PATENT DOCUMENT

Publication Number: US-10788368-B1
Application Number: US-201816144960-A
Country: US
Kind Code: B1

Title: Thermal isolation structure

Abstract:
Disclosed here is a system including a multi-wavelength integrated light source having one or more heaters. The system can comprise a substrate including a light source section, the heater(s), and a plurality of sections. The sections can include multiple materials, where the material for a given section can be based on one or more targeted criteria. For example, one section can have a targeted criteria of being optically transparent. Another section can have a targeted criteria of providing mechanical support, and another section can have a targeted criteria of being a thermal insulator. In some instances, openings in the substrate can be formed and filled with one or more materials to form a window (e.g., a section having a targeted criteria of being optically transparent) and a thermal isolator (e.g., a section having a targeted criteria of being thermally insulating).

Claims:
The invention claimed is: 
     
       1. A system comprising:
 a first portion including: 
 one or more optical components including one or more light source sections, and 
 one or more first heaters proximate to the one or more light source sections; and 
 a second portion including one or more first sections, one or more second sections, and one or more third sections, 
 the one or more first sections including a first material, wherein the first material comprises amorphous silicon and is optically transparent in at least a wavelength range, the one or more second sections including a second material, wherein the second material provides mechanical support to the second portion, and the one or more third sections including a third material, wherein the third material has a lower thermal conductivity than the second material, 
 wherein the one or more third sections of the second portion are located proximate to the one or more first heaters and the one or more light source sections of the first portion. 
 
     
     
       2. The system of  claim 1 , wherein the one or more first sections are windows. 
     
     
       3. The system of  claim 1 , wherein the second material includes crystalline silicon. 
     
     
       4. The system of  claim 1 , wherein the third material includes amorphous silicon. 
     
     
       5. The system of  claim 1 , wherein the first material and the third material are the same material. 
     
     
       6. The system of  claim 1 , wherein the third material has a lower thermal conductivity than the first material. 
     
     
       7. The system of  claim 1 , wherein each third section is located proximate to a unique first heater. 
     
     
       8. The system of  claim 1 , wherein at least one third section is located proximate to at least two of the one or more first heaters. 
     
     
       9. The system of  claim 1 , further comprising:
 one or more second heaters included in the first portion, wherein the one or more third sections are not located proximate to the one or more second heaters. 
 
     
     
       10. The system of  claim 9 , wherein the one or more second heaters are associated with one or more light sources having a lower shift in wavelength with change in temperature than one or more light sources associated with the one or more first heaters. 
     
     
       11. The system of  claim 1 , wherein the second portion further includes:
 one or more fourth sections including a fourth material, wherein the fourth material has a lower thermal conductivity than the second material, and 
 wherein the third material has a lower thermal conductivity than the fourth material. 
 
     
     
       12. The system of  claim 1 , wherein:
 at least one of the one or more second sections is located around three or more sides of at least one of the one or more third sections. 
 
     
     
       13. The system of  claim 1 , wherein the first portion and the second portion are included in a substrate, the system further comprising:
 an interposer bonded to the substrate. 
 
     
     
       14. A method for forming a system, the method comprising:
 providing a substrate, the substrate including a first material; 
 forming a plurality of first openings for windows in the substrate; 
 forming a plurality of second openings for thermal isolators in the substrate; 
 depositing a second material in the plurality of first openings, wherein the second material is optically transparent; 
 depositing a third material in the plurality of second openings, wherein the third material has a lower thermal conductivity than the first material; and 
 locating the plurality of second openings proximate to one or more light source sections and one or more heaters. 
 
     
     
       15. The method of  claim 14 , wherein forming the plurality of first openings and forming the plurality of second openings occur simultaneously. 
     
     
       16. The method of  claim 14 , wherein depositing the second material and the third material occur simultaneously. 
     
     
       17. The method of  claim 14 , wherein the second material and the third material are the same material. 
     
     
       18. The method of  claim 14 , wherein forming the plurality of first openings includes etching to a first depth, wherein forming the plurality of second openings includes etching to a second depth, wherein the first depth is greater than the second depth. 
     
     
       19. The method of  claim 14 , further comprising:
 bonding the substrate to an interposer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. Provisional Patent Application No. 62/565,837, filed Sep. 29, 2017, the entire disclosure of which is incorporated herein by reference for all purposes. 
    
