Heterogeneous substrate bonding for photonic integration

Information

  • Patent Grant
  • 11482513
  • Patent Number
    11,482,513
  • Date Filed
    Tuesday, June 25, 2019
    4 years ago
  • Date Issued
    Tuesday, October 25, 2022
    a year ago
Abstract
A method of fabricating a composite integrated optical device includes providing a substrate comprising a silicon layer, forming a waveguide in the silicon layer, and forming a layer comprising a metal material coupled to the silicon layer. The method also includes providing an optical detector, forming a metal-assisted bond between the metal material and a first portion of the optical detector, forming a direct semiconductor-semiconductor bond between the waveguide, and a second portion of the optical detector.
Description
BACKGROUND OF THE INVENTION

Silicon integrated circuits (“ICs”) have dominated the development of electronics and many technologies based upon silicon processing have been developed over the years. Their continued refinement led to nanoscale feature sizes that can be critical for making complementary metal oxide semiconductor CMOS circuits. On the other hand, silicon is not a direct bandgap materials. Although direct bandgap materials, including III-V compound semiconductor materials, such as indium phosphide, have been developed, there is a need in the art for improved methods and systems related to photonic ICs utilizing silicon substrates.


SUMMARY OF THE INVENTION

According to an embodiment of the present invention, techniques related to semiconductor fabrication processes are provided. Merely by way of example, embodiments of the present invention have been applied to methods and systems for bonding heterogeneous substrates for use in photonic integration applications. More particularly, an embodiment of the present invention utilizes a hybrid bonding structure including a metal/semiconductor bond and a semiconductor/semiconductor bond in order to achieve low optical loss and high electrical conductivity. The semiconductor/semiconductor bond may be an interface assisted bond. However, the scope of the present invention is broader than this application and includes other substrate bonding techniques.


According to an embodiment of the present invention, a hybrid integrated optical device is provided. The hybrid integrated optical device includes a substrate including a silicon layer and a compound semiconductor device bonded to the silicon layer. The hybrid integrated optical device also includes a bonding region disposed between the silicon layer and the compound semiconductor device. The bonding region includes a metal-semiconductor bond at a first portion of the bonding region. The metal-semiconductor bond includes a first pad bonded to the silicon layer, a bonding metal bonded to the first pad, and a second pad bonded to the bonding metal and the compound semiconductor device. The bonding region also includes an interface assisted bond at a second portion of the bonding region. The interface assisted bond includes an interface layer positioned between the silicon layer and the compound semiconductor device. The interface assisted bond provides an ohmic contact between the silicon layer and the compound semiconductor device.


According to another embodiment of the present invention, a method of fabricating a hybrid integrated optical device is provided. The method includes providing a substrate comprising a silicon layer and providing a compound semiconductor device. The method also includes forming a bonding region disposed between the silicon layer and the compound semiconductor device. The bonding region includes a metal-semiconductor bond at a first portion of the bonding region. The metal-semiconductor bond includes a first pad bonded to the silicon layer, a bonding metal bonded to the first pad, and a second pad bonded to the bonding metal and the compound semiconductor device. The bonding region also includes an interface assisted bond at a second portion of the bonding region. The interface assisted bond includes an interface layer positioned between the silicon layer and the compound semiconductor device, wherein the interface assisted bond provides an ohmic contact between the silicon layer and the compound semiconductor device.


Numerous benefits are achieved by way of the present invention over conventional techniques. For example, embodiments of the present invention provide methods and systems suitable for providing a bond with good mechanical strength, good electrical conductivity, sufficient compliance to allow the composite or hybrid bonding of semiconductor materials with different coefficients of thermal expansion with good reliability, and which also has good optical transparency. This combination of benefits allows both electrical and optical functionality across the bonded interface between two or more distinct semiconductor materials. These and other embodiments of the invention along with many of its advantages and features are described in more detail in conjunction with the text below and attached figures.





BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 illustrates an example of a photodiode with a low stress bond between a substrate and a silicon substrate;



FIG. 2 illustrates a bonded structure according to an embodiment of the present invention;



FIG. 3 illustrates a phase diagram showing alloy stability according to an embodiment of the present invention;



FIG. 4 is a simplified schematic diagram of a compound semiconductor structure bonded to a silicon substrate according to an embodiment of the present invention;



FIGS. 5A-5C are simplified schematic diagrams illustrating bond interfaces according to an embodiment of the present invention;



FIGS. 6A-6B are simplified schematic diagrams illustrating bond interfaces according to another embodiment of the present invention;



FIG. 7 is a simplified flowchart illustrating a method of fabricating a hybrid semiconductor structure according to an embodiment of the present invention; and



FIG. 8 is a simplified flowchart illustrating a method of fabricating a hybrid semiconductor structure according to another embodiment of the present invention.





DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Embodiments of the present invention relate to an apparatus and method that preferably uses a bonding stress for wafer bonding and utilizes an intermediate layer to facilitate the transition from silicon and the like to another material for optical coupling as well as electron transport. Embodiments of the present invention preferably incorporate low stress, low temperature wafer bonding known in the industry and preferably comprise a thin film intermediate layer for optical coupling as well electron transport.



FIG. 1 illustrates an example of a photodiode with a low stress bond between a III-V substrate and a silicon substrate. FIG. 2 illustrates a bonded structure according to an embodiment of the present invention. As illustrated in FIG. 2, two interfaces 712 and 714 are provided. First interface 712 is positioned between a silicon substrate 720 and an intermediate layer 718. Second interface 714 is located between intermediate layer 718 and a second semiconductor layer 716. Embodiments of the present invention are preferably used in the bonding process to facilitate integration of heterogeneous materials. Embodiments that facilitate integration preferably share the stress due to lattice mismatch between the silicon crystal and the second semiconductor that can form at these two interfaces and can be greatly reduced because of the reduced need for crystalline in the intermediate layer. The intermediate layer can be an alloy whose composition can be graded across the layer to facilitate the bonding at both interfaces 712 and 714.


