Structure And Fabricating Method Of Distributed Feedback Laser

Abstract

A structure of distributed feedback (DFB) laser includes a grating layer having a phase-shift grating structure and a gratingless area. In addition, both side-surfaces of the DFB laser are coated with anti-reflection coating to improve SMSR and to obtain good slope efficiency (SE). The grating layer is divided by the phase-shift grating structure in a horizontal direction into a first grating area and a second grating area adjacent to a laser-out surface of the DFB laser. The phase-shift grating structure provides a phase-difference distance, such that a shift of phase exists between the micro-grating structures located within the first grating area and the other micro-grating structures located within the second grating area. The gratingless area located within the second grating area contains no micro-grating structure, and moreover, the gratingless area will not change the phase of the micro-grating structures located within the second grating area.

Claims

1. A distributed feedback laser structure, applicable to generate a laser beam with a laser wavelength, comprising: a semiconductor-laminated structure, generating the laser beam with the laser wavelength upon receiving an electric current, emitting the laser beam from a laser-out surface located at a lateral side thereof; a grating layer, located on the semiconductor-laminated structure, including a plurality of micro-grating structures arranged in a horizontal direction, the plurality of micro-grating structures being separated to each other largely by spacing equal to one half of the laser wavelength; and, a ridge structure, located on the grating layer; wherein the grating layer includes, in the horizontal direction, a first grating area, a phase-shift grating structure, a second grating area and a gratingless area, the laser-out surface is adjacent to the second grating area, the phase-shift grating structure is located at a junction area of the first grating area and the second grating area, a width of the phase-shift grating structure provide a phase-difference distance between the micro-grating structures in the first grating area and the micro-grating structures in the second grating area, and the gratingless area containing no said micro-grating structure is located in the second grating area.

2. The distributed feedback laser structure of claim 1, wherein the phase-difference distance provided by the phase-shift grating structure is equal to one quarter of the laser wavelength, a width of the gratingless area is at least larger than 10 times of the laser wavelength, and the width of the gratingless area is an integer multiple of one half of the laser wavelength, such that a phase of the micro-grating structures in the second grating area is kept no change.

3. The distributed feedback laser structure of claim 2, wherein a width of the first grating area is larger than or equal to one third of a total width of the grating layer, a width of the second grating area containing the gratingless area is no larger than two third of the total width of the grating layer, and the width of the gratingless area is less than or equal to one third of the total width of the grating layer.

4. The distributed feedback laser structure of claim 2, wherein the phase-shift grating structure is located adjacent to a middle portion of the grating layer in the horizontal direction, so that a width of the first grating area is approximately equal to a width of the second grating area containing the gratingless area.

5. The distributed feedback laser structure of claim 3, wherein both the width of the first grating area and the width of the second grating area containing the gratingless area are approximately equal to one half of the total width of the grating layer, and the width of the gratingless area is within one sixth to one third of the total width of the grating layer.

6. The distributed feedback laser structure of claim 2, wherein the grating layer with the total width has a coupling strength L within 25, the first grating area has a first coupling strength, the second grating area excluding the gratingless area has a second coupling strength, the gratingless area has a third coupling strength, the first coupling strength is larger than the second coupling strength, the second coupling strength is larger than the third coupling strength, and the third coupling strength is equal to 0.

7. The distributed feedback laser structure of claim 1, wherein the semiconductor-laminated structure includes: a semiconductor substrate; a lower cladding layer, located on the semiconductor substrate; a separated confinement hetero-structure (SCH) layer, located on the lower cladding layer; an active region layer, located on the lower SCH layer; an upper SCH layer, located on the active region layer; and, a spacer layer, located on the upper SCH layer; wherein the grating layer is located on the spacer layer; wherein the ridge structure, located on the grating layer, further includes an upper cladding layer on the grating layer and a contact layer on the upper cladding layer.

8. The distributed feedback laser structure of claim 7, wherein the semiconductor-laminated structure further includes: a first anti-reflection coating (AR), located on the laser-out surface at the lateral side of the semiconductor-laminated structure; and, a second AR, located to another lateral side of the semiconductor-laminated structure by opposing to the laser-out surface; wherein an optical reflectivity of the first AR and the second AR is lower than 1%.

