The present invention relates to a stacked laser arrangement and a method for producing such a laser array.
For various applications, including virtual reality or augmented reality, laser diodes are used to generate visual information, the light from which is guided to the user's eye via suitable optics. Various laser diodes are used for the red, green and blue color range by placing them on a corresponding carrier and, if necessary, aligning them precisely with the optics.
The conventional manufacturing techniques required for this are often complex and expensive. In addition, the laser diodes arranged on a circuit board require complex optics in order to correctly align the different colors on the user's lens. Although these so-called squint angles can be compensated for by suitable lenses, these are often larger, which is undesirable for smaller applications, e.g. for spectacles.
There is therefore a need to find a space-saving solution for laser arrangements, especially for the virtual reality or augmented reality sector, which can also be implemented cost-effectively.
This need is met by the objects of the independent patent claims. Further developments and embodiments of the proposed principle are given in the sub-claims.
The inventors propose stacking several laser devices in a suitable form with spacers arranged between them in such a way that an easy-to-process and space-saving arrangement is created. This makes it possible to use the spacers for contacting the laser arrangements. Due to the low thickness, a stack with very small dimensions can be realized. The spacers can be contacted by various means, whereby a different resonator length can also be utilized. In addition, various stacked devices can be created in this way, i.e. laser devices with single ridges but also with multiple ridges. Depending on the desired light output power, the number of stacked laser arrangements of individual colors can be varied.
In one proposed aspect, a stacked laser arrangement comprises a first laser device with a light exit side and a semiconductor body forming a resonator with an active zone and with two main sides and side surfaces arranged substantially perpendicular thereto. The laser device comprises at least one contact area on a first of the two main sides, for example in the form of a contact surface. In addition, a first spacer with a first main contact side and a contact side surface is provided, wherein the first main contact side comprises at least one contact line which leads from a contact area to a connection surface on or adjacent to the contact side surface. According to the proposed principle, the first laser device is now attached to the first spacer with the first main side facing the first contact main side. The at least one contact area of the laser device is electrically connected to the contact area of the first main contact side of the spacer, and the side surfaces of the first laser device are spaced apart from the contact side surface. This arrangement allows the stacked laser arrangement to be placed directly on a carrier and supplied with power via the contacts on the main contact side of the spacer.
Stacking laser devices with the special spacer design enables 90 degree offset or even vertical mounting with simultaneous electrical contacting to single or multiple edge emitting laser diodes to the nearest electromechanical interface of the carrier. This results in an emission distance of half the laser thickness and the thickness of the spacer or less, depending on the position of the laser beam.
In some aspects, laser devices are provided for this purpose which, in operation, generate a beam with a radiation profile which comprises a fast axis and a slow axis, i.e. is elliptical in shape. The proposed laser arrangement ensures that the fast axis is essentially perpendicular to the main contact side. As a result, when installing such a laser arrangement with one or more devices on a carrier, the fast axis of the radiation profile runs parallel to a surface of the carrier, which allows particularly close mounting on the carrier and thus simplifies the arrangement of further elements.
In some further aspects, the contact side surface comprises a beveled area on which the connection surface is arranged. Depending on the requirements and needs, the connection surface can be designed differently on the contact side surface. In some aspects, the contact side surface is flat and the connection surface is designed as a simple metal layer, for example. In another embodiment, the contact side surface comprises one or more notches or recesses in which the connection surface is arranged. A notch comprises the property of providing a slightly larger surface area. In this way, a slight variation in the amount of solder or other conductive interconnect material can be tolerated, as excess material can remain in the recess. It is also possible to achieve precise positioning on a carrier using a corresponding pin that fits into the notch or recess.
A further aspect relates to the configuration of the geometric dimensions of the spacer and the laser device. In some aspects, a length of the first spacer is less than a length of the first laser device. The laser device thus protrudes beyond the spacer. This protrusion can occur both adjacent to the light emitting side and on the side facing away. In this embodiment, the first spacer is thus set back with respect to the light emission side.
Some further aspects deal with the stacking of several such laser devices and/or several spacers arranged on both sides of the device. This enables, on the one hand, flexible mounting (the contacts for the laser device can also be arranged on different sides of the laser device), and, on the other hand, stacking or combining several such arrangements. In one aspect, the first laser device comprises at least one contact area on a second of the two main sides.
A second spacer is provided with a first main contact side and a contact side surface, wherein the main contact side comprises at least one contact line which leads from a contact area to a connection surface on or adjacent to the contact side surface. The second spacer is thus designed similarly or identically to the first spacer. The orientation of the stacked laser arrangement can also be identified by different designs of the connection surface of the two spacers. According to the proposed principle, the first laser device is now attached with the second main side to the first main contact side of the second spacer. The at least one contact area of the second main side is also electrically conductively connected to the contact area of the first main contact side of the second spacer. Likewise, the side surfaces of the first laser device can optionally be spaced apart from the contact side surface of the second spacer. In particular, the two spacers can have the same dimensions so that the contact side surfaces are at the same distance from the laser device and are therefore at the same height. This enables precise and level positioning on a carrier.
