Epitaxial formation support structures and associated methods
First Claim
1. A method of manufacturing a solid state lighting (SSL) device, the method comprising:
- providing an uncured support substrate having a coefficient of thermal expansion (CTE) substantially similar to a CTE of N-type gallium nitride (GaN);
sintering the uncured support substrate to produce a cured support substrate having a sintered planar surface that is at least substantially uniformly flat;
bonding a formation structure directly to the sintered planar surface; and
forming an SSL structure over the formation structure.
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Abstract
Epitaxial formation support structures and associated methods of manufacturing epitaxial formation support structures and solid state lighting devices are disclosed herein. In several embodiments, a method of manufacturing an epitaxial formation support substrate can include forming an uncured support substrate that has a first side, a second side opposite the first side, and coefficient of thermal expansion substantially similar to N-type gallium nitride. The method can further include positioning the first side of the uncured support substrate on a first surface of a first reference plate and positioning a second surface of a second reference plate on the second side to form a stack. The first and second surfaces can include uniformly flat portions. The method can also include firing the stack to sinter the uncured support substrate. At least side of the support substrate can form a planar surface that is substantially uniformly flat.
29 Citations
17 Claims
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1. A method of manufacturing a solid state lighting (SSL) device, the method comprising:
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providing an uncured support substrate having a coefficient of thermal expansion (CTE) substantially similar to a CTE of N-type gallium nitride (GaN); sintering the uncured support substrate to produce a cured support substrate having a sintered planar surface that is at least substantially uniformly flat; bonding a formation structure directly to the sintered planar surface; and forming an SSL structure over the formation structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of manufacturing a solid state lighting (SSL) device, comprising:
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firing a support substrate having a coefficient of thermal expansion (CTE) substantially similar to a CTE of N-type gallium nitride (GaN), wherein a side of the fired support substrate includes a planar surface that is at least substantially uniformly flat; attaching a formation structure to the planar surface to form a template structure, the formation structure having a CTE different from the CTE of the support substrate, and the template structure having a CTE substantially similar to the CTE of the support substrate; and epitaxially growing an SSL structure directly on the formation structure, wherein the SSL structure includes a first semiconductor material, a second semiconductor material, and an active region between the first and second semiconductor materials. - View Dependent Claims (13, 14, 15, 16, 17)
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Specification