9. A method for fabricating a distributed feedback laser, comprising: Step (A): applying a semiconductor epitaxy process to form a semiconductor-laminated structure on a semiconductor substrate, the semiconductor-laminated structure generating a laser beam with a laser wavelength upon receiving an electric current, the semiconductor-laminated structure emitting the laser beam from a laser-out surface located at a lateral side of the semiconductor-laminated structure; Step (B): applying e-beam writer and nano imprint processes to form a grating layer on the semiconductor-laminated structure, the grating layer including a plurality of micro-grating structures arranged a horizontal direction, the plurality of micro-grating structures being separated from each other by spacing largely equal to one half of the laser wavelength; and, Step (C): applying a semiconductor epitaxy process and a yellow-light process to form a ridge structure on the grating layer; wherein the grating layer includes, in the horizontal direction, a first grating area, a phase-shift grating structure, a second grating area and a gratingless area, the laser-out surface is adjacent to the second grating area, the phase-shift grating structure is located at a junction area of the first grating area and the second grating area, a width of the phase-shift grating structure provide a phase-difference distance between the micro-grating structures in the first grating area and the micro-grating structures in the second grating area, and the gratingless area containing no said micro-grating structure is located in the second grating area.

10. The method for fabricating a distributed feedback laser of claim 9, wherein the phase-difference distance provided by the phase-shift grating structure is equal to one quarter of the laser wavelength, a width of the gratingless area is at least larger than 10 times of the laser wavelength, and the width of the gratingless area is an integer multiple of one half of the laser wavelength, such that a phase of the micro-grating structures in the second grating area is kept no change.

11. The method for fabricating a distributed feedback laser of claim 10, wherein a width of the first grating area is larger than or equal to one third of a total width of the grating layer, a width of the second grating area containing the gratingless area is no larger than two third of the total width of the grating layer, and the width of the gratingless area is less than or equal to one third of the total width of the grating layer.

12. The method for fabricating a distributed feedback laser of claim 10, wherein the phase-shift grating structure is located adjacent to a middle portion of the grating layer in the horizontal direction, so that a width of the first grating area is approximately equal to a width of the second grating area containing the gratingless area.

13. The method for fabricating a distributed feedback laser of claim 11, wherein both the width of the first grating area and the width of the second grating area containing the gratingless area are approximately equal to one half of the total width of the grating layer, and the width of the gratingless area is within one sixth to one third of the total width of the grating layer.

14. The method for fabricating a distributed feedback laser of claim 10, wherein the grating layer with the total width has a coupling strength L within 25, the first grating area has a first coupling strength, the second grating area excluding the gratingless area has a second coupling strength, the gratingless area has a third coupling strength, the first coupling strength is larger than the second coupling strength, the second coupling strength is larger than the third coupling strength, and the third coupling strength is equal to 0.

15. The method for fabricating a distributed feedback laser of claim 9, wherein the semiconductor-laminated structure includes: a semiconductor substrate; a lower cladding layer, located on the semiconductor substrate; a separated confinement hetero-structure (SCH) layer, located on the lower cladding layer; an active region layer, located on the lower SCH layer; an upper SCH layer, located on the active region layer; and, a spacer layer, located on the upper SCH layer; wherein the grating layer is located on the spacer layer; wherein the ridge structure, located on the grating layer, further includes an upper cladding layer on the grating layer and a contact layer on the upper cladding layer.

16. The method for fabricating a distributed feedback laser of claim 15, wherein the semiconductor-laminated structure further includes: a first anti-reflection coating (AR), located on the laser-out surface at the lateral side of the semiconductor-laminated structure; and, a second AR, located to another lateral side of the semiconductor-laminated structure by opposing to the laser-out surface; wherein an optical reflectivity of the first AR and the second AR is lower than 1%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The present invention will now be specified with reference to its preferred embodiment illustrated in the drawings, in which:

[0036] FIG. 1A and FIG. 1B are schematic top and front views of a conventional distributed feedback laser, respectively;

[0037] FIG. 2A and FIG. 2B are schematic top and front views of another conventional distributed feedback laser, respectively;

