Laser diode and method for manufacturing a laser diode
11251587 ยท 2022-02-15
Assignee
Inventors
Cpc classification
H01S5/02234
ELECTRICITY
H01S2301/02
ELECTRICITY
H01S2301/176
ELECTRICITY
H01S5/18386
ELECTRICITY
H01S5/18391
ELECTRICITY
International classification
Abstract
A laser diode and a method for manufacturing a laser diode are disclosed. In an embodiment a laser diode includes a surface emitting semiconductor laser configured to emit electromagnetic radiation and an optical element arranged downstream of the semiconductor laser in a radiation direction, wherein the optical element includes a diffractive structure or a meta-optical structure or a lens structure, and wherein the optical element and the semiconductor laser are cohesively connected to each other.
Claims
1. A laser diode comprising: a surface emitting semiconductor laser configured to emit electromagnetic radiation; and an optical element arranged downstream of the semiconductor laser in a radiation direction, wherein the optical element comprises a diffractive structure or a meta-optical structure or a lens structure, wherein the optical element and the semiconductor laser are cohesively connected to each other by a connector, and wherein the connector surrounds the semiconductor laser and the optical element in lateral directions.
2. The laser diode according to claim 1, wherein the optical element is in direct contact with a radiation exit surface of the surface emitting semiconductor laser facing the optical element.
3. The laser diode according to claim 1, wherein the optical element is formed with a material having the same refractive index as the connector.
4. The laser diode according to claim 1, wherein a region between the optical element and the semiconductor laser is filled with non-gaseous material.
5. The laser diode according to claim 1, wherein the optical element does not completely cover a radiation exit surface of the semiconductor laser facing the optical element.
6. The laser diode according to claim 1, wherein the optical element terminates flush with the semiconductor laser in the lateral directions.
7. The laser diode according to claim 1, wherein the diffractive structure or the meta-optical structure or the lens structure is arranged at a distance from a radiation exit surface of the semiconductor laser facing the optical element.
8. The laser diode according to claim 1, further comprising an anti-reflection layer arranged exclusively on an outwardly exposed surface of the optical element.
9. The laser diode according to claim 1, further comprising an electrical contact surface arranged on a surface of the semiconductor laser facing the optical element, wherein the contact surface is not covered by the optical element.
10. The laser diode according to claim 1, wherein the semiconductor laser comprises electrical contact surfaces exclusively on a side facing away from the optical element.
11. The laser diode according to claim 1, further comprising: a mask, wherein the mask is formed in a vertical direction between the optical element and the semiconductor laser, and wherein the mask is configured to generate a pictogram.
12. The laser diode according to claim 11, further comprising: a spacer, wherein the spacer is arranged in the vertical direction between the optical element and the semiconductor laser, wherein the spacer is transparent for the radiation emitted by the semiconductor laser, wherein the spacer is set at a predetermined distance between the mask and the semiconductor laser, and wherein the semiconductor laser, the spacer and the optical element are cohesively connected to each other.
13. The laser diode according to claim 1, wherein the semiconductor laser and the optical element are laterally enclosed by a cladding, wherein the semiconductor laser and the optical element remain uncovered from the cladding in plan view, and wherein the cladding is configured to reflect or absorb the electromagnetic radiation.
14. The laser diode according to claim 13, wherein the cladding comprises a material which is radiation-absorbing at least for visible light or for light in an infrared spectral range, wherein the cladding completely laterally encloses the semiconductor laser and the optical element, and wherein the cladding partially covers side surfaces of the optical element such that the side surfaces of the optical element remain uncovered by the cladding at least from a vertical height or at least from an upper edge of the diffractive structure, the meta-optical structure or the lens structure.
15. The laser diode according to claim 13, wherein the cladding completely covers side surfaces of the semiconductor laser, wherein the cladding at least partially covers side surfaces of the optical element, wherein the semiconductor laser and the optical element are covered in plan view by a cover layer transmissive for radiation, and wherein the cover layer adjoins the cladding.
16. The laser diode according to claim 15, wherein a material of the cladding is not transmissive for radiation and the cladding is not transmissive for light in an infrared spectral range, and wherein a material and a layer thickness of the cover layer are selected such that the cover layer is not transmissive for light in a visible spectral range and transmissive for light in the infrared spectral range.
