Patent ID: 10840418

Abstract:
Systems and methods for fabricating parabolic LEDs are provided. The parabolic shape of the LEDs is precisely-controlled and highly-uniform across a substrate. By precisely controlling the shape, and providing a high-uniformity across the substrate, the luminance and process yield of the LEDs is enhanced. The precise-control and high-uniformity of the shape is enabled via a precisely-shaped and highly-uniform mask formed on the substrate. The ability to precisely-control both the shape and uniformity the mask is achieved by forming the mask utilizing three-dimensional (3D) patterning and/or machining methods. The mask includes a precisely-shaped boss with the same shape as the LED, and a cylindrical protrusion extending beyond the boss. The combination of the boss and cylindrical protrusion allows for the mask to be over-etched, without significantly effecting the shape of the LED. Thus, any non-uniformities etching process do not decrease the luminance, nor uniformity, of the LEDs.