[0038] FIG. 3A and FIG. 3B are schematic top and front views of an embodiment of the distributed feedback laser structure in accordance with the present invention, respectively;

[0039] FIG. 4A to FIG. 4C show computer-simulated results of normalized gains (g*L) with respect to corresponding normalized detuning (L), optical selectivity ((g1-g2)) with respect to corresponding normalized gains (g*L), and SE ratios (AR/HR) with respect to corresponding normalized gains (g*L), respectively, according to the conventional distributed feedback laser of FIG. 1B, in which different labels stand for different phases so as thereby to observe easily random phasing caused by mirror splitting;

[0040] FIG. 5A to FIG. 5C show computer-simulated results of normalized gains (g*L) with respect to corresponding normalized detuning (L), optical selectivity ((g1-g2)) with respect to corresponding normalized gains (g*L), and SE ratios (AR/HR) with respect to corresponding normalized gains (g*L), respectively, according to the conventional distributed feedback laser of FIG. 2B, in which different labels stand for different phases so as thereby to observe easily random phasing caused by mirror splitting;

[0041] FIG. 6A to FIG. 6C show computer-simulated results of normalized gains (g*L) with respect to corresponding normalized detuning (L), optical selectivity ((g1-g2)) with respect to corresponding normalized gains (g*L), and SE ratios (AR/HR) with respect to corresponding normalized gains (g*L), respectively, according to the distributed feedback laser structure of FIG. 3B, in which different labels stand for different phases so as thereby to observe easily random phasing caused by mirror splitting; and

[0042] FIG. 7A to FIG. 7D demonstrate schematically and orderly different steps of the fabricating method of the distributed feedback laser in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0043] The invention disclosed herein is directed to a distributed feedback laser structure and a fabricating method thereof. In the following description, numerous details are set forth in order to provide a thorough understanding of the present invention. It will be appreciated by one skilled in the art that variations of these specific details are possible while still achieving the results of the present invention. In other instance, well-known components are not described in detail in order not to unnecessarily obscure the present invention.

[0044] Referring now to FIG. 3A and FIG. 3B, top and front views of an embodiment of the distributed feedback laser (DFB laser) structure are shown, respectively. In this embodiment, the DFB laser structure 3 largely includes a semiconductor-laminated structure 31, a grating layer 32 and a ridge structure 33.

[0045] The semiconductor-laminated structure 31 can generate a laser beam with a laser wavelength , as an electric current is received. The laser beam is emitted from a laser-out surface 38 of the semiconductor-laminated structure 31. The laser-out surface 38 is located to a lateral side of the semiconductor-laminated structure 3, and thus the semiconductor-laminated structure 3 can fulfill the structuring of a typical edge-emitting laser diode. The semiconductor-laminated structure 31 of the present invention includes a semiconductor substrate 311, a lower cladding layer 312 located on the semiconductor substrate 311, a lower separated confinement hetero-structured (SCH) layer 313 located on the lower cladding layer 312, an active region layer 314 located on the lower SCH layer 313, an upper SCH 315 located on the active region layer 314, a spacer layer 316 located on the upper SCH layer 315, a first anti-reflection coating (AR) 391 and a second AR 392. As shown, the grating layer 32 is located on the spacer layer 316, and the ridge structure 33 is located on the grating layer 32. The ridge structure 33 further includes an upper cladding layer 331 located right on the grating layer 32 and a contact layer 332 located on the upper cladding layer 331. In this embodiment, the spacer layer 316 further includes an InP inter layer 3161 located on the upper SCH layer 315, an etching stop layer 3162 located on the InP inter layer 3161, and an InP spacer layer 3163 located on the etching stop layer 3162. The first AR 391 is located on the laser-out surface 38 at a lateral side of the semiconductor-laminated structure 3, while the second AR 392 is located on the laser-out surface 38 at another lateral side of the semiconductor-laminated structure 3. In this embodiment, another applicable range of optical reflectivity for both the first AR 391 and the second AR 392 is lower than 1%, preferably (but not limited to) about 0.1%.

