PATENT DOCUMENT

Publication Number: US-11322910-B2
Application Number: US-202016792317-A
Country: US
Kind Code: B2

Title: Indium-phosphide VCSEL with dielectric DBR

Abstract:
An optoelectronic device includes a carrier substrate, with a lower distributed Bragg-reflector (DBR) stack disposed on an area of the substrate and including alternating first dielectric and semiconductor layers. A set of epitaxial layers is disposed over the lower DBR, wherein the set of epitaxial layers includes one or more III-V semiconductor materials and defines a quantum well structure and a confinement layer. An upper DBR stack is disposed over the set of epitaxial layers and includes alternating second dielectric and semiconductor layers. Electrodes are coupled to apply an excitation current to the quantum well structure.

Claims:
The invention claimed is: 
     
       1. An optoelectronic device, comprising:
 a carrier substrate; 
 a lower distributed Bragg-reflector (DBR) stack disposed on an area of the substrate and comprising alternating first dielectric and semiconductor layers; 
 a set of epitaxial layers disposed over the lower DBR, wherein the set of epitaxial layers comprises one or more III-V semiconductor materials and defines:
 a quantum well structure; and 
 a confinement layer; 
 
 an upper DBR stack disposed over the set of epitaxial layers and comprising alternating second dielectric and semiconductor layers; 
 electrodes coupled to apply an excitation current to the quantum well structure, 
 wherein at least one of the electrodes comprises a metal ring disposed at an inner side of at least one of the DBR stacks in proximity to the quantum well structure; and 
 one or more metal vias passing through the at least one of the DBR stacks so as to connect the metal ring at the inner side of the at least one of the DBR stacks to an electrical contact on an outer side of the at least one of the DBR stacks. 
 
     
     
       2. The optoelectronic device according to  claim 1 , wherein the carrier substrate comprises a silicon (Si) wafer. 
     
     
       3. The optoelectronic device according to  claim 2 , and comprising complementary metal oxide semiconductor (CMOS) circuits formed on the Si wafer and coupled to drive the electrodes. 
     
     
       4. The optoelectronic device according to  claim 1 , wherein the alternating first dielectric and semiconductor layers comprise alternating layers of silicon dioxide (SiO 2 ) and amorphous silicon (a-Si). 
     
     
       5. The optoelectronic device according to  claim 1 , wherein the alternating first dielectric and semiconductor layers comprise alternating layers of aluminum nitride (AlN) and a-Si. 
     
     
       6. The optoelectronic device according to  claim 1 , wherein the one or more III-V semiconductor materials are selected from a group of materials consisting of indium phosphide (InP), indium-gallium-arsenide (InGaAs), indium-gallium-arsenide-phosphide (InGaAsP), aluminum-gallium-indium-arsenide (AlGaInAs) and aluminum-gallium-arsenide-antimonide (AlGaAsSb). 
     
     
       7. The optoelectronic device according to  claim 1 , wherein the confinement layer comprises:
 a central part comprising a III-V semiconductor material; and 
 a peripheral part surrounding the central part and comprising a dielectric material. 
 
     
     
       8. The optoelectronic device according to  claim 7 , wherein the peripheral part comprises aluminum oxide (Al 2 O 3 ). 
     
     
       9. The optoelectronic device according to  claim 1 , wherein the confinement layer comprises a buried tunnel junction. 
     
     
       10. The optoelectronic device according to  claim 1 , wherein the second dielectric and semiconductor layers comprise alternating layers of SiO 2  and amorphous silicon. 
     
     
       11. The optoelectronic device according to  claim 1 , wherein the electrodes comprise metal rings disposed at the inner sides of both the lower DBR stack and the upper DBR stack in proximity to the quantum well structure, and the one or more metal vias comprise multiple metal vias passing through both of the lower and the upper DBR stacks so as to connect the metal rings to respective electrical contacts. 
     
     
       12. A method for fabricating an optoelectronic device, the method comprising:
 depositing a set of epitaxial layers comprising III-V semiconductor materials on a III-V substrate so as to form a quantum well structure; 
 forming a confinement layer over the quantum well structure; 
 depositing alternating first dielectric and semiconductor layers so as to form a lower distributed Bragg-reflector (DBR) stack; 
 bonding the III-V substrate to a carrier substrate so that the lower DBR stack is positioned between the quantum well structure and the carrier substrate, and then removing the III-V substrate; 
 after removing the III-V substrate, depositing alternating second dielectric and semiconductor layers over the set of epitaxial layers so as to form an upper DBR stack; and 
 coupling electrodes to apply an excitation current to the quantum well structure by depositing a metal ring over at least one side of the quantum well structure at an inner side of at least one of the DBR stacks, before forming the upper DBR stack, and forming one or more metal vias passing through the at least one of the DBR stacks so as to connect the metal ring at the inner side of the at least one of the DBR stacks to an electrical contact on an outer side of the at least one of the DBR stacks. 
 
     
     
       13. The method according to  claim 12 , wherein forming the confinement layer comprises laterally etching one of the epitaxial layers, so that the confinement layer comprises a central part comprising a III-V semiconductor material and a peripheral part comprising a dielectric material surrounding the central part. 
     
