Visible Light Laser Diode and Manufacturing Method of Visible Light Laser Diode

The present invention relates to a visible light laser diode and a manufacturing method thereof and having an etching stopper layer in the vicinity of an active layer.

FIG. 11 is a sectional view illustrating a prior art visible light laser diode. This visible light laser diode has an oscillation wavelength of 633 nm. In the figure, reference numeral 1 designates an n-type GaAs substrate. Using an MOCVD apparatus, an n-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 2 having a thickness of 1.5 .mu.m, an undoped Ga.sub.0.5 In.sub.0.5 P active layer 6 having a multiple quantum well structure, a first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a having a thickness of 0.25 .mu.m, a Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 having a thickness of 5 nm, and a second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b having a thickness of 1.25 .mu.m are successively formed on the n-type GaAs substrate 1. After the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is formed into a mesa shape by selective etching, using again the MOCVD apparatus, an n-type GaAs current blocking layer 4 is formed on a portion where the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is etched and removed. Further, a p-type GaAs cap layer 5 is formed on the mesa shaped second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b and the n-type GaAs current blocking layer 4 to form a layer structure, and an n-type and p-type electrode 13 and 14 are formed on the lowermost and uppermost surfaces, respectively, of this layer structure.

A function of an etching stopper layer and a production method of a mesa shaped cladding layer will be described.

At first, in order for lateral mode control of the visible light laser diode, it is required to keep the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a to a predetermined thickness, (in the case of illustrated prior art visible light laser diode structure, 0.25 .mu.m) and to form the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b in a mesa shape. In this example, however, because the same material, (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P, is used for both the first and second cladding layers, there is no difference in the etching rates of the layers. Therefore, it is impossible to form the two cladding layers into the above-described shape by forming the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b directly on the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a.

Accordingly, an etching stopper layer having a predetermined thickness, comprising a material having an etching rate sufficiently lower than that of (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P to the etchant used for forming, the mesa shape of (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P, is introduced between the first and second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers, whereby it is possible to form these layers into a cladding layer of the mesa shape having a skirt of a predetermined thickness. As shown in FIG. 12(a), when a sulfuric acid series etching solution is used, the above-described etching stopper layer 9, employing Ga.sub.0.5 In.sub.0.5 P having an etching rate which is around one-fiftieth of the etching rate of (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P and having a thickness of 5 nm, is formed between the first and second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b.

When a SiN film 12 is used as a mask and the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is etched with the above-described sulfuric acid series etching solution as shown in FIG. 12(b), by the function of the Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 having a sufficiently lower etching rate than the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b, it is possible to stop the etching with satisfactory controllability just before reaching the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a and to form a cladding layer comprising the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a having a predetermined thickness and the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b having a mesa shape on the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6.

Subsequently, as shown in FIG. 12(c), an n-type GaAs current blocking layer 4 is formed where the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is etched and removed to form the mesa shape. After removing the SiN film 12 which was used as a mask in the above-described process of etching the cladding layer, a p-type GaAs cap layer 5 is formed on the exposed top surfaces of the mesa shaped second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b and the n-type GaAs current blocking layer 4, whereby a predetermined layer structure is formed.

Further, p-type and n-type electrodes 14 and 13 are formed on the upper surface of the p-type GaAs cap layer 5 and the lower surface of the n-type GaAs substrate 1, respectively, whereby a visible light laser diode as shown in FIG. 11 is obtained.

The visible light laser diode which is manufactured by the above-described method including the process of forming the mesa shaped cladding layer, is driven by applying a required driving current between the n-type and p-type electrodes 13 and 14 to emit a laser beam with a wavelength of 633 nm.

In the prior art visible light laser diode, GaAs is frequently used for the substrate, and generally an etching stopper layer is formed comprising Ga.sub.0.5 In.sub.0.5 P, lattice matching with the GaAs substrate to form a cladding layer on an active layer into a predetermined shape. Other than the above-described layer structure, Japanese Published Patent Application No. Sho 3-112186 discloses a visible light laser diode in which a buffer layer of Ga.sub.0.5 In.sub.0.5 P having a thickness of 40 .ANG. is introduced between two cladding layers of AlGaInP and AlGaAs in order to improve the voltage-current characteristic and to enhance the controllability of etching.