Intermediate layer 718 is preferably thin, ranging from between approximately 4-5 monolayers to more than approximately 60-70 monolayers, substantially allowing the optical and thermal conduction properties to be virtually unaffected while the electron transport can preferably be achieved via actual carrier transport across the layer. In some embodiments of the present invention, intermediate layer 718 forms thermal and electric contacts at both the first interface and second interface. Embodiments of the present invention can be used in the fabrication of a plurality of high performance optoelectronic components, including but not limited to modulators, lasers, detectors, amplifiers, couplers, wavelength tunable optical components and/or circuits, combinations thereof, or the like. Embodiments as described herein are applicable to a variety of material systems including silicon as illustrated by silicon substrate 720 and/or the like and second semiconductor materials 716, which can be a compound semiconductor material. Utilizing embodiments of the present invention, heterogeneous materials (e.g., compound semiconductors and silicon substrates can be integrated on a common substrate.


The term “bandgap” as used throughout this application includes but is not limited to the energy difference between the top of the valence band and the bottom of the conduction band. The term “optical coupling” as used throughout this application includes but is not limited to placing two or more electromagnetic elements including optical waveguides close together so that the evanescent field generated by one element does not decay much before it reaches the other element. The term “electron transport” as used throughout this application includes but is not limited to an electron transport chain coupling a chemical reaction between an electron donor and an electron acceptor to the transfer of H+ ions across a membrane, through a set of mediating chemical or biochemical reactions. The term “complementary metal oxide semiconductor” as used throughout this application includes but is not limited to technologies for making integrated circuits, microprocessors, microcontrollers, static RAM, digital logic circuits, analog circuits, and highly integrated transceivers.


Embodiments of the present invention optionally utilize several features of intermediate layer 718 as illustrated in FIG. 2. According to an embodiment, the thickness of the intermediate layer 718 is very thin, ranging from a few monolayers (i.e., around 10 Å in thickness) to tens of monolayers. In an embodiment, the intermediate layer is deposited using a deposition technique that provides for uniform coverage at small thicknesses. Exemplary deposition techniques include PVD, ALD, sputtering, e-beam deposition, or the like. Intermediate layer 718 is preferably deposited at relatively low temperatures ranging from temperatures less than 200° C. At these low temperatures, there preferably exist small differences of thermal expansion (i.e., differences in the coefficient of thermal expansion (CTE)) between first interface 712 and second interface 714. Intermediate layer 718 preferably forms thermal contacts at the interfaces and is preferably thermally conductive. Intermediate layer 718 preferably forms good electrical contacts at both interfaces and is preferably electrically conductive. It is not necessary to be crystalline in nature so that the lattice matching at both interfaces is not an issue. In some embodiments, intermediate layer 718 is an alloy material for which the composition varies across the layer.


Embodiments of the present invention are applicable to an apparatus that includes a semiconductor layer that is provided over an intermediate layer that is provided over a silicon substrate layer. The intermediate layer has a lower thermal conductivity than the semiconductor layer. The apparatus also includes a plurality of interfaces that are provided between the semiconductor layer and the underlying layer(s), thereby preventing crystalline lattice mismatch.


Embodiments of the present invention also include a bonding method including forming first and second bonding surfaces on first and second materials, respectively, at least one of the bonding surfaces including an intermediate layer. The method also includes enhancing activation of at least one of said first and second bonding surfaces, terminating at least one of said first and second bonding surfaces with species allowing formation of chemical and electrical bonds, and annealing said first and second materials at a temperature.



FIG. 3 illustrates a phase diagram showing alloy stability according to an embodiment of the present invention. As illustrated in FIG. 3, the stability of the alloy makes such an alloy suitable for use as an intermediate layer such as intermediate layer 718. In some embodiments, the alloy (e.g., InxPdy) has a small thickness to accommodate stress at the semiconductor-semiconductor interface.


While the embodiments of the invention described herein are directed to wafers used in the semiconductor industry, the invention is also applicable to thermoelectric (TE) cooling technology as well as virtually any application including optical coupling and electron transport.


Merely by way of example, an intermediate layer suitable for use according to embodiments of the present invention is InxPdy, for example, In0.7Pd0.3, which is an alloy that is stable up to very high temperatures as illustrated in FIG. 3. This alloy forms an ohmic contact at interfaces with both silicon and/or III-V materials for which the doping types at either side can be either p-type or n-type. Thus, embodiments of the present invention provide an intermediate layer that provides both ohmic contact between materials on both sides of the intermediate layer, adhesion, optical quality including transparency (i.e., low optical loss), stress accommodation, and other benefits. Other suitable alloys include germanium palladium, gold/germanium, Au/Sn, Al/Mg, Au/Si, palladium, indium/tin/silver alloys, metal alloys containing Bi, Sn, Zn, Pb, or In, combinations thereof, or the like. The optimal alloy will generally have eutectic or peritectic points, and will allow a bonding process temperature in the 350° C. to 500° C. range.



FIG. 4 is a simplified schematic diagram of a compound semiconductor structure bonded to a silicon substrate according to an embodiment of the present invention. Referring to FIG. 4, a composite metal/semiconductor bond is illustrated in relation to bonding of a compound semiconductor device 810 to a silicon-based substrate 805. In the embodiment illustrated in FIG. 4, the silicon-based substrate 805 is a silicon-on-insulator (SOI) substrate although this is not required by embodiments of the present invention. The SOI substrate includes a silicon handle layer 806, a silicon oxide layer 807, and a silicon layer 808, which may be single crystal silicon. Planarizing material is used in the embodiment illustrated in FIG. 4 as well as an interconnect metal that provides for electrical conductivity between portions of the compound semiconductor device 810 and the silicon layer 808 of the SOI substrate. In the embodiment illustrated in FIG. 4, the compound semiconductor device 810 extends to a height above the top surface of the silicon layer 808.


As illustrated in FIG. 4, several bonds are formed between silicon layer 808 and the compound semiconductor device 810. Bond 1 is a metal/metal bond. Associated with Bond 1, pads (not shown in FIG. 4 but illustrated in following figures) are defined on both the SOI substrate (e.g., silicon layer 808) and the compound semiconductor device 810. These pads can include an adhesion metal such as Ti or Cr and a barrier metal such as Pt or Ni. The metal used for the bonding process will typically be a eutectic solder with a eutectic point in the 350° C.-500° C. range. An example of such a eutectic solder is AuGe.