17. A method of manufacturing a laser diode, the method comprising: providing a plurality of surface emitting semiconductor lasers in a first composite; providing a plurality of optical elements in a second composite; cohesively connecting the plurality of optical elements in the second composite and the plurality of semiconductor lasers in the first composite, wherein the optical element and the semiconductor laser are at least partially encapsulated or injected in a cladding body formed by a connector; and singulating the optical elements and the semiconductor laser, wherein after singulating exactly one optical element is assigned to each semiconductor laser.
18. A laser diode comprising: a surface emitting semiconductor laser configured to emit electromagnetic radiation; an optical element arranged downstream of the semiconductor laser in a radiation direction; and a mask, wherein the optical element comprises a diffractive structure or a meta-optical structure or a lens structure, wherein the optical element and the semiconductor laser are cohesively connected to each other, wherein the mask is arranged in a vertical direction between the optical element and the semiconductor laser, and wherein the mask is configured to generate a pictogram.
19. The laser diode according to claim 18, further comprising: a spacer, wherein the spacer is arranged in the vertical direction between the optical element and the semiconductor laser, wherein the spacer is transparent for the radiation emitted by the semiconductor laser, wherein the spacer is set at a predetermined distance between the mask and the semiconductor laser, and wherein the semiconductor laser, the spacer and the optical element are cohesively connected to each other.
20. The laser diode according to claim 18, wherein the semiconductor laser, the mask and the optical element are laterally enclosed by a cladding, wherein the semiconductor laser and the optical element remain uncovered from the cladding in plan view, and wherein the cladding is configured to reflect or absorb the electromagnetic radiation.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Advantageous embodiments and developments of the laser diode and the method of manufacturing a laser diode will become apparent from the exemplary embodiments described below in association with the figures:
(2)
(3)
(4)
(5)
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
(6) In the exemplary embodiments and figures, similar and similarly acting constituent parts are provided with the same reference symbols. The elements illustrated in the figures and their size relationship among one another should not be regarded as true to scale. Rather, individual elements may be represented with an exaggerated size for the sake of better representability and/or for the sake of better understanding.
(7)
(8) Further, the laser diode 1 comprises a carrier 30 arranged on a major surface of the semiconductor laser 10. For example, the carrier 30 is a substrate on which the semiconductor laser 10 is manufactured. In particular, the semiconductor laser 10 is manufactured by means of an epitaxial process on the carrier 30. An optical element 20 is arranged on one side of the semiconductor laser 10 facing away from the carrier 30. The optical element 20 is arranged downstream of the semiconductor laser 10 in the radiation direction L. The optical element 20 comprises a diffractive structure 200 or a meta-optical structure 200 or a lens structure 200 which is configured to influence electromagnetic radiation E emitted by the semiconductor laser 10. For example, the diffractive structure 200 comprises elements 205 arranged periodically along the main plane of extension of the optical element 20, which in at least one spatial direction transverse to the emission direction L have a magnitude in the order of the wavelength range of the emitted electromagnetic radiation E. For example, the optical elements 205 are formed as recesses in a first layer 201 of the optical element 20. In particular, the recesses with which the elements 205 are formed may be filled with a gaseous material. The elements 205, which are shown schematically in
(9) The semiconductor laser 10 and the optical element 20 are mechanically fixed to each other by means of a connection means 50. For example, the connection means 50 is an adhesive, in particular an epoxy resin or a silicone. The connection means 50 is arranged on a radiation exit surface 10a of the laser diode 10. The connection means 50 forms in particular a connecting layer 50. The connecting layer 50 is arranged in a vertical direction, for example, between the optical element 20 and the semiconductor laser 10. For example, a region between the optical element 20 and the semiconductor laser 10 is filled with non-gaseous material. In particular, the connection means 50 completely covers the radiation exit surface 10a. The optical element 20, in particular the first layer 201, is formed, for example, with a material having the same refractive index as the connection means 50.
(10) A first contact surface 41 and a second contact surface 42 are arranged on the carrier 30. By means of the first contact surface 41 and the second contact surface 42, the laser diode 1 can be electrically contacted and operated. The first contact surface 41 is located on a side of the carrier 30 facing away from the semiconductor laser 10. For example, the side of the carrier 30 facing away from the semiconductor laser 10 is completely covered by the first contact surface 41. The laser diode 1 can be mounted with the first contact surface 41 on an electrically conductive surface, which can also serve as a heat sink for the laser diode 1. The second contact surface 42 is arranged on one side of the carrier 30, facing away from the first contact surface 41, laterally next to the semiconductor laser 10. For example, the second contact surface 42 can be electrically contacted by means of a bonding wire 43.
(11)
(12) The optical element 20 terminates flush with the semiconductor laser 10 in lateral directions R which are perpendicular to the radiation direction L of the semiconductor laser 10. In particular, the optical element 20 does not project beyond the semiconductor laser 10 in lateral directions R. The optical element 20 is formed by a first layer 201 and a second layer 202. The second layer 202 is not contiguous and is arranged in recesses of the first layer 201. For example, the second layer 202 is completely surrounded on all sides by the first layer 201. The first 201 and the second 202 layer form elements 205 which act as a diffractive structure 200 for the electromagnetic radiation E emitted by the semiconductor laser 10.
(13) It is possible that the elements 205 are formed by substructures of the meta-optical structure 200 or the lens structure 200. The substructures of the meta-optic structure 200 or the lens structure 200 can be completely surrounded on all sides by the first layer 201. Especially in this sense the diffractive structure 200 or the meta-optic structure 200 or the lens structure 200 is embedded in the optical element 20, especially in the first layer 201. The first layer 201 serves in particular as a planarization layer and/or as an encapsulation layer of the optical element 20. Deviating from
(14) The diffractive structure 200, the meta-optical structure 200 or the lens structure 200 is arranged at a distance from the side 10a of the semiconductor laser 10 facing the optical element. In particular, the distance D between the diffractive structure 200, the meta-optical structure 200 or the lens structure 200 and the radiation exit surface 10a can be adapted via the thickness of the connection means 50 and/or the thickness of the optical element 20, in particular the first layer 201.
(15) If the optical element 20 comprises a lens structure 200, the element 205 can be formed as a lens. In particular, element 205 forms an optical substructure of the lens structure 200. The majority of elements 205 may form one or more rows of lenses. The elements 205 can be embedded in the first layer 201. The elements 205 may have a higher or lower refractive index than a material of the first layer 201. For example the refractive indices of the elements 205 and the material of the first layer 201 differ by at least 0.1, 0.2, 0.5 or by at least 0.5, for example between 0.1 and 1 inclusive or between 0.1 and 2 inclusive. The first layer 201 may be formed as a planarization layer or as an encapsulation layer of the diffractive structure 200, the meta-optical structure 200, the lens structure 200 or the optical element 20.
(16) Furthermore, an anti-reflection layer 8 is arranged on a surface of the optical element 20 facing away from the semiconductor laser 10. In particular, the anti-reflection layer 8 is arranged exclusively on an outwardly exposed surface 1a of the optical element 20.
(17)
(18) The semiconductor laser 10 is cohesively connected to a housing 60 on a side facing away from the optical element 20 by means of the second contact surface 42. For example, the housing 60 is at least partially electrically conductive and serves as a heat sink and for electrical contacting of the semiconductor laser 10. The first contact surface 41 is arranged on the radiation exit surface 10a of the semiconductor laser 10. The first contact surface 41 is electrically conductively connected to the housing 60 by means of a bonding wire 43. In particular, the bonding wire 43 and the second contact surface 42 are not electrically conductively connected to each other via the housing 60. The first electrical contact surface 41 is arranged on the radiation exit surface boa of the semiconductor laser 10 facing the optical element 20. The optical element 20 does not completely cover the radiation exit surface boa of the semiconductor laser 10. In particular, the first contact surface 41 is not covered by the optical element 20.
(19) The optical element 20 is formed by a first layer 201 and a second layer 202. The first layer 201 has a plurality of recesses which are completely filled with the material of the second layer 202. The first 201 and the second 202 differ in at least one optical property, such as their refractive index, their reflectivity and/or their absorption for electromagnetic radiation E emitted by the semiconductor laser 10. The first 201 and the second 202 form a diffractive structure 200 comprising a plurality of elements 205 configured to influence electromagnetic radiation E emitted by the semiconductor laser 10.
(20) According to
(21) Deviating from
(22)
(23) The connection means 50 is arranged at least on the radiation exit surface 10a of the semiconductor laser 10. In addition, the connection means 50 is arranged in the housing 60 such that side surfaces of the semiconductor laser 10, which connect the side of the semiconductor laser 10 facing away from the optical element 20 and the side of the semiconductor laser 10 facing away from the optical element 10a, are covered. The connection means 50, for example, can be arranged in a method step in the housing 60 such that all radiation exit surface 10a of the semiconductor laser 10 are covered with a predetermined thickness of the connection means 50. In a further method step, optical elements 20 can be arranged on the semiconductor lasers 10, so that the optical elements 20 are arranged downstream of the semiconductor lasers 10 in a radiation direction L. In a subsequent method step, additional connection means 50 is arranged in the housing 60 so that the optical elements 20 are completely covered by the connection means 50. In a subsequent method step, the laser diodes 1 are singulated along the separation lines 7. For example, the laser diodes 1 are singulated along the separation lines 7 by means of a sawing or laser cutting process.
(24)
(25) Furthermore, in a method step B, a plurality of optical elements 20 with diffractive structures 200, meta-optical structures 200 or with lens structures 200 are provided in a second composite 120. The plurality of optical elements 20 is cohesively connected to each other. In particular, the optical elements 20 are manufactured in a common process. The diffractive structures 200, the meta-optical structures 200 or the lens structures 200 are formed with elements 205 which are arranged, for example, on a surface of a first layer 201 of the optical element 20 facing away from the laser diode 10. Alternatively, the diffractive structures 200, the meta-optical structures 200 or the lens structures 200 can be completely surrounded by the material of the first layer 201 of the optical element 20. For example, the diffractive structures 200 or the lens structures 200 can be formed by varying the thickness of the optical element 20.
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(29) The exemplary embodiment shown in
(30) For the electromagnetic radiation emitted by the semiconductor laser 10, the material of the cladding 90 may be chosen to be not transmissive. For example, the cladding material 90 acts radiation-absorbing or radiation-reflecting. In particular, the cladding is not transmissive for electromagnetic waves with a peak wavelength of the light emitted by the semiconductor laser 10. By covering the side surfaces of the semiconductor chip 10 and/or the optical element 20, it can be prevented that the electromagnetic radiation emitted by the semiconductor laser 10 is emitted laterally from the semiconductor laser 10 or from the optical element 20, before it hits the diffractive structures 200, the meta-optical structures 200 or the lens structures 200.
(31) A layer, such as the cladding 90 or the cover layer 91, is transmissive for radiation if preferably at least 50%, 60%, 70%, 80% or at least 90% of the radiation emitted by the semiconductor laser can be transmitted through this layer. On the other hand, a layer is not transmissive if it transmits not more than 50%, 40%, 30%, 20%, 10% or not more than 5% of the radiation emitted by the semiconductor laser.
(32) According to
(33) In
(34) The exemplary embodiment shown in
(35) The exemplary embodiment shown in
(36) The exemplary embodiment shown in
(37) The exemplary embodiment shown in
(38) In particular, the mask 25 is a shadow mask. The mask 25 may comprise patterns which, in particular, form a predefined pictogram. The mask 25 is preferably a mask 25 that forms a pictogram. The mask 25 may comprise regions transmissive for radiation that define the shape of the pictogram to be displayed. Regions that are not transmissive for radiation may be formed by a radiation-absorbing and/or a radiation-reflecting material. For example, the regions not transmissive for radiation of the mask 25 may be formed by a metal or metal alloy.
(39) The mask 25 may comprise regions transmissive for radiation that allow the radiation emitted by the semiconductor laser 10 to pass the mask 25 unhindered or essentially unhindered. The regions transmissive for radiation may be openings or free regions of the mask 25. It is also possible that the regions transmissive for radiation of the mask 25 are formed by a material transmissive for radiation. Due to the regions transmissive for radiation and the regions not transmissive for radiation, the mask can form an arbitrary pattern and thus an arbitrary pictogram. During operation, the particularly compact laser diode 1 with the semiconductor laser 10, the mask 25 and the optical element 20 can project a pictogram onto a target surface without any additional aids.
(40) The exemplary embodiment shown in
(41) The exemplary embodiment shown in
(42) The mask 25 is arranged in particular on a surface of the spacer 51 facing away from the semiconductor laser 10. It is possible that the mask 25 is applied directly to the spacer 51. The mask 25 can be applied to the spacer 51 by means of a coating or a deposition process, for example by vapor deposition or sputtering.
(43) The exemplary embodiments shown in
(44) In contrast, the laser diodes 1 each comprise a mask 25, a spacer 51 and, in particular, an anti-reflection layer 8. The laser diode 1 described in connection with
(45) Deviating from the
(46) The patent application claims the priority of German patent application DE 10 2017 112 235.4, the disclosure content of which is hereby incorporated by reference.
(47) The invention is not restricted to the exemplary embodiments by the description on the basis of said exemplary embodiments. Rather, the invention encompasses any new feature and also any combination of features, which in particular comprises any combination of features in the patent claims and any combination of features on the exemplary embodiments, even if this feature or this combination itself is not explicitly specified in the patent claims or exemplary embodiments.