     
       14. The method according to  claim 12 , wherein forming the confinement layer patterning and then regrowing one of the epitaxial layers so as to form a buried tunnel junction in a central part of the one of the epitaxial layers. 
     
     
       15. The method according to  claim 12 , wherein depositing the alternating first dielectric and semiconductor layers comprises forming the lower DBR stack on the carrier substrate, and wherein bonding the III-V substrate comprises bonding the set of epitaxial layers to the lower DBR stack on the carrier substrate. 
     
     
       16. The method according to  claim 12 , wherein depositing the alternating first dielectric and semiconductor layers comprises forming the lower DBR stack on the III-V substrate over the set of epitaxial layers and the confinement layer, and wherein bonding the III-V substrate comprises bonding lower DBR stack on the III-V substrate to the carrier substrate. 
     
     
       17. The method according to  claim 12 , wherein the III-V semiconductor materials deposited in the set of epitaxial layers are selected from a group of materials consisting of indium phosphide (InP), indium-gallium-arsenide (InGaAs), indium-gallium-arsenide-phosphide (InGaAsP), aluminum-gallium-indium-arsenide (AlGaInAs) and aluminum-gallium-arsenide-antimonide (AlGaAsSb). 
     
     
       18. The method according to  claim 12 , wherein coupling the electrodes comprises depositing metal rings at the inner sides of both the lower DBR stack and the upper DBR stack in proximity to the quantum well structure, and forming multiple metal vias passing through both of the lower and the upper DBR stacks so as to connect the metal rings to respective electrical contacts.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application 62/808,314, filed Feb. 21, 2019, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to semiconductor devices, and particularly to optoelectronic devices and their manufacture. 
     BACKGROUND 
     VCSELs (vertical-cavity surface-emitting lasers) are semiconductor lasers, wherein the highly directional laser radiation is emitted from the top or bottom of the laser in a direction perpendicular to the substrate. VCSELs are manufactured either as single lasers or as laser arrays, and they are capable of high emission powers. 
     SUMMARY 
     Embodiments of the present invention that are described hereinbelow provide improved methods for manufacturing VCSELs, as well as VCSELs produced by such methods. 
     There is therefore provided, in accordance with an embodiment of the invention, an optoelectronic device, including a carrier substrate and a lower distributed Bragg-reflector (DBR) stack disposed on an area of the substrate and including alternating first dielectric and semiconductor layers. A set of epitaxial layers is disposed over the lower DBR, wherein the set of epitaxial layers includes one or more III-V semiconductor materials and defines a quantum well structure and a confinement layer. An upper DBR stack is disposed over the set of epitaxial layers and includes alternating second dielectric and semiconductor layers. Electrodes are coupled to apply an excitation current to the quantum well structure. 
     In some embodiments, the carrier substrate includes a silicon (Si) wafer. In a disclosed embodiment, the device includes complementary metal oxide semiconductor (CMOS) circuits formed on the Si wafer and coupled to drive the electrodes. 
     In one embodiment, the alternating first dielectric and semiconductor layers include alternating layers of silicon dioxide (SiO 2 ) and amorphous silicon (a-Si). Alternatively, the alternating first dielectric and semiconductor layers include alternating layers of aluminum nitride (AlN) and a-Si. 
     In a disclosed embodiment, the III-V semiconductor materials are selected from a group of materials consisting of indium phosphide (InP), indium-gallium-arsenide (InGaAs), and indium-gallium-arsenide-phosphide (InGaAsP) aluminum-gallium-indium-arsenide (AlGaInAs) and aluminum-gallium-arsenide-antimonide (AlGaAsSb). 
     In some embodiments, the confinement layer includes a central part including a III-V semiconductor material, and a peripheral part surrounding the central part and including a dielectric material. In one embodiment, the peripheral part includes aluminum oxide (Al 2 O 3 ). Additionally or alternatively, the confinement layer includes a buried tunnel junction. 
     In a disclosed embodiment, the second dielectric and semiconductor layers include alternating layers of SiO 2  and amorphous silicon. 
     In some embodiments, at least one of the electrodes includes a metal ring disposed in proximity to the quantum well structure. In a disclosed embodiment, the device includes one or more metal vias passing through at least one of the DBR stacks so as to connect the metal ring at an inner side of the at least one of the DBR stacks to an electrical contact on an outer side of the at least one of the DBR stacks. 
     There is also provided, in accordance with an embodiment of the invention, a method for fabricating an optoelectronic device, the method including depositing a set of epitaxial layers including III-V semiconductor materials on a III-V substrate so as to form a quantum well structure. A confinement layer is formed over the quantum well structure. Alternating first dielectric and semiconductor layers are deposited so as to form a lower distributed Bragg-reflector (DBR) stack. The III-V substrate is bonded to a carrier substrate so that the lower DBR stack is positioned between the quantum well structure and the carrier substrate, and then removing the III-V substrate. After removing the III-V substrate, alternating second dielectric and semiconductor layers are deposited over the set of epitaxial layers so as to form an upper DBR stack. Electrodes are coupled to apply an excitation current to the quantum well structure. 