Bond 2 as illustrated in FIG. 4 can be either a direct semiconductor/semiconductor bond or a metal-assisted semiconductor/semiconductor bond. For the metal-assisted semiconductor/semiconductor bond, a thin metal layer (e.g., ranging from one to a few monolayers to a few tens of monolayers) is deposited to improve the robustness of the interface and to better accommodate the CTE differences between silicon and the compound semiconductor device. In an embodiment, the thin metal layer is less than 50 Å in thickness. The very thin interfacial metal will still allow light to pass through without significant attenuation. The direct semiconductor/semiconductor bond can be formed using techniques including either chemical activation or plasma activation of the surfaces and joining the materials together with pressure and low temperature in order to bond the two surfaces together. Direct semiconductor bonding is useful in devices employing evanescent coupling in a waveguide structure as it will have lower optical attenuation than metal-assisted semiconductor bonding.



FIGS. 5A-5C are simplified schematic diagrams illustrating bond interfaces according to an embodiment of the present invention. As illustrated in FIG. 5A, the compound semiconductor device 820 has been thinned so that the top surface of the compound semiconductor device 820 is coplanar with the top surface of silicon layer 808. A planarizing material has been used to provide a planar surface extending above the top surface of silicon layer 808. Portions of the planarizing material have been removed (e.g., using a masking and etching process) and interconnect metals have been used to provide for electrical connectivity between portions of the silicon layer 808 and portions of the compound semiconductor device 820.



FIG. 5B illustrates additional details related to Bond 1 including pads 830 and 832 that provide for adhesion between the silicon layer 808, the bonding metal 834 and the compound semiconductor device 820. As discussed in relation to FIG. 4, pads 830 and 832 can include an adhesion metal such as Ti or Cr and a barrier metal such as Pt. The bonding metal 834 can be a eutectic solder such as AuGe. Other pad materials include Ni, W, refractory metals used as barrier layers in silicon-based devices, or the like, and other bonding metals include AuSn, InPd, InSn, InSnAg alloys, combinations thereof, or the like. These materials are listed merely by way of example and other materials that provide for adhesion between surfaces and/or barrier functionality are also included within the scope of the present invention.



FIG. 5C illustrates the use of an interface layer 840 between the compound semiconductor device 820 and the silicon layer 808. As discussed previously, the metal-assisted semiconductor/semiconductor bond illustrated in FIG. 5C includes a thin metal layer that provides beneficial functions including improving the robustness of the interface and accommodating CTE differences between the materials bonded to either side of this interface layer. Interface layers can include suitable materials including materials that provide peritectic properties including metals such as InPd, other metal alloys, combinations thereof, or the like. Gettering materials such as Ti or Cr can also be integrated with the interface layer to getter surface oxides and improve bond properties. For thin layers of interfacial metals, light will be able to pass without significant attenuation. The low optical loss provided by embodiments of the present invention include absorption coefficients that can be computed using waveguide models and the measured absorption properties of the interface layer. The use of an interface layer 840 will also provide an ohmic contact between the silicon layer 808 and the compound semiconductor device 820. Thus, embodiments of the present invention provide an interface that is electrically conductive without significant optical absorption.


Although FIGS. 5A-5C illustrate bonding of a compound semiconductor device to an SOI substrate, embodiments of the present invention are not limited to the bonding of a device to a substrate. Other embodiments of the present invention are applicable to substrate to substrate bonding, also referred to as wafer bonding. Thus, the compound semiconductor device illustrated in the figures can be replaced with a compound semiconductor substrate in the processes and structures described herein. One of ordinary skill in the art would recognize many variations, modifications, and alternatives.


As illustrated in FIG. 5C, an interface layer 840 such as a thin layer (e.g., less than 100 Å) of a metal alloy such as InxPdy, can be used to accommodate some of the CTE mismatch between the two semiconductor materials. In other embodiments, the interface layer is not present and a direct semiconductor/semiconductor bond is formed for Bond 2. Embodiments of the present invention utilize both a metal/metal bond illustrated by Bond 1 and a direct semiconductor/semiconductor bond or an interface assisted semiconductor/semiconductor bond illustrated by Bond 2. Such a hybrid bonding approach utilizes the benefits provided by both types of bonds to reduce or overcome the disadvantages of low temperature semiconductor/semiconductor bonding including the weak interface as well as the disadvantages of metal/metal bonding including high optical loss in the vicinity of the metal/metal bond. Thus, embodiments of the present invention provide for high strength bonds and electrical conductivity (Bond 1) while enabling low optical loss and electrical conductivity in regions of the structure suitable for light propagation (Bond 2).



FIGS. 6A-6B are simplified schematic diagrams illustrating bond interfaces according to another embodiment of the present invention. In the case where light propagates parallel to the interface formed at Bond 2 and evanescent coupling is used between the silicon layer 808 and the compound semiconductor device 820, a combination of direct semiconductor-semiconductor bonding and metal-assisted semiconductor-semiconductor bonding may be employed to form Bond 2. This can be achieved by selective patterning of the thin interfacial metal. Referring to FIG. 6A, Bond 2′ between the silicon layer 808 and the compound semiconductor device 810 is illustrated. Bond 2′ includes not only an interface layer 840′ similar to layer 840 in FIG. 5C, but a direct semiconductor-semiconductor bond 842. In the embodiment illustrated in FIG. 6B, the interface layer 840′ is patterned to provide regions that are free of the interface layer, which may be a metal layer. As an example, in a light emitting device, the direct semiconductor-semiconductor bond could be positioned adjacent the light emission region to prevent absorption of light by the interface layer. The combination of an interface layer with a direct semiconductor-semiconductor bond thus provides benefits associated with each of the bonding techniques in a hybrid manner.


