VCSEL with an intergrated heat sink and method of making

Claim 1

A method for making a VCSEL with an integrated heat sink comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region; forming a mesa with a surface and a trench, wherein said trench extends from said contact region into a portion of said second stack of distributed Bragg reflectors, and wherein said trench is adjacent to a portion of said mesa; forming a first dielectric layer overlying said substrate and covering a portion of said trench with a portion of said contact region being exposed; forming a conductive layer overlying said substrate; forming a seed layer having a pattern, said pattern of said seed layer having an opening on said mesa exposing a portion of said conductive layer; and plating a metal selectively on said seed layer generating a layer on said seed layer for removal of heat, thereby generating an integrated heat sink.

Claim 2

A method for making a VCSEL with an integrated heat sink comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region; forming a mesa with a surface and a trench, wherein said trench extends from said contact region into a portion of said second stack of distributed Bragg reflectors, and wherein said trench is adjacent to a portion of said mesa; forming a first dielectric layer overlying said substrate and covering a portion of said trench with a portion of said contact region being exposed; forming a conductive layer overlying said substrate; forming a seed layer having a pattern, said pattern of said seed layer having an opening on said mesa exposing a portion of said conductive layer; and plating a metal selectively on said seed layer generating a layer on said seed layer for removal of heat, thereby generating an integrated heat sink.

Claim 9

A method for making a VCSEL having a heat sink comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region having a ohmic metal layer disposed thereon; forming a masking layer with a pattern on the ohmic metal layer, wherein the pattern exposes portions of the ohmic metal layer while covering other portions of the ohmic metal layer; transferring the pattern into the ohmic metal layer and into the second stack of distributed Bragg reflectors to form a mesa having a surface; forming a dielectric layer on the substrate covering the surface of the mesa and the masking layer; forming a layer on the dielectric layer, the layer exposing the dielectric layer on the mesa; etching the dielectric layer exposed on the mesa, thereby removing the dielectric layer on the mesa and exposing the ohmic metal layer on the mesa; forming a second dielectric layer on the surface of the mesa; forming a metal layer on the dielectric layer and on the second dielectric layer; forming a seed layer having a pattern, the pattern of the seed layer forming an opening on a portion of the second dielectric layer; and plating a second metal selectively on the seed layer, thereby generating a VCSEL.

Claim 10

A method for making a VCSEL having a heat sink comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region having a ohmic metal layer disposed thereon; forming a masking layer with a pattern on the ohmic metal layer, wherein the pattern exposes portions of the ohmic metal layer while covering other portions of the ohmic metal layer; transferring the pattern into the ohmic metal layer and into the second stack of distributed Bragg reflectors to form a mesa having a surface; forming a dielectric layer on the substrate covering the surface of the mesa and the masking layer; forming a layer on the dielectric layer, the layer exposing the dielectric layer on the mesa; etching the dielectric layer exposed on the mesa, thereby removing the dielectric layer on the mesa and exposing the ohmic metal layer on the mesa; forming a second dielectric layer on the surface of the mesa; forming a metal layer on the dielectric layer and on the second dielectric layer; forming a seed layer having a pattern, the pattern of the seed layer forming an opening on a portion of the second dielectric layer; and plating a second metal selectively on the seed layer, thereby generating a VCSEL.

Claim 17

A method for making a VCSEL having auto-aligned heat sink comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region having a ohmic metal layer disposed thereon; forming a masking layer having a pattern on the ohmic metal layer, the pattern of the masking layer exposes portions of the ohmic metal layer, while covering other portions of the ohmic metal layer; etching the exposed portions of the ohmic metal layer to expose portions of the contact region; etching the exposed portions of the contact region into a portion of the second stack of distributed Bragg reflectors to form a mesa, thereby exposing a portion of the second stack of distributed Bragg reflectors; forming a dielectric layer overlying portions of contact layer and covering a portion of the trench; forming a metal layer on the dielectric layer, the trench and the mesa; forming seed layer having a pattern, the pattern of the seed layer forming an opening on a portion of the metal layer; and plating a second metal selectively on the seed layer, thereby an auto-aligned heat sink.

Claim 18

A method for making a VCSEL having auto-aligned heat sink comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region having a ohmic metal layer disposed thereon; forming a masking layer having a pattern on the ohmic metal layer, the pattern of the masking layer exposes portions of the ohmic metal layer, while covering other portions of the ohmic metal layer; etching the exposed portions of the ohmic metal layer to expose portions of the contact region; etching the exposed portions of the contact region into a portion of the second stack of distributed Bragg reflectors to form a mesa, thereby exposing a portion of the second stack of distributed Bragg reflectors; forming a dielectric layer overlying portions of contact layer and covering a portion of the trench; forming a metal layer on the dielectric layer, the trench and the mesa; forming seed layer having a pattern, the pattern of the seed layer forming an opening on a portion of the metal layer; and plating a second metal selectively on the seed layer, thereby an auto-aligned heat sink.

Claim 19

A method for controlling an aperture of a light emitting device comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region; forming a mesa with a surface and a trench, wherein said trench extends from said contact region into a portion of said second stack of distributed Bragg reflectors, and wherein said trench is adjacent to a portion of said mesa; forming a first dielectric layer overlying said substrate and covering a portion of said trench with a portion of said contact region being exposed; forming a conductive layer overlying said substrate; forming a seed layer having a pattern, said pattern of said seed layer having an opening on said mesa exposing a portion of said conductive layer; and plating a metal selectively on said seed layer generating a metal layer on said seed layer, said metal of said metal layer encroaches on said surface of said mesa to form an orifice, thereby sizing said orifice of said light emitting device.

Claim 20

A method for controlling an aperture of a light emitting device comprising the steps of: providing a substrate having a surface with a first stack of distributed Bragg reflectors, a first cladding region, an active region, a second cladding region, a second stack of distributed Bragg reflectors, and a contact region; forming a mesa with a surface and a trench, wherein said trench extends from said contact region into a portion of said second stack of distributed Bragg reflectors, and wherein said trench is adjacent to a portion of said mesa; forming a first dielectric layer overlying said substrate and covering a portion of said trench with a portion of said contact region being exposed; forming a conductive layer overlying said substrate; forming a seed layer having a pattern, said pattern of said seed layer having an opening on said mesa exposing a portion of said conductive layer; and plating a metal selectively on said seed layer generating a metal layer on said seed layer, said metal of said metal layer encroaches on said surface of said mesa to form an orifice, thereby sizing said orifice of said light emitting device.