Title of Invention

A NITRIDE BASED SEMICONDUCTOR LIGHT EMITTING DEVICE WITH ENHANCED LUMINOUS EFFICIENCY AND BRIGHTNESS AND METHOD OF MANUFACTURING THE SAME

Abstract The present invention provides a light emitting device and a method of manufacturing the light emitting device. According to the present invention, the light emitting device comprises a substrate, an N-type semiconductor layer (20) formed on the substrate, and a P-type semiconductor layer (40) formed on the N-type semiconductor layer (20), wherein a side surface including the N-type or P-type semiconductor layer has a slope of 20 to 80° from a horizontal plane. Accordingly, there is an advantage in that the characteristics of a light emitting device such as luminous efficiency, external quantum efficiency and extraction efficiency are enhanced and the reliability is secured such that light with high luminous intensity and brightness can be emitted.
Full Text Technical Meld
[1] The present invention relates to a light emitting device and a method of manu-
facturing the same. More particularly, the present invention relates to a nitride based
semiconductor light emitting device with enhanced luminous efficiency and brightness
and a method of manufacturing the light emitting device.
Background Art
[2] A light emitting device refers to an element in which minority carriers (electrons or
holes) injected using a p-n junction structure of a semiconductor are produced and
certain light is emitted due to recombination of the carriers. A light emitting source is
formed from any one or combination of compound semiconductor materials such as
GaAs, AlGaAs, GaN, InGaN and AlGalnP, so that a variety of colors can be im-
plemented. For example, a red light emitting device may be formed from GaAsP or the
like; a green light emitting device may be formed from GaP, InGaN or the like; a blue
light emitting device may be formed using an InGaN/GaN double hetero structure; and
a UV light emitting device may be formed using an AlGaN/GaN or AlGaN/AlGaN
structure.
[3] In particular, GaN has a direct bandgap of 3.4eV at a normal temperature and a
direct energy bandgap of 1.9eV (InN) to 3.4eV (GaN) or 6.2eV (A1N) by combining
with a substance such as InN or A1N. Thus, GaN is a substance with great applicability
to an optical element due to its broad wavelength range from visible light to ultraviolet
light. Since the wavelength can be adjusted in such a manner, full-color imple-
mentation can be made by means of red, green and blue light emitting devices with a
short wavelength range, so that the applicability to a general illumination market as
well as a display device market is expected to be greatly increased.
[4] Light emitting devices have characteristics of lower power consumption, longer
lifespan, better installation in a narrow space and stronger resistance against vibration
as compared with existing bulbs or fluorescent lamps. Since the light emitting devices
are used as display devices and backlights and have superior characteristics in view of
the reduction in power consumption and the durability, many studies for applying the
light emitting devices to a general illumination field have been recently conducted. In
the future, their applicability is expected to extend to a backlight of a large-sized LCD-
TV, a vehicle headlight and general illumination. To this end, it is necessary to
improve luminous efficiency of light emitting devices, solve a heat dissipation

problem, and achieve high brightness and output of the light emitting devices.
[5] Many techniques for enhancing the performance of light emitting devices have been
currently developed. There are various indexes indicating the performance of light
emitting devices, such as luminous efficiency (lm/W), internal quantum efficiency (%),
external quantum efficiency (%) and extraction efficiency (%). The extraction
efficiency is determined as a ratio of electrons injected into the light emitting device to
photons emitted to the outside of the light emitting device. That is, the light emitting
device becomes bright as the extraction efficiency becomes high. Since the extraction
efficiency of the light emitting device is much influenced by the shape and surface
pattern of a chip, the structure of a chip and a packaging type, careful attention should
be paid when designing the light emitting device.
rgi Fi°. 1 is a sectional view showin0 a conventional li^ht emitting device with a
horizontal structure.'
[7] Referring to Fig. 1, the light emitting device comprises a substrate 1, an N-type
semiconductor layer 2 formed on the substrate 1, an active layer 3 formed on a portion
of the N-type semiconductor layer 2 and a P-type semiconductor layer 4. That is, after
the N-type semiconductor layer 2, the active layer 3 and the P-type semiconductor
layer 4 have been sequentially formed on the substrate 1, predetermined regions of the
P-type semiconductor layer 4 and the active layer 3 are etched to expose a portion of
the N-type semiconductor layer 2. Then, a predetermined voltage is applied to top
surfaces of the exposed N-type semiconductor layer 2 and the P-type semiconductor
layer 4.
[8] Fig. 2 is a sectional view showing a conventional light emitting device with a flip
chip structure.
[9] Referring to Fig. 2, the light emitting device comprises an N-type semiconductor
layer 2, an active layer 3 and a P-type semiconductor layer 4, which are sequentially
formed on a base substrate 1. The light emitting device further comprises a submount
substrate 5 onto which the base substrate 1 is flip-chip bonded using metal bumps 8
and 9. To this end, the N-type semiconductor layer 2, the active layer 3 and the P-type
semiconductor layer 4 are sequentially formed on the predetermined substrate 1, and
portions of the P-type semiconductor layer 4 and the active layer 3 are etched to
expose the N-type semiconductor layer 2 such that a light emitting cell can be formed.
Further, the additional submount substrate 5 is prepared to form first and second
electrodes 6 and 7 thereon, and the P-type and N-type metal bumps 8 and 9 are then
formed on the first and second electrodes 6 and 7, respectively. Thereafter, the light
emitting cell is bonded with the submount substrate 5 such that P and N electrodes of
the light emitting cell are bonded with the P-type and N-type metal bumps 8 and 9, re-
spectively, to fabricate a light emitting device. Since such a conventional light emitting

device with a flip chip structure has high heat dissipation efficiency and hardly has
shield of light, there is an advantage in that its light efficiency is increased by 50% or
more as compared with a conventional light emitting device. Further, since a gold wire
for driving a light emitting device is not necessary, many applications to a variety of
small-sized packages can be considered.
[10] Light produced from a light emitting layer of a light emitting device is emitted from
all the surfaces of a chip, and light extraction efficiency is generally determined by a
critical angle of light. However, when the conventional light emitting device is etched
to expose an N-type semiconductor layer, side surfaces of the P-type semiconductor
layer and the active layer are vertically processed such that a portion of light produced
within the light emitting device is totally reflected on the etched surface that is
processed vertically from a horizontal plane. Then, a considerable amount of light to
be totally reflected is not emitted to the outside but dissipated within the light emitting
device due to the internal reflection. That is, there is a problem in that luminous
efficiency in which electric energy is converted into light energy and the light is then
emitted to the outside of a light emitting device is low.
Disclosure of Invention
Technical Problem
[11] The present invention is conceived to solve the aforementioned problems. Ac-
cordingly, an object of the present invention is to provide a light emitting device for
emitting light with high luminous intensity and brightness by enhancing characteristics
of luminous efficiency, external quantum efficiency, extraction efficiency and the like
and improving reliability, and a method of manufacturing the light emitting device.
Technical Solution
[12] According to an aspect of the present invention for achieving the objects, there is
provided a light emitting device, comprising a plurality of light emitting cells each
including an N-type semiconductor layer and a P-type semiconductor layer formed on
a portion of the N-type semiconductor layer on a substrate. The N-type semiconductor
layer of one light emitting cell and the P-type semiconductor layer of another adjacent
light emitting cell may be connected to each other, and a side surface including the N-
type or P-type semiconductor layer of the light emitting cell has a slope of 20 to
80°from a horizontal plane. The light emitting device may further comprise a wire for
connecting the N-type semiconductor layer of one light emitting cell and the P-type
semiconductor layer of another adjacent light emitting cell, a transparent electrode
layer on the P-type semiconductor layer, and P-type and N-type ohmic metal layers
containing Cr or Au on the P-type and N-type semiconductor layers, respectively.
[13] According to another aspect of the present invention, there is provided a light