     In one embodiment, forming the confinement layer includes laterally etching one of the epitaxial layers, so that the confinement layer includes a central part including a III-V semiconductor material and a peripheral part including a dielectric material surrounding the central part. Alternatively, forming the confinement layer patterning and then regrowing one of the epitaxial layers so as to form a buried tunnel junction in a central part of the one of the epitaxial layers. 
     In a disclosed embodiment, depositing the alternating first dielectric and semiconductor layers includes forming the lower DBR stack on the carrier substrate, and bonding the III-V substrate includes bonding the set of epitaxial layers to the lower DBR stack on the carrier substrate. Alternatively, depositing the alternating first dielectric and semiconductor layers includes forming the lower DBR stack on the III-V substrate over the set of epitaxial layers and the confinement layer, and bonding the III-V substrate includes bonding lower DBR stack on the III-V substrate to the carrier substrate. 
     In some embodiments, coupling the electrodes includes depositing a metal ring over at least one side of the quantum well structure, before forming the upper DBR stack. In a disclosed embodiment, coupling the electrodes includes forming one or more metal vias passing through at least one of the DBR stacks so as to connect the metal ring at an inner side of the at least one of the DBR stacks to an electrical contact on an outer side of the at least one of the DBR stacks. 
     The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic sectional view of a VCSEL, in accordance with an embodiment of the invention; 
         FIGS. 2A and 2B  are flowcharts that schematically illustrate the fabrication process of a VCSEL, in accordance with an embodiment of the invention; 
         FIG. 3  is a schematic sectional view of a structure after an epi-growth step, in accordance with an embodiment of the invention; 
         FIG. 4  is a schematic sectional view of a structure after a CMOS step and a lower DBR deposition step, in accordance with an embodiment of the invention; 
         FIG. 5  is a schematic sectional view of a structure after a bonding step, in accordance with an embodiment of the invention; 
         FIG. 6  is a schematic sectional view of a structure after a lateral etch step, in accordance with an embodiment of the invention; 
         FIG. 7  is a schematic sectional view of a structure after a gap fill step, in accordance with an embodiment of the invention; 
         FIG. 8  is a schematic sectional view of a structure after an upper DBR deposition step, in accordance with an embodiment of the invention; 
         FIG. 9  is a schematic sectional view of a completed VCSEL after a passivation step, in accordance with an embodiment of the invention; 
         FIGS. 10A and 10B  are schematic sectional views of a VCSEL, in accordance with another embodiment of the invention; 
         FIGS. 11A, 11B, 11C, 11D, 11E and 11F  are schematic sectional views of structures formed in successive steps of a process of fabrication of the VCSEL of  FIGS. 10A /B, in accordance with an embodiment of the invention; 
         FIG. 12  is a schematic sectional view of a VCSEL, in accordance with yet another embodiment of the invention; and 
         FIGS. 13A, 13B and 13C  are schematic sectional views of structures formed in successive steps of a process of fabrication of the VCSEL of  FIG. 12 , in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Overview 
     Vertical-cavity surface-emitting lasers (VCSELs) based on indium phosphide (InP) are capable of emitting light in the wavelength range from 1350 nm to 2000 nm. (The terms “optical radiation” and “light” as used in the present description and in the claims refer generally to any and all of visible, infrared, and ultraviolet radiation.) The InP-chips carrying the VCSELs can be bonded to a carrier substrate, such as a silicon (Si) substrate in order to take advantage of the complementary metal-oxide semiconductor (CMOS) control circuits on a Si-wafer. (The term “substrate” as used in the present description and in the claims can refer either to a complete wafer or to a part of a wafer, such as in a semiconductor chip.) 
     InP-based VCSELs can be fabricated by first depositing a lower reflector over the Si-substrate. The reflector may comprise either a distributed Bragg-reflector (DBR) stack or a photonic crystal mirror (PCM), and is generally designed to have a reflectivity exceeding 99% at the laser wavelength. A DBR comprises repetitive pairs of high- and low-index materials, wherein the thickness of each layer is a quarter of the local wavelength of the light emitted by the VCSEL (i.e., the free-space wavelength divided by the index of refraction of the material at the wavelength). A PCM comprises periodic optical nanostructures, whose band-gap can be tailored so that the PCM functions as a high-reflectivity mirror. 
     Next, epitaxial layers, comprising InP-layers and a multiple quantum well (MQW) stack, are deposited over the lower reflector to form the active region of the VCSEL. An InP-based MQW stack may comprise (but is not limited to) In x Ga 1-x As, In x Al y Ga 1-x-y As, In x Ga 1-x As y P 1-y  and/or In x Ga 1-x As y N 1-y , wherein 0≤x,y≤1. The barrier material can comprise (but is not limited to) InP, In a Al 1-a As, In a Al b Ga 1-a-b As, In a Ga 1-a As b P 1-b  and/or In a Ga 1-a As b N 1-b , wherein 0≤a,b≤1. The typical thickness of each of the quantum well and barrier layers is in the nanometer range (for example, between 1 and 15 nm). The typical number of quantum well layers can be in the range of 3 to 15, with similar numbers of barrier layers. Then an upper reflector, similar to the lower reflector (but typically with lower reflectivity), is deposited over the epitaxial layers, and electrodes are deposited and patterned on the epitaxial layers so as to apply an excitation current to the MQW. 
