U.S. patent application number 13/195279 was filed with the patent office on 2011-12-01 for photonic structures for efficient light extraction and conversion in multi-color light emitting diodes.
This patent application is currently assigned to THE REGENTS OF THE UNIVERSITY OF CALIFORNIA. Invention is credited to Aurelien J. F. David, Frederic S. Diana, Pierre M. Petroff, Claudr C.A. Weisbuch.
Application Number | 20110291130 13/195279 |
Document ID | / |
Family ID | 37947351 |
Filed Date | 2011-12-01 |
United States Patent
Application |
20110291130 |
Kind Code |
A1 |
Diana; Frederic S. ; et
al. |
December 1, 2011 |
PHOTONIC STRUCTURES FOR EFFICIENT LIGHT EXTRACTION AND CONVERSION
IN MULTI-COLOR LIGHT EMITTING DIODES
Abstract
A high efficiency light emitting diode (LED) comprised of a
substrate, a buffer layer grown on the substrate (if such a layer
is needed), a first active region comprising primary emitting
species (PES) that are electrically-injected, a second active
region comprising secondary emitting species (SES) that are
optically-pumped by the light emitted from the PES, and photonic
crystals, wherein the photonic crystals act as diffraction gratings
to provide high light extraction efficiency, to provide efficient
excitation of the SES, and/or to modulate the far-field emission
pattern.
Inventors: |
Diana; Frederic S.; (Santa
Clara, CA) ; David; Aurelien J. F.; (Palo Alto,
CA) ; Petroff; Pierre M.; (Santa Barbara, CA)
; Weisbuch; Claudr C.A.; (Paris, FR) |
Assignee: |
THE REGENTS OF THE UNIVERSITY OF
CALIFORNIA
Oakland
CA
|
Family ID: |
37947351 |
Appl. No.: |
13/195279 |
Filed: |
August 1, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12845308 |
Jul 28, 2010 |
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13195279 |
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11251365 |
Oct 14, 2005 |
7768023 |
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12845308 |
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Current U.S.
Class: |
257/89 ; 257/98;
257/E33.073; 438/29 |
Current CPC
Class: |
B82Y 20/00 20130101;
G02B 2006/1213 20130101; H01L 2933/0083 20130101; H01L 33/502
20130101; H01L 33/20 20130101 |
Class at
Publication: |
257/89 ; 257/98;
438/29; 257/E33.073 |
International
Class: |
H01L 33/58 20100101
H01L033/58; H01L 33/02 20100101 H01L033/02 |
Claims
1. A phosphor that is patterned with one or more photonic
crystals.
2. The phosphor of claim 1, wherein the photonic crystals are
patterned to extract light emitted by the phosphor.
3. The phosphor of claim 2, wherein the phosphor is positioned on
or above a light emitting diode (LED) and the phosphor emits the
light when optically-pumped by light emitted by the LED.
4. The phosphor of claim 3, wherein the photonic crystals are
patterned to extract the light emitted by the LED.
5. The phosphor of claim 4, wherein the photonic crystals are
patterned for extracting total internal reflection (TIR) or
waveguided (WG) modes of the light emitted by the phosphor and the
LED.
6. The phosphor of claim 5, wherein the phosphor is positioned
relative to a low refraction index layer to prevent coupling of the
phosphor's evanescent waves to the TIR or WG modes of the light
emitted by the LED or the phosphor.
7. The phosphor of claim 5, wherein the photonic crystals are
one-dimensional (1D) gratings having a periodicity, such that the
TIR or WG modes of the LED light emitted by the LED, or the light
emitted by the phosphors, are diffracted at angles nearly parallel
to the LED's layers, so that the diffracted light propagates nearly
in-plane in the phosphor.
8. The phosphor of claim 5, further comprising means for confining
or thinning one or more layers containing the TIR or WG modes, in
order to increase the TIR or WG modes' overlap with the photonic
crystals.
9. The phosphor of claim 3, further comprising a plurality of the
phosphors, wherein different ones of the phosphors are positioned
on different regions of the LED to form multi-color pixels, and
each type of pixel in the multi-color pixels has a different
photonic crystal to obtain homogeneous efficiency and
directionality for all colors.
10. The phosphor of claim 3, wherein the photonic crystals increase
excitation of the phosphors by the light emitted by the LED.
11. The phosphor of claim 3, wherein the photonic crystals are
one-dimensional (1D) gratings that diffract differently different
components of the light emitted by the LED or the phosphors.
12. The phosphor of claim 3, wherein the photonic crystals are
one-dimensional (1D) gratings integrated at different positions on
the LED, with different orientations, to diffract the light emitted
by the LED or the phosphor in more than one direction.
13. The phosphor of claim 3, wherein the photonic crystals are
two-dimensional (2D) gratings that improve extraction of the light
emitted by the LED or the phosphors in more than one direction.
14. The phosphor of claim 3, wherein the photonic crystals are
fabricated on separate membranes and then are positioned on the
LED.
15. A method of fabricating a phosphor, comprising patterning the
phosphor with one or more photonic crystals.
16. The method of claim 15, wherein the photonic crystals are
patterned to extract light emitted by the phosphor.
17. The method of claim 16, further comprising positioning the
phosphor on or above a light emitting diode (LED) such that the
phosphor emits the light when optically-pumped by light emitted by
the LED.
18. The method of claim 17, wherein the photonic crystals are
patterned to extract the light emitted by the LED.
19. The method of claim 18, wherein the photonic crystals are
patterned for extracting total internal reflection (TIR) or
waveguided (WG) modes of the light emitted by the phosphor and the
LED.
20. The method of claim 19, wherein the phosphor is positioned
relative to a low refraction index layer to prevent coupling of the
phosphor's evanescent waves to the TIR or WG modes of the light
emitted by the LED or the phosphor.
21. The method of claim 19, wherein the photonic crystals are
one-dimensional (1D) gratings having a periodicity, such that the
TIR or WG modes of the LED light emitted by the LED, or the light
emitted by the phosphors, are diffracted at angles nearly parallel
to the LED's layers, so that the diffracted light propagates nearly
in-plane in the phosphor.
22. The method of claim 19, further comprising confining or
thinning one or more layers containing the TIR or WG modes, in
order to increase the TIR or WG modes' overlap with the photonic
crystals.
23. The method of claim 17, further comprising fabricating a
plurality of the phosphors, wherein different ones of the phosphors
are positioned on different regions of the LED to form multi-color
pixels, and each type of pixel in the multi-color pixels has a
different photonic crystal to obtain homogeneous efficiency and
directionality for all colors.
24. The method of claim 17, wherein the photonic crystals increase
excitation of the phosphors by the light emitted by the LED.
25. The method of claim 17, wherein the photonic crystals are
one-dimensional (1D) gratings that diffract differently different
components of the light emitted by the LED or the phosphors.
26. The method of claim 17, wherein the photonic crystals are
one-dimensional (1D) gratings integrated at different positions on
the LED, with different orientations, to diffract the light emitted
by the LED or the phosphor in more than one direction.
27. The method of claim 17, wherein the photonic crystals are
two-dimensional (2D) gratings that improve extraction of the light
emitted by the LED or the phosphors in more than one direction.
28. The method of claim 17, wherein the photonic crystals are
fabricated on separate membranes and then are positioned on the
LED.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims the benefit
under 35 U.S.C. Section 120 of co-pending and commonly-assigned
U.S. Utility application Ser. No. 12/845,308, filed on Jul 28,
2010, by Frederic S. Diana, Aurelien J. F. David, Pierre M.
Petroff, and Claude C. A. Weisbuch, entitled "PHOTONIC STRUCTURES
FOR EFFICIENT LIGHT EXTRACTION AND CONVERSION IN MULTI-COLOR LIGHT
EMITTING DEVICES," attorneys' docket number 30794.142-US-C1
(2005-534-2), which application claims the benefit under 35 U.S.C.
Section 120 of U.S. Utility application Ser. No. 11/251,365, filed
on Oct. 14, 2005, now U.S. Pat. No. 7,768,023, issued Aug. 3, 2010,
by Frederic S. Diana, Aurelien J. F. David, Pierre M. Petroff, and
Claude C. A. Weisbuch, entitled "PHOTONIC STRUCTURES FOR EFFICIENT
LIGHT EXTRACTION AND CONVERSION IN MULTI-COLOR LIGHT EMITTING
DEVICES," attorneys' docket number 30794.142-US-01
(2005-534-1);
[0002] which applications are incorporated by reference herein.
[0003] This application is related to the following co-pending and
commonly-assigned applications:
[0004] U.S. Utility application Ser. No. 11/067,910, filed on Feb.
28, 2005, by Claude C. A. Weisbuch, Aurelien J. F. David, James S.
Speck, and Steven P. DenBaars, entitled "SINGLE OR MULTI-COLOR HIGH
EFFICIENCY LIGHT EMITTING DIODE (LED) BY GROWTH OVER A PATTERNED
SUBSTRATE," attorneys' docket number 30794.122-US-01 (2005-145-1),
now U.S. Pat. No. 7,291,864, issued Nov. 6, 2007;
[0005] U.S. Utility application Ser. No. 11/067,956, filed on Feb.
28, 2005, by Claude C. A. Weisbuch, Aurelien J. F. David, and
Steven P. DenBaars, entitled "HIGH EFFICIENCY LIGHT EMITTING DIODE
(LED) WITH OPTIMIZED PHOTONIC CRYSTAL EXTRACTOR," attorneys' docket
number 30794.126-US-01 (2005-198-1), now U.S. Pat. No. 7,582,910,
issued Sep. 1, 2009;
[0006] U.S. Utility application Ser. No. 11/067,957, filed on Feb.
28, 2005, by Claude C. A. Weisbuch, Aurelien J. F. David, James S.
Speck, and Steven P. DenBaars, entitled "HORIZONTAL EMITTING,
VERTICAL EMITTING, BEAM SHAPED, DISTRIBUTED FEEDBACK (DFB) LASERS
BY GROWTH OVER A PATTERNED SUBSTRATE," attorneys' docket number
30794.121-US-01 (2005-144-1), now U.S. Pat. No. 7,345,298, issued
Mar. 18, 2008; and
[0007] U.S. Utility application Ser. No. 10/938,704, filed Sep. 10,
2004, by Carole Schwach, Claude C. A. Weisbuch, Steven P. DenBaars,
Henri Benisty, and Shuji Nakamura, entitled "WHITE, SINGLE OR
MULTI-COLOR LIGHT EMITTING DIODES BY RECYCLING GUIDED MODES,"
attorneys' docket number 30794.115-US-01 (2004-064-1), now U.S.
Pat. No. 7,223,998, issued May 29, 2007;
[0008] all of which applications are incorporated by reference
herein.
BACKGROUND OF THE INVENTION
[0009] 1. Field of the Invention
[0010] The invention is related to photonic crystals and to light
emitting diodes (LEDs) comprised of multiple-wavelength light
sources such as phosphors.
[0011] 2. Description of the Related Art
[0012] By analogy to atomic or molecular crystals, a photonic
crystal can be described as a material or system presenting a
spatial modulation of its index of refraction or dielectric
permittivity. The modulation can be periodic, quasi-periodic, or
only possess a short-range order. The periodicity of the lattice,
when applicable, which can be one-dimensional (1D), two-dimensional
(2D), or three-dimensional (3D), usually scales with the visible to
infrared wavelengths for most applications. A distributed Bragg
reflector (DBR) is the archetype of the 1D photonic crystal. DBRs
present band structures analogous to that of electrons in crystals,
with forbidden energies or photonic gaps, where there is no
possibility for a photon to propagate. Defects can be introduced in
the lattice to form photonic cavities or waveguides (these defects
introduce states in the photonic bandgap which allow strongly
localized modes, or light propagation, at the corresponding
frequency). Photonic crystals have given rise to numerous
applications in optoelectronic and photonic integrated devices.
[0013] A light emitting diode (LED) is a semiconductor device that
emits light when electrically biased in the forward direction,
which is known as electroluminescence (EL). An LED is usually
comprised of two layers of a semiconducting material. One layer is
doped with impurities to make it n-doped (i.e., with mobile
electrons), while the other layer is doped with another type of
impurities to make it p-doped (i.e., with mobile holes). This forms
a structure called a p-n junction. When forward biased, electrons
are injected into the junction from the n-region and holes are
injected from the p-region. The electrons and holes release energy
in the form of photons as they recombine. The wavelength of light,
and therefore its color, depends on the bandgap energy of the
materials forming the p-n junction. Very thin active layers of
smaller band-gap materials, as compared to the p and n layers,
referred to as quantum wells (QWs), can be introduced between the p
and n layers to greatly increase the overall efficiency of the LEDs
and vary the wavelength of emitted light.
[0014] Semiconductor materials quality has improved, mainly due to
the improvements of their synthesis or growth techniques over the
past two decades, namely molecular beam epitaxy (MBE),
metal-organic chemical vapor deposition (MOCVD), liquid phase
epitaxy (LPE), etc. The external quantum efficiency of
semiconductor devices has then greatly improved, and new wavelength
ranges have been obtained. Nitride compounds (GaN and related
alloys AlGaN and InGaN) are now efficient emitters for violet and
blue light, giving .about.30 lumens/watt for commercially available
LEDs, while phosphide (AlGaInP) and arsenide (GaAs/AlGaAs)
compounds are widely used for red and infrared applications,
producing .about.30 lumens/watt for commercially available LEDs.
LEDs are nearly as efficient as fluorescent tubes, but only in blue
and red wavelength ranges.
[0015] The green-yellow portion of the visible spectrum is thus
still lacking efficiency, while the combination of different colors
on a single substrate (for example, as required in RGB pixels for
color display applications, for white light emission, or for any
other colored light generation requiring color mixing) is very
limited with the semiconductors grown by the conventional methods
mentioned previously. Alternative materials should be used, and
phosphors can offer good solutions.
[0016] A phosphor is a material that can produce light after its
excitation via the absorption of energy from an external source.
The excitation source may comprise a sufficiently high-energy light
beam produced by an LED. The generation of light by the phosphor
from absorbed light is called photoluminescence (PL), also referred
to as fluorescence.
[0017] Phosphors can be made of inorganic materials (garnets with
rare earths), light emitting molecules or polymers, or
semiconductor nanocrystal quantum dots (NQDs). The II-VI and III-V
NQD systems offer both high absorption coefficients (and thus short
absorption lengths) in the ultraviolet (UV) and blue ranges, and
the possibility of changing the effective index of refraction by
changing the matrix in which these NQDs are embedded (for example,
SiO.sub.2, TiO.sub.2, or polymer and resins), without modifying the
QD internal emission properties (center wavelength and width of
emission band).
[0018] In the following, the term "phosphor" is used to represent
any type of material performing light conversion, independently of
its real nature (inorganic materials, light emitting molecules or
polymers, colloidal quantum dots, or any other type of light
emitting nanoparticles).
[0019] There are two basic combination schemes involving phosphors
and LEDs: [0020] (1) Blue-emitting LED combined with phosphors.
This solution is currently used to produce white LEDs by combining
blue emitting LEDs (in the GaN/InGaN system) with yellow
photoluminescent phosphors. Color rendering, mixing, the different
directionalities of the LED (directional) and phosphors (isotropic)
emissions, and the overall efficiency of such devices are the most
important issues related to this scheme. [0021] (2) A UV-emitting
LED combined with phosphors. In general, this method can provide
both better color rendering and isotropy than (1), or better white
equilibrium. However, the overall efficiency is still low.
[0022] These methods can produce a wide range of colors, from the
blue to the red, and thus provide a solution for the low-cost
fabrication of RGB displays, because phosphors can be positioned
precisely to form the different pixels.
[0023] FIG. 1 illustrates a conventional EL-PL multi-color
structure 100 that includes a phosphor layer 102, also known as
secondary emitting species (SES) 102, coating the top of an LED
104, which includes a primary emitting species (PES) 106, a buffer
layer 108, a substrate 110 and metal contacts 112 connected to a
power supply 114. When forward biased, electrons (e.sup.-) are
injected into the p-n junction of the PES 106 from the n-region and
holes (h.sup.+) are injected from the p-region, wherein the
electrons and holes cause the PES 106 to release energy in the form
of photons 118 as they recombine. The SES 102 are optically-excited
116 after partly or fully absorbing directly extracted light 118
produced by the electrically-pumped PES 106. The absorption by the
SES 102 occurs due to the presence of allowed electronic
transitions in resonance with the PES 106 photon energies. The SES
102 then re-emits photons 116 of lower energies, or longer
wavelengths, upon relaxation to their ground states. This PL by the
SES 102 is used for display or lighting, sometimes in combination
with the light emitted by the PES 106. This emission scheme is also
referred to as light conversion.
[0024] For this structure to be highly efficient, the following
requirements should be met: [0025] it should be comprised of
emitting species with high internal quantum efficiencies (defined
as the ratio of the total emitted light intensity to the total
absorbed light intensity), [0026] it should maximize the extraction
of both PES and SES emissions (possibly in different directions),
and [0027] it should maximize the absorption of the PES emission by
the SES.
[0028] However, one of the major difficulties with such
semiconductor-based structures is caused by the loss of large
portions of both PES and SES light emissions due to total internal
reflexion (TIR), as shown schematically in FIGS. 2A, 2B and 2C.
[0029] FIG. 2A illustrates a device 200 comprised of a
semiconductor (dielectric) substrate 202 having planar layers with
a high index of refraction (n) and including PES 204. Above the
device 200 is an outer medium 206 (air or an epoxy layer) with a
low n. Extracted emissions 208 from the PES 204 towards the outer
medium 206 are shown, as are lost emissions 210 towards the
substrate 202. Total internal reflections (TIR) 212 are also shown,
which result in a lowest-order waveguided (WG) mode 214, also known
simply as a guided mode, through the thin layers of the substrate
202.
[0030] When light is emitted within the planar layers of the
substrate 202 with high values of n, only a limited cone of beams
can be directly extracted upwards 208 into the outer medium 206.
This "escape cone" defines the portion of a solid angle associated
with directions of possible direct extraction 208. The escape
cone's opening half-angle will be referred to as .theta..sub.c in
the following (.theta..sub.c=arcsin(n.sub.out/n.sub.in)). The
higher the difference in indices of refraction, the smaller
.theta..sub.c, the narrower the escape cone.
[0031] The TIR modes 212, which remain trapped in the optically
dense (high index) materials of the substrate 202, are mainly lost,
due to internal re-absorption and non-radiative relaxation
mechanisms, while sometimes escaping through the sides of the
device 200. As WG modes 214, these can represent more than 50% of
the overall emission by the PES 204, which are embedded in these
high index layers. This loss mechanism is detrimental to the
maximization of the extraction of the PES 204 emission.
[0032] When phosphors 216 (with a lower index) are placed on top of
the optically dense layers 202 (with a higher index), a large part
of their emissions 208 is also waveguided 214 inside the high index
layers, as shown in FIGS. 2B and 2C, wherein 208a is emitted light
directly extracted and absorbed by the phosphors 216, 208b is the
PL emitted from the phosphors 216, 214a is a lower-order excitation
WG mode and 214b is a higher-order excitation WG mode.
[0033] Indeed, electric dipoles, located sufficiently close to a
high index layer, always exhibit emissions comprised of evanescent
waves, which can efficiently couple to TIR modes. This is shown in
the device 300 of FIG. 3A, which includes an electric dipole 302 as
a source emitting at .lamda..sub.0, close to a dense planar medium
304 (where n.sub.in>n.sub.out), i.e., at a distance d typically
smaller than .lamda..sub.0, and producing evanescent waves 306,
which couple to TIR or WG modes 308 inside the high index layer
304.
[0034] FIG. 3B shows dipole emission diagrams for an horizontal and
a vertical dipole in a medium with n=1.5 close to a planar cavity
of n=2.5. Air is present above the structure, while a substrate
with n=1.7 was chosen to be included in the bottom of the
structure. The diagrams show the different contributions that
combine to produce the dipoles emission: directly extracted light
in air (k.sub..parallel./k.sub.0<1), TIR
(1<k.sub..parallel./k.sub.0<1.7), and WG modes
(k.sub..parallel./k.sub.0>1.7) are present, wherein k.sub.0 is
the wavevector of light in a vacuum and k.sub..parallel. is the
in-plane component of the wavevector of light for the medium 304.
FIG. 3C is a schematic illustrating the multilayer chosen for these
simulations.
[0035] The closer the emitting dipoles 302 are to the denser planar
medium 304, the larger the fraction of evanescent waves 306
(>50% of the overall emission for dipoles located in the
vicinity of the interface, d<100 nm), and therefore of the TIR
modes in the denser planar medium 304. It should be mentioned that
near the interface, the 1D Purcell factor is not negligible and can
reach 1.6 for these structures. This factor corresponds to the
increase of the spontaneous emission rate k.sub.r of the SES, with
the internal quantum efficiency given by
.eta..sub.int=k.sub.r/(k.sub.r+k.sub.nr) for most light-emitting
materials, with k.sub.nr the non-radiative recombination rate. NQDs
can offer sufficiently high absorption coefficients such that the
PES light can be absorbed within a few hundreds of nanometers,
corresponding to the region of high Purcell factor.
[0036] With current state-of-art multi-color LEDs, the TIR or WG
light is usually lost, and this accounts in a large part for the
limited external efficiency of LEDs. The reduced overall
efficiencies cause the devices to overheat, because higher applied
voltages are necessary to compensate for the losses, and materials
degradation is faster.
[0037] Furthermore, the phosphors that are commonly used
(rare-earth garnets) are limited by the concentration of emitting
ions, implying the LEDs to be coated with thick epoxy and phosphors
mixtures (typically 1 mm in height or more), often in the form of a
half-sphere to out-couple some TIR modes. These large dimensions in
turn imply a reduction of brightness, and obviously of compactness,
of the device.
[0038] There is a need in the art for improving the far-field
patterns of the different components of emission (QWs, phosphors),
which make the color rendering angle-dependent: for example, white
light LEDs produced by combining blue QWs and yellow phosphors
appear bluish in the middle and yellow in the outer regions of the
far-field pattern (the color-rendering is not isotropic).
[0039] For these reasons, there is a need in the art for improving
multi-color LEDs characteristics.
SUMMARY OF THE INVENTION
[0040] The present invention discloses design principles for and
examples of high efficiency, bright, light emitting diodes (LEDs)
emitting at various wavelengths by use of several emitting species
and optimized photonic crystals. The LED is comprised of a
substrate, a buffer layer grown on the substrate (if such a layer
is needed), a first active region comprising primary emitting
species (PES) that are electrically-injected, a second active
region comprising secondary emitting species (SES) that are
optically-pumped by the light emitted from the PES, and photonic
crystals that extract waveguided modes emitted by the PES to
optically pump the SES. The photonic crystals, acting as
diffraction gratings, provide high light extraction efficiency,
efficient excitation of the SES, and/or ways to design the
far-field emission pattern for optimal shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Referring now to the drawings in which like reference
numbers represent corresponding parts throughout:
[0042] FIG. 1 illustrates a conventional
electroluminescence-photoluminescence multi-color LED structure,
wherein phosphors or secondary emitting species (SES) are
optically-pumped by a semiconductor light-emitting diode comprising
electrically-pumped light primary emitting species (PES).
[0043] FIG. 2A illustrates device structure where total internal
reflection (TIR) modes (represented as a single waveguided mode)
are lost in conventional devices, while FIGS. 2B and 2C illustrate
a conventional structure showing the two emitting species and the
TIR involved for both of them.
[0044] FIGS. 3A, 3B, and 3C illustrate coupling of evanescent waves
produced by an external electric dipole source to propagating and
TIR or WG modes inside the nearby high index planar layers.
[0045] FIGS. 4A and 4B illustrate evanescent WG mode excitation of
phosphors, wherein the effect is enhanced by concentrating as much
as possible the field near the interface semiconductor/phosphor
layers, by using an intermediate layer of a smaller index of
refraction.
[0046] FIG. 5A illustrates a structure that includes a buffer
layer, a first active region including a PES, photonic crystal or
grating, and a second active layer including a SES, whereas FIGS.
5B and 5C are graphs that illustrate a complex dispersion
relationship (reduced frequency vs. reduced in-plane wavevector) of
a WG mode in a planar cavity modulated by a grating on its surface,
as shown in the schematic of FIG. 5A.
[0047] FIG. 6 is a scanning electron microscope (SEM) image that
shows a 165 nm periodicity, 180 nm deep, 1D grating etched in a 2
.mu.m-thick GaN buffer layer MOCVD-grown on top of a sapphire
substrate, wherein the GaN buffer also contains InGaN QWs as
PES.
[0048] FIGS. 7A and 7B illustrate the structure of an LED, while
FIGS. 7C and 7D are plots of two angular resolved PL measurements
of the LED.
[0049] FIGS. 8A and 8B are plots that show measured modal
dispersion relationships (reduced frequency vs. reduced in-plane
wavevector) deduced from measured angular spectrum of FIG. 5C.
[0050] FIG. 9 illustrates a complementary device structure that
combines several gratings or photonic crystals to extract different
WG modes.
[0051] FIGS. 10A and 10B are device structures that illustrate
photon recycling combined with the simultaneous extraction of both
excitation (violet) and phosphors PL (green) WG modes for high
light conversion efficiency.
[0052] FIG. 11 is a device structure that illustrates photon
recycling combined with the simultaneous extraction of both PES and
SES WG modes for high light conversion efficiency, with
intermediate layers for the improved coupling of the TIR or WG
modes to the photonic crystals.
[0053] FIG. 12 is a flowchart illustrating the steps performed in
the fabrication of a device according to a preferred embodiment of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0054] In the following description of the preferred embodiment,
reference is made to the accompanying drawings which form a part
hereof, and in which is shown by way of illustration a specific
embodiment in which the invention may be practiced. It is to be
understood that other embodiments may be utilized and structural
changes may be made without departing from the scope of the present
invention.
Overview
[0055] The present invention describes new multiple-light sources
LEDs that provide increased light extraction and conversion
efficiencies, as well as increased brightness, while retaining
planar structures. The LEDs contain several emitting species, each
providing light emission in a range of wavelengths. Some of the
species are electrically-pumped, while other species are
optically-pumped. Photonic crystals, acting as diffraction
gratings, ensure efficient light extraction, efficient excitation
of the optically-pumped species, and/or provide with a means for
modifying the far-field emission pattern.
[0056] The LED is comprised of a substrate, a buffer layer grown on
the substrate (if such a layer is necessary), a first active region
including electrically-pumped PES, photonic crystals acting as
diffraction gratings, and a second active region including
optically-pumped SES. The SES absorbs part of the light emitted by
the PES, and then re-emits light at a different wavelength range or
at several ranges of wavelengths if multiple emitting species are
combined in the SES. The LED may, for example, act as a white light
source. In order to overcome the problem of light extraction, one
or more photonic crystals can be included (for instance, at the
interface between the two emitting species). These gratings can
diffract light emitted in the TIR modes, thereby enhancing overall
light extraction. They can also increase excitation of the SES by
enhancing their interaction with the light emitted by the PES. The
gratings may act on either one or all of the emitted wavelengths,
possibly with different effects on the overall efficiency and
far-field emission patterns.
[0057] If the SES layer is placed on top of the high index layers,
the photonic crystals are used as extractors for all TIR or WG
cavity modes. If the SES layer is placed away from the high index
layers, for example, using a membrane and an air gap, or a very low
index intermediate layer between the SES and the high index layers,
two photonic crystals may be used: one on top of the high index
layers to extract the PES WG modes and one in the SES layers in
order to scatter the WG modes induced in this layer as well. The
depth of the photonic crystals can then be modified to increase the
fraction of light which is emitted upwards. The pitch and basis of
the photonic crystals are used to control the far-field emission
pattern.
Technical Description
[0058] In current structures, the excitation of the SES by the
emission of the PES cannot be highly efficient because only a small
part of the PES light is directly extracted, e.g., on the order of
10%. The required extraction of the TIR modes generates numerous
novel ideas for the improvement of phosphors light conversion
efficiency.
[0059] One approach is described in U.S. Utility application Ser.
No. 10/938,704, filed Sep. 10, 2004, by Carole Schwach, Claude C.
A. Weisbuch, Steven P. DenBaars, Henri Benisty, and Shuji Nakamura,
entitled "WHITE, SINGLE OR MULTI-COLOR LIGHT EMITTING DIODES BY
RECYCLING GUIDED MODES," attorneys' docket number 30794.115-US-01
(2004-064-1), now U.S. Pat. No. 7,223,998, issued May 29, 2007,
which application is incorporated by reference herein. This
application focuses on the problem of light extraction from LEDs
without phosphors, due to the efficient conversion of the TIR modes
of a thin LED structure to WG modes.
[0060] The present invention, on the other hand, is directed to
efficiency, color rendering, and brightness issues with
phosphors-on-LED. The key to extract all TIR modes, increase the
absorption of the PES emission by the SES, and re-distribute the
far-field PES and SES emission pattern, lies in the 3D engineering
of the index of refraction of the films constituting the device.
The typical building-blocks of photonic devices should be
considered and implemented: waveguides or planar cavities,
reflectors, gratings, photonic crystals, etc., in combination with
traditional geometric approaches (spherical-shaped phosphor layer,
textured surface, etc.) Brightness and compactness may be improved
by using SES of higher absorption coefficients, i.e., with an
increased concentration of emitting centers or dipoles, such as
emitting molecules or NQDs.
[0061] FIGS. 4A and 4B illustrate WG cavity modes excitation of
phosphors, wherein the effect is enhanced by concentrating as much
as possible the field near the interface semiconductor/phosphor
layers, by using an intermediate layer of a smaller index of
refraction, for example, on top of the buffer layer.
[0062] Specifically, FIG. 4A illustrates a device 400 comprised of
a substrate 402 having a low index, one or more active layers 404,
and a phosphor layer 406. The WG mode 408 leaks into the phosphor
layer 406, resulting in PL emissions 410 from the phosphor layer
406.
[0063] In addition, FIG. 4B shows illustrates a device 412
comprised of a sapphire substrate 414 with n=1.8, a 2 .mu.m thick
GaN buffer layer 416 with n=2.5, a 500-1000 nm thick AlGaN barrier
layer 418 with n=2.3-2.4, a 100-300 nm thick GaN waveguide layer
420 including QWs 422 with n=2.5, and a 1 .mu.m thick QDs film 424
with n.apprxeq.1.5+0.1, wherein the WG mode 426 leaks into the QDs
film 424. The corresponding indices of refraction (n) are indicated
in the graph 428 to the right of the device 412.
[0064] Such an effect is enhanced by incorporating an intermediate
layer of lower index in the PES layer in order to increase the
excitation of the SES by the PES WG cavity modes, and also by
optimizing the index difference between the two materials. With
such geometry, the SES will emit a large portion of their total
emission into TIR or WG modes of the multilayer structure. Again,
this emission limits the overall efficiency of the device.
[0065] Incorporation of a grating or of a photonic crystal between
the phosphors and the high index layer allows these modes to be
extracted. A single photonic crystal is sufficient to extract both
contributions (from the PES and from the SES), even though a large
energy difference exists between the two luminescence bands, as
illustrated in the following.
[0066] FIG. 5A illustrates a structure 500 that includes a support
structure 502 (such as a buffer layer formed on top of a
substrate), a first active region 504 including one or more PES in
a PES layer that are electrically injected, one or more gratings or
photonic crystals 506, and a second active region 508 including one
or more SES in a SES layer that are optically pumped. Note that the
photonic crystals 506 are formed proximate to the first and second
regions 504 and 508.
[0067] The photonic crystals 506 extract the WG modes 510 emitted
by the PES 504 to optically pump the SES 508. In addition, the
photonic crystals 506, acting as scattering centers or diffraction
gratings, extract the WG modes 510 emitted by the PES 504, extract
the WG modes 512 emitted by the SES 508, which results in
diffracted light 514 being emitted through the SES 508, and control
directionality or isotropy of far-field emission patterns.
[0068] Generally, the photonic crystals 506 comprise one or more
intermediate layers integrated above or below the PES layer 504 or
the SES layer 508. One or more of the intermediate layers may be
textured.
[0069] In one embodiment, the photonic crystals 506 are
one-dimensional (1D) diffraction gratings that provide light
extraction in all directions close to a direction perpendicular to
the gratings. In another embodiment, the photonic crystals 506 are
periodic, quasi-periodic, or short-range ordered two-dimensional
(2D) scattering centers or diffraction gratings that provide
omni-directional light extraction or directional far-field emission
patterns. In yet another embodiment, the photonic crystals 506 are
randomly textured two-dimensional (2D) scattering regions that
provide omni-directional light extraction and isotropic emission
far-field patterns.
[0070] Parameters of the photonic crystals 506 are chosen such that
light extraction is optimized upwards or downwards. Moreover, the
parameters of the photonic crystals 506 may vary across the
LED.
[0071] FIGS. 5B and 5C show the calculated complex dispersion
relationship (reduced frequency vs. reduced in-plane wavevector) of
a WG mode in a multilayer, including a planar cavity, with a
shallow 1D grating on its surface, as shown in the schematic of
FIG. 5A. Dashed lines are the light lines for radiation in air or
in the sapphire substrate. For this WG mode and this device
geometry, both frequencies (corresponding to the excitation light
and to the phosphors PL) can be simultaneously extracted at
different angles. Different frequencies precisely occur in the case
of phosphors on LED.
[0072] Experimental results have established the proof of concept.
A 2 .mu.m-thick GaN buffer layer was grown on a sapphire substrate
by MOCVD and several samples were cut from this wafer. Processing
steps, including holographic exposures, were then performed to form
1D gratings (of various periodicities .LAMBDA.) on the top surface
of the samples, and over large areas. The depths of the gratings
were between 150 and 200 nm, as shown in FIG. 6.
[0073] Specifically, FIG. 6 shows a 165 nm periodicity, 180 nm
deep, 1D grating etched in a 2 .mu.m-thick GaN buffer layer
MOCVD-grown on top of a sapphire substrate. The GaN buffer also
contains InGaN QWs as the PES (not resolved in this SEM image). A 2
.mu.m-thick GaN layer between air and sapphire can theoretically
contain between 10 and 20 WG modes (in the wavelengths range 400 to
800 nm). The gratings were coated with CdSe NQDs (drop cast from
toluene solution), which formed layers approximately 1 .mu.m thick,
after drying.
[0074] FIGS. 7A and 7B illustrate the same multilayer structure 700
that includes CdSe NQD phosphors 702 coating a GaN layer 704
containing InGaN QWs 706 grown by MOCVD on top of a sapphire
substrate 708, and a 1D grating 710 on top of the GaN layer. In
both FIGS. 7A and 7B, a detector 712 is positioned above the
multilayer 700 at an azimuth angle .theta.. The sample is rotated
to present either the grating lines parallel (FIG. 7A) or
perpendicular (FIG. 7B) to the rotation plane of the detector.
[0075] Measurements were performed on the structures of FIGS. 7A
and 7B using two different grating periodicities but with the same
GaN/AlGaN wafer, and the same CdSe NQD phosphors. FIGS. 7C and 7D
show two angular resolved PL measurements, which combine the
different PL spectra collected as a function of the azimuth angle
(far-field emission pattern), after exciting both violet InGaN QWs
and yellow-green NQD phosphors with a UV HeCd laser beam
(.lamda..sub.0=325 nm).
[0076] FIG. 7C shows an angular measurement parallel to the grating
(of periodicity 260 nm) as a reference. Indeed, the grating can
effectively diffract light only in the directions which are near
the perpendicular to the grating lines. Two major bands of emission
can be seen around 410 nm and 520 nm; these are the directly
extracted PL from the InGaN QWs and the NQD phosphors,
respectively. Note the quasi-isotropic shape of the emission aside
from side peaks, which are assigned to scattered light and/or WG
modes escaping from the sides of the sample. Finally, the spectrum
is comprised of a finer structure made of several thinner curves:
these are caused by Fabry-Perot constructive interferences stemming
from the presence of the two interfaces GaN/air and GaN/sapphire,
as well as from the diffraction of WG modes that do not propagate
parallel to the grating lines.
[0077] FIG. 7D shows an angular measurement perpendicular to the
grating. In this case, several closely spaced curved lines clearly
appear in the spectrum on top of the directly extracted PL and
Fabry-Perot modulations. Those lines are the radiative components
of the WG modes which, in the direction perpendicular to the
grating, are produced via diffraction. These lines are labeled as
"diffracted modes" in the following.
[0078] By comparing FIGS. 7C and 7D, since the spectra were
acquired on the same sample and in the same conditions, one can
clearly observe an increase of PL signal in the perpendicular
direction as compared to the parallel one, at almost all
wavelengths and almost all angles. There is, therefore, increased
light extraction of both PES and SES emissions at least in
directions close to the perpendicular to the grating (2D gratings
or photonic crystals will provide omni-directional extraction).
[0079] FIGS. 8A and 8B show modal dispersion relationships (reduced
frequency vs. reduced in-plane wavevector) directly obtained from
the measured angular spectrum of FIG. 5C (because
k.sub..parallel.=k.sub.0 sin .theta.), wherein .LAMBDA.=260 nm in
FIG. 8A, and from another measurement on a similar sample, but with
.LAMBDA.=220 nm, in FIG. 8B. The major difference between the two
plots is that the diffracted modes are simply shifted downwards
when the periodicity decreases, as can be expected from scale
invariance. The change of periodicity modifies the light extraction
and directionalities of the diffracted light from both emissions.
The extraction is more vertical in the case of the larger
periodicity. Finally, it is clear from those two plots that only
sufficiently high-order WG modes (those of low effective index of
refraction) are efficiently diffracted; the high index ones are
localized in the inner part of the GaN layer and do not overlap as
much with the grating as the others.
[0080] These results show that a simple grating can increase the
extraction of both PES and SES emissions. The overall increased PL
of the SES thus stems from two complementary effects. First, the
improved extraction of the PES emission increases the excitation of
the SES, which in turn produces a more intense directly extracted
emission, and secondly, the grating extracts the WG modes induced
by the SES emission into evanescent waves. They also show that a
single grating can redirect parts of the emission in a controllable
way (because the diffracted modes direction only depends on the
geometry of the layers and periodicity of the grating) and allow
compensating for non-isotropic color-rendering issues with current
LEDs.
[0081] From these basic examples, it is possible to generalize the
principles and formulate a number of alternatives and/or
complementary structures:
[0082] [1] The SES layer can be positioned above a low refraction
index layer (air gap or low index dielectric, such as porous
silicon dioxide), thus canceling the coupling of the SES evanescent
waves to TIR substrate modes or WG cavity modes. SES WG modes are
then present inside this layer and not in the high index layers,
where only PES WG modes are propagating. Although this separation
of the phosphor layer from the main substrate suppresses the
Purcell effect, it can allow for a better thermal insulation of the
phosphor layer from the LED substrate, the temperature of which can
increase by 100.degree. C. under operation. This separation implies
the following point.
[0083] [2] More than one 1D grating can be integrated to the
structure, in order to diffract differently the various light
emission components. Another grating can be processed on the top
surface of the phosphor, as shown in FIG. 9, which illustrates a
device 900 that includes a substrate 902, a buffer layer 904 with
first and second gratings 906, 908, the latter also acting as a
confining layer, a PES layer 910, and a phosphor layer 912,
separated from the substrate 902 and buffer layer 904 by an air gap
or a low index dielectric 914. The phosphor layer 912 may include a
surface grating or photonic crystal 916. Moreover, in this figure,
918 comprises the WG modes from the PES layer 910, 920 comprises
the light extracted from the PES layer 920, 922 comprises the WG
modes from the phosphor layer 912 (the SES) and 924 comprises the
light diffracted from the SES.
[0084] Alternatively, a 1D grating can be made with a periodicity
such that the PES WG modes will be diffracted at angles nearly
parallel to the layers. The diffracted light would then propagate
nearly in-plane in the phosphor layer. This would be of interest
since a larger absorption occurs when light can propagate over
longer distances in an absorbing material. In planar devices,
longer distances are available in-plane: a higher absorption of the
PES light by the SES would then be achieved and only thin coatings
of phosphors should be needed.
[0085] Several 1D gratings can be integrated at different positions
with different orientations for each of them to obtain diffraction
in more than one direction.
[0086] [4] 2D photonic crystals acting as 2D diffraction gratings
can be integrated instead of several 1D gratings, improving the
extraction in all directions, while reducing processing complexity.
In turn, more than one 2D photonic crystal can be used to affect
the various light emission components differently. Other
alternatives are available, but the scheme presented above would
still be of practical interest in those new approaches, involving
processes such as Lateral Epitaxy Overgrowth (LEO). (See U.S.
Utility application Ser. No. 11/067,910, filed on Feb. 28, 2005, by
Claude C. A. Weisbuch, Aurelien J. F. David, James S. Speck, and
Steven P. DenBaars, entitled "SINGLE OR MULTI-COLOR HIGH EFFICIENCY
LIGHT EMITTING DIODE (LED) BY GROWTH OVER A PATTERNED SUBSTRATE,"
attorneys' docket number 30794.122-US-01 (2005-145-1), no U.S. Pat.
No. 7,291,864, issued Nov. 6, 2007, which application is
incorporated by reference herein.) The right periodicity can be
chosen as described above to allow both extractions.
[0087] [5] Confining layers can be introduced or substrate removal
techniques applied to effectively thin down the main WG layer, in
order to increase the outside WG mode leak or overlap with the
photonic crystals and/or to possibly take advantage of microcavity
effects. (See U.S. Utility application Ser. No. 11/067,956, filed
on Feb. 28, 2005, by Claude C. A. Weisbuch, Aurelien J. F. David,
and Steven P. DenBaars, entitled "HIGH EFFICIENCY LIGHT EMITTING
DIODE (LED) WITH OPTIMIZED PHOTONIC CRYSTAL EXTRACTOR," attorneys'
docket number 30794.126-US-01 (2005-198-1), now U.S. Pat. No.
7,582,910, issued Sep. 1, 2209, which application is incorporated
by reference herein). The LEO technique could also be applied here
in combination to a surface grating or photonic crystal 914 for the
phosphor layer 910, similar to what is illustrated in FIG. 9.
[0088] [6] More than one emitting species can be included, both as
PES or SES. The method can be applied to the UV or blue PES.
[0089] [7] Different SES can be positioned on different regions of
a device to form multi-color pixels. In turn, for each type of
pixel, a different photonic crystal can be processed to obtain
homogeneous efficiency and directionality for all colors.
[0090] [8] The integration of metallic or dielectric mirrors (such
as distributed Bragg reflectors or DBRs) positioned below or above
the active layers can improve extraction efficiency, as shown in
FIGS. 10A and 10B, which illustrate the use of photon "recycling"
combined with the simultaneous extraction of both PES and SES WG
modes for high light conversion efficiency. The directly extracted
PES light can be redirected to have it perform more than one pass
through the SES layer. This is done by introducing a metallic or
dielectric mirror above the SES layer. Specifically, FIGS. 10A and
10B illustrate devices 1000 that each includes a substrate/buffer
layer 1002, a confining layer 1004, an active layer 1006 including
PES 1008, a grating 1010, phosphor layer 1012 and DBR 1014 for
excitation transparent for the PL of the phosphor layer 1012. In
FIG. 10A, the WG modes 1016, 1018 leak into the phosphor layer
1010, resulting in radiation modes 1020 and modes 1022 reflected by
the mirror 1014. In FIG. 10B, the WG modes 1016, 1018 leak into the
phosphor layer 1010, resulting in lost emission 1024 and modes 1022
reflected by the mirror 1014. The mirrors reflect both the directly
extracted excitation and the radiation induced by the grating or
photonic crystal lights.
[0091] FIG. 11 illustrates how intermediate layers can be included
between the phosphor and the high index layers also in combination
with metallic or dielectric mirrors. Specifically, FIG. 11
illustrates a device 1100 that includes a substrate/buffer layer
1102, a patterned confining layer or DBR 1104, an active layer 1106
including PES 1108 and an air gap or a low index dielectric 1110.
DBRs 1112, 1114, 1116 provide for excitation transparent for the PL
of a phosphor layer 1118. The WG modes 1120 of the PES 1108 leak
1122 into the phosphor layer 1118, resulting in WG modes 1124 for
the phosphor layer 1118 (SES), diffracted SES emissions 1126, and
reflected modes 1128 and modes 1130.
[0092] The integration of metallic or dielectric mirrors also
allows the device to redirect the portions of emitted light which
escape in unwanted directions. This is accomplished by DBRs 1112,
1114, 1116. For example, DBR 1112 is placed below the substrate
1102 to reflect downwards propagating emissions upwards.
[0093] Other mirrors or DBRs can be positioned above and below the
different emitting species in order to form microcavities (i.e.,
planar cavities with thicknesses on the order of one wavelength).
This allows, for instance, the invention to improve the extraction
efficiency and/or modify the directionality of the far-field
emission pattern.
[0094] Direct processing over an active layer can induce defects
and a loss of internal efficiency (for example, InGaN QWs can be
damaged by dry etching). Alternative approaches to avoid the
grating fabrication on the LED surface include:
[0095] [9] Fabrication of some of the photonic crystals on separate
membranes with high index of refraction (for example, on
Si.sub.3N.sub.4 membranes), which would then be positioned on the
LEDs.
[0096] Deposition of a sol-gel film with a high refractive index
(e.g., TiO.sub.2) on the LED surface to fabricate the photonic
crystal and deposit the phosphor film subsequently.
Process Steps
[0097] Finally, FIG. 12 is a flowchart illustrating the steps
performed in the fabrication of a device according to an embodiment
of the present invention.
[0098] Block 1200 represents the step of (optionally) forming a
buffer layer on a substrate.
[0099] Block 1202 represents the step of forming a first active
region layer on the buffer layer (or directly on the substrate, if
the buffer layer is not used), wherein the first active region
layer includes of one or more primary emitting species (PES) in a
PES layer that are electrically-injected.
[0100] Block 1204 represents the step of forming one or more
photonic crystals on the first active region layer. Preferably, the
photonic crystals may comprise one or more intermediate layers
integrated at different positions with different orientations to
obtain diffraction in more than one direction, e.g., above or below
the PES layer or the SES layer. In addition, one or more of the
intermediate layers may be textured.
[0101] In the resulting structure, the photonic crystals, acting as
scattering centers or diffraction gratings, extract evanescent WG
modes emitted by the PES to optically pump the SES, extract the WG
modes emitted by the SES, and control directionality or isotropy of
far-field emission patterns.
[0102] In one embodiment, the photonic crystals are one-dimensional
(1D) diffraction gratings that provide light extraction in all
directions close to a direction perpendicular to the gratings. In
another embodiment, the photonic crystals are periodic,
quasi-periodic, or short-range ordered two-dimensional (2D)
scattering centers or diffraction gratings that provide
omni-directional light extraction or directional far-field emission
patterns. In yet another embodiment, the photonic crystals are
randomly textured two-dimensional (2D) scattering regions that
provide omni-directional light extraction and isotropic emission
far-field patterns.
[0103] Parameters of the photonic crystals may be chosen such that
light extraction is optimized upwards or downwards. Moreover, the
parameters of the photonic crystals may vary across the LED.
[0104] Block 1206 represents the step of forming a second active
region layer on the photonic crystals, wherein the second active
region layer includes of one or more secondary emitting species
(SES) in an SES layer that are optically-pumped.
[0105] Block 1208 represents the step of (optionally) forming
metallic or dielectric mirrors on the device. The mirrors may be
used for redirecting portions of emitted light that escape in
unwanted directions, or the mirrors may be used to recycle light
emitted from the PES or SES. Further, the mirrors may be positioned
above or below the PES layer or the SES layer to form
microcavities.
[0106] Block 1210 represents the step of (optionally) coating the
SES layer with another layer providing air insulation or improved
light extraction efficiency.
[0107] Note that other embodiments may alter the order of steps or
repeat various steps, in order to form the photonic crystals
proximate to the first and second active regions, although not
necessarily between the first and second active regions.
[0108] In addition, although in one embodiment, the first active
region, second active region and photonic crystals are supported by
a substrate, other embodiments may add the step of removing the
first active region, second active region and photonic crystals
from the substrate, and then supporting the first active region,
second active region and photonic crystals on some other
structure.
Conclusion
[0109] This concludes the description of the preferred embodiment
of the present invention. The foregoing description of one or more
embodiments of the invention has been presented for the purposes of
illustration and description. It is not intended to be exhaustive
or to limit the invention to the precise form disclosed. Many
modifications and variations are possible in light of the above
teaching. It is intended that the scope of the invention be limited
not by this detailed description, but rather by the claims appended
hereto.
* * * * *