Semiconductor Light Source, Cover Body and Method
20230086879 · 2023-03-23
Inventors
- Darshan Kundaliya (Middleton, MA, US)
- Alan Lenef (BELMONT, MA, US)
- Thomas Dreeben (Swampscott, MA, US)
Cpc classification
H01L2933/0091
ELECTRICITY
H01S5/18
ELECTRICITY
H01S5/02257
ELECTRICITY
H01S5/0087
ELECTRICITY
H01L33/507
ELECTRICITY
H01L2933/0083
ELECTRICITY
International classification
Abstract
In an embodiment a semiconductor light source includes an optoelectronic semiconductor chip configured to emit radiation and a cover body arranged on the optoelectronic semiconductor chip, wherein the cover body comprises a light-transmissive base body, wherein the light-transmissive base body comprises a plurality of recesses with inclined side faces, the recesses start at an emission side of the light-transmissive base body remote from the optoelectronic semiconductor chip and narrow towards the optoelectronic semiconductor chip, wherein a mirror coating is provided at top regions of the recesses next to the emission side, and wherein bottom regions of the recesses closest to the optoelectronic semiconductor chip are free of the mirror coating.
Claims
1. A semiconductor light source comprising: an optoelectronic semiconductor chip configured to emit radiation; and a cover body arranged on the optoelectronic semiconductor chip, wherein the cover body comprises a light-transmissive base body, wherein the light-transmissive base body comprises a plurality of recesses with inclined side faces, the recesses start at an emission side of the light-transmissive base body remote from the optoelectronic semiconductor chip and narrow towards the optoelectronic semiconductor chip, wherein a mirror coating is provided at top regions of the recesses next to the emission side, and wherein bottom regions of the recesses closest to the optoelectronic semiconductor chip are free of the mirror coating.
2. The semiconductor light source according to claim 1, wherein the recesses are of pyramidal shape or of conical shape.
3. The semiconductor light source according to claim 1, wherein a height of the mirror coating is between 10% and 40% inclusive of an overall height of the recesses.
4. The semiconductor light source according to claim 3, wherein the overall height of the recesses is between 5 μm and 50 μm inclusive.
5. The semiconductor light source according to claim 1, wherein, seen in cross-section, a half-angle between the inclined side faces of the recesses is between 12° and 35° inclusive.
6. The semiconductor light source according to claim 1, further comprising a wavelength converter configured to convert at least part of the radiation into a secondary radiation, wherein the wavelength converter is arranged between the optoelectronic semiconductor chip and the cover body.
7. The semiconductor light source according to claim 6, wherein the wavelength converter is a plane-parallel plate, and wherein the cover body is attached to the wavelength converter by a first adhesive arranged between the cover body and the wavelength converter.
8. The semiconductor light source according to claim 6, wherein the cover body comprises a bottom recess on a side opposite the plurality of recesses and facing the wavelength converter, the bottom recess is surrounded by a rim, wherein an air gap is located between the cover body and the wavelength converter, wherein the wavelength converter is at least partially located in the bottom recess and at least partially surrounded by the rim, or the rim is located on a side of the wavelength converter facing the cover body.
9. The semiconductor light source according to claim 1, wherein the cover body comprises a wavelength conversion material configured to convert at least part of the radiation into a secondary radiation.
10. The semiconductor light source according to claim 1, wherein the mirror coating is a broadband dielectric multilayer mirror.
11. The semiconductor light source according to claim 1, wherein, seen in top view of the emission side, the recesses are of rectangular, trigonal, hexagonal, elliptic or circular fashion.
12. The semiconductor light source according to claim 1, wherein, seen in cross-section, the recesses are of symmetric fashion, and wherein the recesses run through at least 50% of the light-transmissive base body, in a direction perpendicular to the emission side.
13. The semiconductor light source according to claim 1, wherein, outside the recesses, the emission side is flat.
14. The semiconductor light source according to claim 1, wherein, seen in top view of the emission side, a period length of a pattern of the recesses is between 10 μm and 0.1 mm inclusive.
15. The semiconductor light source according to claim 1, wherein, seen in top view of the emission side, the recesses are arranged in a hexagonal or rectangular grid.
16. The semiconductor light source according to claim 1, wherein the optoelectronic semiconductor chip is a light-emitting diode or a laser diode configured to emit near-ultraviolet radiation or visible light.