     Advanced VCSELs employ methods and structures to confine both the electrical current and the optical radiation within the VCSEL. Confinement of the electrical current brings the carriers into a well-defined volume within the central area in the MQW stack of the VCSEL, and the optical confinement controls the spatial modes of the optical radiation generated by the VCSEL. One method for confining the electrical current in InP-based VCSELs comprises implanting protons in areas around the desired current path. Another method uses a laterally-etched buried tunnel junction (BTJ) for both optical and electrical confinement. VCSELs utilizing PCMs may confine the optical radiation by selectively modifying the photonic crystal structure. 
     Good thermal conductivity between the VCSEL and the substrate is important in order to carry away the heat generated by the VCSEL excitation current. The thermal conductivity may suffer based on the choice of the materials and thicknesses of the lower reflector and other layers at the VCSEL/substrate interface. 
     Optimizing the performance of InP-based VCSELs calls for a high degree of both electrical and optical confinement, as well good thermal conductivity from the VCSEL to the substrate. The embodiments of the present invention that are described herein address these needs so as to enable the fabrication of InP-based VCSELs with high output power and high efficiency, as well as good optical mode confinement. 
     The disclosed embodiments combine, in an InP-based epitaxial stack, an MQW stack comprising a confinement layer and having lower and upper DBRs that comprise alternating layers of semiconductor and dielectric materials. Typical InP-based materials (besides InP itself) comprise, but are not limited to, In x Ga 1-x As, In x Al y Ga 1-x-y As, In x Ga 1-x As y P 1-y , In x Ga 1-x As y N 1-y , Al x Ga 1-x As y Sb 1-y , In a Al 1-a As, In a Al b Ga 1-a-b As, In a Ga 1-a As b P 1-b  and In a Ga 1-a As b N 1-b . The confinement layer, which optionally comprises a BTJ, is etched laterally, thus generating a space in the peripheral part surrounding the central part (core) of the MQW. The generated space can subsequently be filled with a dielectric material, which confines both the electrical currents and the optical field into the central core. 
     A lower DBR comprising alternating layers of commonly used semiconductor and dielectric materials provides inherently good thermal conductivity from the VCSEL into the substrate. In some embodiment, a dielectric material, such as aluminum nitride (AlN), is used to further improve the thermal conductivity. Electrodes are deposited and patterned onto the epitaxial layers so as to apply an excitation current to the quantum well structure. In some embodiments, in order to enhance heat removal from the active region, one or both of the electrodes comprise metal rings disposed in proximity to the quantum well structure. One or more metal vias pass through one or both of the DBR stacks so as to connect the metal ring at the inner side of the DBR stack to an electrical contact on the outer side of the DBR stack. 
     Although the disclosed embodiments use an epitaxial stack based on InP, other III-V semiconductor materials, such as gallium-arsenide (GaAs) and gallium-aluminum-arsenide (GaAlAs), may alternatively be used. Additionally or alternatively GaSb and/or GaN may be used for wider spectral coverage. (For a GaSb-based system, the wavelength is around 2 μm or longer. For a GaN-based system, the wavelength is typically below 500 nm.) Furthermore, other semiconductor carrier substrates may be used instead of Si. However, Si has the benefit that, based on a well-established process technology, CMOS-circuits with very tight design rules (small lateral dimensions) may be manufactured with a high yield on the surface of the substrate and coupled to drive the VCSELs. 
     Device Description 
       FIG. 1  is a schematic sectional view of a VCSEL  20 , in accordance with an embodiment of the invention. 
     VCSEL  20  comprises a semiconductor substrate, such as a silicon (Si) substrate  22 . On Si-substrate  22  there is deposited a lower DBR  24  comprising alternating layers of semiconductor material and dielectric material, wherein the thickness of each layer is a quarter of the local wavelength of the light emitted by VCSEL  20 . A sufficient number of layer-pairs is formed in order to achieve high reflectivity, for example 99% reflectivity. Lower DBR  24  may comprise, for example, alternating layers of amorphous silicon (a-Si) as the semiconductor material and silicon dioxide (SiO 2 ) as the dielectric material. Alternatively using AlN as the dielectric material, the thermal conductivity from VCSEL  20  to substrate  22  may be increased substantially over that achieved with SiO 2 . 
     Above lower DBR  24  is an MQW stack  28  sandwiched between a lower contact  26 , comprising n-type InP, and a p-type InP (p-InP) layer  30 . As noted above, MQW stack  28  typically comprises quantum well materials such as In x Ga 1-x As, In x Al y Ga 1-x-y As, In x Ga 1-x As y P 1-y  and/or In x Ga 1-x As y N 1-y , with barrier layers comprising InP, In a Al 1-a As, In a Al b Ga 1-a-b As, In a Ga 1-a As b P 1-b  and/or In a Ga 1-a As b N 1-b . Above p-InP layer  30  is a confinement layer  31 , followed by an upper n-InP contact  34 . Confinement layer  31  in the pictured embodiment comprises a BTJ  32  in its central part, which may be surrounded by a dielectric fill  36  in its peripheral part. BTJ  32  typically comprises a pair of p + - and n + -layers, with the p + -layer adjacent to upper contact  34 . Dielectric fill  36  typically comprises aluminum oxide (Al 2 O 3 ). An upper DBR  38 , comprising alternating layers of silicon nitride (SiN) and a-Si, is deposited over upper contact  34 . 
