Surface-Emitting Semiconductor Structure for High-Intensity Low-Fill Arrays
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Solution Overview
Problem
Conventional semiconductor laser arrays face challenges in achieving high light intensity while maintaining a low fill factor, which complicates the realization of optical elements.
Innovation Solution
A semiconductor component with a larger active zone than emission region, structured in a stack-like manner with mirror layers, where the active zone is laterally delimited by a diaphragm, and the emission region has reduced reflectivity to enhance light coupling, allowing for efficient light emission perpendicular to the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the active zone cross section is increased to achieve higher light intensity, then the fill factor increases, but the complexity of realizing optical arrays increases
Solution Approach 1:
The invention segments the active zone from the emission region by introducing a diaphragm structure. The active zone is divided into a first portion (in the first substrate) and a second portion (in the second substrate), allowing independent optimization of each region. This segmentation enables the active zone to be larger while the emission region remains small, resolving the contradiction between light intensity and array complexity.
Solution Approach 2:
The invention transitions from a planar configuration to a three-dimensional stacked configuration. By extending the active zone in the vertical dimension (across two substrates separated by a spacing layer), the patent achieves a larger effective active zone area without increasing the lateral emission region footprint. This dimensional change allows higher light intensity while maintaining low fill factor for array integration.
2Ease of manufacture
If the emission region size is reduced to lower fill factor for array integration, then light intensity decreases, but array realization becomes easier
Solution Approach 1:
The invention implements a nested structure where the emission region is contained within the larger active zone. The first mirror layer and second mirror layer are nested within the spacing layer, which itself is nested between the two substrates. This nesting allows the emission region to be small (for easy array integration) while the active zone extends beyond it (for high light intensity).
Solution Approach 2:
By utilizing the vertical dimension with the spacing layer between substrates, the active zone can extend laterally beyond the emission region boundaries in the horizontal plane. This dimensional extension allows the active zone to be larger than the emission region, enabling small emission regions for easy array integration while maintaining large active zones for high light intensity generation.
3Productivity
If the active zone is laterally enlarged to increase light generation, then the emission region must be enlarged, but this increases the fill factor and complicates array realization
Solution Approach 1:
The diaphragm structure segments the active zone into distinct portions in different substrates, allowing the active zone to be laterally enlarged for high productivity while the emission region (the smaller overlapping area) remains compact. This segmentation decouples the relationship between active zone size and emission region size.
Solution Approach 2:
The invention uses the vertical stacking dimension to accommodate a laterally enlarged active zone. The first and second portions of the active zone are positioned in different substrates separated by the spacing layer, allowing lateral enlargement of the active zone without proportional enlargement of the emission region, thus maintaining low fill factor while improving productivity.
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 configuration enables high light intensity with a lower fill factor, facilitating easier realization of optical arrays and achieving equivalent light intensity to conventional arrays.
Implementation Method 1
a first mirror layer, a second mirror layer, and an active zone extending between the two mirror layers substantially parallel to the surface for generating the light
Implementation Method 2
the emission region has reduced reflectivity to enhance light coupling, allowing for efficient light emission perpendicular to the surface
Data Source
AI summary
A semiconductor component for emitting light includes a main element having an emission region extending on a surface of the main element for emitting the light. A first mirror layer, a second mirror layer, and an active zone extending between the first mirror layer and the second mirror layer substantially parallel to the surface for generating the light are provided in the emission region. The active zone is laterally delimited by a diaphragm such that the active zone has a cross section oriented parallel to the surface that is greater than a cross section of the emission region.