In another embodiment, the first spacer comprises a second main contact side opposite the first main contact side with at least one contact area and a contact line connected thereto. The spacer is thus equipped with contact lugs or contact areas on both sides and thus allows two laser devices to be attached to it. Accordingly, a second laser device is provided in one embodiment, which comprises a light emission side and a semiconductor body forming a resonator with an active zone, two main sides and side surfaces arranged essentially perpendicular to it. The laser device comprises at least one contact area on a first of the two main sides. It is now attached to the first spacer with the first main side facing the second main contact side of the first spacer.
Likewise, the at least one contact area is electrically connected to the contact area of the second main contact side of the first spacer, and the side surfaces of the second laser device are spaced apart from the contact side surface of the first spacer.
Some further aspects relate to the design of the spacers. For example, they can be made from a dielectric material that comprises one or more conductive contact lugs or conductors on its surface. The conductive areas comprise a metallic layer, a metallic layer sequence or another conductive material. Alternatively, a semiconductor material such as silicon or a ceramic such as AlN can also be used. Generally, a thickness of the spacers is less than a thickness of the first and/or second laser arrangement attached to the main contact side.
Another aspect is the use of laser devices themselves as spacers, provided that they comprise the same contact structure as the spacers described above. In one embodiment, the first and/or the second spacer is thus formed by a third laser device with a light-emitting side and a semiconductor body forming a resonator with an active zone and with two main sides and side surfaces arranged substantially perpendicular thereto.
According to the proposed principle, a length of the third laser device is shorter than a length of one of the first and second laser devices but longer than a length of the other of the first and second laser devices. The different lengths allow contact areas to be provided on the exposed portion of the third laser device, which contact the laser device connected to this side, i.e. the first or second laser device. For this purpose, metallic contact lines can be provided on one of the main sides, which in turn are insulated from the semiconductor body of the third laser device. In other aspects, the n- or p-doped sides form common connection surfaces. Thus, in some aspects, an insulated n-doped side of the semiconductor body of the third laser device contacts a p-doped side from the first and/or second laser device. Alternatively, an isolated p-doped side of the semiconductor body of the third laser device may contact an n-doped side from the first and/or second laser device.
In some further aspects, the first and/or the second laser device can also be designed as a spacer. In this way, a stack of laser devices can be created, with some of the laser devices also forming spacers.
A further aspect relates to a method for generating a stacked laser arrangement. A first laser device is provided. This comprises a light-emitting side and a semiconductor body forming a resonator with an active zone, and with two main sides and side surfaces arranged essentially perpendicularly thereto. The first laser device also comprises at least one contact area for electrical connection on a first of the two main sides. In addition, a first spacer with a first main contact side and a contact side surface is provided. The main contact side comprises at least one contact line that leads from a contact area to a connection surface on or adjacent to the contact side surface. As already explained above, the connection surface can assume various shapes and structures.
In a subsequent step, contact areas of the first laser device and the spacer are aligned with each other. The main side of the first laser device, which comprises the contact area, is then attached to the first main side of the spacer, and the contact areas of the first laser device and the spacer are conductively connected to each other. The side surfaces of the first laser device are spaced apart from the contact side surface. This arrangement allows the stacked laser arrangement to be placed directly on a carrier and supplied with power via the contacts on the main contact side of the spacer. The laser device is not “in the way”.
In a further example, the spacer with the contact side surface is arranged on a carrier in such a way that a fast axis of a radiation profile emitted during operation of the laser device runs essentially parallel to a surface of the carrier. This avoids a possible downward limitation of the laser beam.
In one embodiment of the method, the first laser device comprises at least one contact area on a second of the two main sides. According to the proposed principle, a second spacer is provided with a first main contact side and a contact side surface. The contact main side also comprises at least one contact line leading from a contact area to a connection surface on or adjacent to the contact side surface. The second spacer and the first laser device are now attached to each other. This is done in such a way that the first laser device is aligned with the second main side facing the first main contact side of the second spacer and the at least one contact area of the second main side is electrically connected to the contact area of the first main contact side of the second spacer. The laser device is also mechanically attached to the spacer, either by the electrical connection (for example by means of a solder) or by an adhesive or the like. The side surfaces of the first laser device are spaced apart from the contact side surface.