     In an alternative embodiment (not shown in the figures), confinement layer  31  comprises, for example, a laterally-etched p-type semiconductor layer, without a BTJ, and upper contact  34  may also comprise p-type material. The changes needed in the process described below in order to accommodate this alternative sort of confinement layer will be apparent to those skilled in the art. 
     VCSEL  20  has been etched to generate a mesa-type structure with a sidewall  44 . Mesa-type structure of VCSEL  20  is typically cylindrical, and consequently sidewall  44  is a continuous cylindrical surface. However, alternative embodiments may use other shapes of the mesa-type structure, such as, for example, cubical, and consequently the mesa-type structure may have several sidewalls. Cathode and anode electrodes  40  and  42  have been deposited and patterned on lower and upper contact layers  26  and  34 , respectively, to provide excitation current paths for VCSEL  20 . Again, due to the cylindrical mesa-type structure, electrodes  40  and  42  are concentric rings. 
     A more detailed description of the structure and fabrication process of VCSEL  20  is provided in  FIGS. 2-9 , below. 
     Method of Fabrication 
       FIGS. 2A and 2B  together present a flowchart  100  that schematically illustrates the fabrication process of VCSEL  20 , in accordance with an embodiment of the invention. Sectional views of structures created in key process steps are shown in  FIGS. 3-9 , and they will be referred to at the appropriate steps of flowchart  100 . In this embodiment, lower DBR  24  is formed by deposition of layers on Si-substrate  22  (the carrier substrate), while the epitaxial layers making up the active region of the VCSEL are deposited on a III-V substrate, such as in InP substrate, and are then bonded to the lower DBR. In alternative embodiments, as described below with reference to  FIGS. 10A /B and  12 , the lower DBR is formed on the III-V substrate over the set of epitaxial layers and the confinement layer, this lower DBR on the III-V substrate is then bonded to the carrier substrate. 
     The fabrication process starts with a start step  102 , from which the fabrication process initially follows two parallel paths. In a CMOS step  104 , CMOS circuits  224  are fabricated on Si-substrate  22  ( FIGS. 1 and 4 ). In a lower DBR deposition step  106 , a multilayer structure comprising alternating layers of SiO 2  and a-Si, with quarter-wave thicknesses at the VCSEL  20  wavelength, is deposited over Si-substrate  22  forming lower DBR  24 . The deposition can be performed, for example, by PVD (Physical Vapor Deposition), CVD (Chemical Vapor Deposition), or PECVD (Plasma-Enhanced CVD), or other methods such as ALD (Atomic Layer Deposition), MOCVD (metal organic CVD), MBE (molecular beam epitaxy), or CBE (chemical beam epitaxy). A resulting structure  220  is detailed in  FIG. 4 . In an epi-growth step  108 , epitaxial layers are grown on an InP-wafer  202  (beginning with an InGaAs etch-stop layer  204 ), as is detailed in  FIG. 3 . In a dicing step  110 , InP-wafer  202  is diced into chips, wherein each chip will later become VCSEL  20 . The two paths of steps  104 - 106  and steps  108 - 110  converge in a bonding step  112 , wherein each InP-chip is flipped over and bonded to Si-substrate  22 . A resulting structure  240  is detailed in  FIG. 5 . 
     In a substrate removal step  114 , the remaining part of InP-wafer  202  is removed, down to etch-stop layer  204 . In a stop layer removal step  116 , layer  204 , shown in  FIG. 3 , is removed. In an anode electrode step  117 , a metal layer is deposited and patterned to form anode electrode  42 . In a hard mask deposition step, an SiO 2  hard mask  264 , shown in  FIG. 6 , is deposited and patterned over upper contact  34 . In a first mesa etch step  120 , a partial mesa with sidewall  44  is etched down to p-InP layer  30 . 
     As shown in  FIG. 6 , in a lateral etch step  122 , BTJ  32  is etched so that it remains in place only in the core part of VCSEL  20 , and a gap  226  is hollowed out between upper contact  34  and p-InP layer  30 . As shown in  FIG. 7 , in a gap fill step  124 , a fill layer  282  of dielectric material, such as Al 2 O 3 , is deposited over the entire structure using atomic layer deposition (ALD). 
     In a fill layer etch step  126 , most of fill layer  282  is etched away, leaving only the material filling gap  226 , as well as some material around the previously etched mesa. In a second mesa etch step  128 , the previously etched mesa sidewall  44  is continued down to lower contact  26 . In a SiN spacer deposition step  130  and in a SiN spacer etch step  132 , a SiN-layer is respectively deposited and then etched to form a SiN spacer  304  around the side of the mesa, as shown in  FIG. 8 . 
     With further reference to  FIG. 8 , in a cathode electrode step  134 , cathode electrode  40  is deposited and patterned. In a third mesa etch step  136 , sidewall  44  of the mesa structure is etched down to lower contact DBR  24  (as shown in  FIG. 9 ). In a hard mask etch step  138 , most of hard mask  264  is etched away. In an upper DBR deposition step  140 , upper DBR  38  is deposited as alternating layers of SiN and a-Si, as detailed in  FIGS. 1 and 8 . In an upper via step  142 , vias are opened to access cathode and anode electrodes  40  and  42 , respectively. In a lower via step  144 , vias are opened to access the metal layers in CMOS-circuits  224 . 