    
     FIELD OF THE DISCLOSURE 
     This relates to a thermal isolation structure and methods for forming thereof. More specifically, this relates to a thermal isolation structure in a multi-wavelength integrated light source including one or more heaters. 
     BACKGROUND OF THE DISCLOSURE 
     Optical spectroscopy can be an analytical technique. Conventional systems and methods for optical spectroscopy can include emitting light. A portion of the emitted light energy can be absorbed at one or more wavelengths. This absorption can cause a change in the properties of the light. 
     Many different types of light sources may be suitable for optical spectroscopy. One type of light source can include semiconductor lasers, which may have suitable characteristics for a given application. For example, lasers can have single frequency emissions with narrow linewidths and can be capable of tuning to a certain target emission wavelength(s). The precision and accuracy of the emission wavelengths of the light source can be important for achieving quantitatively accurate spectroscopic measurements for some applications. In some instances, optical spectroscopy may benefit from multi-wavelengths measurements. Additionally or alternatively, optical spectroscopy can be suitable for use in portable electronic devices, which may benefit from reduced power consumption. Light sources that can emit multiple wavelengths of light, can be tuned to within a certain amount of precision, and with reduced power consumption can be desired. 
     SUMMARY OF THE DISCLOSURE 
     Disclosed herein is a system including a multi-wavelength integrated light source having one or more heaters. The system can comprise a substrate including a light source section and a heater. In some examples, the substrate can include one or more optical components such as an outcoupler. Additionally, the substrate can include a plurality of sections. The plurality of sections can include multiple materials, where the selected material for each section can be based on one or more targeted criteria. For example, one section can have a targeted criterion of being optically transparent in at least a wavelength range (e.g., visible wavelengths). Another section can have a targeted criterion of providing mechanical support, and another section can have a targeted criterion of being a thermal insulator. In some instances, a window (e.g., a section having a targeted criterion of being optically transparent) and a thermal isolator (e.g., a section having a targeted criterion of being a thermal insulator) can be formed in a support. The support can be a substrate that is single and continuous before a window and a thermal isolator are formed. Openings in the substrate can be formed and filled with one or more materials, which can form the window and the thermal isolator. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an exemplary system in which examples of the disclosure can be implemented. 
         FIG. 2  illustrates an exemplary arrangement of a plurality of light sources included in a system according to examples of the disclosure. 
         FIG. 3A  illustrates a top view of an exemplary light source including one or more integrated heaters according to examples of the disclosure. 
         FIG. 3B  illustrates a top view of an exemplary light source including sections located on different epitaxial chips according to examples of the disclosure. 
         FIG. 4  illustrates a cross-sectional view of an integrated light source system without thermal isolation according to examples of the disclosure. 
         FIG. 5  illustrates a cross-sectional view of an integrated light source system with thermal isolation according to examples of the disclosure. 
         FIG. 6  illustrates an exemplary process for forming a system including one or more thermal isolators according to examples of the disclosure. 
         FIG. 7  illustrates a cross-sectional view of an integrated light source system with a partially etched support for thermal isolation according to examples of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description of examples, reference is made to the accompanying drawings in which it is shown by way of illustration specific examples that can be practiced. It is to be understood that other examples can be used and structural changes can be made without departing from the scope of the various examples. 
     Various techniques and process flow steps will be described in detail with reference to examples as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of one or more aspects and/or features described or referenced herein. It will be apparent, however, to one skilled in the art, that one or more aspects and/or features described or referenced herein may be practiced without some or all of these specific details. In other instances, well-known process steps and/or structures have not been described in detail in order to not obscure some of the aspects and/or features described or referenced herein. 
     Further, although process steps or method steps can be described in a sequential order, such processes and methods can be configured to work in any suitable order. In other words, any sequence or order of steps that can be described in the disclosure does not, in and of itself, indicate a requirement that the steps be performed in that order. Further, some steps may be performed simultaneously despite being described or implied as occurring non-simultaneously (e.g., because one step is described after the other step). Moreover, the illustration of a process by its depiction in a drawing does not imply that the illustrated process is exclusive of other variations and modification thereto, does not imply that the illustrated process or any of its steps are necessary to one or more of the examples, and does not imply that the illustrated process is preferred. 