[0046] According to general operation theory of the edge-emitting laser diode, carriers of electrons and electric holes would be injected into the active region layer, and confined in quantum well layer by a carrier barrier layer, such that corresponding material gains would be generated through composite lighting. The confinement theory is that, since the carrier barrier layer has a higher material energy gap than the quantum well layer does, a lower quantum energy level would be formed at the quantum wells. As long as the carriers are captured by the corresponding quantum wells, then it is hard for the carries to escape. Thereupon, a laser optical field would be confined, by the upper and lower cladding layers, in a long and narrow resonant chamber formed by the upper SCH layer, the lower SCH layer and the active region layer. According to the confinement theory, the refractive index n of the upper and lower cladding layers is lower than that of the upper SCH layer, the lower SCH layer and the active region layer. Thus, according to the total-reflection theory, the optical field would induce a mode in the material having a higher n value, and then propagate. The coupling degree between the optical field and the quantum wells in the active region layer determines the modal gain. A higher modal gain would be easier to overcome the optical loss, such that the lasing can be achieved. Also, the threshold current for lasing would be lowered easily as well.

[0047] In one embodiment of the present invention, the semiconductor substrate 311 can be an InP substrate. By epitaxy processes, the lower cladding layer 312, the lower SCH layer 313, the active region layer 314, the upper SCH layer 315 and the spacer layer 316 are formed orderly on the InP substrate 311. The InP substrate 311, the lower cladding layer 312 and the lower SCH layer 313 all have n-typed doping while the upper cladding layer 331 and the contact layer 332 both has p-typed doping. The lower cladding layer 312 and the upper cladding layer 331 are made of InP. The active region layer 314 can be made of In.sub.1-x-yAl.sub.xGa.sub.yAs, in which x and y are both real numbers within 01. The contact layer 332 can be made of InGaAs. Both the lower SCH layer 313 and the upper SCH layer 315 can be made of In.sub.1-zAl.sub.zAs, in which z is a real number within 01. Since material compositions, structural thicknesses, doping concentrations and other parameters for layers of the semiconductor-laminated structure of the present invention can be selected from those for the conventional distributed feedback laser and are not characteristics of the present invention, thus details thereabout are omitted herein. In addition, the material compositions, the structural thicknesses, the doping concentrations and the other parameters for individual layers of the semiconductor-laminated structure of the present invention are not limited to the aforesaid embodiment.

[0048] In this embodiment, the grating layer 32, located on the InP spacer layer 3163 in the spacer layer 316 of the semiconductor-laminated structure 31, includes a plurality of micro-grating structures arranged in a horizontal direction. Spacing between neighboring micro-grating structures is largely equal to the laser wavelength , or one half of the laser wavelength (i. e., /2). In this embodiment, the spacing for the plurality of micro-grating structures is equal to one half of the laser wavelength . Practically, the laser wavelength is the wavelength in the waveguide, equivalently equal to .sub.0/n.sub.eff; in which .sub.0 is the vacuum wavelength, and n.sub.eff is an equivalent refractive index of the semiconductor waveguide. In this embodiment, the grating layer 32 includes, in the horizontal direction, a first grating area 321, a phase-shift grating structure 322, a second grating area 323, and a gratingless area 324. The laser-out surface 38 is adjacent to the second grating area 323. The phase-shift grating structure 322, located at a junction area of the first grating area 321 and the second grating area 323, has a width to provide a phase-difference distance to the micro-grating structures in the first grating area 321 and those in the second grating area 323. In addition, the gratingless area 324, located in the second grating area 323, contains no micro-grating structure.