The bonding processes described herein can be performed in the temperature range from about 350° C. to about 500° C. In a particular embodiment, the temperature associated with the bonding process is in the temperature range of 400° C.-450° C. These temperatures are below the temperature at which CMOS circuits, which may be previously fabricated on the SOI substrate, would be damaged. This enables the integration of complex electrical functions while still providing a robust bond between the dissimilar materials discussed herein.



FIG. 7 is a simplified flowchart illustrating a method of fabricating a hybrid semiconductor structure according to an embodiment of the present invention. The method 900 includes providing a substrate comprising a silicon layer (910), providing a compound semiconductor device (e.g., an InP semiconductor laser) (912), and forming a bonding region disposed between the silicon layer and the compound semiconductor device. Forming the bonding region includes forming a metal-semiconductor bond at a first portion of the bonding region (914). The metal-semiconductor bond includes a first pad bonded to the silicon layer, a bonding metal bonded to the first pad, and a second pad bonded to the bonding metal and the compound semiconductor device. Forming the bonding region also includes forming an interface assisted bond at a second portion of the bonding region (916). The interface assisted bond includes an interface layer (e.g., InxPdy) positioned between the silicon layer and the compound semiconductor device. The interface assisted bond provides an ohmic contact between the silicon layer and the compound semiconductor device. In an embodiment, the interface layer has a thickness less than 50 Å.


According to an embodiment, the substrate includes an SOI wafer including a silicon substrate, an oxide layer disposed on the silicon substrate, and the silicon layer is disposed on the oxide layer. In embodiments utilizing a laser or other light generator, the second portion of the bonding region can be substantially free from the interface layer at a position adjacent an active region of the laser or optical generator in order to reduce optical losses. The bonding processes can be performed using low temperature bonding processes, for example, at a temperature ranging from about 350° C. to about 500° C., more particularly, from about 400° C. to about 450° C.


It should be appreciated that the specific steps illustrated in FIG. 7 provide a particular method of fabricating a hybrid semiconductor structure according to an embodiment of the present invention. Other sequences of steps may also be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Moreover, the individual steps illustrated in FIG. 7 may include multiple sub-steps that may be performed in various sequences as appropriate to the individual step. Furthermore, additional steps may be added or removed depending on the particular applications. One of ordinary skill in the art would recognize many variations, modifications, and alternatives.



FIG. 8 is a simplified flowchart illustrating a method of fabricating a hybrid semiconductor structure according to another embodiment of the present invention. The method 950 includes providing an SOI substrate (960) and providing a compound semiconductor device (962), which can also be referred to as a compound semiconductor die. In an embodiment of the present invention, the SOI substrate includes one or more optical components such as waveguides, optical isolators, reflective structures, or the like and the compound semiconductor device is an InP gain medium.


The method also includes patterning metals in a first bond region (964). The metals can be deposited or formed in a variety of manners. The first bond region can be used for metal-metal bonding and/or for metal-assisted semiconductor-semiconductor bond on one or both materials. After the metals are patterned, a surface treatment is performed (966), for example, a chemical treatment of the surface(s), a plasma activation for a semiconductor-semiconductor bond without metal assist, or the like. The surface treatment can be performed in a controlled atmosphere such as an inert environment, a reduced pressure atmosphere such as a vacuum, or the like. The method further includes positioning the compound semiconductor device on the SOI substrate, such as a receptor site (968) and applying heat and pressure to join the compound semiconductor device to the SOI substrate (970). In an embodiment, the joining step simultaneously effects both metal-based and semiconductor-based bonds.


It should be appreciated that the specific steps illustrated in FIG. 8 provide a particular method of fabricating a hybrid semiconductor structure according to another embodiment of the present invention. Other sequences of steps may also be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Moreover, the individual steps illustrated in FIG. 8 may include multiple sub-steps that may be performed in various sequences as appropriate to the individual step. Furthermore, additional steps may be added or removed depending on the particular applications. One of ordinary skill in the art would recognize many variations, modifications, and alternatives.


It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.

