Manufacturable RGB laser diode source
First Claim
1. A method for manufacturing an integrated multi-wavelength light emitting device, the method comprising:
- providing a first substrate having a first surface region;
forming a first epitaxial material overlying the first surface region, the first epitaxial material comprising a release region, an n-type cladding region, a first active region comprising at least one active layer overlying the n-type cladding region, and a p-type cladding region overlying the active region, the first active region being configured for emission at a first wavelength;
providing a second substrate having a second surface region;
forming a second epitaxial material overlying the second surface region, the second epitaxial material comprising a release region, an n-type cladding region, a second active region comprising at least one active layer overlying the n-type cladding region, and a p-type cladding region overlying the active region, the second active region being configured for emission at a second wavelength;
patterning the first epitaxial material and the second epitaxial material to form a plurality of first epitaxial dice and a plurality of second epitaxial dice overlying the first substrate and the second substrate, respectively, each of the plurality of first epitaxial dice and the plurality of second epitaxial dice corresponding to at least one light emitting device;
transferring at least one of the first plurality of epitaxial dice and at least one of the second plurality of epitaxial dice from the first substrate and the second substrate, respectively, to a carrier wafer by selectively etching the release region, separating from the substrate each of the epitaxial dice that are being transferred, and selectively bonding to the carrier wafer each of the epitaxial dice that are being transferred; and
processing the transferred first epitaxial dice and the second epitaxial dice on the carrier wafer to form a plurality of light emitting devices capable of emitting at least the first wavelength and the second wavelength.
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Accused Products
Abstract
A multi-wavelength light emitting device is manufactured by forming first and second epitaxial materials overlying first and second surface regions. The first and second epitaxial materials are patterned to form a plurality of first and second epitaxial dice. At least one of the first plurality of epitaxial dice and at least one of the second plurality of epitaxial dice are transferred from first and second substrates, respectively, to a carrier wafer by selectively etching a release region, separating from the substrate each of the epitaxial dice that are being transferred, and selectively bonding to the carrier wafer each of the epitaxial dice that are being transferred. The transferred first and second epitaxial dice are processed on the carrier wafer to form a plurality of light emitting devices capable of emitting at least a first wavelength and a second wavelength.
273 Citations
36 Claims
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1. A method for manufacturing an integrated multi-wavelength light emitting device, the method comprising:
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providing a first substrate having a first surface region; forming a first epitaxial material overlying the first surface region, the first epitaxial material comprising a release region, an n-type cladding region, a first active region comprising at least one active layer overlying the n-type cladding region, and a p-type cladding region overlying the active region, the first active region being configured for emission at a first wavelength; providing a second substrate having a second surface region; forming a second epitaxial material overlying the second surface region, the second epitaxial material comprising a release region, an n-type cladding region, a second active region comprising at least one active layer overlying the n-type cladding region, and a p-type cladding region overlying the active region, the second active region being configured for emission at a second wavelength; patterning the first epitaxial material and the second epitaxial material to form a plurality of first epitaxial dice and a plurality of second epitaxial dice overlying the first substrate and the second substrate, respectively, each of the plurality of first epitaxial dice and the plurality of second epitaxial dice corresponding to at least one light emitting device; transferring at least one of the first plurality of epitaxial dice and at least one of the second plurality of epitaxial dice from the first substrate and the second substrate, respectively, to a carrier wafer by selectively etching the release region, separating from the substrate each of the epitaxial dice that are being transferred, and selectively bonding to the carrier wafer each of the epitaxial dice that are being transferred; and processing the transferred first epitaxial dice and the second epitaxial dice on the carrier wafer to form a plurality of light emitting devices capable of emitting at least the first wavelength and the second wavelength. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A method for manufacturing an integrated multi-wavelength light emitting device, the method comprising:
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providing a first gallium and arsenic containing substrate having a first surface region; forming a first gallium and arsenic containing epitaxial material overlying the first surface region, the first epitaxial material comprising a release region, an n-type cladding region, a first active region comprising at least one active layer overlying the n-type cladding region, and a p-type cladding region overlying the active region, the first active region being configured for emission at a first red wavelength providing a second gallium and nitrogen containing substrate having a second surface region; forming a second gallium and nitrogen containing epitaxial material overlying the second surface region, the second epitaxial material comprising a release region, an n-type cladding region, a second active region comprising at least one active layer overlying the n-type cladding region, and a p-type cladding region overlying the active region, the second active region being configured for emission at a second green wavelength providing a third gallium and nitrogen containing substrate having a third surface region; forming a third gallium and nitrogen containing epitaxial material overlying the third surface region, the third epitaxial material comprising a release region, an n-type cladding region, a third active region comprising at least one active layer overlying the n-type cladding region, and a p-type cladding region overlying the active region, the third active region being configured for emission at a third blue wavelength patterning the first epitaxial material, the second epitaxial material, and the third epitaxial material to form a plurality of first epitaxial dice, a plurality of second epitaxial dice, and a plurality of third epitaxial dice overlying the first substrate, the second substrate, and the third substrate, respectively, each of the-epitaxial dice corresponding to at least one light emitting device; transferring at least one of the first plurality of epitaxial dice, the second plurality of epitaxial dice, and the third plurality of epitaxial dice from the first substrate, the second substrate, and the third substrate to a carrier wafer by selectively etching the release region, separating from each of the first substrate, the second substrate, and the third substrate each of the first epitaxial dice, the second epitaxial dice, and the third epitaxial dice that is being transferred, and selectively bonding to the carrier wafer each of the first epitaxial dice, the second epitaxial dice, and the third epitaxial dice that is being transferred; and processing the transferred first epitaxial dice, the second epitaxial dice, and the third epitaxial dice on the carrier wafer to form an RGB emitting devices capable of emitting a red wavelength, a green wavelength, and a blue wavelength. - View Dependent Claims (34, 35, 36)
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Specification