17. A cover body for a semiconductor light source, the cover body comprising: a light-transmissive base body; and a mirror coating, wherein the light-transmissive base body comprises a plurality of recesses with inclined side faces, the recesses start from an emission side of the light-transmissive base body and narrow in a direction away from the emission side, and wherein the mirror coating is provided only at top regions of the recesses next to the emission side, such that bottom regions of the recesses remote from the emission side are free of the mirror coating.
18. A method for producing the cover body according to claim 17, the method comprising: providing a light-transmissive base plate, forming the recesses into the light-transmissive base plate so that the light-transmissive base body is created, and applying the mirror coating on the top regions of the recesses.
19. The method according to claim 18, wherein the light-transmissive base plate is a glass plate or a plastics plate, wherein the recesses are formed by laser induced deep etching of the light-transmissive base plate, and wherein the applying the mirror coating at the top regions of the recesses includes in the stated order: completely providing the recesses with the mirror coating, providing a mask layer on the mirror coating, removing the mirror coating from the bottom regions, and removing the mask layer.
20. The method according to claim 18, wherein a plurality of the light-transmissive base bodies and an assigned mirror coating are produced on a wafer level, followed by a dicing into individual light-transmissive base bodies.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] In the figures:
[0054]
[0055]
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
[0062]
[0063]
[0064]
[0065]
[0066]
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0067] In
[0068] The optoelectronic semiconductor chip 2 may be attached to the wavelength conversion means 6 with a second adhesive 62, and the wavelength conversion means 6 may be attached to the cover body 5 with a first adhesive 61. The adhesives 61, 62 are, for example, silicone glues. If the respective surfaces are optically smooth, other bonding techniques, such as wafer bonding, may be used. High temperature bonding techniques may also be used including low-temperature glass bonding or ceramic-based cermet bonds. As a further option, the optoelectronic semiconductor chip 2 may comprise a back side mirror 21 and a chip extraction structure 22.
[0069] The cover body 5 comprises a transparent base body 3 and a mirror coating 4. The base body 3 comprises a plurality of recesses 32 that may completely or virtually completely run through the base body 3 from an emission side 30 towards the wavelength conversion means 6. The recesses 32 are, for example, pyramids. Top regions 34 of the base body 3 next to the emission side 30 are provided with the mirror coating 4 while bottom regions 35 adjacent to the optoelectronic semiconductor chip 2 are free of the mirror coating 4. In a direction perpendicular to the emission side, for example, the top regions 34 amount to a quarter or to a third of a depth of the recesses 32.
[0070] For example, the wavelength conversion means 6 is a ceramic plate comprising at least one phosphor like Ce:YAG. Thus, the wavelength conversion means 6, which may also be referred to as a phosphor plate, has a comparably high refractive index n.sub.p, compared with the refractive index n.sub.o of surrounding air. Consequently, there is a cutoff angle θ.sub.c concerning total internal reflection at a side of the wavelength conversion means 6 facing the cover body 5.
[0071] By means of the cover body 5, a maximum emission angle θ.sub.em is decreased. This is explained below in more detail with reference to
[0072] Hence, according to
[0073]
[0074] The partial mirror coating 4 can be applied using CVD, ALD, or other conformal dielectric thin-film deposition processes. For light inside the surface structure 3, 32, the mirror coating 4 should be highly reflective for all angles up to the critical angle θ.sub.c for light exiting the pyramid surfaces 3, 32. The mirror coating 4 extends only partially from the uppermost feature of the surface structure 3, 32. In two dimensions, this corresponds to the pyramid apex. The fabrication of the reflective coatings can be accomplished by several methods, including partially filling the structure 3, 32 with a resist or other temporary barrier material. The barrier material can be again applied using soft-imprint techniques, ultraviolet lithography to cure only the valley regions, or other methods.
[0075] Generally, for wavelengths in the visible spectrum, metal or dielectric-enhanced metal coatings are possible for the mirror coating 4, but not preferred due to the comparably high losses generated. The strong light recycling effects of the mirror coating 4 tend to amplify the losses and degrade the directional efficiency advantage. By using dielectric thin films for the mirror coating 4, imperfect reflection implies some transmission of light through the coating 4. While this can degrade the angular performance a bit, it will not reduce overall efficacy or efficiency of the semiconductor light source 1.
