is IEC 61000-4-2, EIAJ, MIL STD, -883D, E (3015). The representative standard in Korea is KN61000-4-4 (Korean version of IEC61000-4-2). 
         [0104]    The bonding of the chip  100  to the sub-mount  60  may be achieved using the following method. 
         [0105]    In accordance with one method, the unit device chip  100  is mounted on the sub-mount  60  using an adhesive. Thereafter, a pressure is thermally applied to the unit device chip  100 , thereby bonding the unit device chip  100  to the sub-mount  60 . 
         [0106]    In accordance with another method, the unit device chip  100  is aligned with the sub-mount  60 , and is mounted on (brought into contact with) the sub-mount  60 . Thereafter, bonding is carried out using a frictional heat generated in accordance with ultrasonic vibrations. 
         [0107]    In the latter case, the metal plate for the support layer  40  of the chip  100  may be made of Au, and Au balls may be arranged on an area facing the chip  100 . When ultrasonic (U/S) bonding is carried out, it is possible to improve bonding characteristics, in particular, thermal characteristics. 
         [0108]      FIG. 13  illustrates an example of a 3D through hole interconnection (THI) sub-mount provided with zener diodes  64  to achieve an improvement in ESD property. 
         [0109]    As shown in  FIG. 13 , the sub-mount  60  includes a mount portion  61  to which a light emitting device chip is bonded. A pair of electrodes  62  and  63  are formed at the mounting portion  61 . The electrode  62  is a positive electrode to come into contact with the first electrode  30  or support layer  40  of the chip  100 , whereas the electrode  63  is a negative electrode to come into contact with a second electrode  70  of the chip  100  which will be described later. Of course, the electrodes  62  and  63  may be arranged at positions opposite to those of the above-described case. Also, the objects, to which the electrodes  62  and  63  are to be bonded, may be changed. 
         [0110]    When the zener diodes  64  are coupled to the chip  100  in such a manner that they are coupled to the electrodes  62  and  63  in opposite directions, to exhibit opposite polarities, respectively, a circuit shown in  FIG. 14  is established. 
         [0111]    That is, in the circuit of  FIG. 14 , the zener diodes  64  are connected to the chip  100  in parallel in such a manner that the zener diodes  64  are connected to the electrodes  62  and  63  connected to the chip  100  in opposite directions, to exhibit opposite polarities, respectively. When an excessive voltage higher than a breakdown voltage of the zener diodes  64  is applied to the chip  100  in the circuit of  FIG. 14 , current flows through the zener diodes  64 . 
         [0112]    As described above, it may be possible to reflect light emitted from the chip  100 , using the reflection plate  65  which is separately provided at the mount portion  61  of the sub-mount  60 , as described above. 
         [0113]      FIG. 15  illustrates light emitting device chips  100  respectively attached to a plurality of sub-mounts  60 . The sub-mounts  60  are connected to one another, and form a planar structure. Chips  100  are then attached to the connected sub-mounts  60 . Thus, a light emitting device package structure is completely fabricated. The light emitting device package structure is finally separated into individual packages which will be used. 
         [0114]    After completion of the bonding of the chip  100  to the sub-mount  60 , the substrate  10  is separated from the semiconductor layer  20  by irradiating a laser to the bonded structure at the side of the substrate  10 . 
         [0115]    That is, an eximer laser is irradiated to the substrate  10 . The laser beam passes through the substrate  10 , and locally generates heat at the interface between the substrate (sapphire substrate)  10  and the semiconductor layer  20 . The generated heat resolves GaN into Ga and N 2  gas at the interface between the sapphire substrate  10  and the GaN layer of the semiconductor layer  20 . As a result, the sapphire substrate  10  is separated from the semiconductor layer  20 . This process is called a “laser lift off process”. 
         [0116]    Since the separation of the substrate  10  is carried out under the condition in which each chip  100  has been separated from the package structure, but has been still attached to the associated sub-mount  60 , it is possible to reduce the processing time and to maintain a superior thin film quality, as compared to the case in which the laser lift off process is carried out under the condition in which the chip  100  has not been separated from the package structure. 