     Disclosed herein is a system including a multi-wavelength integrated light source having one or more heaters. The system can comprise a substrate including a light source section and a heater. In some examples, the substrate can include one or more optical components such as an outcoupler. Additionally, the substrate can include a plurality of sections. The plurality of sections can include multiple materials, where the selected material for each section can be based on one or more targeted criteria. For example, one section can have a targeted criterion of being optically transparent in at least a wavelength range (e.g., visible wavelengths). Another section can have a targeted criterion of providing mechanical support, and another section can have a targeted criterion of being a thermal insulator. In some instances, a window (e.g., a section having a targeted criterion of being optically transparent) and a thermal isolator (e.g., a section having a targeted criterion of being a thermal insulator) can be formed in a support. The support can be a substrate that is single and continuous before the window and the thermal isolator are formed. Openings in the substrate can be formed and filled with one or more materials, which can form the window and the thermal isolator. 
     Representative applications of methods and apparatuses according to the present disclosure are described in this section. These examples are provided solely to add context and aid in the understanding of the described examples. It will be apparent to one skilled in the art that the described examples may be practiced without some or all of the specific details. Other applications are possible, such that the following examples should not be taken as limiting. 
       FIG. 1  illustrates an exemplary system in which examples of the disclosure can be implemented. System  110  can include a display  112 , a light source  114 , a detector  116 , and buttons  118 . The light source  114  can be configured to emit multiple wavelengths of light. In some examples, the light source  114  can include one or more tunable semiconductor lasers. Tunable light sources can have many applications (e.g., trace gas detection, environmental monitoring, biomedical diagnostics, telecommunications, and industrial process controls) in portable electronic devices. Some applications can benefit from light sources with high precision tunability, narrow or extremely narrow linewidths, single frequency emission, and multi-wavelengths emissions. Additionally, some applications can benefit from portable electronic devices including multi-wavelengths tunable light sources with reduced power consumption. One way to reduce the power requirements for operating the light source  114  can be to use thermal isolation structures, as will be described below. 
     The precision and accuracy of the emission wavelengths of the light source can be important for achieving quantitatively accurate spectroscopic measurements for some applications. Precise and accurate tuning of the light source can be associated with high power consumption. Higher power consumption can be due to changes in temperature of the light source, increased injection currents, thermal crosstalk in a system comprising a plurality of light sources, and the like. For example, the wavelength of light emitted by a light source (e.g., a laser) can depend on the temperature of the light source, where a change in temperature can cause a shift in wavelength (i.e., a deviation from the target wavelength). For example, light emitted by a light source can shift 0.1-1 nm/K depending on the materials used and the design of the light source. The shift in wavelength can be reduced by controlling (e.g., stabilizing) the temperature of the light source. 
     In some examples, light sources can have efficiencies less than unity (i.e., 100%). For example, some light sources can have efficiencies between 5-50%. The efficiencies can be increased by driving higher injection currents. In some instances, driving the light source with higher injection currents can generate significant waste heat and/or require more power consumption. The waste heat can cause a shift in the emissions wavelength, where compensating for the shift can increase the power requirements more. 
     The power requirements can be multiplied in optical spectroscopy, for example, used for certain applications. In some applications, a plurality (e.g., 10-20, 50-100, etc.) of distinct wavelengths of emitted light may be suitable. In some spectroscopic applications (e.g., applications where narrow spectroscopic absorption features can be measured or highly precise quantifications can be made), highly accurate wavelengths can be beneficial. In some examples, highly accurate wavelengths can include no more than a 0.01 nm deviation from the target wavelength. In some examples, highly accurate wavelengths can include no more than a 0.005 nm deviation from the target wavelength. An exemplary application where highly accurate wavelengths may be desirable can include spectroscopic measurements of gases. 
     For spectroscopy systems including a plurality of light sources configured to emit a plurality (e.g., 50-100) of distinct wavelengths, each light source can experience transient effects. Additionally, the plurality of the light sources can be arranged in close proximity to one another (e.g., in portable electronic devices), which can cause the light sources to be susceptible to thermal crosstalk. In some instances, the system may compensate the transient effects and thermal crosstalk, but at the cost of more power. 
       FIG. 2  illustrates an exemplary arrangement of a plurality of light sources included in a system according to examples of the disclosure. The system  200  can include a plurality (e.g., at least 3-10) of light sources  214  formed on the substrate  218  (e.g., a die, chip, or wafer). For example, the plurality of light sources  214  can be grown on the same epitaxial wafer and delineated using lithography. In some examples, the integration can be based on silicon waveguides (e.g., silicon photonics) and/or indium phosphide (InP) waveguides. For example, the plurality of light sources  214  can include one or more lasers whose reflective section(s) (e.g., grating section(s)), gain section, and/or heater(s) can be included on the same substrate  218 . Alternatively, the reflective section(s) of a given laser can be included on one type of substrate (e.g., a silicon substrate), while its gain section and heater(s) can be included on another type of substrate (e.g., a III-V substrate). 
