LED CHIP WITH INTEGRATED ELECTROMECHANICAL SWITCH
20180026160 ยท 2018-01-25
Inventors
- Peter Van Delft (Aachen, DE)
- Theodorus Johannes Petrus Van Den Biggelaar (Aachen, DE)
- Harald Josef Guenther Radermacher (Aachen, DE)
- Bob Bernardus Anthonius Theunissen (Aachen, DE)
Cpc classification
H01L27/15
ELECTRICITY
H01L33/62
ELECTRICITY
H01L2933/0066
ELECTRICITY
International classification
H01L33/00
ELECTRICITY
Abstract
The invention provides an LED chip having an integrated electrostatic switch for electromechanical control of the LED. A suspended beam switch floats above a conductive control electrode, and by a charging of the electrode may be attracted downward to make connection between an LED structure and an external electrode. Components are mounted on a common substrate so that a fully integrated LED with MEMS switch is formed. Methods for producing the LED chip are further provided, in which production of the switching mechanism is fully integrated with the production of the LED structure.
Claims
1. An LED chip, comprising: a semiconductor substrate; first and second external terminals; an LED structure connected between the first and second external terminals, the LED structure comprising a first semiconductor layer and a second semiconductor layer over the first semiconductor layer, each layer having a top surface and a bottom surface; a suspended beam electrostatic switch connected in series with the LED structure between the first and second external terminals, or in parallel with the LED structure; a third external terminal; and a control electrode connected to the third external terminal for controlling the suspended beam electrostatic switch, the first semiconductor layer comprising two electrically isolated sub-portions isolated by a dividing channel in the first semiconductor layer and physically connected at their bottom surfaces by the semiconductor substrate, the second semiconductor layer partially covering the top surface of the first semiconductor layer, an internal terminal being connected to the anode or cathode of the LED structure and disposed on the top surface of one sub-portion of the lower semiconductor layer, and the second external terminal being disposed on the top surface of the other sub-portion of the lower semiconductor layer, and the control electrode being disposed on a surface within the dividing channel.
2. An LED chip as claimed in claim 1, wherein the suspended beam electrostatic switch extends across the dividing channel separating the two sub-portions, having one end physically and electrically connected to either the second external terminal or the internal terminal.
3. An LED chip as claimed in claim 1, wherein the suspended beam electrostatic switch comprises a suspended clamp electrode suspended above the dividing channel, being physically connected to, and electrically isolated from, a floating bridge electrode, the bridge electrode having a first end suspended above the internal terminal and a second end suspended above the second external terminal, and both electrodes hinge from a secondary support structure positioned adjacent to the lower semiconductor layer, spanning across the dividing channel.
4. A method of producing an LED chip having an integrated electrostatic switch, the method comprising: providing an LED structure on a semiconductor substrate, comprising providing a first semiconductor layer and a second semiconductor layer over the first semiconductor layer, each semiconductor layer having a top surface and a bottom surface, and the second semiconductor layer partially covers the top surface of the first semiconductor layer; providing first and second external terminals and connecting the LED structure between the two; forming a channel between the top and bottom surface of the lower semiconductor layer, thereby providing a lower semiconductor layer having two electrically isolated sub-portions, the two sub-portions connected at their bottom surface by the substrate; providing a suspended beam electrostatic switch in series with the LED structure between the first and second external terminals, or in parallel with the LED structure; providing a control electrode for controlling the suspended beam electrostatic switch; providing a third external terminal and connecting said terminal to the control electrode; and providing an internal terminal on the top surface of one sub-portion of the lower semiconductor layer, the second external terminal being provided on the top surface of the alternate sub-portion of the lower semiconductor layer, and the control electrode being provided on a surface within the dividing channel.
5. A method as claimed in claim 4, further comprising providing a planarizing layer within the dividing channel, and the control electrode being provided on the planarizing layer.
6. A method as claimed in claim 4, wherein providing the suspended beam electrostatic switch comprises forming a sacrificial layer over the dividing channel, forming the suspended beam switch over the sacrificial layer, and subsequently removing the sacrificial layer to leave a suspended beam switch, suspended across the dividing channel.
7. A method as claimed in claim 6, wherein forming the switch comprises forming an electrode over the dividing channel, with a first end physically and electrically connected to either the internal terminal or the second external contact and a second end disposed above the other of the internal terminal or second external terminal, separated by the sacrificial layer.
8. A method as claimed in claim 7, wherein forming the switch comprises forming a clamp electrode on the sacrificial layer, positioned above the dividing channel, and forming an electrically isolated but physically connected bridge electrode, having a first end disposed on the sacrificial layer, above the internal terminal, and a second end disposed on the sacrificial layer, above the second external terminal.
