Distributed Feedback Laser Array with Tunnel Junction
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Solution Overview
Problem
The existing broad-area distributed feedback laser arrays require complex manufacturing processes and increased costs due to the need for multiple lenses to align laser fields from stacked DFB laser bars, resulting in a poorer laser field emission.
Innovation Solution
A distributed feedback laser array design incorporating a substrate, semiconductor stacked structure with two light-emitting modules and a tunnel junction, where the first electrode layer has a predetermined pattern to control lasing spots, eliminating the need for intermediate lenses and enhancing laser field integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple DFB laser bars are stacked to form a DFB laser array, then the emitting power is increased, but the laser field quality deteriorates and multiple lenses are required for alignment
Solution Approach 1:
The patent merges multiple DFB laser bars into a single integrated laser array structure with a unified substrate and electrode system. The laser array integrates multiple light-emitting modules side-by-side on one substrate, eliminating the need for separate lens assemblies for each bar. This combining approach maintains high emitting power while simplifying the optical alignment system.
Solution Approach 2:
The patent implements a universal electrode structure that serves multiple functions: it provides electrical connection to all laser bars simultaneously, enables independent control of each light-emitting module through patterned electrodes, and maintains thermal management across the entire array. This multi-functional design reduces the need for separate control systems for each laser bar.
2Reliability
If multiple lenses are installed between DFB laser bars to improve laser field quality, then the laser field emission is improved, but the manufacturing process becomes complicated and cost increases
Solution Approach 1:
The patent extracts and eliminates the intermediate lens components from the laser array structure. By redesigning the laser bar configuration and electrode system, the invention achieves proper laser field emission without requiring separate lens assemblies between individual laser bars, thereby simplifying manufacturing.
Solution Approach 2:
The patent introduces a patterned electrode layer as an intermediary between the laser active regions and the external control system. This electrode pattern serves as a mediator that enables precise control of current distribution across multiple light-emitting modules, achieving good laser field quality through electrical control rather than optical components.
3Ease of manufacture
If a tunnel junction is installed between light-emitting modules, then the manufacturing process is simplified and integration is improved, but the device structure becomes more complex
Solution Approach 1:
The patent combines multiple light-emitting modules into a single integrated semiconductor structure with shared substrate and electrode systems. The tunnel junction is integrated within this unified structure, allowing simultaneous fabrication of multiple laser bars through standard semiconductor processing techniques, thereby simplifying manufacturing despite the complex internal structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the manufacturing process, improves laser field emission, and reduces costs by using a tunnel junction between light-emitting modules and a patterned electrode layer to control lasing spots, increasing emitting power and optimizing the laser field.
Implementation Method 1
The tunnel junction is installed between the two light-emitting modules
Implementation Method 2
the active layer comprises multiple lasing spots along a first direction for generating the at least one laser
Data Source
AI summary
A distributed feedback (DFB) laser array includes a substrate, a semiconductor stacked structure, a first electrode layer, and a second electrode layer. The semiconductor stacked structure is formed above a surface of the substrate and includes two light-emitting modules and a tunnel junction. Each light-emitting module of the two light-emitting modules includes an active layer, a first cladding layer, and a second cladding layer. The active layer is installed between the first cladding layer and the second cladding layer, and the active layer has multiple lasing spots along a first direction, wherein the multiple lasing spots are used for generating multiple lasers. The tunnel junction is installed between the two light-emitting modules. The first electrode layer is formed above the semiconductor stacked structure. The second electrode layer is formed above another surface of the substrate.