emitting device comprising a substrate formed with a plurality of light emitting cells
each including an N-type semiconductor layer and a P-type semiconductor layer
formed on the N-type semiconductor layer and a submount substrate flip-chip bonded
- onto the substrate. Preferably, the N-type semiconductor layer of one light emitting cell
and the P-type semiconductor layer of another adjacent light emitting cell are
connected to each other, and a side surface including at least the P-type semiconductor
layer of the light emitting cell has a slope of 20 to 80°from a horizontal plane. The
light emitting device may further comprise a wire for connecting the N-type semi-
conductor layer of one light emitting cell and the P-type semiconductor layer of
another adjacent light emitting cell.
[14] According to further aspect of the present invention, there is provided a method of
manufacturing a list"* prm'ttina dev'c« rnmnrisino.flip stp.ns nf sp.nnp.ntiallv forminp N-
type and P-type semiconductor layers on a substrate; forming an etching mask pattern,
of which side surface is not perpendicular to but inclined at a predetermined slope from
a horizontal plane, on the P-type semiconductor layer; and removing the etching mask
pattern and the P-type semiconductor layer exposed through the etching mask pattern.
[15] According to still further aspect of the present invention, there is a method of manu-
facturing a light emitting device comprising the steps of removing a portion of the N-
type semiconductor layer exposed due to the removal of the P-type semiconductor
layer to form a plurality of light emitting cells; and connecting the N-type semi-
conductor layer of one light emitting cell and the P-type semiconductor layer of
another adjacent light emitting cell through a conductive wire.
[16] According to still further aspect of the present invention, there is a method of manu-
facturing a light emitting device comprising the step of flip-chip bonding the substrate
onto an additional submount substrate after the step of removing the P-type semi-
conductor layer and the etching mask pattern. The method of manufacturing a light
emitting device may further comprise the steps of removing a portion of the N-type
semiconductor layer exposed through the removal of the P-type semiconductor layer to
form a plurality of light emitting cell; and connecting the N-type semiconductor layer
of one light emitting cell and the P-type semiconductor layer of another adjacent light
emitting cell through a conductive wire, after the step of removing the P-type semi-
conductor layer and the etching mask pattern.
[17] The step of forming the plurality of light emitting cells may comprise the steps of
forming an etching mask pattern, of which side surface is not perpendicular to but
inclined at a predetermined slope from a horizontal plane, on the P-type semiconductor
layer; removing the N-type and P-type semiconductor layers exposed through the
etching mask pattern to form a plurality of light emitting cells; and removing the
etching mask pattern.

[18] The N type semiconductor layer of one light emitting cell and the P type semi-
conductor layer of another adjacent light emitting cell may be connected with the
conductive wire through a bridge or step coverage process.
[19] A photoresist with a thickness of 3 to 50D may be used in the step of forming the
etching mask pattern. The step of forming the etching mask pattern may comprise the
steps of: applying the photoresist onto the P-type semiconductor layer; light exposing
the photoresist in accordance with a predetermined mask pattern; and developing the
light-exposed photoresist without a baking process after the light exposure. The step of
forming the etching mask pattern may comprise the steps of: applying the photoresist
onto the P-type semiconductor layer; light exposing the photoresist in accordance with
a predetermined mask pattern; hard baking the light-exposed photoresist at a
temperature of 100 to 140°C; and developing the hard-baked photoresist.
[20] After the step of removing the P-type semiconductor layer and the etching mask
pattern, the method of manufacturing a light emitting device may further comprise the
steps of removing a rear surface of the substrate at a certain thickness; and depositing
Al, Ti, Ag, W, Ta, Ni, Ru or an alloy thereof onto the rear surface of the substrate.
[21]
[22]
Advantageous Effects
[23] In a light emitting device and a method of manufacturing the same according to the
present invention, light produced from a side surface of a semiconductor layer, which
is not perpendicular to but inclined at a predetermined slop from a horizontal plane, is
not totally reflected but emitted to the outside of the light emitting device. Therefore,
more enhanced characteristics of light extraction efficiency, external quantum
efficiency, luminous efficiency or the like can be obtained. Further, a light emitting
device of the present invention emits light with high luminous intensity and brightness
and can be applied to a variety of products in which a superior light characteristic is
necessary.
Brief Description of the Accompanying Drawings
[ 24] The above and other objects, features and advantages of the present invention will
become apparent from the following description of preferred embodiments given in
conjunction with the accompanying drawings, in which:
[25] Figs. 1 and 2 are sectional views showing conventional light emitting devices, re-
spectively;
[26] Fig. 3 is a conceptual sectional view illustrating a light emitting device with a hori
zontal structure according to the present invention;
[27] Figs. 4 and 5 are sectional views illustrating a process of manufacturing a light

emitting device according to a first embodiment of the present invention;
[28] Figs. 6 to 9 are sectional views illustrating a process of manufacturing a light
emitting device according to a second embodiment of the present invention;
[29] Figs. 10 to 13 are sectional views illustrating a process of manufacturing a light
emitting device according to a third embodiment of the present invention;
[30] Figs. 14 to 17 are sectional views illustrating a process of manufacturing a light
emitting device according to a fourth embodiment of the present invention;
[31] Fig. 18 is a conceptual sectional view illustrating a light emitting device with a flip
chip structure according to the present invention;
[32] Figs. 19 to 23 are sectional views illustrating a process of manufacturing a light
emitting device according to a fifth embodiment of the present invention;
[331 Figs. 24 to 28 are sectional views illustrating a process of manufacturing a light
emitting device according to a sixth embodiment of the present invention;
[34] . Fig. 29 is a sectional view showing a seventh embodiment according to the present
invention; and
[35] Figs. 30 and 31 are conceptual sectional views illustrating a difference between
effects of the light emitting devices according to the prior art and the present invention.
Best Mode for Carrying Out the Invention
[36] Hereinafter, a light emitting device and a manufacturing method thereof according
to the present invention will be described in detail with reference to the accompanying
drawings. However, the present invention is not limited to the embodiments set forth
herein but can be implemented in different forms. Rather, the preferred embodiments
are merely provided to allow the present invention to be completely described herein
and to fully convey the scope of the invention to those skilled in the art.
[37] Fig. 3 is a conceptual sectional view illustrating a light emitting device with a
horizontal structure according to the present invention.
[38] Referring to Fig. 3, the light emitting device comprises a substrate 10, and an re-
type semiconductor layer 20, an active layer 30 and a P-type semiconductor layer 40,
which are sequentially formed on the substrate 10. Each of side surfaces of the P-type
semiconductor layer 40, the active layer 30 and a portion of the N-type semiconductor
layer 20 has a slope of 80 to 20° from a horizontal plane such that a critical angle of
light can be changed by such surfaces and light can be easily extracted. Therefore,
luminous efficiency of a light emitting device can be improved.
[39] Figs. 4 and 5 are sectional views illustrating a process of manufacturing a light
emitting device according to a first embodiment of the present invention.
[40] Referring to Fig. 4, an N-type semiconductor layer 20, an active layer 30 and a P-
type semiconductor layer 40 are sequentially formed on a substrate 10.

[41] The substrate 10 refers to a general wafer used for fabricating a light emitting
device and is made of at least any one of Al O , SiC, ZnO, Si, GaAs, GaP, LiAl 0 ,
BN, A1N and GaN. In this embodiment, a crystal growth substrate made of sapphire is
used.
[42] A buffer layer (not shown) may be further formed on the substrate 10 to reduce
lattice mismatch between the substrate 10 and the subsequent layers upon growth of
crystals. The buffer layer may contain GaN or A1N that is a semiconductor material.
[43] The N-type semiconductor layer 20 is a layer in which electrons are produced and is
preferably made from GaN doped with N-type impurities. However, the N-type semi-
conductor layer 20 is not limited thereto but may use a material layer having a variety
of semiconductor properties. The N-type semiconductor layer 20 including N-type Al
Ga N I-x
40 is a layer in which holes are produced and is preferably made from GaN doped with
P-type impurities. However, the P-type semiconductor layer 40 is not limited thereto
but may use a material layer with a variety of semiconductor properties. The P-type
semiconductor layer 40 including P-type Al Ga N(0 X 1-X
embodiment. Moreover, InGaN may be used as the semiconductor layer. Further, each
of the N-type and P-type semiconductor layers 20 and 40 may be formed as a multiple
layer.
[44] The active layer 30 has a predetermined bandgap and is a region where a quantum
well is formed so that electrons and holes are recombined. The active layer 30 may
contain InGaN. The wavelength of light emitted through the combination of electrons
and holes varies according to the kind of a material constituting the active layer 30.
Therefore, it is preferred that a semiconductor material contained in the active layer 30
be controlled depending on a target wavelength.
[45] The aforementioned material layers are formed through a variety of deposition and
growth methods including MOCVD (Metal Organic Chemical Vapor Deposition),
CVD (Chemical Vapor Deposition), PCVD (Plasma-enhanced Chemical Vapor
Deposition), MBE (Molecular Beam Epitaxy), HVPE (Hybride Vapor Phase Epitaxy)
and the like.
[46] Thereafter, portions of the P-type semiconductor layer 40 and the active layer 30
are removed through a predetermined etching process to expose a portion of the N-typc
semiconductor layer 20. An etching mask pattern is formed on the P-type semi-
conductor layer 40, and the P-type semiconductor layer 40 and the active layer 30 are
then removed through a dry or wet etching process to expose the N-type semi-
conductor layer 20.
[47] Generally, in order to perform the etching process, a photoresist has been applied
onto a top surface of the P-type semiconductor layer 40 at a thickness of 1 to 2D, and