In another example, the first spacer comprises a second main contact side opposite the first main contact side with at least one contact line. A second laser device is now provided here with a light emission side and a semiconductor body forming a resonator, wherein the semiconductor body comprises an active zone, two main sides and side surfaces arranged essentially perpendicularly thereto. In addition, the laser device comprises at least one contact area on a first of the two main sides. The first spacer and the second laser device are aligned with each other and attached to each other in such a way that the second laser device lies with the first main side facing the second main contact side of the first spacer. At the same time, the at least one contact area of the laser device is electrically conductively connected to the contact area of the second main contact side of the first spacer and the side surfaces of the second laser device are spaced apart from the contact side surface.
Some aspects deal with a design of the first and/or second spacer. For example, a recess, indentation or notch can be provided here, which can be produced by etching, milling, laser cutting or other measures. This element extends from the first main contact side in the direction of the second main contact side. A contact line is also created, in particular as a metallic layer that extends from the contact area to the recess. The recess or indentation can also be metallized. The contact surface is also created on the main contact side.
In some aspects, the first and/or second spacer is thinner or of the same thickness as the laser devices. It can be made of a dielectric material, for example a ceramic. This in turn can be processed at wafer level and structured with the contact surfaces. The spacers are then cut from the wafer composite.
Further aspects and embodiments according to the proposed principle will become apparent with reference to the various embodiments and examples described in detail in connection with the accompanying drawings.
The following embodiments and examples show various aspects and their combinations according to the proposed principle. The embodiments and examples are not always to scale. Likewise, various elements may be shown enlarged or reduced in size in order to emphasize individual aspects. It is understood that the individual aspects and features of the embodiments and examples shown in the figures can be readily combined with each other without affecting the principle of the invention. Some aspects have a regular structure or shape. It should be noted that slight deviations from the ideal shape may occur in practice without, however, contradicting the inventive concept.
In addition, the individual figures, features and aspects are not necessarily shown in the correct size, and the proportions between the individual elements are not necessarily correct. Some aspects and features are emphasized by enlarging them. However, terms such as “above”, “above”, “below”, “below”, “larger”, “smaller” and the like are shown correctly in relation to the elements in the figures. It is thus possible to deduce such relationships between the elements on the basis of the figures.
The spacers 8′ 8 comprise one or more leads on their respective surfaces, which are electrically conductively connected to the contact areas on the main sides of the laser device 2, 3 and 4. The contact leads on the spacers lead to connection surfaces 82 or 82′ on the side surfaces of the spacers facing the carrier 50. These contact surfaces connect the spacer mechanically and electrically to the corresponding contact surfaces of the carrier 5. As shown in
For contacting the individual laser devices, a contact line can be formed on a side surface of the spacer 8 or 8′. For example, a contact surface can be prepared on the side of the spacer 8 or 8′ facing the laser device, which is electrically conductively connected to the corresponding contact area of the laser device. In some embodiments, this results in the spacer 8′ having a contact lead and a contact area on each of its main sides, while the spacers 8 only have such an area on one of their two main sides. The contact areas lead along the main side via leads to connection surfaces in or on the side surface of the respective spacer.
Alternatively, it is also possible, for example, to equip the two outer spacers 8 without a contact, provided that the laser devices 4 or 2 are only contacted via one of their main sides. In this case, the two spacers 8′ each comprise two contact areas, which are opposite the main side facing the laser device 2 or 4. The respective other side of the spacer elements 8′ also comprises either one contact area or two contact areas or no contact areas at all, depending on the design of the laser device 3. This allows a very flexible design and structuring of the various spacers 8′ according to the requirements and design of the laser devices to be stacked on top of each other. A spacer can thus have either none, one or several contact areas on its surface. Likewise, one or more contact areas can be provided on the opposite main side of the spacer. The contact areas lead via contact lines to corresponding connection surfaces on the side surface, with which the spacer is then placed on a PCB board, an intermediate carrier or another element and fastened mechanically and electrically.
On the main side, a laser device 4 with its contact is applied to the contact area 84 and mechanically and electrically attached thereto. An attachment of an electrical and mechanical nature to a carrier 5 is achieved via a solder material 81, which fills the space between a contact surface 56 on the carrier 5 and the connection surface 82 on the beveled side. On the one hand, the solder material creates an electrical connection and, on the other, also leads to improved mechanical retention. For further improvement, an additional adhesive or similar can be provided on the side facing away from the laser device to further strengthen and improve the mechanical mounting.
The beveled side surface makes it possible to compensate for variations in the amount of solder material 81 used. Depending on the amount of solder, this fills the space between the contact 56 on the carrier 5 and the connection surface 82 more or less completely. However, the bevel ensures that the spacer is correctly aligned with its lowest area and arranged vertically on the carrier 5.
This design can be varied with additional contact areas on the side surface.
