Patent Description:
Significant gains in diode laser brightness over the past decade have been made through lengthening of the laser resonator cavity (i.e., making the chip longer). Once diode lasers reached about <NUM> in cavity length, further attempts to scale brightness and power through cavity length scaling stalled due to a reduction in the power conversion efficiency incurred by going even longer. It is desirable to be able to continue scaling the diode laser length if the cause of the efficiency penalty could be identified and overcome.

Broad area uniform contacts which run along the length of the diode have been used to provide current to the quantum well. It is known that longer cavity length diode lasers suffer from a large asymmetry in the photon density, carrier density, gain and recombination lifetime along the length of the cavity. It is believed that these conditions cause the current density profile (despite having uniform contact) along the length of the cavity to also suffer from non-uniformity. In other words, it is likely that certain areas of the chip draw more current than other areas of the chip, and it is unlikely that the areas which draw the most current are the most optimal position for that current to go. It is desirable to engineer the current density along the length of the diode to overcome the penalty associated with this non-uniformity to enable diode lasers which either operate with greater power conversion efficiency or which operate with equivalent power conversion efficiency with greater output power.

Reference is made to the following documents:
<CIT> discloses a wide stripe semiconductor waveguide, which is cleaved at a Talbot length thereof, the wide stripe semiconductor waveguide having facets with mirror coatings. A system provides for selective pumping the wide stripe semiconductor waveguide to create and support a Talbot mode. In some embodiments the gain is patterned so that a single unique pattern actually has the highest gain and hence it is the distribution that oscillates.

<CIT> discloses an edge-emitting semiconductor laser chip having an active zone (<NUM>) in which electromagnetic radiation is generated during operation of the semiconductor laser chip (<NUM>) and at least one structured contact strip (<NUM>) which is structured in such a way that charge carrier injection into the active Zone (<NUM>) decreases towards one side of the semiconductor laser chip (<NUM>) on which a decoupling facet (<NUM>) of the semiconductor laser chip (<NUM>) is located.

The invention is defined by the enclosed claims.

Several techniques for controlling the longitudinal current density profile in a high-power diode laser are described. For example, patterning of the epi-side dielectric with apertures or producing apertures through proton implantation allows control of the current density profile at the quantum wells through the adjustment of the spacing between these features due to lateral current spreading - the further apart the spacers, the lower the current density at the aperture. In one dimension, if we define the current aperture width as A and the space between the edges of two adjacent apertures as B, keeping other conditions the same, the average current density at the quantum well will increase if A is made larger or B is made smaller (and vice versa). B can be kept smaller than the lateral diffusion length of current so that the spreading (averaging) will actually occur. The size of the aperture (and spacing) in the orthogonal direction will indeed have an effect as well, because current spreading is in 2D. In other words, the present technology contemplates creating apertures of varying width or spacing along the longitudinal direction.

The present technology can be used to control the current injection profile in the longitudinal direction of a high-power diode laser in order to optimize current densities as a function of position in the cavity to promote higher reliable output power and increase the electrical to optical conversion efficiency of the device beyond the level which can be achieved without application of this technique. This approach can be utilized, e.g., in the fabrication of semiconductor laser chips to improve the output power and wall plug efficiency for applications requiring improved performance operation.

The accompanying drawings, which are incorporated into and form a part of the disclosure, illustrate embodiments of the technology and, together with the description, serve to explain the principles of the technology.

This technology enables diode lasers which either operate with greater power conversion efficiency or which operate with equivalent power conversion efficiency with greater output power. This is achieved through careful control of the current density profile in the longitudinal direction of the device in order to overcome local current crowding and longitudinal spatial hole burning effects which limit the efficiency and power of long-cavity high power diode lasers.