     The term “device” as used throughout can refer to a single standalone component that can operate alone for a given function, or can refer to a system including multiple components that operate together to achieve the same functions. As used throughout this specification, a system, such as an optical sensing system, can include a device. 
     In some examples, the light sources  214  can be located in close proximity to one another. For example, the separation distance(s) between adjacent light sources can be 10-100 μm. The plurality of light sources  214  can be integrated using, for example, wafer-bonding, evanescent coupling, grating coupling, butt-coupling (e.g., near-field facet coupling), epitaxial growth, or any other suitable means. Once formed and integrated, the outputs of the plurality of light sources  214  can be combined. In some instances, one or more of the plurality of light sources  214  can be configured to emit light at a different wavelength range than other light sources  214 . In this manner, combining the outputs of the plurality of light sources  214  can allow the system the capability of tuning along a wide range of wavelengths. 
     The plurality of light sources  214  can be coupled to the sources  204 , which can be coupled to the controller  202 . The controller  202  can send one or more signals to one or more (e.g., each) sources  204 , where the signals can be indicative of a drive current (or voltage) applied to one or more of the plurality of light sources  214 . The plurality of light sources  214  can be coupled to a temperature control system  220 . In some examples, the temperature control system  220  can be a closed-loop temperature control system configured to measure the temperature of the plurality of light sources  214 . The controller  202  and/or the temperature control system  220  can also be configured to compare the measured temperature(s) (using one or more detectors, not shown) to the target temperature(s). Additionally, the temperature control system  220  can control the temperature(s) of the light sources  214  when a certain amount of difference between the measured and target temperatures exists. The temperature control system  220  can include a plurality of temperature sensors. In some examples, each light source  214  can be coupled to a separate temperature sensor(s). In some examples, the controller  202  can be in communication with the temperature control system  220 . In some examples, the controller  202  can include the temperature control system  220 . 
     Examples of the disclosure can be applied to any type of light source. One exemplary type of light source can include, but is not limited to, a laser, such as the one illustrated in  FIG. 3A . Laser  312  can be configured as a Distributed Bragg Reflector (DBR) laser, which can include DBR section  312 A, phase section  312 C, gain region or gain segment  312 D, and DBR section  312 B. DBR section  312 A and DBR section  312 B can include one or more diffraction gratings located on or above the active region (not shown). The diffraction gratings can be configured to provide optical feedback to at least partially reflect light back into the laser cavity to form a resonator. In some examples, the diffraction gratings can be configured to reflect only narrow bands of wavelength(s) to produce a single longitudinal mode wavelength. The period of the gratings can be adjusted to achieve specific emission wavelengths. The DBR section  312 A can be configured to have partial transmission and can be configured as an outcoupler, while the DBR section  312 B can be configured for total reflection. Although  FIG. 3A  illustrates a laser including DBR sections, examples of the disclosure can include reflective sections (e.g., a metal mirror at the rear facet of the laser  312 ). Additionally, examples of the disclosure can be applied to other types of lasers. 
     The phase section  312 C can be configured for tuning by aligning the cavity mode (i.e., lasing wavelength) to the peaks of the DBR reflectivity spectra. In some examples, the phase section  312 C can be omitted from the laser  312 . The gain segment  312 D can be configured to amplify light energy. 
     Heat from any of the sections (e.g., DBR section  312 A, phase section  312 C, gain segment  312 D, and DBR section  312 B) of the laser  312  can spread to any of the other sections. In some examples, one or more of the DBR and phase sections can be coupled to a temperature sensor included in a temperature control system (e.g., the temperature control system  220  illustrated in  FIG. 2 ). While the DBR and phase sections may be temperature controlled (e.g., nominally held at a nearly constant temperature), the gain segment  312 D can be affected by changes in generated heat (e.g., from the laser being driven by a current source). For example, the source (e.g., the source  204  illustrated in  FIG. 2 ) can reduce the drive current of the gain segment  312 D. The lower drive current can lead to a reduced heat load in the gain segment  312 D, which can lead to a drop in the temperature of the gain segment  312 D and decreased power requirement. The temperature drop in the gain segment  312 D can cause an increase in heat flow between the gain segment  312 D and one or more of the DBR section  312 A, the DBR section  312 B, and the phase section  312 C. Alternatively, the temperature drop in gain segment  312 D can lead to a decrease in heat flow in the opposite direction. 