Claims
  • 1. An integrated optical device comprising: a semiconductor substrate that forms: an uppermost substrate surface, anda recess within the uppermost substrate surface, the recess forming a lower substrate surface;a first metal pad bonded directly to the lower substrate surface within the recess;a compound semiconductor device, comprising a compound semiconductor material, with a second metal pad bonded thereto, wherein: the compound semiconductor device includes a planar uppermost surface and a lower device surface,the second metal pad is bonded to the lower device surface; anda bonding metal, comprising InxPdy, wherein the bonding metal bonds the first metal pad to the second metal pad.
  • 2. The integrated optical device of claim 1, further comprising a planarizing material that fills at least a portion of the recess that is not occupied by: the compound semiconductor device,the first metal pad,the second metal pad, andthe bonding metal,and wherein, in the portion of the recess, the planarizing material extends to a height above the lower substrate surface that exceeds a height of the planar uppermost surface of the compound semiconductor device above the lower substrate surface.
  • 3. The integrated optical device of claim 2, wherein the planarizing material forms a planar surface that is above the uppermost substrate surface and above the planar uppermost surface of the compound semiconductor device.
  • 4. The integrated optical device of claim 2, wherein the planarizing material: extends above at least some portions of the uppermost substrate surface, andextends above the planar uppermost surface of the compound semiconductor device.
  • 5. The integrated optical device of claim 4, wherein the planarizing material forms one or more openings, wherein interconnect metal couples with at least one of: the uppermost substrate surface, orthe planar uppermost surface of the compound semiconductor device.
  • 6. The integrated optical device of claim 5, wherein the planarizing material forms two or more openings, wherein at least one portion of the interconnect metal couples with both the uppermost substrate surface, and the planar uppermost surface of the compound semiconductor device, through respective ones of the two or more of the openings.
  • 7. The integrated optical device of claim 1, wherein x=0.7 and y=0.3.
  • 8. The integrated optical device of claim 1, wherein the first metal pad or the second metal pad comprises at least one of Ti, Cr, Pt, Ni or W.
  • 9. The integrated optical device of claim 1, wherein: the semiconductor substrate comprises a waveguide;the compound semiconductor device is configured to emit light; andthe compound semiconductor device and the semiconductor substrate are configured to couple the light emitted by the compound semiconductor device, into the waveguide.
  • 10. The integrated optical device of claim 1, wherein: the first metal pad, the second metal pad, and the bonding metal form a first bond coupling the lower substrate surface with the lower device surface;the compound semiconductor device has a planar lowermost surface, which is lower than the lower device surface; andthe lower substrate surface and the planar lowermost surface of the compound semiconductor device are in surface to surface contact with one another.
  • 11. The integrated optical device of claim 10, wherein the compound semiconductor device is a light-emitting device.
  • 12. The integrated optical device of claim 10, wherein the compound semiconductor device is a detector.
  • 13. The integrated optical device of claim 1, wherein the planar uppermost surface of the compound semiconductor device is coplanar with the uppermost substrate surface.
  • 14. The integrated optical device of claim 1, wherein: the compound semiconductor device has a planar lowermost surface, which is lower than the lower device surface; andthe semiconductor substrate and the compound semiconductor device form a direct semiconductor/semiconductor contact between the lower substrate surface and the planar lowermost surface of the compound semiconductor device.
CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/633,343, filed on Jun. 26, 2017, entitled “METHOD AND SYSTEM FOR HETEROGENEOUS SUBSTRATE BONDING FOR PHOTONIC INTEGRATION,” which application is a continuation of U.S. patent application Ser. No. 14/880,936, filed on Oct. 12, 2015, entitled “METHOD AND SYSTEM FOR HETEROGENEOUS SUBSTRATE BONDING FOR PHOTONIC INTEGRATION,” now U.S. Pat. No. 9,709,735, issued on Jul. 18, 2017, which application is a continuation of U.S. patent application Ser. No. 14/135,006, filed on Dec. 19, 2013, entitled “METHOD AND SYSTEM FOR HETEROGENEOUS SUBSTRATE BONDING FOR PHOTONIC INTEGRATION,” now U.S. Pat. No. 9,190,400, issued on Nov. 17, 2015, which application is a division of U.S. patent application Ser. No. 12/902,621, filed on Oct. 12, 2010, entitled “METHOD AND SYSTEM OF HETEROGENEOUS SUBSTRATE BONDING FOR PHOTONIC INTEGRATION,” now U.S. Pat. No. 8,630,326, issued on Jan. 14, 2014, which application claims priority to U.S. Provisional Patent Application No. 61/251,132, filed on Oct. 13, 2009, entitled “HETEROGENEOUS WAFER BONDING FOR PHOTONIC INTEGRATION.” The disclosures of all of the above-identified applications are hereby incorporated by reference in their entireties for all purposes. Additionally, the disclosure of U.S. Pat. No. 8,611,388 is hereby incorporated by reference in its entirety for all purposes.