Japanese Published Patent Application No. Hei 3-73584 discloses a semiconductor laser device having an oscillation wavelength of below 660 nm, which is manufactured by a method including a process of successively forming a Ga.sub.0.5 In.sub.0.5 P etching stopper layer (with a thickness of 0.05 .mu.m) and a GaAs current blocking layer (with a thickness of 0.6 .mu.m) on a (Al.sub.0.6 Ga.sub.0.4).sub.0.5 In.sub.0.5 P cladding layer and a process of selectively etching a portion of the GaAs current blocking layer.

The prior art visible light laser diode and the manufacturing method thereof are as described above. In order to form the first and second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b on the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6 into a predetermined shape, it is unavoidably required to introduce the Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 between the two cladding layers 3a and 3b. In addition, it is not possible to remove the Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 after forming the first and second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b into predetermined shapes, and a layer structure in which the Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 partly remains above the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6 results, as shown in FIG. 11. Since the Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 has a thickness of 5 nm, a quantum well is formed between the first and second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b, and the energy level of this quantum well is in the vicinity of 640 nm in wavelength. During forming (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers 3d and 3e and a Ga.sub.0.5 In.sub.0.5 P well layer 9b and varying the well width of the Ga.sub.0.5 In.sub.0.5 P well layer 9b, the wavelength of photoluminescent (PL) light as measured at 4.2.degree. K is converted into a band gap energy and plotted by white circles as shown in FIG. 13(a), while solid line 1 shown in FIG. 13(b) shows the energy band gap as a theoretical value obtained from calculation of wave functions, and these represent the above-described results.

Since the above-described Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 having a thickness of 5 nm serves as a kind of absorption layer to light of an oscillation wavelength of 633 nm which is emitted from the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6, it is a light sink and the current characteristic is deteriorated at high output, degrading the performance of the visible light laser diode. When the oscillation wavelength of the visible light laser diode is in the 670 nm band, the layer structure with the remaining Ga.sub.0.5 In.sub.0.5 P etching stopper layer 9 absorbs no light and causes no problem. However, recent development of the crystal growth technique enables utilization of the quantum effect which occurs due to reducing the active layer well width, thereby to shorten the oscillation wavelength in a visible laser diode. For example, a visible light laser diode replacing a HeNe Gas laser having a wavelength of 633 nm, having an active layer of a well width below 4 nm has been described in various papers presented before Societies, for instance, Japanese Journal of Applied Physics, Autumn of 1992. The shortening of the oscillation wavelength of such visible light laser diodes is required for application to optical disks, bar code readers, laser beam printers, or the like, as a trend of the times. This enables improvement in the speed of data writing into an optical disk, reduction in the required power, or the like. This further eases data recorded in a high vision system, further advancing the shortening of wavelength, hereby making the above-described problems unavoidable ones.

Japanese Journal of Applied Physics, Vol. 29, No. 9, September, 1990, 11.L1669-L1671, discloses a 632.7 nm visible light laser diode, which comprises a p-type (Al.sub.0.19 Ga.sub.0.81).sub.0.5 In.sub.0.5 P etching stopper layer (with a thickness of 5 nm) disposed on a p-type (Al.sub.0.6 Ga.sub.0.4).sub.0.5 In.sub.0.5 P inner cladding layer (with a thickness of 0.25 .mu.m) disposed on an undoped (Al.sub.0.19 Ga.sub.0.81).sub.0.5 In.sub.0.5 P active layer, and a p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P outer cladding layer (with a thickness of 0.7 .mu.m) formed into a mesa-shape. Though this layer structure is free from light absorption by the etching stopper layer, when the p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P outer cladding layer is formed into the mesa shape, the p-type (Al.sub.0.19 Ga.sub.0.81).sub.0.5 In.sub.0.5 P etching stopper layer including 19% of Al has a small etching selectivity ratio relative to the p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P outer cladding layer, and it was impossible to stop the etching sufficiently.

It is an object to provide a visible light laser diode including an etching stopper layer having a high etching controllability and free from light absorption from an active layer, having a low laser oscillation threshold, and having an improved current characteristic at high output oscillation.

It is another object of the present invention to provide a manufacturing method thereof.