[0076] The operation of cover body 5 is most easily understood in two dimensions. Referring to
[0077] As scattering from the semiconductor chip 2, the phosphor plate 6, and recycling reflections from the mirror coating 4 tend to create an internal Lambertian spectral radiance distribution inside a given pyramid, one can assume that the internal light incident on an uncoated surface of the pyramid is close to Lambertian. Referring again to
[0078] As both the outside mirror coating surfaces and pyramid surfaces are assumed to be specular, one can observe that the dashed ray path leading to emission angle θ.sub.b with respect to the surface normal will be largest if the emission point from the right-hand pyramid is just below the mirror coating 4. Light generated in the location above this point will be reflected back into the pyramid by the mirror coating 4. Light generated below this point will be partially reflected from either the mirror coating 4 or uncoated pyramid surface parts of the neighbor pyramid. Thus, the maximum emission angle θ.sub.b will be determined by the ray path shown for emission at E. Light generated along the solid ray path is direct emission from E that is not reflected from any surface. The maximum emission angle for this ray angle is θ.sub.a. All other light will be directly recycled into the neighboring pyramid as shown by the dashed-dot line. The final extent of the emitted angular distribution from the structure will be determined by the maximum of θ.sub.a and θ.sub.b.
[0079] Restricting the ray geometry to two dimensions, one can derive simple formulas for the maximal rays in
[0080] and θ.sub.b=π/2−θ.sub.a, where the maximum emission angle qem is determined by θ.sub.em=max(θ.sub.a, θ.sub.b).
[0081] For example, a typical ratio of the mirror height h2 to the pyramid height h is about 0.25. The pyramid height h is, for example, about 20 μm, and the angle ϕ may be around 20°.
[0082] In
[0083] In
[0084] As an option, the cover body 5 may include a wavelength conversion material 66. Thus, the cover body 5 may simultaneously be the wavelength conversion means.
[0085] For example, the circular recesses 32 are arranged in a hexagonal grid. Between adjacent recesses 32, the emission side 30 may be flat. Moreover, there can be an edge region of the emission side all around the recesses 32 so that the edge region is free of the recesses 32.
[0086] In
[0087] Otherwise, what has been stated for
[0088] In connection with
[0089] In a first method step M1, a light-transmissive base plate 39 for a plurality of the light-transmissive base bodies 3 is provided. Then, see method step M2 and
[0090] For example, the inverted cones were fabricated using laser induced deep etching technique on 4″ and 6″ glass wafers. The center-to-center pitch P between adjacent cones is, for example, 50 μm or 25 μm and a pitch-to-depth ratio is maintained at ≤1. The cones were arranged in a hexagonal fashion within a 1030 μm×1030 μm square for each base body 3. Thus, each square basically forms one of the cover bodies 5 and is preferably equivalent to the dimension of a white ceramic platelet 6 or LED die 2. The base bodies 3 may form a large array on a 4″ or 6″ or 8″ or 12″ wafer as shown in
[0091] Exemplarily dimensions of the resulting recesses 32 are illustrated in
[0092] According to
[0093] Thus, for example, a photoresist is spin coated uniformly on top of the mirror coating 4 covering the cones 32. This is followed by ultraviolet exposure using a photomask and a mask aligner that exposes only the bottom regions 35 of the recesses 32. After the exposure, ultraviolet exposed photoresist is removed using a standard photoresist developer and leaving reflector coating 4 at the bottom regions 35 open to air for further etching in that region. Remaining non-exposed photoresist 42 stays on the top as a mask to protect the mirror coating during the subsequent etching process performed in method step M5.
[0094] Then, in method step M6, etching of the mirror coating 4 is done, for example, using CHF3/Ar/O2 or CH4F8/Ar/O2 or CF4/Ar/O2 reactive ion etching chemistry in a reactive ion etching tool, not shown. The resulting structure is shown in
[0095] Finally, in method step M7 the base plate 39 is diced so that the individual cover bodies 5 result, compare also
[0096] As an option, the base plate 39 may be applied on a semiconductor wafer comprising a plurality of the semiconductor chips 2 and/or on a wavelength conversion means wafer prior to dicing. Thus, it is possible that dicing of the semiconductor wafer and/or of the wavelength conversion means wafer is done simultaneously with the dicing of the base plate 39.