     In a conductor deposition step  146 , conductors  322  and  324  are deposited and patterned to function as RDLs (redistribution layers), connecting anode and cathode electrodes  42  and  40 , respectively, to CMOS-circuits  224 . In a passivation step  148 , SiN is deposited over VCSEL  20 , and a pad is opened through the passive layer to enable electrical contact to the chip. 
     An end step  150  finishes the process. At this stage Si-substrate  22  can be diced to produce chips with single VCSELs or arrays of VCSELs. 
       FIG. 3  is a schematic sectional view of a structure  200  after epi-growth step  108 , in accordance with an embodiment of the invention. 
     Structure  200  can be fabricated on a 3″ InP-wafer  202 , for example, but other wafer diameters may alternatively be used. First InGaAs stop layer  204  is deposited over InP-wafer  202 . The following layers have been epitaxially grown over InGaAs stop layer  204 : upper contact  34 , BTJ  32 , p-InP layer  30 , MQW stack  28 , and lower contact  26 . A typical total thickness of the epitaxial layers is 2.5 microns. The terms “upper” and “lower” are defined by the orientation that structure  200  will have after flipping it over in bonding step  112 . 
       FIG. 4  is a schematic sectional view of structure  220  after CMOS step  104  and lower DBR deposition step  106 , in accordance with an embodiment of the invention. 
     Structure  220  can be fabricated on a 300 mm Si-wafer  22 , for example, but other wafer diameters may alternatively be used. In CMOS step  104 , using a standard CMOS-process, CMOS circuits  224  have been fabricated on Si-wafer  22 . In lower DBR deposition step  106 , lower DBR  24  has been deposited over CMOS circuits  224 . An inset  228  shows the structure of lower DBR  24  with alternating layers of SiO 2    230  and a-Si  232 . The thicknesses of the layers, for example, can be 224 nm for SiO 2    230  and 93 nm for a-Si  232 . The number of layers can be chosen to achieve the desired level of reflectivity. 
       FIG. 5  is a schematic sectional view of structure  240  after bonding step  112 , in accordance with an embodiment of the invention. 
     In bonding step  112 , an InP-chip  242 , produced from structure  200  in dicing step  110 , is flipped over relative to the orientation shown in  FIG. 3 , and bonded onto structure  220  by InP-to-oxide bonding. Alternatively, direct oxide-to-oxide bonding can be used if an additional oxide layer is deposited over the InP. 
       FIG. 6  is a schematic sectional view of a structure  260  after lateral etch step  122 , in accordance with an embodiment of the invention. 
     Structure  260  comprises structure  220  of  FIG. 4 , as well as the following remaining layers of structure  200  of  FIG. 3  (listed from bottom to top): Lower contact  26 , MQW stack  28 , p-InP layer  30 , BTJ  32 , and upper contact  34 . In addition, structure  260  comprises anode electrode  42  and hard mask  264 . Upper contact  34  and BTJ  32  have been etched to define a partial mesa-structure with sidewall  44 , and BTJ  32  has been etched laterally to hollow out gap  226  between p-InP layer  30  and upper contact  34 , with only a core part of the BTJ remaining. 
       FIG. 7  is a schematic sectional view of a structure  280  after gap fill step  124 , in accordance with an embodiment of the invention. 
     Structure  280  is identical to structure  260  of  FIG. 6 , except for the addition of fill layer  282 , which has been deposited over structure  260  so as to fill conformally gap  226 . Fill layer  282  comprises Al 2 O 3 , for example, deposited using a highly conformal ALD deposition process. Alternatively, other dielectric materials may be used. 
       FIG. 8  is a schematic sectional view of a structure  300  after upper DBR deposition step  140 , in accordance with an embodiment of the invention. 
     Structure  300  comprises the same layers as structure  280  of  FIG. 7 , after a continued mesa etch and a partial etch of fill layer  282 . In addition, structure  300  comprises cathode electrode  40  and SiN spacer  304 . Upper DBR  38  has been deposited over structure  300 , comprising alternating layers of SiN and a-Si. 
     The thickness and numbers of upper DBR layers depend on the design targets. As an example, for a 940 nm target VCSEL wavelength, the thickness of each a-Si layer is about 86 nm. Generally, the thickness of each layer is roughly equal to the wavelength/(4.0*index-of-material-at-this-wavelength). The material pairs used in the upper DBR choice can include (but are not limited to) SiN/a-Si, SiO2/a-Si, or AlN/a-Si, for example. The upper mirror reflectivity can also vary, but generally it is larger than 99%, while that of the bottom DBR is generally larger than 99.9%. To reach this reflectivity range generally requires at least three pairs of alternating SiO2/a-Si or other DBR materials. Alternatively, it is possible to use two pairs of AlN/a-Si and another two pairs of SiO2/a-Si to reach such this reflectivity range. 
     The layer thickness of SiN spacer  304  can be a few tens of nanometers to a few hundred nanometers, or even higher. Alternatively, the spacer layer can be made of materials other than SiN, such as (but not limited to) SiO2, AlOx, or AlN, for example. 
       FIG. 9  is a schematic sectional view of completed VCSEL  20  after passivation step  148 , in accordance with an embodiment of the invention. 