Three techniques for controlling the longitudinal current density at the quantum wells along the length of the diode are described. The first is based on high power broad area diode lasers which use a plurality of apertures (also referred to herein as a plurality of vias) through a dielectric to define the emitting area. The second is based on similar devices which instead create the current aperture through proton implantation in the region of semiconductor which is to be rendered non-conductive. In both cases, the area defined by the aperture controls the location of current injection. By creating a pattern of small (~<NUM> to ~<NUM> diameter) vias, the current injection area becomes pixelated (in either <NUM> or <NUM> dimensions). Lateral spreading of the current injected in these areas as it flows down to the quantum wells leads to a reduction of the average current density at the position of the quantum wells. By adjusting the size and spacing of these small apertures in the dielectric or implant region, the injection current profile can be engineered along the length of the diode. The third technique provides a diode laser that has been formed utilizing a patterned-contact layer approach. Exemplary semiconductor materials herein include Si, Ge, GaAs, GaP, InAs, InP, AlAs, GaN and GaSb, as well as ternary, quaternary and quintenary compound semiconductors based on combinations of these material systems.

The injection current profile is engineered in a way to promote higher current density flow to regions of the laser which operate at higher efficiency and/or to overcome the effects of longitudinal current crowding in very long cavity diode lasers. The technique can be applied to edge-emitting semiconductor lasers of various designs, including GaAs-based devices operating in the 6xx-12xx nm wavelength band, InP-based devices operating in the 13xx-21xx nm band, and GaN-based devices operating in the 3xx-5xx nm band.

<FIG> shows a cross-sectional side view of an embodiment of an engineered current-density profile diode laser that has been formed utilizing the dielectric-confined approach of the present technology. <FIG> shows the epitaxial growth direction <NUM> and the laser emission direction <NUM>, which is the longitudinal direction of the laser diode <NUM>. The laser diode <NUM> includes a first portion of semiconductor material <NUM>, an active region <NUM>, a second portion of semiconductor material <NUM>', a patterned dielectric insulator <NUM> and a metal contact <NUM>. The lines <NUM> represent current that would flow between the metal contact <NUM> and the active region <NUM> if a current source is appropriately applied. <FIG> illustrates how current density <NUM> varies along the longitudinal position of laser diode <NUM> according to the pattern of vias in the dielectric insulator <NUM>. Example semiconductor materials for <NUM> and <NUM>' can be selected from the group consisting of Si, Ge, GaAs, GaP, InAs, InP, AlAs, GaN and GaSb, as well as ternary, quaternary and quintenary compound semiconductors based on combinations of materials from the group.

An example fabrication process for the dielectric-confined approach of <FIG> is as follows:.

<FIG> shows a cross-sectional side view of an embodiment of an engineered current-density profile diode laser that has been formed utilizing the implant-confined approach of the present technology. <FIG> shows the epitaxial growth direction <NUM> and the laser emission direction <NUM>, which is the longitudinal direction of the laser diode <NUM>. The laser diode <NUM> includes a first portion of semiconductor material <NUM>, an active region <NUM>, a second portion of semiconductor material <NUM>', a patterned proton implant area <NUM> (within said second portion of semiconductor material <NUM>') and a metal contact <NUM>. The lines <NUM> represent current that would flow between the metal contact <NUM> and the active region <NUM> if a current source is appropriately applied. <FIG> illustrates how current density <NUM> varies along the longitudinal position of laser diode <NUM> according to the pattern of vias formed by the proton implant area <NUM>. Example semiconductor materials for <NUM> and <NUM>' can be selected from the group consisting of Si, Ge, GaAs, GaP, InAs, InP, AlAs, GaN and GaSb, as well as ternary, quaternary and quintenary compound semiconductors based on combinations of materials from the group.

Lateral current spreading in the layers between the contact and quantum well active region will cause the average linear current density at the active region to be related to the fill factor (% via openings in the dielectric) at the contact layer. The spacing between apertures needs to be kept smaller than the average lateral current diffusion length (~<NUM> to <NUM>) between the contact layer and the quantum well so that the current density profile is smooth at the quantum well.

An example fabrication process for the implant-confined approach of <FIG> is as follows:.

In some cases, the photoresist and implantation will happen before the blanket metal deposition. This will allow a short wet or dry etch to be performed to remove the highly doped cap layer in order to reduce the lateral diffusion length.