Other objects and advantages of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description and specific embodiment are given by way of illustration only, since various changes and modifications within the scope of the invention will become apparent to those skilled in the art from this detailed description.

According to a first aspect of the present invention, a visible light laser diode includes an etching stopper layer comprising a material having a sufficiently low etching rate in a predetermined etching solution compared to the etching rate of the material forming the cladding layer and having a larger band gap energy in bulk than the band gap energy of the active layer, and including a layer having such a thickness that stops the etching at the surface of the etching stopper layer or at a predetermined position therein and having an energy quantum level exceeding a band gap energy corresponding to the oscillation wavelength of the visible light laser diode. Therefore, the cladding layer can be selectively etched with satisfactory controllability with the etching stopper layer to make a predetermined shape. After the etching process, even in a laminated structure having the etching stopper layer partly remaining in the cladding layer, it is possible to prevent the etching stopper layer from absorbing light emitted from the active layer.

According to a second aspect of the present invention, a visible light laser diode includes an etching stopper layer comprising a material having an etching rate which is below one-fiftieth of that of the cladding layer in the etching performed with sulfuric acid series etching solution.

According to a third aspect of the present invention, a visible light laser diode includes a plurality of semiconductor layers grown on a GaAs substrate, the active layer is a multiple quantum well structure employing GaInP, the cladding layer is a thin crystalline film comprising AlGaInP, and the etching stopper layer is a quantum well structure employing a GaInP thin crystalline film having a large Ga composition and a lattice constant smaller than that of the GaAs substrate. Therefore, the etching stopper layer has a high selectivity relative to the cladding layer, and a quantum well having a tensile stress producing a larger band gap energy than that of the active layer is formed in the cladding layer, whereby the cladding layer can be formed into a predetermined shape with good controllability, and it is possible to prevent the etching stopper layer from absorbing light emitted from the active layer.

According to a fourth aspect of the present invention, a visible light laser diode is a 633 nm band visible light laser diode including an active layer comprising Ga.sub.0.5 In.sub.0.5 P, the cladding layer is an AlGaInP thin crystalline layer having a band gap energy in bulk of 2.34 eV, and the etching stopper layer is a GaInP thin crystalline layer having a band gap energy in bulk of 2.00 eV and is provided at a predetermined position of the cladding layer to form a single quantum well having an approximately 5 nm width well.

According to a fifth aspect of the present invention, a visible light laser diode is a 633 nm band visible light laser diode including an active layer comprising Ga.sub.0.5 In.sub.0.5 P, the cladding layer is a thin crystalline layer comprising (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P, and the etching stopper layer comprises a multiple quantum well structure of alternately laminated Ga.sub.x In.sub.1-x P (0.53.ltoreq.x.ltoreq.0.57) thin crystalline layers and (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P thin crystalline layers so that the sum of thicknesses of the Ga.sub.x In.sub.1-x P thin crystalline layers is about 5 nm.

According to a sixth aspect of the present invention, a visible light laser diode includes the etching stopper layer disposed at such a position that the stress of the lattice strain caused by the lattice mismatch between the etching stopper layer and the GaAs structure is applied to the active layer.

According to a seventh aspect of the present invention, a visible light laser diode is a 633 nm band visible light laser diode including an active layer comprising Ga.sub.0.5 In.sub.0.5 P, and the etching stopper layer has a multiple quantum well structure with alternately laminated Ga.sub.x In.sub.1-x P (0.53.ltoreq.x.ltoreq.0.57) thin crystalline layers and (Al.sub.y Ga.sub.1-y).sub.1-x P (0.7.ltoreq.y.ltoreq.0.53, 0.53.ltoreq.x.ltoreq.0.57) thin crystalline layers.

According to an eighth aspect of the present invention, a visible light laser diode includes an etching stopper layer comprising a laminated layer having a plurality of Ga.sub.x In.sub.1-x P thin crystalline layers with a total thickness exceeding 5 nm.

According to a ninth aspect of the present invention, a manufacturing method of a visible light laser diode includes employing a material having a sufficiently lower etching rate in a predetermined etching solution than the etching rate of the material forming the cladding layer and having a larger band gap energy in bulk than the band gap energy of the active layer, and forming an etching stopper layer at a predetermined position in the cladding layer that stops the etching at the surface of the etching stopper layer or at a predetermined position therein and having such a thickness that provides a quantum level energy exceeding the band gap corresponding to the oscillation wavelength of the visible light laser diode.