US Referenced Citations (123)
Number Name Date Kind
4293826 Scifres et al. Oct 1981 A
5190883 Menigaux et al. Mar 1993 A
5319667 Dutting et al. Jun 1994 A
5333219 Kuznetsov Jul 1994 A
5838070 Naruse et al. Nov 1998 A
5858814 Goossen et al. Jan 1999 A
5981400 Lo Nov 1999 A
5987050 Doerr et al. Nov 1999 A
6002507 Floyd Dec 1999 A
6101210 Bestwick et al. Aug 2000 A
6192058 Abeles Feb 2001 B1
6242324 Kub et al. Jun 2001 B1
6429045 Furukawa et al. Aug 2002 B1
6583445 Reedy et al. Jun 2003 B1
6667237 Metzler Dec 2003 B1
6714566 Coldren et al. Mar 2004 B1
6728279 Sarlet et al. Apr 2004 B1
6759746 Davies Jul 2004 B1
6828657 Hara et al. Dec 2004 B2
6888989 Zhou et al. May 2005 B1
6959863 Figuet et al. Nov 2005 B2
7058096 Sarlet et al. Jun 2006 B2
7256483 Epler et al. Aug 2007 B2
7257283 Liu et al. Aug 2007 B1
7633988 Fish et al. Dec 2009 B2
7755113 Yamazaki et al. Jul 2010 B2
7851332 Yamazaki et al. Dec 2010 B2
7972875 Rogers et al. Jul 2011 B2
8106379 Bowers Jan 2012 B2
8222084 Pallesasse et al. Jul 2012 B2
8290014 Junesand et al. Oct 2012 B2
8368995 Dallesasse et al. Feb 2013 B2
8445326 Dallesasse et al. May 2013 B2
8463088 Asghari et al. Jun 2013 B1
8559470 Dallesasse et al. Oct 2013 B2
8605766 Dallesasse et al. Dec 2013 B2
8611388 Krasulick et al. Dec 2013 B2
8615025 Dallesasse et al. Dec 2013 B2
8630326 Krasulick et al. Jan 2014 B2
8722464 Dallesasse et al. May 2014 B2
8735191 Marchena May 2014 B2
8768123 Yao et al. Jul 2014 B2
8859394 Dallesasse et al. Oct 2014 B2
9159631 Marchena et al. Oct 2015 B2
9190400 Krasulick et al. Nov 2015 B2
9461026 Dallesasse et al. Oct 2016 B2
9659993 Dallesasse et al. May 2017 B2
9709735 Krasulick Jul 2017 B2
9922967 Krasulick Mar 2018 B2
10373939 Krasulick Aug 2019 B2
20020096717 Chu et al. Jul 2002 A1
20020106893 Furukawa et al. Aug 2002 A1
20020197013 Liu et al. Dec 2002 A1
20030042494 Worley Mar 2003 A1
20030128724 Morthier Jul 2003 A1
20040037342 Blauvelt et al. Feb 2004 A1
20040077135 Fan et al. Apr 2004 A1
20040142575 Brewer Jul 2004 A1
20040182914 Venugopalan Sep 2004 A1
20040228384 Oh et al. Nov 2004 A1
20040245425 Delpiano Dec 2004 A1
20040253792 Cohen et al. Dec 2004 A1
20040259279 Erchak et al. Dec 2004 A1
20050211465 Sunohara et al. Mar 2005 A1
20050211993 Sano et al. Sep 2005 A1
20050213618 Sochava et al. Sep 2005 A1
20050226284 Tanaka et al. Oct 2005 A1
20060002443 Farber et al. Jan 2006 A1
20060057836 Nagarajan et al. Mar 2006 A1
20060093062 Yun May 2006 A1
20060121373 Yang et al. Jun 2006 A1
20060124954 Akaishi Jun 2006 A1
20060246636 Imai et al. Nov 2006 A1
20070002924 Hutchinson et al. Jan 2007 A1
20070280326 Piede et al. Dec 2007 A1
20080135859 Cho Jun 2008 A1
20080181557 Wang et al. Jul 2008 A1
20090016399 Bowers et al. Jan 2009 A1
20090065891 Dantz et al. Mar 2009 A1
20090135861 Webster et al. May 2009 A1
20090245316 Sysak et al. Oct 2009 A1
20090267173 Takahashi et al. Oct 2009 A1
20090278233 Pinnington et al. Nov 2009 A1
20090294803 Nuzzo et al. Dec 2009 A1
20090294814 Assefa et al. Dec 2009 A1
20100006972 La Tulipe, Jr. et al. Jan 2010 A1
20100059822 Pinguet et al. Mar 2010 A1
20100111128 Qin et al. May 2010 A1
20100166360 Jones et al. Jul 2010 A1
20110008577 Miyake et al. Jan 2011 A1
20110012261 Choi et al. Jan 2011 A1
20110032964 Sauer et al. Feb 2011 A1
20110085572 Dallesasse et al. Apr 2011 A1
20110085577 Krasulick et al. Apr 2011 A1
20110085760 Han et al. Apr 2011 A1
20110086461 Bolis Apr 2011 A1
20110089524 Nonagaki Apr 2011 A1
20110163444 Hayashi Jul 2011 A1
20110165707 Lott et al. Jul 2011 A1
20110211604 Roscher Sep 2011 A1
20110244613 Heck et al. Oct 2011 A1
20110267676 Dallesasse et al. Nov 2011 A1
20120001166 Doany et al. Jan 2012 A1
20120002694 Bowers et al. Jan 2012 A1
20120057079 Dallesasse et al. Mar 2012 A1
20120057609 Dallesasse et al. Mar 2012 A1
20120057610 Dallesasse et al. Mar 2012 A1
20120057816 Krasulick et al. Mar 2012 A1
20120091594 Landesberger et al. Apr 2012 A1
20120104623 Pagaila et al. May 2012 A1
20120120978 Budd et al. May 2012 A1
20120149148 Dallesasse et al. Jun 2012 A1
20120170931 Evans et al. Jun 2012 A1
20120189317 Heck et al. Jul 2012 A1
20120264256 Dallesasse et al. Oct 2012 A1
20120320939 Baets et al. Dec 2012 A1
20130037905 Shubin et al. Feb 2013 A1
20130122617 Lott et al. May 2013 A1
20130189804 Marchena Jul 2013 A1
20130302920 Dallesasse et al. Nov 2013 A1
20150104905 Park et al. Feb 2015 A1
20150123157 Dallesasse et al. May 2015 A1
20160111407 Krasulick Apr 2016 A1
Foreign Referenced Citations (24)
Number Date Country
101349786 Jan 2009 CN
104137262 Nov 2015 CN
105336748 May 2019 CN
2648906 Oct 2013 EP
2648906 Sep 2018 EP
06224404 Aug 1994 JP
2004-063730 Feb 2004 JP
2004311526 Nov 2004 JP
2006173568 Jun 2006 JP
2008-122926 May 2008 JP
2008-233707 Oct 2008 JP
2013-507792 Apr 2013 JP
6059151 Dec 2016 JP
6197183 Sep 2017 JP
6205563 Oct 2017 JP
101963465 Mar 2019 KR
11201403688 Dec 2015 SG
201140975 Nov 2011 TW
2005119776 Dec 2005 WO
2011046898 Apr 2011 WO
2012078361 Jun 2012 WO
2013103769 Jul 2013 WO
2013109955 Jul 2013 WO
2014025824 Feb 2014 WO
Non-Patent Literature Citations (91)
Entry
U.S. Appl. No. 14/135,006 received a Non-Final Office Action dated Feb. 6, 2015, 11 pages.
U.S. Appl. No. 14/135,006 received a Notice of Allowance dated Jul. 17, 2015, 8 pages.
U.S. Appl. No. 14/245,191 received a Notice of Allowance dated Apr. 20, 2016, 8 pages.
U.S. Appl. No. 14/261,276 received a Non-Final Office Action dated Mar. 6, 2015, 6 pages.
U.S. Appl. No. 14/261,276 received a Notice of Allowance dated Jun. 11, 2015, 5 pages.