     The temperature control system (e.g., temperature control system  220  illustrated in  FIG. 2 ) can detect the change in temperature within a given laser (e.g., laser  312 ) and can try to correct for the change in heat flow by increasing the amount of applied heat to one or more segments (e.g., the gain segment  312 D) of the laser via any one of the heaters. The laser  312  can include one or more heaters such as heater  312 E (located proximate to the gain segment  312 D), heater  312 F (located proximate to the phase section  312 C), and heater  312 G (located proximate to the DBR section  312 A). In some examples, the heaters can be any type of element capable of generating heat, including but not limited to a resistor (e.g., patterned metal or lightly-doped, ohmic semiconductor material). As discussed above, the heaters can be used to tune the emissions wavelengths of the light source, which may increase the power consumption requirement of the light source. 
     Although the figure illustrates a laser and sections within a certain type of laser, examples of the disclosure are not limited to a laser or the type of laser illustrated. Additionally, examples of the disclosure are not limited to a laser having the illustrated sections formed on the same epitaxial wafer. For example,  FIG. 3B  illustrates a top view of an exemplary light source including multiple epitaxial chips, where some sections (e.g., the DBR section  312 A, the phase section  312 C, the heater  312 F, and the heater  312 G) of the light source can be included in the epitaxial chip  313 A. Other sections (e.g., the DBR section  312 B, the gain segment  312 D, and the heater  313 E) can be included in the epitaxial chip  313 B. Epitaxial chip  313 A and epitaxial chip  313 B can be optically coupled together via optical trace  320 . The terms “optical coupling” and “optically coupled” can include a connection (e.g., an optical path) between two or more components for transferring an optical signal between the components, and optical decoupling refers to the lack of such connection. 
     In addition to the thermal impacts from sections within a given light source, a light source (e.g., when configured in the arrangement illustrated in  FIG. 2 ) can experience thermal crosstalk, where the modulation of at least one light source (e.g., light source  214  illustrated in  FIG. 2 ) can thermally affect a nearby (e.g., adjacent) light source. In some instances, the effects from such thermal crosstalk can lead to higher power consumption to correct for the thermal crosstalk. 
     Higher power consumption may also be required to correct for the injection current to the light source. The injection current may be the current input to the light source to operate the laser. For example, as the injection current to the light sources decreases, the temperature of a segment (e.g., gain segment  312 D) can decrease, and the system can increase the current to a thermally coupled heater (e.g., heater  312 E) in order to maintain the temperature of the light source. Increasing the current to the heater  312 E may lead to higher power consumption. 
     The total power consumption for operating the light source can be due to multiple sub-operations. The sub-operations can include operating the heaters, which may consume power. The power requirements can also be based on the amount of injection current to achieve a targeted power density. One sub-operation that can consume a large percentage of the total power consumption can be tuning the laser. For example, tuning the laser can consume over 50% of the total power consumption for operating the laser. A lower power requirement for tuning the laser may be desired. 
     One way to lower the power requirement can be to change the components used for heating. Another way to lower the power requirement can be to improve the thermal isolation of the heater such that the heating efficiency can be enhanced.  FIG. 4  illustrates a cross-sectional view of an integrated light source system without thermal isolation according to examples of the disclosure. The system  415  can include a substrate  410  and a photonics substrate  430 . 
     In some examples, the substrate  410  can be an interposer. The substrate  410  can include one or more electrical traces configured to route signals for one or more components (e.g., routing signals from the heaters to the temperature control system  220  illustrated in  FIG. 2 ). The substrate  410  can be bonded to a photonics substrate  430 , for example. The photonics substrate  430  can include one or more components included in the light source, such as a light source section  412  and a heater  413 . The photonics substrate  430  can also include one or more optical components such as an outcoupler  432 . Additionally, the photonics substrate can include a support  436 . At least a portion of the window  434  can be formed within the support  436 . 
     Although the figure illustrates the photonics substrate as including a light source section, a heater, an outcoupler, a window, and a support, examples of the disclosure can further include other optical components such as mirrors, feedback detectors, etc. Additionally or alternatively, examples of the disclosure can include a light source system that may not include one or more of the components shown in the figure. 
     The photonics substrate  430  may additionally include optical components, electrical components, or both. Exemplary components can include layers used to form one or more waveguides for propagating light, cladding layers for confining light, routing layers including metal traces and optical traces, insulating layer for insulating the metal traces, passivation layers, encapsulation layers, planarizing layers, supporting layers, and the like. 