According to a tenth aspect of the present invention, a manufacturing method of a visible light laser diode includes forming an active layer of a multiple quantum well structure employing GaInP on a GaAs substrate, forming a first cladding layer on the active layer employing AlGaInP, forming an etching stopper layer having a single quantum well structure or a multiple quantum well structure employing GaInP having a larger Ga composition and a smaller lattice constant than the GaAs substrate on the first cladding layer, forming a second cladding layer employing AlGaInP on the etching stopper layer, and partly etching and removing the second cladding layer to form the same in a predetermined shape.

According to an eleventh aspect of the present invention, a manufacturing method of a visible light laser diode includes a process step of partly etching and removing the second cladding layer to make the same a predetermined shape employing a sulfuric acid series etching solution having a ratio of the etching rates between the second cladding layer and the etching stopper layer that is equal to about 50:1.

According to a twelfth aspect of the present invention, in the manufacturing method of a visible light laser diode, the visible light laser diode is a 633 nm band visible light laser diode employing Ga.sub.0.5 In.sub.0.5 P for the active layer, the first and second cladding layers comprise AlGaInP having a band gap energy in bulk of 2.34 eV, the etching stopper layer comprises GaInP having a band gap energy in bulk of 2.00 eV and having a thickness of about 5 nm, and the second AlGaInP cladding layer is partly etched and removed with a sulfuric acid series etching solution.

According to a thirteenth aspect of the present invention, in the manufacturing method of a visible light laser diode, the visible light laser diode is a 633 nm band visible light laser diode employing Ga.sub.0.5 In.sub.0.5 P for the active layer, the first and second cladding layers comprise (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P, the etching stopper layer has alternately laminated Ga.sub.x In.sub.1-x P (0.53.ltoreq.x.ltoreq.0.57) thin crystalline layers and (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P thin crystalline layers such that the sum of thicknesses of the Ga.sub.x In.sub.1-x P thin crystalline layers is about 5 nm, and the second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer is partly etched and removed with a sulfuric acid series etching solution.

According to a fourteenth aspect of the present invention, a manufacturing method of a visible light laser diode includes forming the first cladding layer having such a thickness that the stress due to the lattice strain that is generated by the lattice mismatching between the etching stopper layer and the GaAs substrate is applied to the active layer, and forming the etching stopper layer on the cladding layer. Therefore, the active layer is stressed in the compressive direction by the tensile strain in the etching stopper layer, whereby it is possible to broaden the band gap energy of the active layer and make the oscillation wavelength shorter.

According to a fifteenth aspect of the present invention, in the manufacturing method of a visible light laser diode, the visible light laser diode is a 633 nm band visible light laser diode employing Ga.sub.0.5 In.sub.0.5 P for the active layer, the first and second cladding layers comprise (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P, the etching stopper layer having a multiple quantum well structure comprises alternating laminations of thin crystalline layers of Ga.sub.x In.sub.1-x P (0.53.ltoreq.x.ltoreq.0.57) and thin crystalline layers of (Al.sub.y Ga.sub.1-y).sub.1-x In.sub.x P (0.7.ltoreq.y.ltoreq.1, 0.53.ltoreq.x.ltoreq.0.57), and the second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer is partly etched and removed with a sulfuric acid series etching solution. Therefore, layers are laminated with a tensile stress applied to the Ga.sub.x In.sub.1-x P thin crystalline layers being cancelled by a stress in the compressive direction applied to the (Al.sub.y Ga.sub.1-y).sub.1-x In.sub.x P thin crystalline layers, whereby it is possible to increase the band gap energy by increasing the number of quantum wells in the etching stopper layer and to obtain high etching controllability with thick layers.

According to a sixteenth aspect of the present invention, in the manufacturing method of a visible light laser diode, the etching stopper layer includes a plurality of Ga.sub.x In.sub.1-x P thin crystalline layers having a total thickness exceeding 5 nm.