[0049] In this embodiment, the phase-difference distance provided by the phase-shift grating structure 322 is one quarter of the laser wavelength (i.e., /4-shift). In addition, the gratingless area 324 has a width at least larger than 10 times of the laser wavelength , but the width thereof is an integer multiple of one half of the laser wavelength (n/2). Thus, the phase of the micro-grating structure in the second grating area 323 won't be varied. Namely, though a majority of the micro-grating structures in the second grating area 323 would be divided into a left portion and a right portion by the gratingless area 324, yet the phases of the micro-grating structures at these two portions are all the same. In other words, even facing the existence of the gratingless area 324, no phase shift occurs to any micro-grating structure in the second grating area 323. In an exemplary embodiment of the present, the width of the first grating area 321 is larger than or equal to one third of a total width of the grating layer 32 in the horizontal direction, and the width of the second grating area 323 containing the gratingless area 324 is no larger than two third of the total width of the grating layer 32. Also, the width of the gratingless area 324 is less than or equal to one third of the total width of the grating layer 32. In the preferred embodiment of the present invention (for example, the structure shown in FIG. 3A and FIG. 3B), the phase-shift grating structure 322 is located adjacent to a middle portion of the grating layer 32 in the horizontal direction, such that the width of the first grating area 321 can be approximately the same as that of the second grating area 323 containing the gratingless area 324. Namely, both the width of the first grating area 321 and the width of the second grating area 323 containing the gratingless area 324 are approximately equal to one half of the total width of the grating layer 32. In addition, the applicable width of the gratingless area 323 is within the total width of the grating layer 32. Preferably, the width of the gratingless area 323 can be, but not limited to, about one quarter of the total width of the grating layer 32. In the embodiment shown in FIG. 3A and FIG. 3B, the total width of the grating layer is about 250 m, the width of the first grating area 321 is about 125 m, the width of the second grating area 321 containing the gratingless area 324 is about 125 m, and the width of the gratingless area 324 is about 62 m. In addition, the gratingless area 324 is located at a place to divide a plurality of micro-grating structures of the second grating area 321 into two portions, where the portion adjacent to the phase-shift grating structure 322 has a width of about 1 m, while another portion adjacent to the laser-out surface has a width of about 62 m. Definitely, the aforesaid limitation on widths is only one of various exemplary examples, and is not to limit the scope of the present invention.

[0050] In this embodiment, the entire grating layer has a coupling strength L for the total width; in which is Kappa, and L is the total width of the grating layer. In particular, the first grating area 321 has a first coupling strength L.sub.1, in which L.sub.1 is the width of the first grating area 321; and, similar to the other portion of the grating layer 32. The area of the second grating area 323 other than the gratingless area 324 has a second coupling strength L.sub.2, and the gratingless area 324 has a third coupling strength L.sub.3. The applicable coupling strength L of the whole grating layer having the total width is within 25. The first coupling strength is larger than the second coupling strength, and the second coupling strength is larger than the third coupling strength. In the preferred embodiment shown in FIG. 3A and FIG. 3B, the coupling strength L of the grating layer with the total width can be but not limited to, about 3.5, and the third coupling strength is equal to 0. Definitely, the aforesaid limitation on the coupling strengths is only one of various exemplary examples, and is not to limit the scope of the present invention.

[0051] In the computer simulations upon the distributed feedback lasers, embodiments thereof shown in FIG. 1B, FIG. 2B and FIG. 3B are involved. Computations of the simulations adopt the method of transfer matrix, and the calculation equations and processes can be referred to Semiconductor Laser Technology (Chinese edition), Tin-Chun Lu and Hsin-Tzong Wang, Wu-Nan Publications. Through matrix manipulations, laser detunes () and the corresponding gains (g) for lasing (lasing) for each mode of the distributed feedback laser can be obtained. Herein, a main mode has the smallest gain g, a side mode has the second smallest gain g, and the difference of the aforesaid two g's is the so-called optical selectivity (or selectivity) related to the SMSR. The higher the selectivity is, the better the SMSR would be. Simulation results according to the equations and criteria provided by the aforesaid reference are presented in FIG. 4A to FIG. 4C, FIG. 5A to FIG. 5C, and FIG. 6A to FIG. 6C; in which FIG. 4A to FIG. 4C show computer-simulated results of normalized gains (g*L) with respect to corresponding normalized detuning (L), optical selectivity ((g1-g2)) with respect to corresponding normalized gains (g*L), and SE ratios (AR/HR) with respect to corresponding normalized gains (g*L), respectively, according to the conventional distributed feedback laser of FIG. 1B, in which different labels stand for different phases so as thereby to observe easily random phasing caused by mirror splitting; FIG. 5A to FIG. 5C show computer-simulated results of normalized gains (g*L) with respect to corresponding normalized detuning (L), optical selectivity ((g1-g2)) with respect to corresponding normalized gains (g*L), and SE ratios (AR/HR) with respect to corresponding normalized gains (g*L), respectively, according to the conventional distributed feedback laser of FIG. 2B, in which different labels stand for different phases so as thereby to observe easily random phasing caused by mirror splitting; and, FIG. 6A to FIG. 6C show computer-simulated results of normalized gains (g*L) with respect to corresponding normalized detuning (L), optical selectivity ((g1-g2)) with respect to corresponding normalized gains (g*L), and SE ratios (AR/HR) with respect to corresponding normalized gains (g*L), respectively, according to the distributed feedback laser structure of FIG. 3B, in which different labels stand for different phases so as thereby to observe easily random phasing caused by mirror splitting.