<FIG> shows a cross-sectional side view of an embodiment of an engineered current-density profile diode laser that has been formed utilizing a patterned-contact layer approach of the present technology. This approach is conceptually similar to the patterned dielectric contact approach. The top epitaxial layer of a diode layer is typically doped p-type to levels in excess of 1E18/cm<NUM>. This very high doping level is needed to form a good ohmic contact when p-metal (typically Ti-Pt-Au) is deposited to the doped GaAs (diodes operating in the 6xx-11xx range and grown on GaAs) or InGaAs (diodes operating in the 12xx-21xx nm range and grown on InP). This high-level doping however does not extend very far into the diode epitaxial structure, and as such the "cap" layer is typically limited to between <NUM> and <NUM> in thickness. While the dielectric contact approach relies on injecting current through vias opened up in an insulating layer placed on top of the cap layer, this method simply removes the cap layer in the regions where reduced current density is required. This works because the removal of the highly doped ohmic contact layer causes an increase in the contact resistance at the metal-semiconductor interface, thereby inhibiting high current flow.

<FIG> shows the epitaxial growth direction <NUM> and the laser emission direction <NUM>, which is the longitudinal direction of the laser diode <NUM>. The laser diode <NUM> includes a first portion of semiconductor material <NUM>, an active region <NUM>, a second portion of semiconductor material <NUM>', a patterned highly doped cap layer <NUM> and a metal contact <NUM>. The lines <NUM> represent current that would flow between the metal contact <NUM> and the active region <NUM> if a current source is appropriately applied. <FIG> illustrates how current density <NUM> varies along the longitudinal position of laser diode <NUM> according to the pattern of dielectric insulator <NUM>. Example semiconductor materials for <NUM> and <NUM>' can be selected from the group consisting of Si, Ge, GaAs, GaP, InAs, InP, AlAs, GaN and GaSb, as well as ternary, quaternary and quintenary compound semiconductors based on combinations of materials from the group.

Broadly, this writing discloses at least the following.

All elements, parts and steps described herein are preferably included. It is to be understood that any of these elements, parts and steps may be replaced by other elements, parts and steps or deleted altogether as will be obvious to those skilled in the art.

Claim 1:
An
engineered current-density profile diode laser (<NUM>; <NUM>; <NUM>), comprising: a first portion of semiconductor material (<NUM>; <NUM>; <NUM>);
a quantum well active region (<NUM>; <NUM>; <NUM>) on said first portion of semiconductor material (<NUM>; <NUM>; <NUM>);
a second portion of said semiconductor material (<NUM>'; <NUM>'; <NUM>') on said active region (<NUM>; <NUM>; <NUM>); a metal contact (<NUM>; <NUM>; <NUM>) on said second portion of said semiconductor material (<NUM>'; <NUM>'; <NUM>'); and
a plurality of current vias (<NUM>; <NUM>; <NUM>) located between said quantum well active region (<NUM>; <NUM>; <NUM>) and said metal contact (<NUM>; <NUM>; <NUM>);
wherein the spacings between said vias (<NUM>; <NUM>; <NUM>) are predetermined to provide a desired current density profile (<NUM>; <NUM>; <NUM>) per longitudinal direction of said diode laser;
said engineered current-density diode laser being characterized in that said
current density (<NUM>; <NUM>; <NUM>) increasing from a zero value to a first value at a first predetermined position along said longitudinal direction;
said current density increasing from said first value to a second value at a second predetermined position, farther in the laser emission direction than said first predetermined position along said longitudinal direction;
said current density decreasing from said second value to a third value, lower than the first value, at a third predetermined position, farther in the laser emission direction than said second predetermined position along said longitudinal direction; and
said current density increasing from said third value to said first value at a fourth predetermined position, farther in the laser emission direction than said third predetermined position along said longitudinal direction,
so that in said engineered current-density profile diode laser local current crowding or longitudinal spatial hole burning effects are reduced.