FIG. 1(a) is a sectional view illustrating a visible light laser diode in accordance with a first embodiment of the present invention, and FIG. 1(b) is a diagram showing the energy band structure of an etching stopper layer.

FIGS. 2(a)-2(c) are views for describing a method for manufacturing a visible light laser diode in accordance with the first embodiment of the present invention.

FIGS. 3(a) and 3(b) are sectional views illustrating a laminated structure before the etching process in a method for manufacturing a visible light laser diode in accordance with a second embodiment of the present invention.

FIGS. 4(a) and 4(b) are sectional views illustrating a laminated structure before the etching process in a method for manufacturing a visible light laser diode in accordance with a third embodiment of the present invention.

FIG. 5 is a sectional view illustrating a laminated structure before the etching-process in a method for manufacturing a visible light laser diode in accordance with a fourth embodiment of the present invention.

FIG. 6 is a graph illustrating the difference between the etching rates of AlGaInP and GaInP by a sulfuric acid series etching solution.

FIGS. 7(a) and 7(b) are diagrams illustrating the relation between the variation in the Ga composition of a Ga.sub.x In.sub.1-x P well layer formed between (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers and the band gap energy thereof.

FIGS. 8(a) and 8(b) are diagrams illustrating the relation between the variation in respective well widths of unstrained Ga.sub.0.5 In.sub.0.5 P and Ga.sub.0.57 In.sub.0.43 P having a tensile strain of 0.5%.

FIGS. 9(a) and 9(b) are diagrams illustrating the relationship among the Ga composition, lattice strain, and PL light emission wavelength of a Ga.sub.x In.sub.1-x P well layer having a thickness of 5 nm.

FIG. 10 is a diagram illustrating the relationship among well width, lattice strain, and oscillation wavelength of a GaInP well layer.

FIG. 11 is a sectional view illustrating a prior art visible light laser diode.

FIGS. 12(a)-12(c) are views for explaining a prior art method for manufacturing a visible light laser diode.

FIGS. 13(a) and 13(b) are diagrams illustrating the relation between variation in the well width of a Ga.sub.0.5 In.sub.0.5 P well layer formed between (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers and the band gap energy thereof (which is obtained from the PL light wavelength of the well layer).

Embodiment 1

A first embodiment of the present invention will be described with reference to the drawings.

FIG. 1(a) is a sectional view illustrating a 633 nm band visible light laser diode according to this first embodiment. In the figure, reference numeral 1 designates an n-type GaAs substrate. Using an MOCVD apparatus, an n-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 2 having a thickness of 1.5 .mu.m, an undoped Ga.sub.0.5 In.sub.0.5 P active layer 6 having a multiple quantum well structure having a quadrupled structure of well and barrier layers having thicknesses of 6 and 8 nm, respectively, and a guide layer having a thickness of 50 to 80 nm, a first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a having a thickness of 0.25 .mu.m, a Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 having a thickness of 5 nm, and a second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b having a thickness of 1.25 .mu.m are successively formed on the n-type GaAs substrate 1. After the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is formed into a mesa shape by selective etching, using again the MOCVD apparatus, an n-type GaAs current blocking layer 4 is formed on a portion where the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is etched and removed. Further, a p-type GaAs cap layer 5 is formed on the top surfaces of the mesa shaped second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b and the n-type GaAs current blocking layer 4 to form a layer structure and an n-type and p-type electrode 13 and 14 are formed on the lowermost and uppermost surfaces, respectively, of this layer structure.

The production method of the above-described mesa shape second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b will be described with reference to FIGS. 2(a)-2(c).

At first, as shown in FIG. 2(a), the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 having a thickness of 5 nm, and comprising Ga.sub.0.57 In.sub.0.43 P which has an etching rate around one-fiftieth of the etching rate of (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P in a sulfuric acid series etching solution, is formed on the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a, and the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is formed on the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10. As shown in FIG. 1(b), the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 having a band gap energy in bulk of 2.00 eV forms a quantum well between the first and second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b having a band gap energy in bulk of 2.34 eV.