then soft-baked at a temperature of 80 to 90°C is performed. Next, an exposure process
in which light in a UV range is irradiated through a predetermined photo mask to
transfer a pattern formed on the mask to the applied photoresist is executed. Thereafter,
the photoresist is hard-baked at a temperature of 100 to 120°C, and a developing
process in which the photoresist at a portion with relatively weak combination through
the exposure process is melted using a solvent is executed. A predetermined etching
mask pattern is formed on'the P-type semiconductor layer 40 through the above
process.
[481 However, in this embodiment, the photoresist is applied at a thickness of 3 to 50D
which is thicker as compared with the prior art when the etching mask pattern is
formed, and the exposure process is performed after the soft-baking. Next, if the
photoresist is directly developed without the hard-baking, a developed side surface of
the remaining photoresist is formed into an inclined surface not perpendicular (90°) to
but inclined at a predetermined slope from a horizontal plane. Subsequently, if exposed
regions of the P-type semiconductor layer 40, the active layer 30 and the pre-
determined N-type semiconductor layer 20 are etched using the etching mask pattern
with such a slope of the side surface, the side surfaces of the etched P-type semi-
conductor layer 40, active layer 30 and N-type semiconductor layer 20 can be similarly
formed into an inclined surface not perpendicular (90°) to but inclined at a pre-
determined slope from the horizontal plane.
[49] That is, after the photoresist has been applied at a thickness of 3 to 50D on the P-type
semiconductor layer 40 of Fig. 4 and light-exposed, a developed etching mask pattern
is immediately formed without the hard-baking. The P-type semiconductor layer 40
and the active layer 30, which are exposed through the etching mask pattern, are
removed through an ICP (Inductive Coupled Plasma) or dry etching process to expose
the N-type semiconductor layer 20. A portion of the exposed N-type semiconductor
layer 20 may be further removed. Thereafter, if the etching mask pattern is removed, a
light emitting device in which the side surfaces of the P-type semiconductor layer 40,
the active layer 30 and a portion of the N-type semiconductor layer 20 are not per-
pendicular (90°) to but inclined at the predetermined slope from a horizontal plane can
be manufactured as shown in Fig. 5.
[50] Alternatively, after a photoresist has been applied at a thickness of 3 to 50D on the P-
type semiconductor layer 40 of Fig. 4 and light-exposed, hard-baking may be
performed. In such a case, if the photoresist is hard-baked at a temperature of 100 to
140°C and then developed, the side surface of the developed photoresist may be etched
to have a slope of 80 to 20° from a horizontal plane. For example, in a case where the
hard-baking is performed at a temperature of 100°C, an etching mask pattern with a
slope of about 80° from the horizontal plane can be obtained, and the side surfaces of

the P-type semiconductor layer 40, the active layer 30 and a portion of the N-type
semiconductor layer 20 can have a slope of about 80° from the horizontal plane using
the etching mask pattern. Further, in a case where the hard-baking is performed at a
temperature of 140°C, an etching mask pattern with a slope of about 20° from the
horizontal plane can be obtained, and the side surfaces of the P-type semiconductor
layer 40, the active layer 30 and a portion of the N-type semiconductor layer 20 can
have a slope of about 20° from the horizontal plane using the etching mask pattern.
[51] The etching mask pattern, which the photoresist with a thickness of 3 to 500 has
been light-exposed and hard-baked at a temperature of 100 to 140°C and then
developed in such a manner, can be used such that the side surfaces of the etched the
P-type semiconductor layer 40, active layer 30 and predetermined N-type semi-
conductor layer 20 have a slope of 80 to 20° from a horizontal plane similarly to the
etching mask pattern. Then, light produced within a light emitting layer is not totally
reflected on the etched side surface with a variety of slopes but emitted to the outside
of a light emitting device.
[52] A transparent electrode layer may be further formed on the P-type semiconductor
layer 40 to reduce resistance of the P-type semiconductor layer 40 and enhancing
transmittance of light, and an additional ohmic metal layer may be further formed on
the P-type semiconductor layer 40 or the exposed N-type semiconductor layer 20 to
facilitate current supply. The transparent electrode layer may be made of ITO (Indium
Tin Oxide), ZnO or a transparent conductive metal, and the ohmic metal layer may be
made of Cr or Au. Further, for the application of voltage, a P-type electrode may be
further formed on the P-type semiconductor layer 40 and an N-type electrode may be
further formed on the N-type semiconductor layer 20.
[53] Further, in order to enhance the heat dissipation characteristic of a light emitting
device, after a rear surface of the substrate 10 has been removed at a predetermined
thickness, Al, Ti, Ag, W, Ni, Ta, Ru or an alloy thereof may be deposited on the rear
surface of the substrate 10.
[54] As can be seen from this figure, a plurality of light emitting devices may be
fabricated on a single substrate 10, which is cut into the individual light emitting
devices. At this time, portions A. shown in Fig. 5 are cutting portions used for in-
dividually cutting the plurality of light emitting devices.
[55] Accordingly, a light emitting device in which the side surfaces of the P-type semi-
conductor layer 40, the active layer 30 and a portion of the N-type semiconductor layer
20 is not perpendicular (90°) to but inclined at the predetermined slope from a
horizontal plane can be manufactured.
[56] The aforementioned process of manufacturing a light emitting device according to
the present invention is merely a specific embodiment, but is not limited thereto.

Various processes and manufacturing methods may be modified or added depending
on the characteristics of devices and the convenience of processes.
[57] Figs. 6 to 7 are sectional views illustrating a process of manufacturing a light
emitting device according to a second embodiment of the present invention.
[58] The second embodiment of the present invention is almost the same as the first
embodiment. In the second embodiment, however, there is provided a light emitting
device in which a plurality of light emitting cells are connected in series, parallel or
series-parallel in a wafer level to reduce the size of the device, and they can be driven
at proper voltage and current to be used for illustration purpose and can also be driven
even with an AC power source. Descriptions overlapping with the previous
embodiment will be omitted herein.
[59] Referring to Fig. 6, an N-type semiconductor layer 20, an active layer 30 and a P-
type semiconductor layer 40 are sequentially formed on a substrate 10 through various
deposition methods including MOCVD (Metal Organic Chemical Vapor Deposition),
CVD (Chemical Vapor Deposition), PCVD (Plasma-enhanced Chemical Vapor
Deposition), MBE (Molecular Beam Epitaxy), HVPE (Hybride Vapor Phase Epitaxy)
and the like. A buffer layer may be further formed on the substrate 10 to reduce lattice
mismatch between the substrate 10 and the subsequent layers upon growth of crystals.
[60] Thereafter, portions of the P-type semiconductor layer 40 and the active layer 30
are removed through a predetermined etching process to expose a portion of the N-type
semiconductor layer 20. That is, after the photoresist has been applied at a thickness of
3 to 50D on the P-type semiconductor layer 40 of Fig. 6 and light-exposed, it is
developed without hard-baking to form an etching mask pattern. The P-type semi-
conductor layer 40 and the active layer 30, which are exposed through the etching
mask pattern, are removed through an ICP (Inductive Coupled Plasma) or dry etching
process to expose the N-type semiconductor layer 20. A portion of the exposed N-type
semiconductor layer 20 may be further removed. Thereafter, if the etching mask
pattern is removed, a light emitting device in which the side surfaces of the P-type
semiconductor layer 40, the active layer 30 and the N-type semiconductor layer 20 are
not perpendicular (90°) to but inclined at the predetermined slope from a horizontal
plane can be manufactured as shown in Fig. 7.
[61] Alternatively, after a photoresist has been applied in a thickness of 3 to 50H on the
P-type semiconductor layer 40 of Fig. 6 and light-exposed, it is hard-baked at a
temperature of 100 to 140°C and developed such that an etching mask pattern can be
formed. After the P-type semiconductor layer 40 and the active layer 30, which are
exposed through the etching mask pattern, have been etched, the etching mask pattern
is removed such that the side surfaces of the etched P-type semiconductor layer 40 and
active layer 30 can have a variety of slopes of 80 to 20°.

[62] Next, in order to form a plurality of light emitting cells on the substrate 10, pre-
determined regions of the exposed N-type semiconductor layer 20 are removed such
that a portion of the substrate 10 can be exposed. To this end, a predetermined mask
pattern is formed on all the portions except the predetermined regions where the
substrate 10 will be exposed, and regions of the N-type semiconductor layer 20 that are
exposed through the mask pattern are then etched such that the plurality of light
emitting cells can be electrically isolated from one another as shown in Fig. 8. At this
time, the mask pattern whose side surface is inclined through the aforementioned
process is formed and then used to etch the exposed N-type semiconductor layer 20
such that the side surface of the N-type semiconductor layer 20 in which the plurality
of light emitting cells are separated from one another is not perpendicular to but
inclined at a predetermineLi SxGpc ixcm a horizontal plane.
[63J Referring to Fig. 9, the N-type semiconductor layer 20 of a light emitting cell and
the P-type semiconductor layer 40 of the adjacent light emitting cell are connected
through a predetermined wiring process. That is, the exposed N-type semiconductor
layer 20 of one light emitting cell and the P-type semiconductor layer 40 of another
adjacent light emitting cell are connected through a wire 60. At this time, the
conductive wire 60 for electrically connecting the N-type and P-type semiconductor
layers 20 and 40 are formed through a bridge process.
[64] The aforementioned bridge process is also called an air-bridge process. In the air-
bridge process, a photosensitive liquid is applied between chips to be connected with
each other through a photo process and developed to form a photoresist pattern, a
material such as metal is first formed into a thin film on the photoresist pattern through
a vacuum vapor deposition method or the like, and a conductive material containing
gold (Au) is applied at a predetermined thickness onto the thin film through an elec-
troplating, electroless plating or metal vapor deposition method. Thereafter, if the
photoresist pattern is removed with a solution of a solvent or the like, a lower portion
of the conductive material is completely removed, and thus, only the bridge-shaped
conductive material is formed in a space between the adjacent light emitting cells.
[65] The wire 60 may be made of not only metal but also all kinds of conductive
materials. It will be apparent that a silicone compound doped with impurities may be
used.
[66] Further, in order to apply an external voltage to the light emitting device, a P-type
bonding pad 50 is formed on the P-type semiconductor layer 40 of the light emitting
cell positioned at one edge of the substrate 10 and an N-type bonding pad 55 is formed
on the exposed N-type semiconductor layer 20 of the light emitting cell positioned at
the other edge of the substrate 10.
[67] The aforementioned process of manufacturing a light emitting device according to

the present invention is merely a specific embodiment but is not limited thereto.
Various modifications can be made or various material films can be further added. For
example, in order to enhance the heat dissipation characteristic of a light emitting
device, after a rear surface of the substrate 10 has been removed at a predetermined
thickness, Al, Ti, Ag, W, Ni, Ta, Ru or an alloy thereof may be deposited on the rear
surface of the substrate 10.
[68] Accordingly, a light emitting device in which the plurality of light emitting cells
each of which side surfaces of the P-type semiconductor layer 40, the active layer 30
and a portion of the N-type semiconductor layer 20 are not perpendicular (90°) to but
inclined at predetermined slope from a horizontal plane are connected with one another
can be manufactured.
[69] Figs. 10 to 13 are sectional views illustrating a process of manufacturing a light
emitting device according to a third embodiment of the present invention.
[70] The third embodiment is almost the same as the second embodiment. In the second
embodiment, the N-type semiconductor layer 20 is first exposed and a portion of the
exposed N-type semiconductor layer 20 is then removed to separate the light emitting
cells from one another. In the third embodiment, however, a plurality of light emitting
cells are first separated, and a portion of an N-type semiconductor layer 20 is then
exposed. Descriptions overlapping with the previous embodiments will be omitted
herein.
[71] Referring to Fig. 10, portions of an N-type semiconductor layer 20, an active layer
30 and a P-type semiconductor layer 40, which are sequentially formed on a substrate
10, are removed to form a plurality of light emitting cells. To this end, after a
photoresist has been applied at a thickness of 3 to 500 on the P-type semiconductor
layer 40 and light-exposed, it is immediately developed without hard-baking such that
an etching mask pattern can be formed. The portions of the P-type semiconductor layer
40, the active layer 30 and the N-type semiconductor pattern 20, which are exposed
through the etching mask pattern, and the etching mask pattern is removed to separate
the light emitting cells from one another. Accordingly, a light emitting device in which
entire side surfaces of the P-type semiconductor layer 40, the active layer 30 and the
N-type semiconductor layer 20 are not perpendicular (90°) to but inclined at a pre-
determined slope can be obtained as shown in this figure. Further, the P-typc semi-
conductor layer 40, the active layer 30 and the N-type semiconductor layer 20 are
removed using the etching mask pattern in which a photoresist is applied at a thickness
of 3 to 50D on the P-type semiconductor layer 40 and light-exposed and hard-baked at a
temperature of 100 to 140°C and then developed. Accordingly, the entire side surfaces
of the P-type semiconductor layer 40, the active layer 30 and the N-type semiconductor
layer 20 can be formed at various slopes of 80 to 20°.

[72] Thereafter, as shown in Fig. 11, portions of the P-type semiconductor layer 40 and
the active layer 30 are removed to expose a portion of the N-type semiconductor layer
20 through a predetermined etching process.
[73] Referring to Fig. 12, the N-type semiconductor layer 20 of one light emitting cell
and the P-type semiconductor layer 40 of another adjacent light emitting cell are
connected with each other through a bridge process.
[74] Further, in order to apply an external voltage to the light emitting device, a P-type
bonding pad 50 is formed on the P-type semiconductor layer 40 of the light emitting
cell positioned at one edge of the substrate 10 and an N-type bonding pad 55 is formed
on the exposed N-type semiconductor layer 20 of the light emitting cell positioned at
the other edge of the substrate 10. '
[75] The aforementioned process of manufacturing a light emitting device according to
the present invention is merely a specific embodiment but is not limited thereto.
Various modifications can be made and various material films may be further added.
For example, in order to enhance the heat dissipation characteristic of a light emitting
device, after a rear surface of the substrate 10 has been removed at a predetermined
thickness, Al, Ti, Ag, W, Ni, Ta, Ru or an alloy thereof may be deposited on the rear
surface of the substrate 10.
[76] Further, even in a case where the plurality of light emitting cells are separated by
etching such that the side surfaces may have various slopes as shown in Fig. 10 and
then etched to expose the N-type semiconductor layer 20, a light emitting device can
be manufactured using the same etching process as described above. That is, as shown
in Fig. 11, the side surfaces of the P-type semiconductor layer 40 and the active layer
30, which are etched to expose the N-type semiconductor layer 20, can be formed at
various slopes.
[77] Accordingly, a light emitting device in which the plurality of light emitting cells
each of which side surfaces of the P-type semiconductor layer 40, the active layer 30
and the N-type semiconductor layer 20 are not perpendicular (90°) to but inclined at
predetermined slope from a horizontal plane are connected with one another can be
manufactured.
[78] Figs. 14 to 17 are sectional views illustrating a process of manufacturing a light
emitting device according to a fourth embodiment of the present invention.
[79] The fourth embodiment is almost the same as the third embodiment. In the third
embodiment, a conductive wire for electrically connecting the N-type semiconductor
layer of one light emitting cell and the P-type semiconductor layer of another adjacent
light emitting cell is formed through a bridge process. In the fourth embodiment,
however, the conductive wire is formed through a step coverage process. Descriptions
overlapping with the previous embodiments will be omitted herein.

[80] Referring to Fig. 14, even in a case where a plurality of light emitting cells are
separated by etching such that the side surfaces may have various slopes and then
etched to expose an N-type semiconductor layer 20 through the aforementioned
process, the side surfaces of P-type semiconductor layer 40 and active layer 30, which
are etched to expose the N-type semiconductor layer 20, are formed with various
slopes. Further, in order to reduce the resistance of the P-type semiconductor layer 40
and enhance the transmittance of light, a transparent electrode layer 85 may be further
formed on a top surface of the P-type semiconductor layer 40. Further, an additional
ohmic metal layer 87 for facilitating the supply of current may be further formed on a
top surface of the P-type semiconductor layer 40 or the exposed N-type semiconductor
layer 20. The transparent electrode layer 85 may be made of ITO (Indium Tin Oxide),
ZnO or a conductive transparent metal, and the ohmic metal layer 87 may be made of
Cr or Au.
[81] Referring to Fig. 15, a continuous insulation layer 70 is formed on an entire surface
of the substrate 10 with the plurality of light emitting cells formed thereon. The
insulation layer 70 covers the side surfaces and top surfaces of the light emitting cells
and the top surfaces of the substrate 10 between the adjacent light emitting cells. For
example, the insulation layer 70 may be formed as a silicone oxide film using a CVD
(Chemical Vapor Deposition) technique.
[82] Since the side surfaces of the light emitting cells are inclined, the insulation layer 70
can easily cover the side surfaces of the light emitting cells. Since the total thickness of
the N-type semiconductor layer 20 and active layer 30 is small and spaces between the
adjacent P-type semiconductor layers 40 are broad, the side surfaces of the P-type
semiconductor layers 40 adjacent to the exposed regions of the N-type semiconductor
layers 20 can be easily covered with the insulation layer 70.
[83] Referring to Fig. 16, an opening portion is formed on each of the exposed N-type
and P-type semiconductor layers 20 and 40 of the light emitting cell by patterning the
insulation layer 70 through a predetermined etching process. If the transparent
electrode layer 85 and/or the ohmic metal layer 87 are formed as shown in this figure,
the transparent electrode layer 85 and/or the ohmic metal layer 87 are exposed through
the opening portion.
[84] Referring to Fig. 17, a wire 80 is formed on the insulation layer 70 with the opening
portion. The wire 80 connects the N-type and P-type semiconductor layers 20 and 40
through the opening portion thereof. That is, the N-type semiconductor layer 20 of one
light emitting cell and the P-type semiconductor layer 40 of another adjacent the light
emitting cell are electrically connected with the wire.
[85] The wire 80 may be formed using a plating technique. That is, after an etching mask
pattern with an opening portion defining a region of the wire 80 has been formed on

the insulation layer 70 and a metal layer has been plated within the opening portion,
the etching mask pattern is removed and thus the wire 80 can be formed.
[86] Further, the wire 80 may be formed using the CVD (Chemical Vapor Deposition) or
PVD (Physical Vapor Deposition) technique. That is, a metal layer is formed using a
vapor deposition technique such as electron beam deposition and then patterned using
a photo and etching process, so that the wire 80 can be formed. Since the side surface
of the light emitting cell is inclined, the metal layer is continuously formed on the
upper side surface of the light emitting cell.
[87] The light emitting device in which the wire 80 is formed as described above has an
advantage in that it is possible to prevent the wire 80 from being disconnected or
shorted due to external pressure and also prevent conductive materials such as metal,
which remains while the wire 80 is formed, from shorting the light emitting cell.
[88] Accordingly, a light emitting device in which the plurality of light emitting cells
each of which side surfaces of the P-type semiconductor layer 40, the active layer 30
and the N-type semiconductor layer 20 are not perpendicular (90°) to but inclined at
predetermined slope from a horizontal plane are connected with one another can be
manufactured.
[89] As described above, the light emitting device according to the present invention is
formed such that the side surfaces of the P-type semiconductor layer, the active layer
and a portion of the N-type semiconductor layer are not perpendicular (90°) to but
inclined at a predetermined slope from a horizontal plane. Therefore, luminous
efficiency of the light emitting device of the present invention can be enhanced as
compared with that of the conventional light emitting device. The reason is that a
photon reflected on a flat surface in the prior art is not reflected on a surface with a
different angle but emitted to the outside.
[90] Fig. 18 is a conceptual sectional view illustrating a light emitting device with a flip
chip structure according to the present invention.
[91] Referring to Fig. 18, the light emitting device comprises a light emitting layer, i.e.
an N-type semiconductor layer 120, an active layer 130 and a P-type semiconductor
layer 140 sequentially formed on a base substrate 110. Further, the light emitting
device comprises a submount substrate 200 onto which the base substrate 110 with the
light emitting layer formed thereon is flip-chip bonded through metal bumps 150 and
155. A side surface of the light emitting layer comprising the P-type semiconductor
layer 140, the active layer 130 and the N-type semiconductor layer 120 is inclined at a
slope of 20 to 80° from the horizontal plane and a critical angle of light is changed due
to the side surface such that the light can be easily extracted. Therefore, luminous
efficiency of the light emitting device can be improved.
[92] Figs. 19 to 23 are sectional views illustrating a process of manufacturing a light

emitting device according to a fifth embodiment of the present invention.
[93] Referring to Fig. 19, an N-type semiconductor layer 120, an active layer 130 and a
P-type semiconductor layer 140 are sequentially formed on a base substrate 110.
[94] The base substrate 110 refers to a general wafer used for fabricating a light emitting
device is made of a transparent substrate such as Al O , ZnO and LiAl O In this
2 3 2 3.
embodiment, a crystal growth substrate made of sapphire is used.
[95] The N-type semiconductor layer 120, the active layer 130 and the P-type semi-
conductor layer 140 are sequentially formed on the substrate 110 through various
deposition methods including MOCVD (Metal Organic Chemical Vapor Deposition),
CVD (Chemical Vapor Deposition), PCVD (Plasma-enhanced Chemical Vapor
Deposition), MBE (Molecular Beam Epitaxy), HVPE (Hybride Vapor Phase Epitaxy)
and the like. A buffer layer may be further formed on the substrate 110 to reduce
lattice mismatch between the substrate 110 and the subsequent layers upon growth of
crystals. The aforementioned components are the same as those in the previous em-
bodiments, and thus, descriptions overlapping with the foregoing components will be
omitted herein.
[96] Thereafter, portions of the P-type semiconductor layer 140 and the active layer 130
are removed through a predetermined etching process to expose a portion of the N-type
semiconductor layer 120. This etching process is the same as that of the previous em-
bodiments.
[97] That is, after a photoresist has been applied at a thickness of 3 to 50D on the P-type
semiconductor layer 140 of Fig. 19 and light-exposed, it is immediately developed
without hard-baking to form an etching mask pattern. The P-type semiconductor 140
and the active layer 130, which are exposed through the etching mask pattern, are
removed through an ICP (Inductive Coupled Plasma) or dry etching process to expose
the N-type semiconductor layer 120. Thereafter, if the etching mask pattern is
removed, side surfaces of the P-type semiconductor layer 140 and the active layer 130
which are not perpendicular (90°) to but inclined at a predetermined slope from the
horizontal plane can be obtained as shown in Fig. 20.
[98] Alternatively, after a photoresist has been applied at a thickness of 3 to 500 on the P-
type semiconductor layer 140 of Fig. 19 and light-exposed, it is hard-baked at a
temperature of 100 to 140°C and then developed such that an etching mask pattern can
be formed. After the P-type semiconductor layer 140 and the active layer 130, which
are exposed through the etching mask pattern, have been etched, the etching mask
pattern is removed such that the side surfaces of the etched P-type semiconductor layer
140 and active layer 130 can have a variety of slopes of 80 to 20°.
[99] A reflection layer for reflecting light may be further formed on a top surface of the
P-type semiconductor layer 140, and an additional ohmic metal layer for facilitating

the supply of current may be further formed on a top surface of the P-type semi-
conductor layer 140 or the exposed N-type semiconductor layer 120. The ohmic metal
layer may be made of Cr or Au.
[100] Further, P-type and N-type metal bumps 155 and 150 are formed on the P-type and
N-type semiconductor layers 140 and 120, respectively, as shown in Fig. 21. Each of
the P-type and N-type metal bumps 155 and 150 may be made of at least one material
selected from the group consisting of Pb, Sn, Au, Ge, Cu, Bi, Cd, Zn, Ag, Ni, Ti and
an alloy thereof. To this end, a photoresist is applied onto an entire structure and a
photoresist pattern (not shown) through which portions of the P-type and N-type semi-
conductor layers 140 and 120 are exposed is formed through a photo-etching process
using a predetermined mask. After a metal film has been deposited on the entire
structure, metal film portions formed on regions other than regions on the P-type and
N-type semiconductor layers 140 exposed through the photoresist pattern and the
photoresist pattern are removed. Accordingly, the P-type and N-type metal bumps 155
and 150 are formed on the P-type and N-type semiconductor layers 140 and 120, re-
spectively.
[101] Next, referring to Fig. 22, an additional submount substrate 200 is prepared to form
P-type and N-type bonding pads 215 and 210 connected to the P-type and N-type metal
bumps 155 and 150, respectively.
[102] At this time, various kinds of superior heat conductive substrates 200 are used as
the submount substrate 200. That is, the submount substrate 200 may be made of SiC,
Si, Ge, SiGe, A1N, metal or the like. In this embodiment, A1N with superior heat con-
ductivity and insulation property is used. The present invention is not limited thereto,
but a metallic material with superior heat and electric conductivity may be employed.
In this case, an insulation or dielectric film is formed on the substrate 200 to suf-
ficiently serve as an insulation. The dielectric film may be made of Si02, MgO and
SiN or an insulating material. Further, each of the P-type and N-type bonding pads 210
and 215 is made of a metal with superior electric conductivity. This is formed through
a screen printing process or a deposition process using a predetermined mask pattern.
[103] Thereafter, the submount substrate 200 is flip-chip bonded onto the base substrate
110 with the light emitting layer formed thereon.
[104] Referring to Fig. 23, in the light emitting device of the present invention, the N-type
and P-type metal bumps 150 and 155 formed on the top of the light emitting layer are
bonded and connected with the N-type and P-type bonding pads 210 and 215 of the
submount substrate 200, respectively. At this time, the bonding pads and metal bumps
may be bonded using heat or ultrasonic waves or simultaneously using the heat and
ultrasonic waves. The metal bumps 150 and 155 and the lower bonding pads 210 and
215 are connected through a variety of bonding methods.

[105] Moreover, the N-type and P-type metal bumps 150 and 155 are not formed on the
top of the light emitting layer but may be formed on the submount substrate 200.
[106] As can be seen from this figure, a plurality of light emitting devices may be
fabricated on a single substrate 10, which is cut into the individual light emitting
devices. At this time, portions A shown in Fig. 23 are cutting portions used for in-
dividually cutting the plurality of light emitting devices.
[107] The aforementioned process of manufacturing a light emitting device according to
the present invention is merely a specific embodiment, but is not limited thereto.
Various processes and manufacturing methods may be modified or added depending
on the characteristics of devices and the convenience of processes. For example, in the
same process as the previous embodiments, the base substrate with the N-type semi-
conductor layer, the active layer and the P-type semiconductor layer sequentially
formed thereon is prepared as shown in Fig. 19. Then, portions of the P-type semi-
conductor layer, the active layer and the N-type semiconductor layer are first removed
to expose the substrate such that the plurality of light emitting devices can be in-
dividually isolated. At this time, the side surfaces of the P-type semiconductor layer,
the active layer and the N-type semiconductor layer, which are etched through the
aforementioned process, may be formed not to be perpendicular (90°) to but inclined at
a predetermined slope.
[108] Accordingly, a light emitting device with a flip chip structure, in which the side
surfaces of the P-type semiconductor layer, the active layer and a portion of the N-type
semiconductor layer are not perpendicular (90°) to but inclined at the predetermined
slope from the horizontal plane, can be manufactured.
[109] Figs. 24 to 28 are sectional views illustrating a process of manufacturing a light
emitting device according to a sixth embodiment of the present invention.
[110] The sixth embodiment is almost the same as the fifth embodiment. In the sixth
embodiment, however, there is provided a light emitting device with a flip chip
structure, in which a plurality of light emitting cells are connected in series, parallel or
series-parallel in a wafer level to reduce the size of the device, and they can be driven
at proper voltage and current to be used for illumination purpose and can also be
driven even with an AC power source. Descriptions overlapping with the previous em-
bodiments will be omitted herein.
[Ill] Referring to Fig. 24, an N-type semiconductor layer 120, an active layer 130 and a
P-type semiconductor layer 140 are sequentially formed on a base substrate 110
through various deposition methods including MOCVD (Metal Organic Chemical
Vapor Deposition), CVD (Chemical Vapor Deposition), PCVD (Plasma-enhanced
Chemical Vapor Deposition), MBE (Molecular Beam Epitaxy), HVPE (Hybride Vapor
Phase Epitaxy) and the like. A buffer layer may be further formed on the substrate 110

to reduce lattice mismatch between the substrate 110 and the subsequent layers upon
growth of crystals.
[112] Thereafter, portions of the N-type semiconductor layer 120, the active layer 130
and the P-type semiconductor layer 140, which are sequentially formed on the base
substrate 110, are removed to form a plurality of light emitting cells. To this end, after
a photoresist has been applied at a thickness of 3 to 50D on the P-typc semiconductor
layer 140 of Fig. 24 and light-exposed, it is immediately developed without hard-
baking to form an etching mask pattern. The P-type semiconductor 140, the active
layer 130 and the predetermined N-type semiconductor layer 120, which are exposed
through the etching mask pattern, are removed through an ICP (Inductive Coupled
Plasma) or dry etching process to separate the light emitting cells from one another.
Next, if the etching mask pattern is removed, a light emitting device in which entire
side surfaces of the etched P-type semiconductor layer 140, active layer 130 and N-
type semiconductor layer 120 are not perpendicular (90°) to but inclined at a pre-
determined slope from the horizontal plane can be obtained as shown in Fig. 25.
[113] Alternatively, after a photoresist has been applied at a thickness of 3 to 50D on the P-
type semiconductor layer 140 of Fig. 24 and light-exposed, it is hard-baked at a
temperature of 100 to 140°C and developed such that an etching mask pattern can be
formed. After the P-type semiconductor layer 140, the active layer 130 and the N-type
semiconductor layer 120, which are exposed through the etching mask pattern, have
been etched, the etching mask pattern is removed such that the side surfaces of the
etched P-type semiconductor layer 140 and active layer 130 can be inclined at various
slopes of 80 to 20°.
[114] Next, portions of the P-type semiconductor layer 140 and the active layer 130 are
removed through a predetermined etching process to expose a portion of the N-type
semiconductor layer 120, as shown in Fig. 26. The exposed N-type semiconductor
layer 120 of one light emitting cell and the P-type semiconductor layer 140 of another
adjacent light emitting cell are connected with each other through a predetermined
conductive wire. At this time, a bridge wire 160 is made of a conductive material, e.g.
metal. It will be apparent that the bridge wire 160 may be made of a silicone
compound doped with impurities. The bridge wire 160 is formed through a bridge
process.
[115] Further, a plurality of metal bumps are formed on the top of the light emitting cells,
and P-lype and N-type metal bumps 155 and 150 are further formed on the P-lype
semiconductor layer 140 of the light emitting cell positioned at one edge of the
substrate 110 and the N-type semiconductor layer 120 of the light emitting cell
positioned the other edge of the substrate, respectively.
[116] Next, as shown in Fig. 27, an additional submount substrate 200 is prepared, on

which a plurality of bonding layers 220, a P-type bonding pad 215 positioned at one
edge of the submount substrate 200 and an N-type bonding pad 210 positioned at the
other edge of the submount substrate are formed.
[ 117] Thereafter, as can be shown in Fig. 28, the aforementioned base substrate 110 with
the plurality of light emitting cells formed thereon is flip-chip bonded onto the
submount substrate 200 to fabricate the light emitting device. The substrates are
bonded with each other through the metal bumps 150 and 155 formed on the top of the
light emitting cell and the bonding layers 220 formed on the submount substrate 200,
respectively. The P-type bonding pad 215 positioned at one edge of the submount
substrate 200 is connected to the P-type metal bump 155 of the light emitting cell
positioned at one edge of the base substrate 110, whereas the N-type bonding pad 210
nnsitinned at the. other edpe of the submount substrate 200 is connected to the N-tVDe
metal bump 150 of the light emitting cell positioned at the other edge of the base
substrate 110.
[118] The aforementioned process of manufacturing a light emitting device according to
the present invention is merely a specific embodiment, but is not limited thereto.
Various processes and manufacturing methods may be modified or added depending
on the characteristics of devices and the convenience of processes. For example, in this
embodiment, the conductive wire for electrically connecting the N-type semiconductor
layer of one light emitting cell and the P-type semiconductor layer of another adjacent
light emitting cell is formed through a bridge process, and the base substrate is then
flip-chip bonded onto the submount substrate. However, the present invention is not
limited thereto. That is, a conductive wire for electrically connecting the N-type semi-
conductor layer of one light emitting cell and the P-type semiconductor layer of
another adjacent light emitting cells may be formed through a step coverage process
which is the same as in the fourth embodiment. Further, an electrode layer may be
formed on the submount substrate when the plurality of light emitting cells are flip-
chip bonded onto the submount substrate such that the N-type semiconductor layer of
one light emitting cell and the P-type semiconductor layer of another adjacent light
emitting cell are electrically connected through the metal bumps.
[119] Accordingly, a light emitting device in which a plurality of flip chip light emitting
cells each having a side surface of a light emitting layer, which is not perpendicular
(90°) to but inclined at a predetermined slope from the horizontal plane, are arrayed on
the submount substrate can be manufactured. The light emitting cells may be
connected in various ways, i.e. in series, parallel or series-parallel, depending on the
desired purpose.
[120] Fig. 29 is a sectional view showing a seventh embodiment according to the present
invention.

[121] The seventh embodiment is almost the same as the sixth embodiment. In this
embodiment, even in a case where a plurality of light emitting cells are separated by
etching such that the side surfaces may have slopes as shown in Fig. 25 and then
etched to expose an N-type semiconductor layer, a light emitting device can be man-
ufactured using the same etching process as the previous embodiment. That is, side
surfaces of a P-type semiconductor layer 140 and an active layer 130 etched to expose
an N-type semiconductor layer 120 are formed with various slopes, as shown in Fig.
29.
[122] Accordingly, a light emitting device in which a plurality of flip chip light emitting
cells each having an entire side surface of a light emitting layer, which is not per-
pendicular (90°) to but inclined at a predetermined slope from the horizontal plane, are
arrayed on the subrnount substrate can be manufactured. The light emitting cells may
be connected in various ways, i.e. in series, parallel or series-parallel, depending on the
desired purpose.
[123] As described above, the light emitting device with a flip chip structure according to
the present invention is formed such that some side surfaces of a light emitting layer
are not particular (90°) to but inclined at a predetermined slope from the horizontal
plane. Therefore, luminous efficiency of the light emitting device of the present
invention can be enhanced as compared with that of the conventional light emitting
device. The reason is that a photon reflected on a flat surface in the prior art is not
reflected on a surface with a different angle but emitted to the outside.
[124] Figs. 30 and 31 are conceptual sectional views illustrating a difference between
effects of the light emitting devices according to the prior art and the present invention.
[125] The light efficiency of a light emitting device may be expressed as internal quantum
efficiency and external quantum efficiency, and the internal quantum efficiency is
determined in accordance with the design and quality of an active layer. The external
quantum efficiency is determined in accordance with a degree where a photon
produced in an active layer is emitted to the outside of a light emitting device.
Referring to Fig. 30 in which a conventional light emitting device is shown, a side
surface of a semiconductor layer is formed perpendicular to a horizontal plane. In such
a case, some portions of photons are not penetrated through the side surface of the
semiconductor layer but reflected thereon, and totally reflected light is not emitted to
the outside but dissipated within the light emitting device. However, referring to Fig.
31 in which a light emitting device according to the present invention is shown, a side
surface of a semiconductor layer is not perpendicular to but inclined at a predetermined
slope from a horizontal plane. In such a case, the inclined side surface makes a critical
angle of light change to help the light to be more easily extracted. Therefore, light
generated in an active layer is not totally reflected but emitted to the outside of the

light emitting device such that external quantum efficiency can be markedly enhanced.
[126] Although the present invention has been described in detail in connection with the
specific embodiments, it will be readily understood by those skilled in the art that
various modifications and changes can be made thereto within the technical spirit and
scope of the present invention. It is also apparent that the modifications and changes
fall within the scope of the present invention defined by the appended claims.
[127]
[128]

WE CLAIM :
1. A light emitting device, comprising:
a plurality of light emitting cells each including an N-type semiconductor
layer (20) and a P-type semiconductor layer (40) formed on a portion of the N-
type semiconductor layer (20) on a substrate (10), wherein the plurality of light
emitting cells are spaced apart each other,
wherein the N-type semiconductor layer (20) of one light emitting cell and
the P-type semiconductor layer (40) of another adjacent light emitting cell are
connected to each other, and a side surface including the N-type (40) or P-type
semiconductor layer (20) of the light emitting cell has a slope of 20 to 80°from a
horizontal plane.
2. The light emitting device as claimed in claim 1, comprising a wire (60 or
80) for connecting the N-type semiconductor layer (40) of one light emitting cell
and the P- type semiconductor layer (20)of another adjacent light emitting cell.
3. The light emitting device as claimed in claim 1 or 2, comprising a
transparent electrode layer (85) on the P-type semiconductor layer (20).
4. The light emitting device as claimed in claim 1 or 2, comprising P-type
and N-type ohmic metal layers (87) containing Cr or Au on the P-type (20) and N-
type semiconductor layers (40), respectively.

5. A light emitting device, comprising:
a substrate (110) formed with a plurality of light emitting cells each
including an N- type semiconductor layer (120) and a P-type semiconductor
layer (140) formed on the N-type semiconductor layer (120); and
a submount substrate (200) flip-chip bonded onto the substrate (110),
wherein the plurality of light emitting cells are spaced apart each
other,wherein the N-type semiconductor layer (120) of one light emitting cell
and the P-type semiconductor layer (140) of another adjacent light emitting cell
are connected to each other, and a side surface including at least the P-type
semiconductor layer (140) of the light emitting cell has a slope of 20 to 80°from
a horizontal plane.
6. The light emitting device as claimed in claim 5, comprising a wire (160)
for connecting the N-type semiconductor layer (120) of one light emitting cell and
the P- type semiconductor layer (140) of another adjacent light emitting cell.
7. A method of manufacturing a light emitting device, comprising the steps
of:
sequentially forming N-type and P-type semiconductor layers (20, 40) on a
substrate (10);
forming an etching mask pattern, of which side surface is not perpendicular
to but inclined at a predetermined slope from a horizontal plane, on the P-type

semiconductor layer (40), such that a side surface of the P-type semiconductor
layer (40) of the light emitting cell has a slope of 20 to 80° from a horizontal
plane;
removing the etching mask pattern and the P-type semiconductor layer (40)
exposed through the etching mask pattern;
removing a portion of the N-type semiconductor layer (20) exposed
through the removal of the P-type semiconductor layer (40) to form a plurality of
light emitting cells which are spaced apart each other; and.
connecting the N-type semiconductor layer (20) of one light emitting cell
and the P- type semiconductor layer (40) of another adjacent light emitting cell
through a conductive wire (60 or 80).
8. The method as claimed in claim 7, comprising the step of flip-chip
bonding the substrate (10) onto an additional submount substrate (200) after the
step of removing the P-type semiconductor layer (40) and the etching mask
pattern.
9. The method as claimed in claim 8, comprising the steps of:
removing a portion of the N-type semiconductor layer (20) exposed due to
the removal of the P-type semiconductor layer (40) to form a plurality of light
emitting cell; and
connecting the N-type semiconductor layer (20) of one light emitting cell
and the P- type semiconductor layer (40) of another adjacent light emitting cell

through a conductive wire (60 or 80), after the step of removing the P-type
semiconductor layer (40) and the etching mask pattern.
10. The method as claimed in claim 7 or 9, wherein the step of forming the
plurality of light emitting cells comprises the steps of:
forming an etching mask pattern, of which side surface is not perpendicular
to but inclined at a predetermined slope from a horizontal plane, on the P-type
semiconductor layer (40);
removing the N-type and P-type semiconductor layers (20, 40) exposed
through the etching mask pattern to form a plurality of light emitting cells; and
removing the etching mask pattern.
11. The method as claimed in claim 7 or 9, wherein the N type semiconductor
layer (20) of one light emitting cell and the P type semiconductor layer (40) of
another adjacent light emitting cell are connected with the conductive wire (60 or
80) through a bridge or step coverage process.
12. The method as claimed in any one of claims 7 to 9, wherein a photoresist
with a thickness of 3 to 50D is used in the step of forming the etching mask
pattern.
13. The method as claimed in claim 12, wherein the step of forming the
etching mask pattern comprises the steps of:

applying the photoresist onto the P-type semiconductor layer (40);
light exposing the photoresist in accordance with a predetermined mask
pattern; and
developing the light-exposed photoresist without a baking process after the
light exposure.
14. The method as claimed in claim 12, wherein the step of forming the
etching mask pattern comprises the steps of:
applying the photoresist onto the P-type semiconductor layer (40);
light exposing the photoresist in accordance with a predetermined mask
pattern; hard baking the light-exposed photoresist at a temperature of 100 to
1400C; and developing the hard-baked photoresist.
15. The method as claimed in claim 7, comprising the steps of:
after the step of removing the P-type semiconductor layer (40) and the
etching mask pattern,
removing a rear surface of the substrate (10) at a certain thickness; and
depositing Al, Ti, Ag, W, Ta, Ni, Ru or an alloy thereof onto the rear
surface of the substrate (10).



Abstract


Light Emitting Device And Method
Of Manufacturing The Same
The present invention provides a light emitting device and a method of
manufacturing the light emitting device. According to the present invention, the light
emitting device comprises a substrate, an N-type semiconductor layer (20) formed on
the substrate, and a P-type semiconductor layer (40) formed on the N-type
semiconductor layer (20), wherein a side surface including the N-type or P-type
semiconductor layer has a slope of 20 to 80° from a horizontal plane. Accordingly,
there is an advantage in that the characteristics of a light emitting device such as
luminous efficiency, external quantum efficiency and extraction efficiency are
enhanced and the reliability is secured such that light with high luminous intensity
and brightness can be emitted.

Documents:

04915-kolnp-2007-abstract.pdf

04915-kolnp-2007-claims.pdf

04915-kolnp-2007-correspondence others.pdf

04915-kolnp-2007-description complete.pdf

04915-kolnp-2007-drawings.pdf

04915-kolnp-2007-form 1.pdf

04915-kolnp-2007-form 3.pdf

04915-kolnp-2007-form 5.pdf

04915-kolnp-2007-international publication.pdf

04915-kolnp-2007-international search report.pdf

4915-KOLNP-2007-(03-02-2014)-ABSTRACT.pdf

4915-KOLNP-2007-(03-02-2014)-CLAIMS.pdf

4915-KOLNP-2007-(03-02-2014)-CORRESPONDENCE.pdf

4915-KOLNP-2007-(03-02-2014)-DESCRIPTION (COMPLETE).pdf

4915-KOLNP-2007-(03-02-2014)-DRAWINGS.pdf

4915-KOLNP-2007-(03-02-2014)-FORM-2.pdf

4915-KOLNP-2007-(03-02-2014)-FORM-3.pdf

4915-KOLNP-2007-(03-02-2014)-FORM-5.pdf

4915-KOLNP-2007-(03-02-2014)-OTHERS.pdf

4915-KOLNP-2007-(03-02-2014)-PA.pdf

4915-KOLNP-2007-(03-02-2014)-PETITION UNDER RULE 137.pdf

4915-KOLNP-2007-(10-06-2014)-CORRESPONDENCE.pdf

4915-KOLNP-2007-(10-06-2014)-FORM-13-1.1.pdf

4915-KOLNP-2007-(10-06-2014)-FORM-13.pdf

4915-KOLNP-2007-(10-06-2014)-OTHERS.pdf

4915-KOLNP-2007-(10-06-2014)-PA.pdf

4915-KOLNP-2007-(10-07-2014)-CORRESPONDENCE.pdf

4915-KOLNP-2007-(10-07-2014)-OTHERS.pdf

4915-KOLNP-2007-(16-04-2013)-CORRESPONDENCE.pdf

4915-KOLNP-2007-(16-04-2013)-OTHERS.pdf

4915-KOLNP-2007-(24-03-2014)-CORRESPONDENCE.pdf

4915-KOLNP-2007-(24-03-2014)-FORM-1.pdf

4915-KOLNP-2007-(24-03-2014)-FORM-13-1.1.pdf

4915-KOLNP-2007-(24-03-2014)-FORM-13-1.2.pdf

4915-KOLNP-2007-(24-03-2014)-FORM-13-1.3.pdf

4915-KOLNP-2007-(24-03-2014)-FORM-13-1.4.pdf

4915-KOLNP-2007-(24-03-2014)-FORM-13.pdf

4915-KOLNP-2007-(24-03-2014)-FORM-5.pdf

4915-KOLNP-2007-(24-03-2014)-PA.pdf

4915-KOLNP-2007-(31-07-2014)-ABSTRACT.pdf

4915-KOLNP-2007-(31-07-2014)-CORRESPONDENCE.pdf

4915-KOLNP-2007-(31-07-2014)-FORM-1.pdf

4915-KOLNP-2007-(31-07-2014)-FORM-2.pdf

4915-KOLNP-2007-(31-07-2014)-FORM-3.pdf

4915-KOLNP-2007-(31-07-2014)-FORM-5.pdf

4915-KOLNP-2007-(31-07-2014)-PA.pdf

4915-KOLNP-2007-ASSIGNMENT-1.1.pdf

4915-KOLNP-2007-ASSIGNMENT.pdf

4915-KOLNP-2007-CORRESPONDENCE OTHERS 1.1.pdf

4915-KOLNP-2007-CORRESPONDENCE OTHERS 1.2.pdf

4915-KOLNP-2007-CORRESPONDENCE.pdf

4915-KOLNP-2007-EXAMINATION REPORT.pdf

4915-KOLNP-2007-FORM 13.pdf

4915-KOLNP-2007-FORM 18.pdf

4915-KOLNP-2007-GPA.pdf

4915-KOLNP-2007-GRANTED-ABSTRACT.pdf

4915-KOLNP-2007-GRANTED-CLAIMS.pdf

4915-KOLNP-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

4915-KOLNP-2007-GRANTED-DRAWINGS.pdf

4915-KOLNP-2007-GRANTED-FORM 1.pdf

4915-KOLNP-2007-GRANTED-FORM 2.pdf

4915-KOLNP-2007-GRANTED-FORM 3.pdf

4915-KOLNP-2007-GRANTED-FORM 5.pdf

4915-KOLNP-2007-GRANTED-SPECIFICATION-COMPLETE.pdf

4915-KOLNP-2007-INTERNATIONAL PUBLICATION.pdf

4915-KOLNP-2007-OTHERS.pdf

4915-KOLNP-2007-PETITION UNDER RULE 137.pdf

4915-KOLNP-2007-REPLY TO EXAMINATION REPORT.pdf

abstract-04915-kolnp-2007.jpg


Patent Number 262563
Indian Patent Application Number 4915/KOLNP/2007
PG Journal Number 35/2014
Publication Date 29-Aug-2014
Grant Date 28-Aug-2014
Date of Filing 18-Dec-2007
Name of Patentee SEOUL VIOSYS CO. LTD.
Applicant Address 65-16, SANDAN-RO 163 BEONG-GIL, DANWAN-GU, ANSAN-SI, GYEONGGI-DO 425-851
Inventors:
# Inventor's Name Inventor's Address
1 LEE, Jong Lam E-1401, PROFESSOR DORMITORY 756, JIGOK-DONG, NAM-GU, POHANG 790-390
2 YOON, Yeo Jin 101-1505, SUPSOK MAEUL APT, SA 1-DONG, SANGNOK-GU, ANSAN , 426-738
3 HWANG, Eu Jin 303, 1569-7 JEONGWANG-DONG, SIHEUNG- 429-856
4 KIM, Dae Won 101-506, SUNGWON APT, SSANGMUN 4-DONG, DOBONG-GU, SEOUL 132-749
5 LEE, Jae Ho 309-1405, LG 3-CHA VILLAGE APT,SEONGBOK-DONG, YONGIN 448-531
PCT International Classification Number H01L 33/00
PCT International Application Number PCT/KR2006/002427
PCT International Filing date 2006-06-22
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10-2005-0053797 2005-06-22 Republic of Korea
2 10-2005-0055179 2005-06-24 Republic of Korea
3 10-2006-0021801 2006-03-08 Republic of Korea