U.S. Appl. No. 14/482,650 received a Final Office Action dated Aug. 3, 2016, 11 pages.
U.S. Appl. No. 14/482,650 received a Non-Final Office Action dated Apr. 21, 2016, 10 pages.
U.S. Appl. No. 14/482,650 received a Notice of Allowance dated Jan. 19, 2017, 8 pages.
U.S. Appl. No. 14/862,435 received a Non-Final Office Action dated Jan. 13, 2017, 6 pages.
U.S. Appl. No. 14/862,435 received a Notice of Allowance dated Nov. 2, 2017, 7 pages.
U.S. Appl. No. 14/880,936 received a Non-Final Office Action dated Jun. 3, 2016, 9 pages.
U.S. Appl. No. 14/880,936 received a Notice of Allowance dated Mar. 14, 2017, 8 pages.
U.S. Appl. No. 15/900,590 received a Non-Final Office Action dated May 15, 2020, 13 pages.
U.S. Appl. No. 15/900,590 received a Notice of Allowance dated May 3, 2019, 7 pages.
Chinese Patent Application CN201380005678.2 received an Office Action dated Mar. 30, 2015, 5 pages.
Analui, et al.; “A Fully Integrated 20-GB/s Optoelectronic Transceiver Implemented in a Standard 0.13-mu-m CMOS SOI Technology”; IEEE Journal of Solid State Circuits, vol. 41, No. 12; Dec. 2006; 11 pages; retrieved from the Internet: <http://ieeexplore.ieee.org/abs_all.jsp?arnumber=4014595&tag=1>.
Bickford, et al. “Electrical Characterization of GaAs Metal Bonded to Si” Applied Physics Letter 89, Jan. 21, 2006; doi: 10.1063/1.2219980, Jul. 7, 2006, retrieved from https://doi.org/10.10631/1.2219980, 3 pages.
Coldren et al., “Tunable Semiconductor Lasers: A Tutorial,” Journal of Lightwave Technology, Jan. 2004 22(1):193-202.
Coldren, “Monolithic Tunable Diode Lasers,” IEEE Journal on Selected Topics In Quantum Electronics, Nov./Dec. 2000; 6(6):988-999.
Flandorfer; Hans, “Phase Relationships in the In-rich part of the In-PD System”, Journal of Alloys and Compounds, vol. 336, Issues 1-2, Apr. 2002, pp. 176-780.
Hildebrand et al., “The Y-Laser: A Multifunctional Device for Optical Communication Systems and Switching Networks,” Journal of Lightwave Technology, Dec. 1993; 11 (12):2066-2075.
Isaksson et al., “10 GB/s Direct Modulation of 40 nm Tunable Modulated-Grating Y-branch Laser,” 10 GB/s Direct Modulation of 40 nm Tunable Modulated-Gialing Y-Branch Laser, in Optical Fiber Communication Conference and Exposition and The National Fiber Optic Engineers Conference, Technical Digest (CD) (Optical Society of America, 2005), paper OTuE2.
Kuznetsov et al., “Asymmetric Y-Branch Tunable Semiconductor Laser with 1.0 THz Tuning Range,” IEEE Photonics Technology Letters, Oct. 1992; 4(10):1093-1095.
Laroy et al., “Characteristics of the New Modulated Grating Y laser (MG-Y) for Future WDM Networks,” Proceedings Symposium IEEE/LEOS Benelux Chapter, 2003, Enschede, pp. 55-58, retrieved from the Internet: <http://leosbenelux.org/symp03/s03p055.pdf>.
Laroy, “New Concepts of Wavelength Tunable Laser Diodes For Future Telecom Networks,” [dissertation] Universiteit Gent, 2006 [in Dutch and English], 162 pages.
Laroy, “New Widely Tunable Laser Concepts For Future Telecommunication Networks,” FTW-symposium, Belgium, 2002; 2 pages total; retrieved from the Internet: <http://photonics.intec.ugent.be/download/pub1625.pdf>.
Magno et al., “Multiphysics Investigation of Thermo-optic Effect in Silicon-on-lnsulator Waveguide Arrays,” Excerpt from the Proceedings of the COM SOL Users Conference 2006, retrieved from the Internet: <http:/lcds.comsol.com/access/dl/papers/1628/Magno.pdf>, 6 pages total.
Morthier et al., “New Widely Tunable Edge-Emitting Laser Diodes at 1.55 1-1m Developed in the European 1ST-project NEWTON,” Semiconductor and Organic Optoelectronic Materials and Devices. Edited by Zah, Chung-En; Luo, Yi; Tsuji, Shinji. Proceedings of the SPIE, 2005; 5624:1-8; retrieved from the Internet: <http://photonics. intec.ugent.be/download/pub 1800.pdf>.
Morthier, “Advanced Widely Tunable Edge—Emitting Laser Diodes and Their Application in Optical Communications,” [presentation], Ghent University—IMEC, 2000, 23 pages total. Can be retrieved from the Internet: <broadband02.ici.ro/program/morthier 3a.ppt>.
Morthier, “New Widely Tunable Lasers for Optical Networks,” NEWTON Project No. IST-2000-28244, Dec. 2001; 5 pages; retrieved from the Internet: <http://www.istoptimist.unibo.iUpdf/network!projectspublic/NEWTON/Deliverables/D01.pdf>.
Passaro et al., “Investigation of Thermo-Optic Effect and Multi reflector Tunable Filter/Multiplexer in SOI Waveguides,” Optics Express, vol. 13, No. 9, May 2005; pp. 3429-3437.
Wesstrom et al., “Design of a Widely Tunable Modulated Grating Y-branch Laser Using the Additive Vernier Effect for Improved Super-Mode Selection,” IEEE 18th International Semiconductor Laser Conference, 2002, 99-100; retrieved from the Internet: <http://photonics.intec.ugent.be/download/pub1603.pdf>.
Wesstrom et al., “State-of-the-Art Performance ofWidelyTunable Modulated Gialing Y Branch Lasers,” Optical Fiber Communication Conference, Technical Digest (CD) (Optical Society of America, 2004), paper TuE2.
Non-Final Office Action dated Apr. 23, 2013 for U.S. Appl. No. 12/902,621; all pages.
Restriction Requirement dated May 17, 2012 for U.S. Appl. No. 12/902,621; all pages.
Non-Final Office Action dated Sep. 18, 2012 for U.S. Appl. No. 12/902,621; all pages.
Notice of allowance dated Oct. 2, 2013 for U.S. Appl. No. 12/902,621; all pages.
Final Office Action dated May 29, 2013 for U.S. Appl. No. 12/903,025; all pages.
Notice of Allowance dated Aug. 8, 2013 for U.S. Appl. No. 12/903,025; all pages.