         [0117]    This is because, although N 2  gas generated during the laser irradiation is spread toward the semiconductor layer  20 , thereby damaging the semiconductor layer  20 , in the latter case, such N 2  gas can be discharged out of the chip  100  at the boundary surfaces of the chip  100  under the condition in which the chip  100  has been separated from the package structure, but has been still attached to the sub-mount  60 , as in the former case. 
         [0118]    After the separation of the substrate  10 , a second electrode  70  is formed at a surface of the semiconductor layer  20  exposed in accordance with the separation of the substrate  10 , as shown in  FIGS. 16 to 18 . A wire bonding process is then carried out to connect the second electrode  70  to the negative electrode  63  formed on the sub-mount  60  by a wire  71 . 
         [0119]    In this case, the second electrode  70  may be an n type electrode. 
         [0120]    For the sub-mount  60 , a planar sub-mount as shown in  FIG. 16 , a 3D sub-mount as shown in  FIG. 17 , or a 3D THI sub-mount as shown in  FIG. 18  may be used. 
         [0121]    In the case using a planar sub-mount  60  shown in  FIG. 16 , the light emitting device chip  100  is bonded to electrodes  62  and  63  formed on an upper surface of the planar sub-mount  60 . Zener diodes  64  may be formed beneath the electrodes  62  and  63 , respectively. 
         [0122]    In the case using a 3D sub-mount shown in  FIG. 17 , the light emitting device chip  100  is bonded to the sub-mount  60 , using a structure as shown in  FIG. 12 . 
         [0123]    On the other hand, in the case using a 3D THI sub-mount shown in  FIG. 18 , a through hole is formed between adjacent sub-mounts. A positive electrode  62  and a negative electrode  63  are then formed to extend along upper and lower surfaces of each sub-mount through the through hole. Zener diodes  64  are formed on the portions of the electrodes  62  and  63  arranged on the lower surface of each sub-mount. 
         [0124]    In order to achieve an enhancement in the light emission efficiency of the chip  100 , a light extraction pattern, which may have various shapes, may be formed on a light emission surface of the chip  100 . 
         [0125]    The pattern formation may be achieved using various methods. One method is a method using a patterned sapphire substrate (PSS). In accordance with this method, a patterned structure is formed on a sapphire substrate, in order to grow thin films for fabrication of a desired device. 
         [0126]    When the sapphire substrate  10  is separated after the fabrication of the device as described, an irregularity pattern enabling light to be effectively emitted is naturally formed at the light emission surface. 
         [0127]    In addition, it is possible to form a micro pattern on the light emission surface, using attachment of PBC (photonic crystals) or nano particles, or nano imprint. 
         [0128]    Meanwhile, a white light emitting device may be fabricated by coating phosphors, such as yellow phosphors, over the outer surface of the chip  100  after completion of the fabrication of the device. 
         [0129]    In this case, blue light emitted from the GaN-based light emitting device is emitted after being partially absorbed by the yellow phosphors, so that white light is emitted. 
         [0130]    The coating of yellow phosphors may be achieved using various methods, for example, a dispensing method, a screen printing method, or a molding method for an epoxy resin mixed with yellow phosphors. 
         [0131]    Thereafter, a filler is formed on the sub-mount  60 . A lens  80  is then bonded to the sub-mount  60  over the chip  100 . The resulting structure, which has been obtained after completion of the above-described processes carried out for a plurality of sub-mounts  60 , is separated into individual devices. Thus, packaging of light emitting devices is completed. 
       Second Embodiment 
       [0132]    Hereinafter, a second embodiment of the present invention will be described with reference to  FIGS. 20 to 30 . No description may be given of the processes of the second embodiment identical to those of the first embodiment. 
         [0133]    First, a method for manufacturing individual semiconductor light emitting device chips will be described. 
         [0134]    As shown in  FIG. 20 , in order to manufacture a light emitting device chip according to this embodiment, a semiconductor layer  20  having a multilayer structure is formed over a sapphire substrate  10 , using a thin film growing method such as a hydride vapor phase epitaxy (HVPE) or a metal organic chemical vapor deposition (MOCVD) method, after formation of a metal buffer layer  90  over the sapphire substrate  10 . 