     Heat conduction paths  417  can form from the heater  413  to the support  436 , as illustrated in the figure. Although the figure uses curved lines to represent the heat conduction paths  417 , such lines merely illustrate a schematic representation of one possible path to which heat can travel. One skilled in the art would understand that heat may not be constrained to following the path shown in the curved lines and may travel in, e.g., a different direction, along a longer path, along a path with a different shape, etc. 
     In some examples, after the photonic substrate  430  is bonded to the substrate  410 , the support  436  may be thinned down. A thinner photonics substrate  430  can lead to an increase in the heat efficiency of the heat conduction paths  417 . The heat can dissipate out to a location on top (e.g., on a side of the photonics substrate  430  that is opposite from the substrate  410 ) of the photonics substrate  430  (e.g., out to the environment and/or to an external housing of the device), which can reduce the heat efficiency (i.e., change in temperature per power) of the heater  413 . In some examples, the support  436  may include a material that has a high thermal conductivity (e.g., 150 W/mK) and/or may not be thinned down. For example, the support  436  can include crystalline silicon. With reduced heat efficiency, the operation of the heater  413  may lead to higher power consumption. 
     A window  434  can be formed in the support  436 . In some examples, the window  434  can be formed before the photonics substrate  430  is bonded to the substrate  410 . The window  434  can include one or more materials (e.g., amorphous silicon). Light emitted from the light source section  412  (e.g., a waveguide) can be directed towards the outcoupler  432  (not shown), the outcoupler  432  can redirect the light to exit the system  415  through the window  434  (not shown). The material(s) for the window  434  can be chosen based on its optical performance (e.g., high transparency in the visible wavelength range). 
     In some examples, the material(s) for the window (e.g., window  434  illustrated in  FIG. 4 ) can be a material that has both optically transparency (e.g., in the visible wavelength range) and a low thermal conductivity.  FIG. 5  illustrates a cross-sectional view of an integrated light source system with thermal isolation according to examples of the disclosure. The system  525  can include a substrate  510  and a photonics substrate  530 . 
     The photonics substrate  530  may additionally include optical components, electrical components, or both. Exemplary components can include layers used to form one or more waveguides for propagating light, cladding layers for confining light, routing layers including metal traces and optical traces, insulating layer for insulating the metal traces, passivation layers, encapsulation layers, planarizing layers, supporting layers, and the like. 
     In some examples, the substrate  510  can be an interposer. The interposer can provide an electrical interface between the components integrated into the system. Exemplary materials for the substrate  510  can include, but are not limited to, aluminum nitride (AlN), aluminum dioxide (Al 2 O 3 ), and silicon. 
     The substrate  510  can be bonded to a photonics substrate  530 , for example. The photonics substrate  530  can include one or more components (e.g., included in a first portion of the photonics substrate  530 ) such as a light source section  512  and a heater  513 . The photonics substrate  530  can also include one or more optical components such as an outcoupler  532 . The outcoupler  532  can be configured to focus, collect, collimate, and/or condition (e.g., shape) the light from light source section  512  (and/or another light source section) towards optics (e.g., located between the outcoupler  532  and the window  534 ) and/or the window  534 ). Additionally, the photonics substrate  530  can include a support  536 . In this manner, the light sources, the photonics integrated circuit, and other components can be co-packaged (e.g., located in the same package). 
     Additionally, the photonics substrate  530  can include a plurality of sections (e.g., included in a second portion of the photonics substrate  530 ). The plurality of sections can include multiple materials, where the selected material for each section can be based on one or more targeted criteria. For example, one section can have a targeted criterion of being optically transparent in at least a wavelength range (e.g., visible wavelengths). Another section can have a targeted criterion of providing mechanical support, and another section can have a targeted criterion of being a thermal insulator. For example, a window  534  (e.g., a section having a targeted criterion of being optically transparent) and a thermal isolator  538  (e.g., a section having a targeted criterion of being a thermal insulator) can be formed in the support  536 . That is, the support  536  can be a substrate that is single and continuous before the window  534  and the thermal isolator  538  are formed. Openings in the substrate can be formed and filled with one or more materials, which can form the window  534  and the thermal isolator  538  (as discussed below). 
     In some examples, the window  534  and the thermal isolator  538  can be formed separately from the support  536 . The support  536  can then be located between the window  534  and the thermal isolator  538 . In some examples, the support  536  can be adhered (e.g., an adhesive can be located between) to the window  534  and the thermal isolator  538 . 
     The thermal isolator  538  can include one or more materials with lower thermal conductivity than the support  536 . For example, the thermal isolator  538  can include amorphous silicon, and the support  536  can include crystalline silicon. The heat conduction paths  517  can form from the heater  513  to the thermal isolator  538 , as illustrated in the figure. The heat conduction paths  517  can be correspondingly similar in functionality and/or structure as the heat conduction paths  417 . The lower thermal conductivity of thermal isolator  538  can reduce the amount of heat dissipation to the top (e.g., on a side of the photonics substrate  530  that is opposite from the substrate  510 ) of the photonics substrate  530  (e.g., out to the environment and/or to an external housing of the device). Reducing the amount of heat dissipation to the top of the photonics substrate  530  can increase the heat efficiency (i.e., the change in temperature per power) of the heater  513 . With increased heat efficiency, the operation of the heater  513  may lead to lower power consumption. 
