Manufacturable RGB display based on thin film gallium and nitrogen containing light emitting diodes
First Claim
1. A method for manufacturing a multi-wavelength light-emitting-diode based display panel device, the method comprising:
- providing at least one carrier wafer;
providing a first substrate having a first surface region;
forming a first gallium and nitrogen containing epitaxial material overlying the first surface region, the first epitaxial material comprising a first release material overlying the first substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing region configured to emit electromagnetic radiation at a first wavelength, and a p-type gallium and nitrogen containing region overlying the first release material;
patterning the first epitaxial material and forming mesas to form a first plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a first pitch between the adjacent die in the array;
forming a first interface region overlying the first epitaxial material, the first interface region comprising a metal, a semiconductor, dielectric, oxide, glass, or a polymer;
subjecting the first release material to a photo electrochemical (PEC) etch to completely or partially remove the first release material;
bonding the first interface region to the at least one carrier wafer to form a bonded structure, while maintaining the first release material completely or partially etched away from the bonded structure;
releasing at least a fraction of the plurality of first dice provided on the first substrate member to transfer a first plurality of dice to the at least one carrier wafer;
wherein each pair of the transferred dice is configured with a second pitch between each pair of dice on a carrier wafer, the second pitch being equal or greater than the first pitch;
providing a second substrate having a second surface region;
forming a second gallium and nitrogen containing epitaxial material overlying the second surface region, the second epitaxial material comprising a second release material overlying the second substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing region configured to emit electromagnetic radiation at a second wavelength, and a p-type gallium and nitrogen containing region overlying the second release material;
patterning the second epitaxial material and forming mesas to form a second plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a third pitch between the adjacent die in the array;
forming a second interface region overlying the second epitaxial material, the second interface region comprising a metal, a semiconductor, dielectric, oxide, glass, or a polymer;
subjecting the second release material to an etching process to completely or partially remove the second release material;
bonding the second interface region to the at least one carrier wafer to form a bonded structure, while maintaining the second release material completely or partially etched away from the bonded structure;
releasing at least a fraction of the plurality of second dice provided on the second substrate member to transfer a second plurality of dice to the at least one carrier wafer wherein each pair of the transferred dice is configured with a fourth pitch between each pair of dice on a carrier wafer, the fourth pitch being equal or greater than the third pitch; and
processing the at least one carrier wafer with at least the first plurality of dice and the second plurality of dice to form a multi-color light emitting diode based display panel device operable at least the first wavelength and the second wavelength.
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Accused Products
Abstract
A method for manufacturing a display panel comprising light emitting device including micro LEDs includes providing multiple donor wafers having a surface region and forming an epitaxial material overlying the surface region. The epitaxial material includes an n-type region, an active region comprising at least one light emitting layer overlying the n-type region, and a p-type region overlying the active layer region. The multiple donor wafers are configured to emit different color emissions. The epitaxial material on the multiple donor wafers is patterned to form a plurality of dice, characterized by a first pitch between a pair of dice less than a design width. At least some of the dice are selectively transferred from the multiple donor wafers to a common carrier wafer such that the carrier wafer is configured with different color emitting LEDs. The different color LEDs could comprise red-green-blue LEDs to form a RGB display panel.
290 Citations
20 Claims
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1. A method for manufacturing a multi-wavelength light-emitting-diode based display panel device, the method comprising:
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providing at least one carrier wafer; providing a first substrate having a first surface region; forming a first gallium and nitrogen containing epitaxial material overlying the first surface region, the first epitaxial material comprising a first release material overlying the first substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing region configured to emit electromagnetic radiation at a first wavelength, and a p-type gallium and nitrogen containing region overlying the first release material; patterning the first epitaxial material and forming mesas to form a first plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a first pitch between the adjacent die in the array; forming a first interface region overlying the first epitaxial material, the first interface region comprising a metal, a semiconductor, dielectric, oxide, glass, or a polymer; subjecting the first release material to a photo electrochemical (PEC) etch to completely or partially remove the first release material; bonding the first interface region to the at least one carrier wafer to form a bonded structure, while maintaining the first release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of first dice provided on the first substrate member to transfer a first plurality of dice to the at least one carrier wafer;
wherein each pair of the transferred dice is configured with a second pitch between each pair of dice on a carrier wafer, the second pitch being equal or greater than the first pitch;providing a second substrate having a second surface region; forming a second gallium and nitrogen containing epitaxial material overlying the second surface region, the second epitaxial material comprising a second release material overlying the second substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing region configured to emit electromagnetic radiation at a second wavelength, and a p-type gallium and nitrogen containing region overlying the second release material; patterning the second epitaxial material and forming mesas to form a second plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a third pitch between the adjacent die in the array; forming a second interface region overlying the second epitaxial material, the second interface region comprising a metal, a semiconductor, dielectric, oxide, glass, or a polymer; subjecting the second release material to an etching process to completely or partially remove the second release material; bonding the second interface region to the at least one carrier wafer to form a bonded structure, while maintaining the second release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of second dice provided on the second substrate member to transfer a second plurality of dice to the at least one carrier wafer wherein each pair of the transferred dice is configured with a fourth pitch between each pair of dice on a carrier wafer, the fourth pitch being equal or greater than the third pitch; and processing the at least one carrier wafer with at least the first plurality of dice and the second plurality of dice to form a multi-color light emitting diode based display panel device operable at least the first wavelength and the second wavelength. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for manufacturing an RGB light-emitting-diode based display panel device, the method comprising:
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providing at least one carrier wafer; providing a first substrate having a first surface region; forming a first gallium and nitrogen containing epitaxial material overlying the first surface region, the first epitaxial material comprising a first release material overlying the first substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing active region configured to emit electromagnetic radiation at a first blue wavelength, and a p-type gallium and nitrogen containing region overlying the first release material; patterning the first epitaxial material and forming mesas to form a first plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a first pitch between the adjacent die in the array; forming a first interface region overlying the first epitaxial material; subjecting the first release material to a photo electrochemical (PEC) etch to completely or partially remove the first release material; bonding the first interface region to the at least one carrier wafer to form a bonded structure, while maintaining the first release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of first dice provided on the first substrate member to transfer a first plurality of dice to the at least one carrier wafer;
wherein each pair of the transferred dice is configured with a second pitch between each pair of dice on a carrier wafer, the second pitch being equal or greater than the first pitch;wherein the PEC etch of the first release region is performed prior to the bonding step; and
wherein the etch selectively completely or partially removes the first release region while leaving a first anchor region intact to support the plurality of first dice before the selective bonding of at least a fraction of the first dice to the carrier wafer;
the first anchor region separates after the selective bonding of the first dice;the method further comprising; providing a second substrate having a second surface region; forming a second epitaxial material overlying the second surface region, the second epitaxial material comprising a second release material overlying the second substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing active region configured to emit electromagnetic radiation at a second green wavelength, and a p-type gallium and nitrogen containing region overlying the second release material; patterning the second epitaxial material and forming mesas to form a second plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a third pitch between the adjacent die in the array; forming a second interface region overlying the second epitaxial material, subjecting the second release material to a photo electrochemical (PEC) etch to completely or partially remove the second release material; bonding the second interface region to the at least one carrier wafer to form a bonded structure, while maintaining the second release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of second dice provided on the second substrate member to transfer a second plurality of dice to the at least one carrier wafer;
wherein each pair of the transferred dice is configured with a fourth pitch between each pair of dice on a carrier wafer, the fourth pitch being equal or greater than the third pitch;wherein the PEC etch of the second release region is performed prior to the bonding step; and
wherein the etch completely or partially selectively removes the second release region while leaving a second anchor region intact to support the plurality of second dice before the selective bonding of at least the fraction of the second dice to the carrier wafer;
the second anchor region separates after the selective bonding of the second dice. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A method for manufacturing an RGB light-emitting-diode based display panel device, the method comprising:
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providing at least one carrier wafer; providing a first substrate having a first surface region; forming a first gallium and nitrogen containing epitaxial material overlying the first surface region, the first epitaxial material comprising a first release material overlying the first substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing active region configured to emit electromagnetic radiation at a first blue wavelength, and a p-type gallium and nitrogen containing region overlying the first release material; patterning the first epitaxial material and forming mesas to form a first plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a first pitch between the adjacent die in the array; forming a first interface region overlying the first epitaxial material; subjecting the first release material to a photo electrochemical (PEC) etch to completely or partially remove the first release material; bonding the first interface region to the at least one carrier wafer to form a bonded structure, while maintaining the first release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of first dice provided on the first substrate member to transfer a first plurality of dice to the at least one carrier wafer, wherein each pair of the transferred dice is configured with a second pitch between each pair of dice on a carrier wafer, the second pitch being equal or greater than the first pitch; providing a second substrate having a second surface region; forming a second epitaxial material overlying the second surface region, the second epitaxial material comprising a second release material overlying the second substrate and at least an n-type gallium and nitrogen containing region, a light emitting gallium and nitrogen containing active region configured to emit electromagnetic radiation at a second green wavelength, and a p-type gallium and nitrogen containing region overlying the second release material; patterning the second epitaxial material and forming mesas to form a second plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a third pitch between the adjacent die in the array; forming a second interface region overlying the second epitaxial material; subjecting the second release material to an etching process to completely or partially remove the second release material; bonding the second interface region to the at least one carrier wafer to form a bonded structure, while maintaining the second release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of second dice provided on the second substrate member to transfer a second plurality of dice to the at least one carrier wafer;
wherein each pair of the transferred dice is configured with a fourth pitch between each pair of dice on a carrier wafer, the fourth pitch being equal or greater than the third pitch;providing a third substrate having a third surface region; forming a third epitaxial material overlying the third surface region, the third epitaxial material comprising a third release material overlying the third substrate and at least an n-type gallium and arsenic containing region, a light emitting gallium and arsenic containing active region configured to emit electromagnetic radiation at a third red wavelength, and a p-type gallium and arsenic containing region overlying the third release material; patterning the third epitaxial material and forming mesas to form a third plurality of dice arranged in an array, each die corresponding to at least one light emitting diode device and being arranged by a fifth pitch between the adjacent die in the array; forming a third interface region overlying the third epitaxial material; subjecting the third release material to an etching process to completely or partially remove the third release material; bonding the third interface region to the at least one carrier wafer to form a bonded structure, while maintaining the third release material completely or partially etched away from the bonded structure; releasing at least a fraction of the plurality of third dice provided on the third substrate member to transfer a third plurality of dice to the at least one carrier wafer;
wherein each pair of the transferred dice is configured with a sixth pitch between each pair of dice on a carrier wafer, the sixth pitch being equal or greater than the fifth pitch;processing the at least one carrier wafer with at least the first plurality of dice, the second plurality of dice, and third plurality of dice to form a light emitting diode based display panel device with a two dimensional array of red, green, and blue light emitting diode devices; wherein a repeating pattern of at least one red light emitting diode device, at least one green light emitting diode device, and at least one blue light emitting diode device form pixels within the RGB display panel device. - View Dependent Claims (19, 20)
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Specification