High efficiency LEDs and methods of manufacturing
First Claim
1. A light emitting diode (LED) chip, comprising:
- an active LED structure comprising an active region between two oppositely doped layers, said active region emitting light in response to an electrical signal applied to at least one of said oppositely doped layers;
a first reflective layer on one of said oppositely doped layers;
a second reflective layer, said first reflective layer between said active region and said second reflective layer said second reflective layer reflecting light not reflected by said first reflective layer, wherein said second reflective layer extends beyond an outer edge of said active LED structure and into a street, said street outside of said active region, wherein said first and second reflective layers are spaced away from said active LED structure such that neither of said first and second reflective layers directly contacts said active LED structure; and
a contact in said street and on a portion of said second reflective layer that extends beyond said outer edge of said active LED structure and into said street, wherein said contact extends through said first reflective layer and contacts a top of said portion of said second reflective layer.
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Accused Products
Abstract
Simplified LED chip architectures or chip builds are disclosed that can result in simpler manufacturing processes using fewer steps. The LED structure can have fewer layers than conventional LED chips with the layers arranged in different ways for efficient fabrication and operation. The LED chips can comprise an active LED structure. A dielectric reflective layer is included adjacent to one of the oppositely doped layers. A metal reflective layer is on the dielectric reflective layer, wherein the dielectric and metal reflective layers extend beyond the edge of said active region. By extending the dielectric layer, the LED chips can emit with more efficiency by reflecting more LED light to emit in the desired direction. By extending the metal reflective layer beyond the edge of the active region, the metal reflective layer can serve as a current spreading layer and barrier, in addition to reflecting LED light to emit in the desired direction. The LED chips can also comprise self-aligned and self-limiting features that simplify etching processes during fabrication.
158 Citations
48 Claims
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1. A light emitting diode (LED) chip, comprising:
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an active LED structure comprising an active region between two oppositely doped layers, said active region emitting light in response to an electrical signal applied to at least one of said oppositely doped layers; a first reflective layer on one of said oppositely doped layers; a second reflective layer, said first reflective layer between said active region and said second reflective layer said second reflective layer reflecting light not reflected by said first reflective layer, wherein said second reflective layer extends beyond an outer edge of said active LED structure and into a street, said street outside of said active region, wherein said first and second reflective layers are spaced away from said active LED structure such that neither of said first and second reflective layers directly contacts said active LED structure; and a contact in said street and on a portion of said second reflective layer that extends beyond said outer edge of said active LED structure and into said street, wherein said contact extends through said first reflective layer and contacts a top of said portion of said second reflective layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A light emitting diode (LED) chip, comprising:
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an active LED structure comprising an active region between two oppositely doped layers, said active region emitting light in response to an electrical signal applied to at least one of said oppositely doped layers, said active LED structure comprising an n-type layer; a current spreading layer on said active LED structure; a dielectric reflective layer on said current spreading layer; a metal reflective layer on said dielectric reflective layer, said dielectric reflective layer between said current spreading layer and said metal reflective layer; and wherein said dielectric reflective layer and said metal reflective layer are separated from said active LED structure; wherein said current spreading layer, said dielectric reflective layer, and said metal reflective layer extend beyond an outer edge of said active region and into a street, said street outside of said active region; and a contact in said street, said contact extending through said current spreading layer and said dielectric reflective layer to said metal reflective layer so as to contact said metal reflective layer. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29)
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30. A light emitting diode (LED) chip, comprising:
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an active region; a first reflective layer on said active region; and a second reflective layer on said first reflective layer such that said first reflective layer is between said active region and said second reflective layer, said second reflective layer reflecting light not reflected by said first reflective layer, wherein said first reflective layer and said second reflective layer extend beyond an outer edge of the active region on a portion of the LED chip and into a street, said street outside of said active region, wherein said second reflective layer is a metal reflective layer; and a contact in said street and extending through said first reflective layer to contact said second reflective layer. - View Dependent Claims (31, 32, 33, 34)
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35. A light emitting diode (LED) chip, comprising:
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an active LED structure comprising an active region; a plurality of layers on a backside of said active LED structure, said plurality of layers comprising a first reflective layer and a second reflective layer, said first reflective layer and said second reflective layer extending into a street, said street outside of said active region; a contact in said street, through a portion of first reflective layer that is in said street, and contacting a portion of said second reflective layer that is in said street; and a via hole on the backside of and into said active LED structure, wherein at least two of said plurality of layers are self-aligned at said via hole; wherein said first and second reflective layers are spaced away from said active LED structure such that neither of said first and second reflective layers directly contacts said active LED structure. - View Dependent Claims (36, 37, 38, 39)
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40. A light emitting diode (LED) chip, comprising:
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an active LED structure comprising an active region; a plurality of layers on a backside of said active LED structure, said plurality of layers comprising a dielectric reflective layer and a metal reflective layer, said dielectric reflective layer extending into a street, said street outside of said active region; and wherein two or more of said plurality of layers are self-aligned in said street and on said backside of said active LED structure, wherein the self-alignment forms a hole through said first reflective layer, and further comprising a contact in said hole and contacting said second reflective layer; and wherein said dielectric reflective layer and said metal reflective layer are separated from said active LED structure. - View Dependent Claims (41, 42, 43, 44, 45, 46, 47, 48)
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Specification