     VCSEL  20  is similar to structure  300  of  FIG. 8 , with anode conductor  322  and cathode conductor  324  added for connecting anode electrode  42  and cathode electrode  40 , respectively, to CMOS circuits  224  through vias opened in steps  142  and  144 . VCSEL  20  is further coated with a SiN passivation layer  326 . 
     Alternative Embodiments 
       FIGS. 10A and 10B  are schematic sectional views of a VCSEL  400 , in accordance with another embodiment of the invention.  FIG. 10A  is a side sectional view, as in the preceding figures, while  FIG. 10B  is a frontal sectional view, taken along a line XB-XB in  FIG. 10A . This embodiment, as well as the embodiment shown in  FIG. 12 , is similar in its materials and principles of structure and fabrication to the embodiment described above, with the exception of certain differences that are described below. For the sake of brevity, the description that follows will focus on these differences. 
     VCSEL  400  comprises epitaxial layers making up an active region  402 , including a quantum well structure and a confinement layer  410  as in the preceding embodiment. A lower DBR  406  is formed on a III-V semiconductor substrate (as shown in  FIG. 11C ) over the layers of active region  402 , and is then bonded to a carrier substrate  408 . The carrier substrate may comprise a semiconductor material, such as a Si wafer as in the preceding embodiment, or a dielectric material, such as an AlN wafer. After bonding to the carrier substrate, the III-V wafer is removed, and an upper DBR  404  is then deposited over active region  402 . As in the preceding embodiment, both lower DBR  406  and upper DBR  404  comprise alternating layers  412  and  414  of a-Si and a dielectric material, such as SiO 2  or AlN. 
     Deposition of both the upper and lower DBR stacks on the III-V wafer in this manner is advantageous in terms of enhancing manufacturability and increasing the process yield, in comparison with depositing the lower DBR stack on the carrier wafer as in the preceding embodiment. Among other benefits, the design of VCSEL  400  obviates the need to handle very thin pieces of III-V wafer, thus reducing loss of yield due to wafer breakage. In the present embodiment, active region  402  can be made very thin, thus facilitating heat dissipation. 
     To further facilitate heat dissipation, VCSEL  400  comprises metal ring electrodes  420  and  424 , in proximity to active region  402  (i.e., close to the heat-generating quantum well structure in the VCSEL). Ring electrodes  420  and  424  in the pictured embodiment are deposited below DBRs  404  and  406 , respectively, and are connected by metal vias  422  through the stacks of DBR layers  412 ,  414  to electrical contacts  416  and  418 , respectively. The ring electrodes comprise a metal with both high electrical conductivity and high thermal conductivity, for example gold. They serve the dual purposes of delivering excitation current to active region  402  and removing heat from the active region—thus reducing the junction temperature and increasing the wall-plug efficiency of the VCSEL. Although only two vias  422  are shown in the sectional view of  FIG. 10B , a larger number of vias may be formed as needed for the purpose of heat dissipation. In an alternative embodiment (not shown in the figures), a ring electrode of this sort may be embedded on only one side of active region  402 , with an external electrode (as in the preceding embodiment, for example) on the other side. 
     As in the preceding embodiment, confinement layer  410  comprises a central part  426 , which comprises a III-V semiconductor material, with a peripheral part comprising a dielectric material surrounding the central part. The current flowing between electrodes  420  and  424  is channeled through this central part  426 , as is the optical energy that is generated by the quantum well structure, giving rise to a well-controlled output beam  428 . 
       FIGS. 11A, 11B, 11C, 11D, 11E and 11F  are schematic sectional views of structures formed in successive steps of a process of fabrication of VCSEL  400 , in accordance with an embodiment of the invention. 
     As shown in  FIG. 11A , active region  402  is formed by growth of epitaxial layers on a III-V semiconductor substrate  430 , such as an InP wafer. A metal layer is deposited over active region  402  and patterned to define ring electrode  424 . The initial mesa etch may also be performed at this stage (as in step  120  of  FIG. 2A ). Confinement layer  410  is then etched laterally (as in step  122 ), for example in a wet etch process, to leave the semiconductor material only in central part  426 . The peripheral part is filled with a dielectric material  434 , for example by ALD, as shown in  FIG. 11B . 
     Next, as shown in  FIG. 11C , lower DBR  406  is formed over active region  402  and ring electrode  424  by depositing layers  412  and  414  in alternation (along with an underlying etch-stop layer of SiN, not shown in this figure). Lower DBR  406  is patterned to define vias  422  through lower DBR  406 . Following deposition and etching of a suitable barrier layer (not shown), a metal, for example gold, is deposited in the vias and over the outer surface of DBR  406 . Vias  422  thus connect ring electrode  424  to electrical contact  418 , both electrically and thermally, as shown in  FIG. 11D . 
     III-V semiconductor substrate  430  is now flipped and bonded to carrier wafer  408 , as shown in  FIG. 11E . The substrates may be bonded together, for example, by bonding the Au of electrical contact  418  to a suitable layer on the surface of the carrier wafer, such as a layer of Au or Au-containing solder, or using a suitable adhesive. Only after this bonding step is substrate  430  removed, for example by wet etching. Ring electrode  420  is then deposited on the outer surface of active region  402 , followed by deposition of the stack of layers of upper DBR  404 , and then etching and metal fill to form vias and electrical contact  416 , as shown in  FIG. 11F . These latter steps are similar to those described above with reference to  FIGS. 11C and 11D , mutatis mutandis. The metal of electrical contact  416  is removed to expose the optical aperture of the VCSEL. 
