VCSEL Aperture Separation for Independent Current and Beam Control

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Solution Overview

Problem

Conventional VCSEL manufacturing methods lack flexibility in independently controlling electrical and optical apertures, resulting in suboptimal laser output characteristics.

Innovation Solution

The VCSEL is designed with separate electrical and optical apertures, allowing independent definition of their dimensions and geometry, enabling flexible control over laser output parameters such as beam width and gain profile.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional VCSEL manufacturing methods are used, then the manufacturing process is simple, but the flexibility in controlling laser output characteristics is limited

Engineering Contradiction:

Improveflexibility in controlling laser outputVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent divides the aperture into two independent components: an electrical aperture defined by the current confinement region and an optical aperture defined by the waveguide structure. This segmentation allows independent control of electrical current injection and optical output characteristics, enabling flexible adjustment of laser output parameters without modifying the entire device structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements different aperture dimensions at different locations within the device. The electrical aperture (current confinement region) has a first diameter while the optical aperture (waveguide) has a second diameter, allowing independent optimization of electrical injection efficiency and optical output beam characteristics. This local differentiation enables precise control over laser output properties.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If separate electrical and optical apertures are implemented, then the laser output characteristics can be independently controlled, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvecontrol over aperture dimensionsVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent defines the electrical aperture through current confinement region formation and the optical aperture through waveguide structure formation as preliminary steps before final device assembly. By establishing these separate aperture definitions early in the manufacturing process, the patent enables precise dimensional control that can be maintained through subsequent fabrication steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent independently adjusts the dimensional parameters of the electrical aperture (first diameter) and optical aperture (second diameter) to optimize device performance. By treating these as separate controllable parameters rather than coupled dimensions, the patent achieves precise control over laser output characteristics while managing manufacturing complexity through systematic parameter optimization.

Inventive Principle:

Principle #35Parameter changes

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 approach enhances the efficiency and performance of VCSELs by allowing independent adjustment of electrical and optical apertures, optimizing laser output characteristics.

Implementation Method 1

The first reflector and the second reflector may each include distributed Bragg reflector (DBR) stacks

Methodology Applied

Scientific EffectBragg reflection: Bragg Diffraction

Implementation Method 2

The active region may further include a multi-quantum well (MQW) layer stack comprising a series of quantum wells disposed between a series of barriers

Methodology Applied

Scientific EffectQuantum confinement and radiative recombination:

Implementation Method 3

The electrical aperture may be defined via an ion implantation procedure

Methodology Applied

Scientific EffectIon implantation: Ion Implantation

Data Source

PatentUS12592544B2Vertical-cavity surface-emitting laser (VCSEL) having separate electrical and optical confinement

Publication Date: 2026.03.31 MELLANOX TECHNOLOGIES LTD(IL)

AI summary

Vertical-cavity surface-emitting lasers (VCSELs) and associated methods of manufacturing are provided. An example VCSEL includes a first reflector, a second reflector, and an active region disposed between the first reflector and the second reflector. The VCSEL further includes an electrical aperture defining a current confinement region configured to direct current to the active region and an optical aperture defining a medium through which light produced by the active region is emitted from the VCSEL. At least one dimension of the optical aperture of the VCSEL is formed independent of the electrical aperture of the VCSEL. In some instances, the dimension of the optical aperture is a first diameter such that the first diameter of the optical aperture is formed independent of a second diameter defined by the electrical aperture.