9. A method as claimed in claim 8, further comprising forming a secondary support structure, disposed on the substrate, adjacent to the first semiconductor layer and spanning across the dividing channel, for providing hinging support for the suspended beam electrostatic switch.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] Examples of the invention will now be described in detail with reference to the accompanying drawings, in which:
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
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DETAILED DESCRIPTION OF THE EMBODIMENTS
[0064] The invention provides an LED chip having an integrated electrostatic switch for electromechanical control of the LED. A suspended beam switch floats above a conductive control electrode, and by a charging of the electrode the switch may be attracted downward to make connection between an LED structure and an external electrode or else make connection across the LED structure. Methods for producing the LED chip are further provided, wherein production of the switching mechanism is fully integrated with the production of the LED structure.
[0065] Embodiments of the invention thus integrate a MEMS switch device within an LED chip, allowing for ON/OFF control of an LED without the need to provide dedicated external driver components to achieve this function. In contrast to transistor switches, MEMS switches do not require dedicated semiconductor layers, and hence integration within an LED chips is both simpler and cheaper. In particular, by fully integrating the fabrication of both the LED element and the switch element, production of the chip may comprise a fully linear process flow which utilizes substantially similar processes to standard LED fabrication techniques.
[0066]
[0067] To the control electrode 10 is attached a third external terminal, for providing to the control electrode an external voltage. On applying a suitable voltage to the control electrode, the suspended beam 12 becomes electrostatically attracted to the electrode, inducing its suspended end to displace downward, and to make contact with internal terminal 18. Electrical connection is then made between first external terminal 16 and the internal terminal 18, thus allowing current to flow between the first 16 and second 20 external terminals, through the LED structure connected between them. Hence the control electrode 10 provides electrostatic actuation of the suspended beam switch 12 and ON/OFF control of the LED chip 22
[0068] In the particular example of
[0069] According to differing examples of this first embodiment, additional non-semiconductive layers may be provided. For example, an isolating or dielectric layer might be applied over the control electrode 10, to isolate the layer conductively from both the two lower layer subportions 2a, 2b surrounding it and the beam switch 12 hanging above. In some examples, this layer might comprise a dielectric layer of SiN. Additionally, by selectively controlling the thickness of such a layer, the separation distance between the control electrode and the beam switch can be controlled. Making the isolation layer thinner will result in a lower control voltage required for actuation of the chip.
[0070] Note further, that although in the given example, the first 2a and second 2b lower semiconductor layer subportions are electrically isolated by a dividing channel 8, or separation lane, different methods to achieve this isolation are also possible. For example, the two subportions might be separated by an isolated layer applied atop the lower-layer, or, the second subportion might, for example, comprise a raised portion being electrically isolated by an insulating layer from the remainder of the layer.
[0071] In one embodiment, the substrate layer may comprise a sapphire substrate layer, such as a patterned sapphire substrate (PSS). Patterned sapphire substrate LEDs carry the advantage of increased brightness compared with LEDs of more conventional substrate composition. The patterning on the surface of the sapphire substrate reduces the amount of light that is reflected back into the LED upon reaching the substrate boundary, and hence improves the overall brightness of the element. However in alternate embodiments, any suitable material may be used for the substrate in accordance with particular light output or production specifications, and in correspondence with the available technologies at the time of fabrication.
[0072] In
[0073] While this first embodiment benefits from a very simple design and structure, it also suffers the deficiency that the drive voltage of the LED itself affects the interaction between the control electrode and the suspended beam. Since the drive current is carried by the very same component as is facilitating the electrostatic switching of the chip, the electrostatic action may be affected by the passing current.
[0074] To circumvent this, according to a second embodiment of the invention, the suspended beam switch is divided into two separateand electrically isolatedelements: one for carrying the LED drive current and another for electrostatically interacting with the control electrode.
[0075] In
[0076] When a voltage is applied to control electrode 10, clamp electrode 34 is electrostatically attracted, and, due to the physical connecting layer 38, pulls with it bridge electrode 36, whose two ends make contact with internal contact 18 and second external contact 20 respectively, thus completing the circuit across the chip.
[0077] Since clamp electrode 34 and bridge electrode 36 are electrically isolated, the drive current of the LED, once the switch is activated, does not interfere with the electrostatic actuation of the switch.
[0078] The physical connecting layer may comprise any suitable insulating or dielectric material, such as for example SiN.
[0079] In other examples, the embodiment might comprise additional insulating, dielectric or support layers. In one example, the dividing channel 8 is partially filled by a planarizing dielectric layer 46, and the control electrode 10 disposed over said layer. Such a planarizing layer acts to elevate the level at which the control electrode is disposed, thus reducing the displacement between said electrode and the suspended switch above. A closer separation allows the switch to be actuated with a lower voltage, for example. A planarizing layer, more generally, may simply provide a flat surface upon which to mount the control electrode, should the method of forming the channel leave a non-even surface at its base.
