Direct-bonded LED arrays and applications
First Claim
1. An apparatus, comprising:
- a first dielectric bonding surface of a first wafer comprising a light emitting diode (LED) array;
a second dielectric bonding surface of a second wafer comprising CMOS driver circuits, one CMOS driver circuit aligned on the second wafer for each LED element of the LED array on the first wafer, each CMOS driver circuit to make a corresponding LED element individually controllable;
coplanar conductive areas on the first dielectric bonding surface of the first wafer comprising electrical contacts of each respective LED element, wherein the coplanar conductive areas are within a horizontal planar footprint of the respective LED element;
coplanar conductive areas on the second dielectric bonding surface of the second wafer comprising electrical contacts of each respective CMOS driver, wherein the coplanar conductive areas are within a horizontal planar footprint of a corresponding LED element of the first wafer;
oxide-to-oxide direct bonds between dielectric areas of the first bonding surface of the first wafer and the second bonding surface of the second wafer, andmetal-to-metal direct bonds between corresponding coplanar conductive areas of the first bonding surface of the first wafer and the second bonding surface of the second wafer.
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Abstract
Direct-bonded LED arrays and applications are provided. An example process fabricates a LED structure that includes coplanar electrical contacts for p-type and n-type semiconductors of the LED structure on a flat bonding interface surface of the LED structure. The coplanar electrical contacts of the flat bonding interface surface are direct-bonded to electrical contacts of a driver circuit for the LED structure. In a wafer-level process, micro-LED structures are fabricated on a first wafer, including coplanar electrical contacts for p-type and n-type semiconductors of the LED structures on the flat bonding interface surfaces of the wafer. At least the coplanar electrical contacts of the flat bonding interface are direct-bonded to electrical contacts of CMOS driver circuits on a second wafer. The process provides a transparent and flexible micro-LED array display, with each micro-LED structure having an illumination area approximately the size of a pixel or a smallest controllable element of an image represented on a high-resolution video display.
14 Citations
14 Claims
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1. An apparatus, comprising:
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a first dielectric bonding surface of a first wafer comprising a light emitting diode (LED) array; a second dielectric bonding surface of a second wafer comprising CMOS driver circuits, one CMOS driver circuit aligned on the second wafer for each LED element of the LED array on the first wafer, each CMOS driver circuit to make a corresponding LED element individually controllable; coplanar conductive areas on the first dielectric bonding surface of the first wafer comprising electrical contacts of each respective LED element, wherein the coplanar conductive areas are within a horizontal planar footprint of the respective LED element; coplanar conductive areas on the second dielectric bonding surface of the second wafer comprising electrical contacts of each respective CMOS driver, wherein the coplanar conductive areas are within a horizontal planar footprint of a corresponding LED element of the first wafer; oxide-to-oxide direct bonds between dielectric areas of the first bonding surface of the first wafer and the second bonding surface of the second wafer, and metal-to-metal direct bonds between corresponding coplanar conductive areas of the first bonding surface of the first wafer and the second bonding surface of the second wafer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. An apparatus, comprising:
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micro-LED structures of an LED array fabricated on a first wafer, each micro-LED structure comprising a single micro-LED; a flat bonding surface of the first wafer including, for each single micro-LED, a first coplanar electrical contact for a p-type semiconductor of the single micro-LED and a second coplanar electrical contact for an n-type semiconductor of the single micro-LED; wherein the first coplanar electrical contact and the second coplanar electrical contact of each single micro-LED are within a horizontal planar footprint of the single micro-LED; a corresponding CMOS driver circuit for each single micro-LED, each corresponding CMOS driver circuit fabricated on a second wafer; a flat bonding surface of the second wafer including, for each corresponding CMOS driver circuit, a first coplanar electrical contact for electrical connection to the p-type semiconductor of the corresponding single micro-LED of the first wafer and a second coplanar electrical contact for electrical connection to the n-type semiconductor of the corresponding single micro-LED of the first wafer; an oxide-to-oxide direct bond between dielectric parts of the flat bonding surfaces of the first wafer and the second wafer; and metal-to-metal direct bonds between respective first coplanar electrical contacts of the first wafer and the second wafer, and metal-to-metal direct bonds between respective second coplanar electrical contacts of the first wafer and the second wafer. - View Dependent Claims (13, 14)
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Specification