     In some examples, the materials included in the thermal isolator  538  can be the same as the materials included in the window  534  (as discussed below). In this manner, the same material can be used for both the window  534  and the thermal isolator  538 , but for exploiting different features. The material for the window  534  can be chosen based on its optical performance, while the material for the thermal isolator  538  can be chosen based on its thermal performance. 
     As discussed above, the light source can include more than one heater (e.g., the heater  312 E, the heater  312 F, and the heater  312 G illustrated in  3 B). The thermal isolator  538  can be located proximate to one heater (e.g., a unique heater such as heater  313 E) or may be a continuous material located proximate to multiple heaters (e.g., at least two heaters). In some examples, multiple thermal isolators  538  can be included in the system, where the thermal isolators can be separated by the support  536 . In some examples, each thermal isolator  538  can be located proximate to a unique heater. In some examples, the thermal isolator can be the same size as the heater. 
     In some examples, some of the heaters can be located proximate to one or more thermal isolators, while others of the heaters may not be located proximate to the one or more thermal isolators. For example, the thermal isolators can be located next to those light sources where increased heat efficiency may have more than a de minimus impact on the power consumption of the light source. As another example, the thermal isolators can be excluded from those light sources and associated heaters (e.g., second heaters) where the speed for heating (or cooling) the light source may have more than a de minimus impact on the performance of the light source. For example, some light sources may experience a larger shift in wavelength (i.e., deviation from the targeted wavelength) with change in temperature. Locating a thermal isolator in close proximity to those light sources may cause a delay in tuning the light source back to its targeted wavelength. The system may exclude thermal isolators (or may include a different type of thermal isolator, discussed below) proximate to those light sources and their associated heaters (e.g., second heaters) that experience a larger shift in wavelength than other light sources and their associated heaters (e.g., first heaters) such that the delay in tuning may be reduced. 
     In some examples, the multiple thermal isolators  538  may include a different type of thermal isolator. The different type of thermal isolator can include, for example, different materials (e.g., a fourth material) having different levels (e.g., lower thermal conductivity than thermal isolator  538 ) of thermal conductivity. The different materials can include a conductivity that is lower than the material for the support  536 . The material for a given thermal isolator  538  can be based on the potential thermal gradient, for example. In some examples, the material for a given thermal isolator can have a thermal conductivity that is lower than the material for the support  536 , but higher than the materials for other thermal isolators. 
       FIG. 6  illustrates an exemplary process for forming the system including one or more thermal isolators according to examples of the disclosure. Process  650  can begin with providing a substrate (e.g., substrate  510  illustrated in  FIG. 5 ) such as an interposer (optional) (step  652  of process  650 ). A photonics substrate (e.g., photonics substrate  530  illustrated in  FIG. 5 ) can be provided (step  654  of process  650 ). Providing the photonics substrate can include forming one or more outcouplers (e.g., outcoupler  532  illustrated in  FIG. 5 ), forming one or more light sources (e.g., including light source section  512  illustrated in  FIG. 5 ), forming one or more heaters (e.g., heater  513  illustrated in  FIG. 5 ), and/or forming one or more other components (e.g., optical traces). The photonics substrate can be bonded to the interposer (optional) (step  656  of process  650 ). The photonics substrate can be thinned down, for example. A plurality of openings can be formed in the support (e.g., support  536  illustrated in  FIG. 5 ) of the photonics substrate (step  658  of process  650 ). At least some of the openings can be for the windows (e.g., window  534  illustrated in  FIG. 5 ), and at least others of the openings can be for the thermal isolator (e.g., thermal isolator  538  illustrate in  FIG. 5 ). In some examples, at least two of the openings can be formed simultaneously. For example, the first openings for the windows and the second openings for the thermal isolators can be formed at the same time. 
     One or more materials (e.g., amorphous silicon) can be deposited in the openings (step  660  of process  650 ). Optionally, in the examples where different materials are used for the windows than for the thermal isolator, step  660  can include depositing one type of material in some of the openings, and an additional step can include depositing another type of material in the others of the openings. In some examples, the materials for different openings can be deposited simultaneously. For example, the material for the thermal isolators can be deposited at the same time as the material for the windows. 