Then, as shown in FIG. 2(b), when using a SiN film 12 provided on the top surface of a part of the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b and having a thickness of 3,000 to 5,000 angstroms as a mask, the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is etched by using the sulfuric acid series etching solution. Because the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 has an etching rate sufficiently lower than that of the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b, it is possible to stop the etching with satisfactory controllability just before it reaches the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a. Further, the mesa shape second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b can be formed with the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a having a thickness of 0.25 .mu.m remaining on the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6.

Then, as shown in FIG. 2(c), an n-type GaAs current blocking layer 4 is formed on a portion where the mesa shaped second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is etched and removed. After removing the SiN film 12 which has been used as a mask while etching the cladding layer, a p-type GaAs cap layer 5 is formed on the exposed top portions of the mesa shaped second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b and the n-type GaAs current blocking layer 4, whereby a predetermined layer structure as shown in FIG. 1 is obtained.

A method for determining the thickness and composition of an etching stopper layer employing GaInP and a function of the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 determined by this method will be described in more detail, with reference to FIG. 6 to FIG. 11.

At first, a description is given of the thickness of an etching stopper layer. The second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b has a thickness of 1.25 .mu.m, and the entire wafer thickness distribution amounts to .+-.10%. Therefore, the thickness distribution of entire wafer becomes:

It will be seen that it is necessary for the etching stopper layer to absorb the thickness distribution of 0.25 .mu.m (250 nm) .

When an etching solution with the mixture ratio of sulfuric acid and water set to 1:1 and at 50.degree. C. is used for etching, because the etching selectivity of the etching solution between AlGaInP and GaInP is about 58 as shown in FIG. 6, the etched depth becomes:

Therefore, from the equations (1) and (2), it will be seen that the etching stopper layer is required to have a thickness of at least 4.3 nm for perfectly stopping etching and, taking errors into considerations, the etching stopper layer can fulfill its function when it has a thickness of about 5 nm.

In order to determine the composition ratio of GaInP used for the etching stopper layer, as shown in FIG. 7(a), a Ga.sub.x In.sub.1-x P well layer 10b having a well width of 15 nm is formed by successively varying the Ga composition (x) between (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers 3d and 3e above the GaAs substrate. On the basis of the wavelength of PL light emission measured with 4.2.degree. K, the variation in the band gap energy of the Ga.sub.x In.sub.1-x P well layer 10b is examined and graphed as shown in FIG. 7(b). It will be seen that the band gap energy is increased with increased Ga composition (x), and the PL light emission wavelength becomes shorter. However, when the Ga composition (x) of the Ga.sub.x In.sub.1-x P well layer 10b is increased to greater than 0.5, the lattice constant becomes, of course, smaller than that of Ga.sub.0.5 In.sub.0.5 P, which is lattice matched with the GaAs substrate. Further, to the Ga.sub.x In.sub.1-x P well layer 10b applied is a stress in the pulling direction. Therefore, if the Ga proportion (x) is excessively increased, the critical stress is exceeded, resulting in the introduction of transpositions.

In order to confirm the presence of the above-described transpositions, a method such as TEM (transmission electron microscopy) has been employed heretofore. In such a method, however, a great deal of labor is required for the measurement. In addition, the measurement range is very narrow, and the reliability is low.

In this first embodiment, there is used a method for measuring the critical thickness through quantum well carrier lifetime evaluation shown in the Proc. of Japan Society of Applied Physics, Autumn, 1992, 17P-ZE-9. As shown in FIG. 8(a), a Ga.sub.x In.sub.1-x P well layer 10c having several Ga compositions (x) is formed by successively varying the thickness thereof between (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers 3d and 3e, and the carrier lifetime is evaluated in each case, thereby confirming the presence of transpositions.