[0097] For example, in a first preferred embodiment, the method can be summarized as follows:
[0098] A glass substrate such as SCHOTT AF32 was first treated with nanosecond and femtosecond lasers at the desired locations. For one individual die component having dimension 1.03 mm×1.03 mm, 480 laser treated locations to produce ˜50 μm diameterט47 μm deep cones in a hexagonal geometry were used. The diameter and depth of the cones were created by hydrofluoric acid-based chemistry by controlling the etching time. If one assumes about 5000 such individual die components on a single 4″ wafer, then there will be ˜2.4 million laser treated regions needed before the etching process.
[0099] For example, in a second preferred embodiment, the method can be summarized as follows:
[0100] 1. Ultrasonically clean the inverted cones recesses on a glass wafer substrate, for example, having 50 μm diameter cones;
2. Coat the structured substrates as mentioned in 1 above with the mirror coating, which is a multilayer dielectric or a metal material;
3. Spin coat positive photoresists such as R1805 or R1813, for example, with 1500 rpm for 90 s;
4. Bake the wafer at 115° C. for 90 s;
5. Expose the photoresist using the specific photomask designed to block part of the inverted cone pattern on the substrate;
6. Develop the exposed area using photoresist developer such as MF316 for 90 s, rinse with deionized water and dry with N2 flush. At this point, the remaining photoresist works as a mask and is protecting top part of the cone recesses from etching chemistry;
7. Etch the mirror regions not protected by photoresist using selective chemistry either using dry ICP-RIE technique or by wet etching;
8. Strip remaining photoresist by spraying acetone and dry;
9. Characterize, for example, by scanning electron microscope, optical microscope, transmittance, or color over angle, to make sure high quality coating of the mirror on the top region of the cone recesses.
[0101] Alternatives would be to use different dielectric material stacks or a metal mirror as the mirror coating 4. The metal mirror would preferably have dielectric enhancement layers.
[0102] Compared with a cover plate without the recesses, the number of dielectric layers of the mirror coating can be reduced, for example, to at most 100 layers or to at most 50 layers or to at most 30 layers. Otherwise, directional emission using dielectric layer stacks without implementing structured surfaces and apex mirror coating would require deposition of hundreds of layers and very thick coatings.
[0103] Otherwise, what has been stated for
[0104] In
[0105] Otherwise, what has been stated for
[0106] According to
[0107] Otherwise, what has been stated for
[0108] Other than shown, as in all other exemplary embodiments, the cover body 5 of
[0109] Thus, the structured surface can be formed in a structured phosphor plate surface. In the case of ceramics, one can use a variety of methods to structure the surface of the phosphor plate. If the ceramic is made using green-state forming processes such as tape-casting or injection molding, embossing or molding techniques can be applied to the green-state surface. If the shrinking during sintering is isotropic, then the aspect ratio of the structure will be maintained from the green state forming. The structured surface can also be made directly into a fully or partially sintered ceramic via laser machining. However, such processes may require additional annealing steps to eliminate local surface damage from the laser processing. In either case, the partial coating can be made as before, or also by filling the bottom regions 35 with a temporary filler material that can be cured before application of the mirror coating 4. After the coating, the filler material is removed with appropriate solvents or other processes that do not damage the reflective coating. The same can apply to all other embodiments, too.
[0110] In another embodiment, where the phosphor plate consists of or comprises phosphor powder in an organic curable matrix such as silicone, optical epoxy, or polysiloxanes, embossing or molding processes can be used to form the structured surface directly into the matrix material. Additionally, in some cases, the phosphor material, like powder in matrix material, may be coated onto a transparent substrate which already has the surface structure on the opposite side. This smooth, phosphor side is glued to the LED chip, for example. The dielectric coating may be applied to the structured side before application of the phosphor, after application of the phosphor, or after gluing the assembly to the LED chip.
[0111] In
[0112] In
[0113] For example, the cover body 5 is mounted onto the wavelength conversion means 6, not illustrated in
[0114] The components shown in the figures follow, unless indicated otherwise, exemplarily in the specified sequence directly one on top of the other. Components which are not in contact in the figures are exemplarily spaced apart from one another. If lines are drawn parallel to one another, the corresponding surfaces may be oriented in parallel with one another. Likewise, unless indicated otherwise, the positions of the drawn components relative to one another are correctly reproduced in the figures.
[0115] The semiconductor light source and the cover body described here is not restricted by the description on the basis of the exemplary embodiments. Rather, the semiconductor light source and the cover body encompass any new feature and also any combination of features, which includes in particular any combination of features in the patent claims, even if this feature or this combination itself is not explicitly specified in the patent claims or exemplary embodiments.
[0116] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments.