Patent ID: 8211722

Claim:
A flip-chip LED fabrication method, comprising the steps of: (a) providing a GaN (Gallium Nitride) epitaxial wafer comprising a substrate and a GaN epitaxial layer arranged on said substrate, said GaN epitaxial layer comprising a N-type GaN ohmic contact layer, a light-emitting layer and a P-type semiconductor layer; (b) forming a first groove in said GaN epitaxial layer at a predetermined location by etching to expose a part of the substrate of said GaN epitaxial wafer; (c) forming a second groove in said GaN epitaxial layer at a predetermined location adjacent to said first groove by etching to expose a part of said N-type GaN ohmic contact layer of said GaN epitaxial layer and to divide said GaN epitaxial layer into two epitaxial layer portions; (d) forming a translucent conducting layer on said epitaxial layer portions; (e) forming a P-type electrode pad and an N-type electrode pad on said translucent conducting layer corresponding to said epitaxial layer portions respectively; (f) forming a first isolation protection layer on said P-type electrode pad, said N-type electrode pad, said first groove and said second groove; (g) forming a metallic reflection layer on said first isolation protection layer adjacent to said P-type electrode pad and corresponding to said translucent conducting layer; (h) forming a second isolation protection layer on said first isolation protection layer and said metallic reflection layer; (i) etching said first isolation protection layer and said second isolation protection layer to form a third groove adjacent to said metallic reflection layer and to expose one lateral side of said N-type electrode pad; (j) employ grinding, laser wafer scribing, chipping and die sorting techniques to separate the processed GaN (Gallium Nitride) epitaxial wafer into multiple individual GaN LED chips; and (k) bonding at least one said individual GaN LED chip to a thermal substrate with a conducting material to electrically connect the P-type electrode pad and N-type electrode pad of each said individual GaN LED chip to the positive solder pad and negative solder pad of said thermal substrate by said conducting adhesive and to let said conducting adhesive climb over said N-type electrode pad into said third groove and be accumulated and cured therein.