Method for fabricating a semiconductor laser device

Abstract: A method for fabricating a semiconductor laser device wherein a first clad layer is formed on a GaAs monocrystal substrate of one conductivity type. The first clad layer is made of a compound semiconductor of one conductivity type represented by the formula, (Al x Ga 1-x ) 0.5 In 0.5 P, wherein 0.4 ≦ x ≦ 1. Then, an active layer of a compound semiconductor of the formula, (Al y Ga 1-y ) 0.5 In 0.5 P, wherein 0 ≦ y ≦ 0.35 is formed on the first clad layer, on which a second clad layer of a compound semiconductor of the other conductivity type represented by the formula defined with respect to the first clad layer. At least one of the first and second clad layers is epitaxially grown at a rate of not larger than 0,5 µ m/hour sufficient to form a monolayer superlattice structure therein and the active layer is epitaxially grown at a rate of not less than 2.0 µ m/hour.

Description: This invention relates to a method for fabricating a semiconductor laser device. One of typical known materials for visible light semiconductor laser devices is (Al x Ga 1-x ) 0.5 In 0.5 P wherein 0 ≦ x ≦ 1. Among compound semiconductors of the elements of Group III-V of the Periodic Table, (AlGa) 0.5 In 0.5 compounds exhibit the highest band gap energy except for nitrides of the element. Accordingly, they are usually applied as a semiconductor laser device capable of emitting light or beam a red color region. For the fabrication of a semiconductor laser device using (AlGa) 0.5 In 0.5 P, a GaAs substrate is first provided, on which the above compound semiconductors are epitaxially grown to form a compound semiconductor structure including a pair of clad layers sandwiching an active layer therebetween. The epitaxial growth is usually effected on the (001) plane of the GaAs substrate because of the ease in the preparation of such a substrate and also in the epitaxial growth. However, if GaInP is grown on the (001) plane of the substrate, a so-called "monolayer supperlattice structure or ordered structure" is automatically formed wherein in atom-planes and Ga atom-planes are alternately arranged in the directions of [ 1 11] and [1 1 1] while intervening a P atom-plane therebetween. This "monolayer superlattice structure" strongly appears in the vicinity of the growth temperature at which crystals of good quality are obtained. The completeness of the structure depends greatly on growth conditions including a feed ratio (i.e. a ratio between the atoms of Group V and the atom of Group III), the growth temperature and the like. The area, in which the "monolayer superlattice" is formed, and the completeness of the arrangement depend on these conditions. The formation of the "monolayer superlattice structure" has been observed not only in the GaInP/(001)GaAs system, but also in (Al x Ga 1-x ) 0.5 In 0.5 P/(001)GaAs systems. The "monolayer superlattice structure" has relation to the magnitude of band gap energy (Eg), the acceptor level (Ea) and the donor level (Ed). It is known that if the degree of the completeness of the arrangement becomes high, the values of Eg, Ea and Ed become small. On the other hand, a low degree of the completeness results in large values of Eg, Ea and Ed. In the semiconductor laser devices using the active layer and clad layers using GaInP or AlGaInP compounds, when the monolayer superlattice structure is formed, there appears a phenomenon where the lasing wavelength becomes longer than expected from the layer compositions. For instance, with GaInP which is lattice-matched with a GaAs substrate, the band gap energy amounts to 1.91 eV, which corresponds to a wavelength of 649 nm. The lasing wavelength of a semiconductor laser device which has been fabricated using the GaInP ranges approximately from 670 to 680 nm. This means that the band gap energy becomes smaller by from 50 to 90 meV. The difference in the wavelength corresponds to a difference in the visibility by about ten times. This presents one of problems to solve under circumstances where there is a strong demand for shorter lasing wavelength. The problem is also involved in the case where AlGaInP is used as the active layer. If the clad layer consisting of a GaInP or AlGaInP compound is doped at high concentrations, a so-called "disordering" takes place to destroy the "monolayer supperlattice structure, resulting in crystals having an ordinary band gap energy. This entails larger values of Eg, Ea and Ed with the reduction of an apparent activity of the dopant. For example, AlInP is grown on a GaAs substrate according to gas source molecular beam epitaxy (GSMBE) while doping with a P-type beryllium dopant. The relation between the electrical activity (i.e. the ratio in concentration between the acceptor and Be) and the concentration of Be is shown in Fig. 1. The figure reveals that as the concentration of Be is increased, the electrical activity is abruptly decreased. The reason for this is considered as follows: the "monolayer superlattice structure" is disordered when the concentration of Be is in the range of from 1 x 10¹⁸ to 2 x 10¹⁹ cm⁻³, so that the acceptor level becomes deep and thus, thermal excitation of positive holes takes place satisfactorily with the concentration of the holes being not increased. For the fabrication of a semiconductor laser device, the clad layers become thick owing to the doping with a dopant. This leads to a high electric resistance in the layers to such an extent that most of the element resistance is concentrated on the clad portion. At the clad portion, the Joule heat is generated with the attendant problem that the power consumption is increased along with an increase of threshold current. On the other hand, the control of the formation of the "monolayer superlattice structure" with the feed source ratio (element of Group V/elements of Group III) has the following problems. Fig. 2 shows a variation curve of band gap energy, Eg, for different growth conditions used in an metalorganic vapor phase epitaxy (MOVPE). As will be seen from the figure, when the feed source ratio is made low and the growth temperature is made high (at a level higher than 700°C), the band gap energy reaches about 1.9 eV which is inherent to the compound semiconductor, GaInP. Thus, the short lasing wavelength can be realized. However, when the growth temperature is made so high that there is obtained a band gap energy of 1.9 eV, there arises the problem that the light emission efficiency is lowered due to the high temperature. JP-63-236,314 and JP 1-286,480 disclose InGaAlP type lasers in which a sandwich of clad-active-clad layers is grown on a GaAs substrate. It is accordingly an aim of the invention to provide a method for fabricating a semiconductor laser device which reduces the problems involved in the prior art techniques and can provide a semiconductor laser device having good working characteristics. It is another aim of the invention to provide a method for fabricating a semiconductor laser device which is free of any adverse influence of the "monolayer superlattice structure" as will be formed in prior art processes and can be worked reliably at low power consumption at a short lasing wavelength. According to the invention, there is provided a method for fabricating a semiconductor laser device which comprises: providing a GaAs monocrystal substrate of one conductivity type; and epitaxially growing a first clad layer of a compound semiconductor of one conductivity type represented by the formula, (Al x Ga 1-x ) 0,5 In 0,5 P, wherein 0.4 ≦ x ≦ 1, on a (001) plane of the substrate; characterised by the further step of epitaxially growing, on the first clad layer, an active layer of a compound semiconductor of the formula, (Al y Ga 1-y ) 0,5 In 0,5 P, wherein 0 ≦ y ≦ 0.35 provided that x and y are so selected that the value of (x - y) is not less than 0.4, the active layer being grown at a rate of not less than 2.0 µm/hour; and epitaxially growing, on the active layer, a second clad layer of a compound semiconductor of the other conductivity type represented by the formula defined with respect to the first clad layer. at least one of the first and second clad layers which is of a p-type conductivity being grown at a rate of not less than 0.5 µm/hour sufficient to form a monolayer superlattice structure therein. The growth rates of the first and second clad layers are preferably in the range of not larger than 0.5 µm/hour. The present invention will be further described hereinafter with reference to the following description of exemplary embodiments of the invention and the accompanying drawings, in which: Fig. 1 is a graph showing the relation between the electrical activity and the concentration of Be in a Be-doped AlInP layer grown by gas source molecular beam epitaxy; Fig . 2 is a graph showing the relation between the growth temperature of GaInP formed by metalorganic vapor phase epitaxy, the ratio of an element of Group V and an elements of Group III and the energy band gap obtained by photoluminescent measurement; Fig. 3 is a graph showing the relation between the band gap energy, Eg, and the growth rate of GaInP grown by gas source molecular beam epitaxy according to the invention; and Fig. 4 is a graph showing the electrical activity of a Be dopant of Be-doped AlInP grown by gas source molecular beam epitaxy of the invention. In the method of the invention, a GaAs monocrystal substrate of one conductivity type is first provided. Prior to formation of a clad layer, the substrate is treated by a usual manner, e.g. it is washed with an organic solvent and then with water, followed by etching with an acid solution in order to remove strain from the surface thereof. The substrate is further subjected to removal of an oxide film from the surface in an atmosphere of a vapor such as of As at an appropriate temperature of from 500 to 550°C. A first clad layer of one conductivity type is subsequently formed on the plane (001) of the substrate by a gas source molecular beam epitaxy using solid gallium having a purity of 99.99999% and solid indium having a purity of 99.99999% as the elements of Group III and also P₂ obtained by thermal decomposition of phosphine gas (PH₃) having a purity of 100%. The epitaxy is carried out at a reduced pressure of 5 x 10⁻⁵ to 1 x 10⁻⁴ Torr. The clad layer formed should have a composition of the formula, (Al x Ga 1-x ) 0.5 In 0.5 P, wherein 0.4 ≦ x ≦ 1. The conductivity of the clad layer may be either of the n type or the p-type. For the n-type conductivity, a Si, S) or the like impurity may be doped at a level of 2 to 50 x 10¹⁷ cm⁻³. Similarly, for the p-type conductivity, an impurity such as Be, Mg or the like may be doped at a level of 2 to 50 x 10¹⁷ cm⁻³. In the practice of the invention, it is important that the formation of the "monolayer superlattice structure" be controlled by controlling the growing rates of the first and second clad layers and an active layer provided therebetween. More particularly, for the clad layers, the formation of the superlattice structure" is necessary. On the contrary, for the active layer, such formation is rather undesirable for the reason discussed hereinafter. In prior art, the control of the formation has relied on the type of dopant used and the control of the feed source ratio between the element of Group V and the elements of Group III and the like. The clad layer is made of the AlGaInP which is doped with an impurity. When the concentration of the dopant is increased to a range of 1 x 10¹⁸ to 1 x 10¹⁹ cm⁻³, the electrical activity is lowered due to disordering of the "monolayer superlattice structure". By the disordering, the acceptor level becomes so deep that positive holes cannot be not thermally excited sufficiently. Thus, the number of the holes are not increased. The electrical activity can be increased by controlling the growing rate of the clad layer. in other words, the clad layers, particularly, a p-type clad layer, should be formed to have the "monolayer superlattice structure". In order to attain a complete arrangement of the "monolayer superlattice structure, the p-type clad layer should be grown at a rate of not larger than 0.5 µm/hour, preferably not less than 0.2 µm/hour, and more preferably from 0.1 to 0.2 µm/hour. When the clad layer is of the n-type conductivity, a high activity is attained easier than in the case of the p-type clad layer because of the physical aspect of the n-type clad layer. However, a high electrical activity is difficult to obtain for the p-type clad layer. More particularly, with the p-type clad layer suitable for emitting a red color beam or light, the formation of the "monolayer superlattice structure" requires a slow growth rate as defined above although the activity of about 1 is obtained for the n-type clad layer at a growth rate of not larger than 1 µm/hour. It will be noted that a buffer layer made, for example, of GaAs may be provided between the substrate and the first clad layer. On the first clad layer. which is either of the n-type or the p-type conductivity, is further formed an active layer. The active layer is epitaxially grown by use of a compound semiconductor of the formula, (Al y Ga 1-y ) 0,5 In 0,5 P, wherein 0 ≦ y ≦ 0.35. In practice, the value of y is so selected that the value of x for the semiconductor used as the clad layer minus the value of y is not less than 0.4. By this, a satisfactory band gap between the clad layer and the active layer is ensured. The active layer should be grown at a rate faster than the clad layer. As stated above, the completeness in arrangement of the "monolayer superlattice structure" depends greatly on the growth rate of crystals. If the growth rate is high, the degree of the completeness is lowered. This is because the elements of Group III arriving at the growing surface have to be in position of atom sites forming the "monolayer superlattice structure" after movement through the surface, so that the time required for bonding and crystallization of the phosphorus atoms arriving at the surface becomes shorter than an average time necessary for the completeness. Accordingly, when the growth rate of the active layer is large, the reduction in the band gap due to the ordering of the crystals derived from the "monolayer superlattice structure" is prevented. As a result, an inherent band gap is obtained, making it possible to make a short lasing wavelength of the resultant semiconductor laser device. The growth rate of the active layer should preferably be not less than 2.0 µm/hour, more preferably not less than 3,0 µm/hour and most preferably from 3.0 µm to 5.0 µm/hour. The active layer is lattice matched with the plane (001) of the substrate. For the formation of the active layer, the elements of Group III and the element of Group V are provided at a predetermined ratios in the same manner as for the first clad layer and epitaxially grown by molecular beam epitaxy under conditions of a temperature of from 450 to 530°C at a reduced pressure of from 5 x 10⁻⁵ to 1 x 10⁻⁴ Torr. The band gap energy of the active layer can be varied within a range of 1.85 eV to 1.91 eV. Thereafter, a second clad layer, which is opposite in the conductivity type to the first layer, is formed on the active layer in the same manner as the first clad layer while care should be taken to the growth rate depending on the conductivity type. The semiconductor having the same composition as in the first clad layer is used except that an impurity capable of imparting the other conductivity type is doped in the compound semiconductor used for the second clad layer. With respect to the conductivity type, if the substrate is made of an n-type semiconductor, the first clad layer should be made of an n-type semiconductor and the second clad layer should be made of a p-type semiconductor. If the substrate is of the p-type, the first clad layer should be of the p-type and the second clad layer should of the n-type. As set out above, at least a p-type clad layer should be grown at a rate of not larger than 0.5 µm/hour. Preferably, both clad layers are grown at a rate of not less than 0.5 µm/hour. The semiconductor laser device where the active layer and the first and second clad layers are formed in such a way as set forth above, a short lasing wavelength of 650 to 660nm is ensured and the device has a low threshold value, a low power consumption, a high operation temperature and good reliability. The active layer and the first and second clad layers may be formed by molecular beam epitaxial techniques including not only gas source MBE, but also metalorganic molecular beam epitaxy (MOMBE), chemical beam epitaxy (CBE) and metalorganic vapor phase epitaxy (MOVPE). The thickness of the active layer is generally in the range of from 0.04 to 0.1 µm and the thickness of the first and second clad layers is generally in the range of from 0.6 to 1.0 µm. The present invention is more particularly described by way of example. Example 1 A GaAs substrate which had been washed with trichloroethane, acetone or methanol and then with water-was provided. The substrate was etched with a mixed solution of H₂SO₄, H₂SO₂ and H₂O at a mixing ratio by volume of 3:1:1 in order to remove the surface strain produced during processing. The GaAs substrate was placed in a molecular beam epitaxy chamber and subjected to treatment in an atmosphere of As at a temperature of from 500 to 550°C to remove an oxide film from the surface thereof. The thus treated substrate was maintained at 600°C, on which GaAs was grown in a thickness of about 0.2 µm as a buffer layer. Thereafter, a first clad layer of (Al x Ga 1-x ) 0.5 In 0.5 P where 0.4 ≦ x ≦ 1 doped with Si at a concentration of 1 x 10¹⁸ cm⁻³ was formed on the buffer layer in a thickness of 0.8 µm at a growth rate of 1.0 µm/hour while lattice matching with the (001) plane of the substrate. While the substrate was kept at 500°C, Ga 0.5 In 0.5 P single crystals were formed on the plane (001) of the substrate as an active layer at a rate of 3 µm/hour to a thickness of about 1 µm. A second clad layer was formed in the same manner as the first clad layer except that an impurity of Be was doped at a concentration of 1 x 10¹⁸ cm⁻³. The compound semiconductors for the active layer and the first and second clad layers were formed according to a gas source molecular beam epitaxial procedure using solid gallium having a purity of 99.99999% maintained at 930°C, solid indium having a purity of 99.99999% maintained at 730°C and P₂ obtained by thermal decomposition of 100% phosphine (PH₃) gas at 900°C under conditions of about 8 x 10⁻⁵ Torr. The above procedure was repeated using a growth rate of the active layer ranging from 0.1 to 4.0 µm. The relation between the band gap energy and the growth rate is shown in Fig. 3. From the figure, it will be seen that the band gap energy is changed from 1.85 eV to 1,19 eV. When the growth rate was not less than about 3 µm/hour, the band gap energy reached approximately 1.9 eV which is inherent to Ga 0.5 In 0.5 P. It will be noted that when the growth rate was about 2 µm, the band gap energy was about 1.9 eV. The laser beam emitted at 650 nm could be obtained. Although Ga 0.5 In 0.5 P was used in the above example, similar results are obtained when there are used the compound semiconductor of the formula, (Al y Ga 1-y ) 0.5 In 0.5 P, wherein 0 ≦ y ≦ 0.35. As will be apparent from the above example, when the growth rate is made higher than the clad layer and is sufficient for disordering the "monolayer superlattice structure", the reduction of the band gap can be prevented, so that a short lasing wavelength is attained. Example 2 This example illustrates the electrical activity of a clad layer of a p-type conductivity doped with Be by changing a growth rate of the clad layer. In the same manner as in Example 1, the buffer layer was formed on the GaAs substrate, on which Al 0.5 In 0.5 P was grown at a temperature of 500°C while doping with a Be concentration of 1 x 10¹⁹ cm⁻³ at a growth rate of from 0.1 µ m to 2.0 µm. The activity of the p-type clad layer was determined by the Hall measurement and a secondary ion mass spectrometry (SIMS). The relation between the electrical activity and the growth rate is shown in Fig. 4. From the figure, it will be seen that when the growth rate is at 0.2 µm/hour, the electrical activity is about 0.8. Where Be is doped, an appropriate concentration of holes is ensured. When the growth rate is about 0.1 µm/hour, the electrical activity is closer to 1. At a growth rate of 0.5 µm/hour, the activity is 0.5. However, if the rate is below 0.1 µm, it will take a relatively long time. When the growth rate was 0.2 µm/hour, the resistivity is changed from 0.3 Ω · cm obtained at a growth rate of 1 µ m/hour, to 0.1 Ω · cm. At a growth rate of 0.5 µm/hour, the resistivity is lower than 0.3 Ω · cm attained at a growth rate of 1 µm/hour and is close to 0.1 Ω · cm with little problem in practical application. If the activity is 0.5 or over. a satisfactory low resistivity is obtained. This is why the growth rate of at least the p-type clad layer is defined as not large than 0.5 µm/hour. As a matter of course, with an n-type clad layer doped such as with Si, the growth rate of not larger than 0.5 µm gives favorable results and is preferably determined as such. The results of the examples are summarized in the following table. From the above table, it will be seen that good results are obtained when the growth rate of the clad layer is not larger than 0.5 µm/hour, preferably not larger than 0.2 µm/hour and more preferably from 0.1 to 0.2 µm/hour and and also when the growth rate of the active layer is not less than 2.0 µm/hour, preferably not less than 3.0 µm/hour. Within these ranges, the resultant semiconductor laser device can be excited at a short wavelength of about 649 nm. If a gas source molecular beam epitaxial technique is used, the growth rate is most preferably from 3.0 to 5.0 µm in consideration of the crystallinity of the active layer.

Claims: A method for fabricating a semiconductor laser device, the method comprising the steps of: providing a GaAs monocrystal substrate of one conductivity type; and epitaxially growing a first clad layer of a compound semiconductor of one conductivity type represented by the formula, (Al x Ga 1-x ) 0.5 In 0.5 P, wherein 0.4 ≦ x ≦ 1, on a (001) plane of the substrate; characterised by the further step of: epitaxially growing, on the first clad layer, an active layer of a compound semiconductor of the formula, (Al y Ga 1-y ) 0.5 In 0.5 P, wherein 0 ≦ y ≦ 0.35 provided that x and y are so selected that the value of (x - y) is not less than 0.4, said active layer being grown at a rate of not less than 2.0 µm/hour.; and epitaxially growing, on the active layer, a second clad layer of a compound semiconductor of the other conductivity type represented by the formula defined with respect to the first clad layer, at least one of the first and second clad layers, which is of a p-type conductivity. being grown at a rate of not larger than 0.5 µm/hour sufficient to form a monolayer superlattice structure therein. A method according to Claim 1, wherein the growth rate of said at least one clad layer is not larger than 0.2 µm/hour. A method according to Claim 1, wherein the growth rate of both first and second clad layers is not larger than 0.5 µm/hour. A method according to Claim 3, wherein the growth rate of both first and second clad layers is not larger than 0.2 µm/hour. A method according to claim 1, 2, 3 or 4, wherein the growth rate of the active layer is not less than 3.0 µm. A method according to Claim 5, wherein the growth rate of the active layer is within a range of from 3.0 µm to 5.0 µm. A method according to any one of claims 1 to 6, wherein one of the first and second clad layers which is of the p-type conductivity is doped with Be.

Inventors: NAKAJIMA MASATO, SUZUKI TOMOKO, TAKAMORI AKIRA, YOKOTSUKA TATSUO, NAKAJIMA, MASATO, SUZUKI, TOMOKO, TAKAMORI, AKIRA, YOKOTSUKA, TATSUO
Applicants: MATSUSHITA ELECTRIC IND CO LTD, MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD
Application year: 1991
Main classification: H01S3
IPC codes: H01S5, H01L33