Non-Final Office Action dated Dec. 5, 2012 for U.S. Appl. No. 12/903,025; all pages.
Final Office Action dated May 16, 2012 for U.S. Appl. No. 12/903,025; all pages.
Non-Final Office Action dated Dec. 29, 2011 for U.S. Appl. No. 12/903,025; all pages.
Final Office Action dated Jun. 17, 2013 for U.S. Appl. No. 13/040,154; all pages.
Notice of Allowance dated Jul. 26, 2013 for U.S. Appl. No. 13/040,154; all pages.
Non-Final Office Action dated Dec. 4, 2012 for U.S. Appl. No. 13/040,154; all pages.
Final Office Action dated May 16, 2012 for U.S. Appl. No. 13/040,154; all pages.
Non-Final Office Action dated Jan. 31, 2012 for U.S. Appl. No. 13/040,154; all pages.
Non-Final Office Action dated Mar. 13, 2012 for U.S. Appl. No. 13/040,179; all pages.
Notice of Allowance dated Jun. 12, 2013 for U.S. Appl. No. 13/040,179; all pages.
Non-Final Office Action dated Dec. 12, 2012 for U.S. Appl. No. 13/040,179; all pages.
Final Office Action dated Aug. 13, 2012 for U.S. Appl. No. 13/040,179; all pages.
Final Office Action dated Dec. 5, 2012 for U.S. Appl. No. 13/040,181; all pages.
Non-Final Office Action dated May 22, 2012 for U.S. Appl. No. 13/040,181; all pages.
Notice of Allowance dated Jun. 16, 2014 for U.S. Appl. No. 13/040,181; all pages.
Notice of Allowance dated Oct. 4, 2013 for U.S. Appl. No. 13/040,184; all pages.
Restriction Requirement dated Dec. 21, 2012 for U.S. Appl. No. 13/040,184; all pages.
Non-Final Office Action dated Apr. 23, 2013 for U.S. Appl. No. 13/040,184; all pages.
Notice of Allowance dated Sep. 19, 2012 for U.S. Appl. No. 13/076,205; all pages.
Notice of Allowance for U.S. Appl. No. 13/112,142 dated Mar. 20, 2012, 8 pages.
Non-Final Office Action dated Aug. 31, 2012 for U.S. Appl. No. 13/527,394; all pages.
Notice of Allowance dated Jan. 29, 2013 forU.S. Appl. No. 13/527,394; all pages.
Notice of Allowance dated Jan. 17, 2014 for U.S. Appl. No. 13/733,337, all pages.
Non-Final Office Action dated Aug. 30, 2013 for U.S. Appl. No. 13/869,408; all pages.
Notice of Allowance dated Jan. 6, 2014 for U.S. Appl. No. 13/869,408; all pages.
U.S. Appl. No. 14/245,191 received a Notice of Allowance, dated May 27, 2016, 8 pages.
U.S. Appl. No. 14/245,191 received a Final Rejection, dated Feb. 24, 2016, 11 pages.
U.S. Appl. No. 14/245,191 received a Non-Final Rejection, dated Aug. 12, 2015, 11 pages.
Pre-Interview Communication dated Apr. 29, 2015 for U.S. Appl. No. 14/562,169, all pages.
U.S. Appl. No. 15/900,590 received a Non-Final Office Action dated Aug. 31, 2018, 5 pages.
U.S. Appl. No. 15/633,343 received a Notice of Allowance dated Mar. 26, 2019, 9 pages.
U.S. Appl. No. 15/633,343 received a Non-Final Office Action dated Nov. 19, 2018, 12 pages.
Office Action dated Aug. 4, 2017 for Chinese Patent Application No. 201510646898.4; all pages.
CN 201510646898.4 filed Jan. 18, 2013 received an Office Action dated Mar. 19, 2018, all pages.
CN 201380005678.2 received an Office Action dated May 19, 2015, 6 pages.
Extended European Search Report dated Dec. 17, 2015 for European Application No. 11847549.0 filed on Nov. 22, 2011; all pages.
European Application No. 13738701.5.0 filed on Jan. 18, 2013 received an office action, dated May 2, 2018.
Extended European Search Report dated Aug. 10, 2015 for European Patent Application No. 13738701.5 filed Jan. 18, 2013; all pages.
International Search Report and Written Opinion dated Jan. 29, 2014 for International Patent Application No. PCT/US2013/053856; all pages.
International Search Report and Written Opinion dated Mar. 21, 2012 for International Patent Application No. PCT/US2011/061951; all pages.
International Search Report and Written Opinion dated Mar. 21, 2012 for International Application No. PCT/US2011/061951 filed on Nov. 22, 2011; all pages.
International Search Report and Written Opinion dated Mar. 1, 2013 for International Application No. PCT/US2013/020226 filed on Jan. 4, 2013; all pages.
International Preliminary Report on Patentability dated Jul. 17, 2014 for International Patent Application PCT/US2013/020226 filed on Jan. 4, 2013; all pages.
International Search Report and Written Opinion dated May 15, 2013 for International Application No. PCT/US2013/022244 filed on Jan. 18, 2013; all pages.
International Preliminary Report on Patentability dated Jul. 31, 2014 for International Patent Application PCT/US2013/022244 filed on Jan. 18, 2013; all pages.
Japanese Office Action dated Jan. 6, 2016 for Japan Application No. JP2013-543191, 5 pages.
Japanese Office Action dated Jul. 25, 2016 for Japan Application No. 2014-553476, filed Jan. 18, 2013; all pages.
First Notice of Reasons for Rejection dated Jan. 6, 2016 for Japanese Patent Application 2013-543191, all pages.
KR 10-2013-7017576 filed Nov. 22, 2011 received an Office Action dated Feb. 5, 2018, all pages.
Notice of Decision to Grant dated Dec. 22, 2018 for Korean Application KR10-2013-7017576, 3 pages.
U.S. Appl. No. 15/900,590 received a Final Office Action dated Dec. 8, 2020, 11 pages.
U.S. Appl. No. 15/900,590 received a Notice of Allowance dated Jul. 29, 2021, 8 pages.
Related Publications (1)
Number Date Country
20200152615 A1 May 2020 US
Provisional Applications (1)
Number Date Country
61251132 Oct 2009 US
Divisions (1)
Number Date Country
Parent 12902621 Oct 2010 US
Child 14135006 US
Continuations (3)
Number Date Country
Parent 15633343 Jun 2017 US
Child 16452212 US
Parent 14880936 Oct 2015 US
Child 15633343 US
Parent 14135006 Dec 2013 US
Child 14880936 US