[0052] From FIG. 6B and FIG. 6C, it is found that the selectivities of the distributed feedback laser of FIG. 3B in accordance with the present invention are clustered within 0.50.7, the normalized gains thereof are within 0.80.9, and the SE ratios thereof are within 78. On the other hand, in FIG. 4B and FIG. 4C for the conventional distributed feedback laser of FIG. 1B, the selectivities thereof are clustered within 1.31.4, the normalized gains thereof are all around 0.4, and the SE ratios thereof are all less than 1. In addition, in FIG. 5B and FIG. 5C for the conventional distributed feedback laser of FIG. 2B, the selectivities thereof are distributed in broader area within 01.5, the normalized gains thereof are within 0.40.6, and the SE ratios thereof are also broadly distributed within 312. By comparing the aforesaid simulation results, it is proved that the distributed feedback laser of the present invention can provide better selectivity and emitting light energy of the front optical surface, so that the whole yield can be raised, and the aforesaid shortcomings of the art can be substantially resolved.

[0053] Referring now to FIG. 7A to FIG. 7D, different steps of the fabricating method of the distributed feedback laser in accordance with the present invention are demonstrated schematically and orderly. In this preferred embodiment, the method for fabricating the distributed feedback laser includes the following steps.

[0054] Step (A): As shown in FIG. 7A, through the metal organic chemical vapor deposition (MOCVD) or other conventional semiconductor epitaxy processes, a semiconductor-laminated structure, a grating layer 32a and a protective layer 34 can be orderly formed on a semiconductor substrate. The semiconductor-laminated structure can generate a laser beam with a specific laser wavelength upon receiving an electric current, and then the laser beam would be emitted out of the semiconductor-laminated structure through a laser-out surface located at a lateral side of the semiconductor-laminated structure. The semiconductor-laminated structure includes, in an ascending order, a semiconductor substrate 311, a lower cladding layer 312, a lower SCH layer 313, an active region layer 314, an upper SCH layer 315 and a spacer layer 316. In particular, the spacer layer 316 further includes, in an ascending order, an InP inter layer 3161, an etching stop layer 3162, and an InP spacer layer 3163.

[0055] Step (B): As shown in FIG. 7B, through e-beam writer and nano imprint processes, a plurality of micro-grating structures arranged in a horizontal direction can be formed at the grating layer 32 on the InP spacer layer 3163 of the semiconductor-laminated structure. These micro-grating structures are spaced to each other largely by spacing equal to the laser wavelength or one half of the laser wavelength. In the horizontal direction, the grating layer 32 includes a first grating area, a phase-shift grating structure, a second grating area and a gratingless area. The aforesaid laser-out surface is adjacent to the second grating area. The phase-shift grating structure is located at the junction area of the first grating area and the second grating area. In addition, the width of the phase-shift grating structure can provide a phase-difference distance between the micro-grating structures in the first grating area and those in the second grating area. Also, the gratingless area is located in the second grating area, and contains no micro-grating structure.

[0056] Then, as shown in FIG. 7C, an epitaxy process is further applied to form orderly an upper cladding layer 331a and a contact layer 332a on the grating layer 32, so that a ridge structure 33a can be formed lately.

[0057] Step (C): As shown in FIG. 7D, by applying a conventional laser yellow-light process upon the upper cladding layer 331a and contact layer 332a, the ridge structure 33a can be formed on the grating layer 32.

[0058] While the present invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be without departing from the spirit and scope of the present invention.