The design of the spacers shown in
The spacers already explained in
The laser devices shown in these embodiments are designed as edge-emitting lasers. The radiation profile of such edge-emitting lasers is elliptical and comprises a so-called fast axis and a corresponding slow axis. The fast axis corresponds to the large main axis of the elliptical radiation profile, while the slow axis corresponds to the small main axis. This results in a radiation profile with a propagation that is lower parallel to the main sides of the respective laser devices than perpendicular to them. For this reason, in some embodiments, the stacked laser arrangement generated here is now rotated by 90° and thus applied offset to a carrier 5. One such embodiment is shown in
In a further embodiment, the proposed concept is now supplemented by using a laser device itself as a spacer, which further reduces the width of the individual elements.
Specifically, the laser device 4 is attached to the submount 80, the laser device 3 is located directly on the laser device 4 and the laser device 2 is located on the laser device 3. The individual laser devices comprise the same width so that their respective side surfaces are flush with each other. However, the laser devices are also less wide than the submount 80 on which the laser device 4 is mounted. This results in a slight gap between the side surface of the submount 80 and the corresponding side surfaces of the laser devices 2, 3 and 4 arranged on it.
For mounting on a carrier 5 as shown in
At the same time, the radiation profile of the individual laser devices is also rotated by 90° so that the radiation profiles 20, 30 and 40 now lie with their fast axis parallel to the surface of the carrier 5.
In this way, even in the rotated arrangement shown here, the laser devices can be very flat, i.e. with only a small height.
The distance 90 shown in the view of
In this respect,
In the same way, the surface of the laser device 3 is also insulated and metallization layers are formed on it. The different resonator length of the devices 2, 3 and 4 ensures that the contact lines run essentially vertically downwards towards the carrier surface and can contact the contact surfaces 56 on the upper side of the carrier via a solder material without another laser device being in the way. The different resonance length can also be used to define the color sequence of the individual laser devices of the laser arrangement.
Another embodiment of a stacked laser arrangement is shown in
In a further embodiment, these aspects can be combined with each other.
The contact surface on the side surface of the spacer 8 leads to a contact line that electrically connects a contact on the rear of the laser device 4 for feeding charge carriers. In contrast to the previous embodiments, this design now allows a more flexible and different arrangement of the laser devices on top of each other.
In one possible embodiment, a first contact line and a second contact line are arranged on the upper side of the laser device 4, which electrically connect the contact surfaces 56′ and 56″ on the carrier surface. The first and second lines are also implemented as metallic conductor layers 84′ and 84″, with the first conductor layer also directly forming the second contact for the laser device 4. The contact line 84″, which connects the contact area 56″, is insulated from the laser device 4 and in turn leads to the rear of the laser device 3, where it makes electrical contact with it. The upper side of the laser device 3 is designed in the same way and comprises a first contact line 84′, which is designed as a feed line for the laser device 3.
A second contact line 84″ in the form of a metallization layer again forms the supply line for the contact of the laser device 2 on the rear side of the laser device. Finally, a last contact area 56″ on the upper side of the carrier 5 is connected to a contact line 84″. In this way, a contact line is provided on the upper side of a laser device, which contacts the laser device itself, as well as a further contact line, which leads as an insulated metallization layer to the rear side of an adjacent laser device arranged thereon.
In an alternative embodiment, however, the laser devices can also be constructed differently so that they face each other in pairs. This is done in such a way that two contacts each contain the same potential.
For example, the n-doped side of the semiconductor body of the laser device 4 faces the submount 8, while the p-doped side of the semiconductor body of the device faces the laser device 3. The side of the laser device 3 that faces the device 4 is also the p-doped side. In this way, the first contact lines 84′ and 84″ on the upper side of the laser device 4 can be connected to a common potential or can also be designed as a common feed. The reason for this is that the p-doped sides of the two laser devices 3 and 4 are opposite each other.
The upper side of the laser device 3 is now the n-doped side. Accordingly, the device 2 is now arranged so that the n-doped side of the laser device 2 is again opposite the upper side of the laser device 3.
Accordingly, the contacts 84″ and 84′ on the upper side of the laser device 3 can also be suitably connected to a potential. In this embodiment, the insulated rear side of a laser device is thus used to realize a contact feed to the “own” semiconductor body on the one hand, but also a feed to the semiconductor body of a neighboring laser device, with the sides facing each other being doped in the same way.
Number | Date | Country | Kind |
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10 2022 106 938.9 | Mar 2022 | DE | national |
The present application is a national stage entry from International Application No. PCT/EP2023/057702, filed on Mar. 24, 2023, published as International Publication No. WO 2023/180553 A1 on Sep. 28, 2023, and claims the priority of the German first filing DE 10 2022 106 938.9 filed Mar. 24, 2022, the disclosures of all of which are hereby incorporated by reference in their entireties.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2023/057702 | 3/24/2023 | WO |