         [0135]    The growth of the semiconductor layer  20 , which has a multilayer structure, can be achieved by first forming an n type GaN semiconductor layer over the substrate  10 , forming an active layer over the n type GaN semiconductor layer, and forming a p type GaN semiconductor layer over the active layer. 
         [0136]    A first electrode  30  is then formed on the semiconductor layer  20 , as shown in  FIG. 21 . The first electrode  30  is a p type electrode or an ohmic electrode, and has a reflection electrode function. Accordingly, the first electrode  30  can achieve an enhancement in light emission efficiency as it reflects light emitted from the active layer of the semiconductor layer  20 . The first electrode  30  may be made of indium tin oxide (ITO). 
         [0137]    A separate support layer  40  may be formed over the first electrode  30 . The support layer  40  may include an anti-diffusion layer  41 . Where plating is carried out over the first electrode  30 , or the support layer  40  is attached to the first electrode  30 , a solder, which may be mainly used in this case, may penetrate into the semiconductor layer  20  in a melted state, so that it may adversely affect light emission characteristics. The anti-diffusion layer  41  functions to avoid such a phenomenon. 
         [0138]    In order to enable a chip to be bonded to a sub-mount, which will be described later, a plate  42  made of a metal such as Cu, Ni, or Au may be subsequently formed on the anti-diffusion layer  41 . For the same purpose, a semiconductor substrate made of, for example, Si, may be attached to the anti-diffusion layer  41 . 
         [0139]    Thereafter, a process for separating the chip structure fabricated as described above into individual unit device chips is carried out. As shown in  FIG. 22 , the substrate  10  is first thinned. Scribing is then carried out using a laser, to define regions corresponding to respective unit device chips. Thereafter, a cutting force is applied to the scribed portions of the chip structure in accordance with a mechanical method, thereby causing the chip structure to be separated into individual chips  100 . 
         [0140]    On the other hand, in accordance with another method for manufacturing individual light emitting device chips, individual device chips may be fabricated using a mesa etching process carried out after the growth of the semiconductor layer  20  which has a multilayer structure, as shown in  FIG. 24 . 
         [0141]    In the mesa etching process, the semiconductor layer  20  grown over the substrate  10  is etched until the n type semiconductor layer is exposed in each device chip region. 
         [0142]    In this case, as shown in  FIG. 25 , a first electrode  30  is then formed. Subsequently, a passivation layer  50  is formed to protect the first electrode  30  and surfaces exposed in accordance with the etching process. Thereafter, a support layer  40  is formed, as shown in  FIG. 26 . The support layer  40  may include a metal plate made of a metal such as Cu, Ni, or Au. 
         [0143]    Subsequently, a process for thinning the substrate  10 , performing laser scribing, and separating chips is carried out in the same manner as described above. Each separated chip  100  has a structure as shown in  FIG. 27 . 
         [0144]    Alternatively, device chips may be fabricated by performing, in place of the mesa etching process, a trench etching process in which the semiconductor layer  20  is etched until the substrate  10  is exposed, as shown in  FIG. 28 . 
         [0145]    The remaining processes are identical to those in the above-described case. Each chip  100 , which is finally obtained, has a structure as shown in  FIG. 29 . 
         [0146]    As shown in  FIG. 30 , each chip  100  is bonded to a sub-mount  60  which is separately fabricated. The bonding of the chip  100  is carried out such that the first electrode  30  of the chip  100  is attached to electrodes  62  and  63  formed on a mounting portion  61  of the sub-mount  60 . 
         [0147]    For the sub-mount  60 , a substrate made of Si, MN ceramic, AlO x , Al 2 O 3 , or BeO, or a PCB substrate may be used. Zener diodes  64  may be formed at the sub-mount  60 , to achieve an improvement in electrostatic discharge (ESD) property. Also, a reflection plate  65  may be formed to achieve an enhancement in light emission efficiency. 
         [0148]    After completion of the bonding of the chip  100  to the sub-mount  60 , the substrate  10  is separated from the semiconductor layer  20  by etching the metal buffer layer  90  of the chip  100 . 
         [0149]    Thereafter, a second electrode is formed at a surface exposed in accordance with the separation of the substrate  10 . A packaging process involving a wire bonding process is then carried out. This process is identical to that of the first embodiment. 
         [0150]    It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Technology Classification (CPC): 7