FIG. 8(b) shows the results of carrier lifetime evaluation for a Ga.sub.0.5 In.sub.0.5 P well layer 10c1 which is strain-free, i.e., lattice matched to the GaAs substrate and has a Ga composition (x) of 0.5, and a Ga.sub.0.57 In.sub.0.43 P well layer 10c2 having a Ga composition (x) of 0.57 corresponding to a tensile strain of 0.5% by respectively varying the layer thickness (well width d) thereof. From FIG. 8(b), with the strain-free Ga.sub.0.5 In.sub.0.5 P well layer 10c1, the relation between the inverse (1/d) of the well width d and the inverse (1/.tau.) to the carrier lifetime is linear as shown by dashed plot m, and it will be seen that no transposition is introduced. On the other hand, with the Ga.sub.0.57 In.sub.0.43 P well layer 10c2 having a tensile strain of 0.5%, the above-described relation is as shown by solid plot n. As the well width d is increased to exceed 15 nm, the carrier lifetime is rather deteriorated. As the well width d is further increased to exceed 30 nm, the carrier lifetime is steeply deteriorated. Thus, it will be seen that transpositions are introduced into the crystal. Conversely, this means that, with the Ga.sub.0.57 In.sub.0.43 P well layer 10c2 in which the Ga composition (x) is set to 0.57 and 0.5% of tensile strain is introduced, the carrier lifetime .tau. is not deteriorated and no transposition is introduced when the thickness is 5 nm.

Further, as shown in FIG. 9(a), a Ga.sub.x In.sub.1-x P well layer 10b1 having a thickness of 5 nm, for which Ga compositions (x) are successively varied, is formed between (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers 3d and 3e, and the PL light emission wavelength at room temperature is evaluated. As a result, the PL light emission wavelength is as shown by solid plot P in FIG. 9(b), and 0.5% of tensile strain is introduced. As described above, however, the PL light emission wavelength of the Ga.sub.x In.sub.1-x P well layer 10b1 having a Ga composition (x) of 0.57, which is free from transposition, is about 615 nm. This PL light emission wavelength is shorter by 5 to 10 nm than the intrinsic oscillation wavelength, and it is seen to be located on the shorter wavelength side of the PL light emission wavelength of the visible light laser diode with an oscillation wavelength of 633 nm.

As shown above, the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 is formed with a thickness of 5 nm between the first and second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b and forms a quantum well having an energy quantum level exceeding the band gap energy of the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6, whereby it can perfectly stop the etching and absorb no light with a wavelength of 633 nm from the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6.

As is seen from FIG. 9(b), so long as the thickness of the GaInP etching stopper layer 10 is 5 nm, even when setting the Ga composition to 0.53, the PL light wavelength is about 623 nm, and the etching stopper layer does not absorb light with a wavelength of 633 nm. Further, when using an etching solution providing for a higher etching selectivity and etching the second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b, it is possible to set the thickness of the GaInP etching stopper layer 10 to be less than 5 nm. As is seen from FIG. 10, showing the result of examination of the relationship among the quantum well width, lattice strain, and oscillation wavelength. By forming the Ga.sub.0.5 In.sub.0.5 P well layer between two (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers, the quantum well, which is formed by the GaInP etching stopper layer 10 having a reduced thickness, has a further increased energy quantum level, and it is possible to cope with a visible light laser diode oscillation wavelength of less than 633 nm.

Japanese Published Patent Application No. Hei 4-25192 shows, in a semiconductor laser element and a manufacturing method thereof, a laminated structure obtained by successively forming a GaInP active layer lattice matched to a GaAs substrate, an AlGaInP cladding layer, a GaInP etching stopper layer, and a GaAs light absorption layer on a GaAs substrate. The band gap energy of the GaInP etching stopper layer is set to be greater than that of the GaInP active layer. The GaInP etching stopper layer of this publication, however, increases the band gap energy through thickness control, and unlike Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 provided in the visible light laser diode of this first embodiment, does not increase the band gap energy by increasing the Ga composition. In addition, as described employing the equations (1) and (2), there is determined a lower limit on the thickness of the etching stopper layer that is introduced in the AlGaInP cladding layer. That is, if the thickness of the etching stopper layer is set to be less than the lower limit in order to increase the band gap energy, etching controllability is lost.

In the manufacturing method of a visible light laser diode according to this first embodiment, the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 employing a thin crystalline film having a band gap energy in bulk of 2.00 eV and having a thickness of 5 nm, is formed between the first and second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b using a thin crystalline film having a band gap energy in bulk of 2.34 eV, and the second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is etched to a predetermined shape using a sulfuric acid series etching solution. Therefore, the etching can be stopped just before reaching the first (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a to form the second (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b into a predetermined shape. Although the visible light laser diode manufactured by the method including this etching process may have a laminated structure in which the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 partly remains on the Ga.sub.0.5 In.sub.0.5 P active layer 6, the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 does not absorb light with an oscillation wavelength of 633 nm from the Ga.sub.0.5 In.sub.0.5 P active layer 6, and it is possible to obtain a visible light laser diode which has a low laser oscillation threshold value and a satisfactory current characteristic at a high power output.