     In some examples, the process can include different etch depths for forming the plurality of openings. For example, the opening for the window may be etched more (i.e., closer to the substrate  710 ) than the opening for the thermal isolator, as illustrated in  FIG. 7 . That is, the first etch depth for the first openings for the window may be greater than the second etch depth for the second openings for the thermal isolator. The system  725 , the photonics substrate  730 , the substrate  710 , the window  734 , the outcoupler  732 , the heater  713 , the heat conduction paths  717 , the light source section  712 , and the support  736  can include one or more correspondingly similar components and/or functions as the components discussed in the context of  FIGS. 4 and 5 . Additionally, the support  736  can include one or more sections located between the thermal isolator  738  and the light source section  712 . That is, the support  736  can be located around multiple (e.g., at least three) sides of the thermal isolator  738 . In this manner, enhanced support may be provided. 
     A system is disclosed. The system can comprise: a substrate including: a first portion including: one or more optical components including one or more light source sections, and one or more first heaters proximate to the one or more light source sections; and a second portion including one or more first sections, one or more second sections, and one or more third sections, the one or more first sections including a first material, wherein the first material is optically transparent in at least a wavelength range, the one or more second sections including a second material, wherein the second material is configured for supporting the second portion, and the one or more third sections including a third material, wherein the third material has a lower thermal conductivity than the second material, wherein the one or more third sections are located proximate to the one or more first heaters and the one or more light source sections. Additionally or alternatively, in some examples, the one or more first sections are windows. Additionally or alternatively, in some examples, the first material includes amorphous silicon. Additionally or alternatively, in some examples, the second material includes crystalline silicon. Additionally or alternatively, in some examples, the third material includes amorphous silicon. Additionally or alternatively, in some examples, the first material and the third material are the same material. Additionally or alternatively, in some examples, the third material has a lower thermal conductivity than the first material. Additionally or alternatively, in some examples, each third section is located proximate to a unique first heater. Additionally or alternatively, in some examples, at least one third section is located proximate to at least two of the one or more first heaters. Additionally or alternatively, in some examples, the system further comprises: one or more second heaters included in the first portion, wherein the one or more third sections are not located proximate to the one or more second heaters. Additionally or alternatively, in some examples, the one or more second heaters are associated with one or more light sources having a lower shift in wavelength with change in temperature than one or more light sources associated with the one or more first heaters. Additionally or alternatively, in some examples, the second portion of the first substrate further includes: one or more fourth sections including a fourth material, wherein the fourth material has a lower thermal conductivity than the second material, and wherein the third material has a lower thermal conductivity than the fourth material. Additionally or alternatively, in some examples, at least one of the one or more second sections is located around three or more sides of at least one of the one or more third sections. Additionally or alternatively, in some examples, the system further comprises: an interposer bonded to the substrate. 
     A method for forming a system is disclosed. The method can comprise: providing a substrate, the substrate including a first material; forming a plurality of first openings for windows in the substrate; forming a plurality of second openings for thermal isolators in the substrate; depositing a second material in the plurality of first openings, wherein the second material is optically transparent; depositing a third material in the plurality of second openings, wherein the third material has a lower thermal conductivity than the first material; and locating the plurality of second openings proximate to one or more light source sections and one or more heaters. Additionally or alternatively, in some examples, forming the plurality of first openings and forming the plurality of second openings occur simultaneously. Additionally or alternatively, in some examples, depositing the second material and the third material occur simultaneously. Additionally or alternatively, in some examples, the second material and the third material are the same material. Additionally or alternatively, in some examples, forming the plurality of first openings includes etching to a first depth, wherein forming the plurality of second openings include etching to a second depth, wherein the first depth is deeper than the second depth. Additionally or alternatively, in some examples, the method further comprises: bonding the substrate to an interposer. 
     Although examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the various examples as defined by the appended claims.

Metadata:
Filing Date: 20180927
Publication Date: 20200929
Grant Date: 20200929
Priority Date: 20170929
Inventors: PELC, Jason
ARBORE, Mark Alan
Assignee: APPLE INC
CPC Classifications: [{"code": "G01J3/0286", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01J3/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J3/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J3/0286", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01J3/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J3/0286", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 72614835