     The inventors studied heat dissipation during operation of VCSEL  400 , on the basis of the thermal properties of the materials in the VCSEL. Most of the heat in active region  402  flows laterally outward toward ring electrodes  420  and  424 ; and vias  422  then conduct the heat out to the upper and lower metal contact layers. In continuous wave (CW) operation of VCSEL  400  at nominal output power and room temperature, the temperature in active region  402  remains moderate, for example not exceeding about 50° C. in some designs, while the outer surfaces of DBRs  404  and  406  are substantially cooler. The cooling effect of the ring electrodes and vias enhances the electrical efficiency and lifetime of the VCSEL, as well as simplifying the process requirements for bonding and packaging of the VCSEL. 
       FIG. 12  is a schematic sectional view of a VCSEL  450 , in accordance with yet another embodiment of the invention. VCSEL  450  is similar in its structure and principles of operation to VCSEL  400 , as shown and described above, except that the confinement layer in an active region  452  of VCSEL  450  comprises a BTJ  454 , which is formed by a process of epitaxial regrowth (rather than the process of lateral etch and dielectric fill as in VCSEL  400 ). This sort of confinement layer requires good control of the regrowth process, but avoids problems of etch inaccuracy in the lateral etching process that is used in the preceding embodiment. 
       FIGS. 13A, 13B and 13C  are schematic sectional views of structures formed in successive steps of a process of fabrication of VCSEL  450  (and specifically of active region  452 ), in accordance with an embodiment of the invention. As shown in  FIG. 13A , BTJ  454  is formed by epitaxially growing a layer of heavily-doped p-type (p++) semiconductor over the lightly-doped p-type (p−) semiconductor layer above the quantum well structure of active region  452 . The p++ layer is etched to a desired depth (to stop at the lightly-doped p-type semiconductor layer) and desired lateral dimensions (to form the current aperture of the VCSEL). A layer  456  of heavily-doped n-type (n++) semiconductor is then regrown over and around the patterned p++ semiconductor, thus creating the BTJ and confinement layer. A layer of metal is deposited over layer  456 , and is then etched to form ring electrode  424 , as shown in  FIG. 13B . Lower DBR  406  is deposited over ring electrode  424  and active region  452 , as shown in  FIG. 13C . The process then continues in the manner described above with reference to  FIGS. 11D /E/F. 
     It will be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.

Metadata:
Filing Date: 20200217
Publication Date: 20220503
Grant Date: 20220503
Priority Date: 20190221
Inventors: PARK, JAE Y.
LAFLAQUIÈRE, ARNAUD
VÉROVE, CHRISTOPHE
TAN, FEI
Assignee: APPLE INC
CPC Classifications: [{"code": "H10H20/8162", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10H20/8142", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10H20/8162", "inventive": false, "first": false, "tree": "[]"}, {"code": "H10H20/8142", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01S5/18341", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18369", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/3095", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/426", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/04257", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/04257", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01S5/0215", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/3095", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/34313", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18377", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/3095", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18369", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/34306", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/34306", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01S5/18341", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01S5/18377", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/11", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/426", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18358", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/0215", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18366", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/34313", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18308", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01S5/02461", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18311", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01S5/18358", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18311", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01S5/02461", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01S5/18366", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/3095", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18358", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18369", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/426", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/34313", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01S5/18308", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01S5/18366", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 69784616