[0080] Additionally, as in the first embodiment, the control electrode may be covered by a dielectric or insulating layer, of, in one example, SiN, for providing insulation or separation from the clamp electrode 34 above. The thickness of this dielectric layer (or layers) determines the separation distance between the control electrode and the clamp electrode, and hence determine the voltage required for actuation of the switch.
[0081] To prevent accidental actuation due to a voltage difference, and hence electrostatic attraction, between the second external contact 20 and the respective over-hanging end of the bridge electrode 36, the surface of the right-hand side of the bridge electrode might, in some examples, have a size which is significantly small, in order to minimize electrostatic forces.
[0082] The die-level integration of the LED and electrostatic switch allow for the chip to be constructed using a linear process flow which utilizes substantially similar processes to standard LED fabrication techniques. In particular, the switch component of the chip may be integrated into, and indeed partly fabricated from, simple manipulations of the orthodox semiconductor layer structures which comprise typical LED chips. Furthermore, the modifications to, or additional steps required within, the process flow are typically steps or procedures which are already well known within the field of MEMS device fabrication. Hence, the methods described below constitute merely an integration of fabrication techniques which are well-known within their respective technical fields, and moreover, for which mature technologies and already exist for implementation.
[0083] In
[0084]
[0085] In one example, the upper 14 and lower 2a, 2b semiconductor layers are epitaxially grown on the substrate layer 6 and subsequently shaped by photolithographic etching in situ to form the structure depicted in
[0086] Once the semiconductor layer structure of
[0087] Note that though in the particular example of
[0088] As illustrated in
[0089] Above the first sacrificial layer 52, a second sacrificial layer 54 is subsequently providedas illustrated in
[0090] As shown in
[0091] The forming of suspended switch 12 may comprise for example depositing a metal layer across the sacrificial layer 54 and patterning or etching the layer so as to cover only the desired portion of the sacrificial layer 54 and second subportion 2b.
[0092] As shown in
[0093] The removal of the sacrificial layers might be performed by etching, for example. In the particular case, for instance, that the dielectric layer 50 is provided comprised of SiN, and the sacrificial layers 52, 54 provided comprised of SiO.sub.2, the sacrificial layer can be etched away by hydrofluoric acid (vapor/wet etching). SiN is resistant to Hydrofluoric acid and hence will remain after the etching process as a dielectric layer 52 on top of the control electrode, to ensure good isolation.
[0094] The example production method depicted by
[0095] Hence, in
[0096]
[0097] After etching/patterning of the planarizing dielectric layer 60, external and internal contact terminals 16, 18, 20 are provided to respective surfaces of the semiconductor layers, and control terminal 10 is provided to the top surface of the planarizing dielectric layer disposed within the dividing channel. A third external terminal (not shown) is also provided, connected with the control terminal, for delivery of an external voltage. As in the first example production method, these terminals are typically formed in situ by deposition and patterning.
[0098] Once contact terminals are providedas shown in
[0099] As depicted in
[0100] With the second sacrificial layer 68 in place, the metal components of the suspended beam switch are subsequently formed. As described above, the suspended beam switch, in the second example embodiment of the invention (see
[0101] Upon forming metal contact elements 36a, 36b, 34, these elements are covered by a dielectric layer 72 (see
[0102] After deposition (or other application) of this dielectric layer, the first and second sacrificial layers 66, 68 are removed (see
[0103] When using a MEMS actuator for switching, sealing the device is important for ensuring a proper functioning of the device, and for maximizing lifetime. Hence, according to a number of embodiments, the LED chip may be encased within an encapsulation arrangement. Several techniques exist within the field of electronic packaging which can hermetically seal sensitive parts of electrical devices.
[0104]
[0105] The example above creates an LED module comprising an LED and a series switch. There may be multiple LEDs in series within each chip. The switch may instead be in parallel with the LED and the same basis processing approach may be applied.
[0106] For example, a parallel architecture may be formed by using the contacts 16,18 as the external anode and cathode terminals, and electrically connecting the contacts 16 and 20 together. In this way the diode is between external contact 18 and 16 (=20), and the switch is also between external contacts 18 and 16 (=20). The electrode 18 in this case needs to be made larger so that it can function both as an external terminal and also as a contact terminal for the electrostatic beam.
[0107] Thus, the same structure but with one additional internal connection, can be used to form a parallel arrangement.
[0108] In another arrangement, all three contacts 16, 18, 20 can be provided as external terminals, and external interconnections may then determine whether the switch is coupled as a series switch or a parallel switch. The overall module will then have four external terminals.
[0109] Of course, other different designs may be used for the series version and for the parallel version. To avoid sharing electrodes, the LED and the switch may be entirely independent within the chip, with five external terminalstwo for the LED three for the switch. External connections made can then determine whether the components are in series or in parallel.
[0110]
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[0112] There are other circuits which may make use of series or parallel switches associated with the LEDs.
[0113] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word comprising does not exclude other elements or steps, and the indefinite article a or an does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.