While this first embodiment describes a visible light laser diode having the above-described laminated structure and with the oscillation wavelength of 633 nm, it is not limited to this embodiment, and the above-described effects are of course obtainable with laser diodes other than the above-described visible light laser diode as well by determining the material and thickness of the etching stopper layer corresponding to the laser diode by the method as described in detail using FIGS. 6 to 11.

Embodiment 2

A visible light laser diode and a manufacturing method thereof according to a second embodiment of the present invention are the same as those in the above-described first embodiment except for an etching stopper layer. Using an MOCVD apparatus, a plurality of semiconductor layers are successively formed on a GaAs substrate 1. FIG. 3(a) is an enlarged sectional view illustrating the laminated structure of an etching stopper layer provided for a visible light laser diode according to this second embodiment. FIG. 3(b) is a sectional view illustrating the laminated structure of a cladding layer formed above an active layer before the etching process,.and this corresponds to FIG. 2(a) of the above-described first embodiment. In the figures, the same reference numerals designate the same or corresponding portions as those shown in FIG. 2 of embodiment 1. Reference numeral 31 designates an etching stopper layer, which includes a p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layer 3b1 having a thickness of 2 nm, a p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layer 3b2 having a thickness of 1 nm, and three p-type Ga.sub.0.57 In.sub.0.43 P well layers 10a1 to 10a3 each having a thickness of 1.7 nm.

As shown in FIG. 3(a), the etching stopper layer 31 is formed by successively forming the p-type Ga.sub.0.57 In.sub.0.43 P well layer 10a1, the p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layer 3b1, the p-type Ga.sub.0.57 In.sub.0.43 P well layer 10a2, the p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layer 3b2, and the p-type Ga.sub.0.57 In.sub.0.43 P well layer 10a3 on a first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a. Subsequently, the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b is formed on the p-type Ga.sub.0.57 In.sub.0.43 P well layer 10a3.

That is, the etching stopper layer 31 in this second embodiment comprises the three p-type Ga.sub.0.57 In.sub.0.43 P well layers 10a1 to 10a3, which correspond to three equally divided portions of the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 having a thickness of 5 nm in the first embodiment, form a multiple quantum well with the first and second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layers 3a and 3b and p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers 3b and 3b2 as quantum barriers. Thus, when etching the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b into the mesa form using the sulfuric acid series etching solution, the etching is stopped at either one of the three-p-type Ga.sub.0.57 In.sub.0.43 P well layers 10a1 to 10a3. Subsequently, the visible light laser diode may be completed such that it has a laminated structure with the etching stopper layer 31 partly remaining on the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6. Again in this case, owing to the multiple quantum well effect, the etching stopper layer 31 has a larger band gap energy than that of the etching stopper layer 10 in the first embodiment.

According to this second embodiment, since there is provided the etching stopper layer 31 having the multiple quantum well structure comprising the p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P barrier layers 3b and 3b2 and p-type Ga.sub.0.57 In.sub.0.43 P well layers 10a1 to 10a3, the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b on the layer 31 can be etched into a predetermined shape with high controllability. Therefore, in the laser operation, light with the oscillation wavelength of 633 nm from the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6 is not absorbed by the upper etching stopper layer 31, and it is possible to obtain a visible light laser diode with a satisfactory current characteristic at high output oscillation.

Embodiment 3

A visible light laser diode and a manufacturing method thereof according to a third embodiment of the present invention are the same as in the first embodiment except for the structure and production method of an etching stopper layer. FIG. 4(a) is a partially enlarged sectional view illustrating an etching stopper layer in the visible light laser diode in this third embodiment. FIG. 4(b) is a view illustrating the laminated structure of a cladding layer formed above an active layer before the etching process, and corresponding to FIG. 2(a) of the first embodiment. In the figures, the same reference numerals designate the same or corresponding portions as those shown in FIGS. 2(a)-2(c) of the first embodiment. Reference numeral 32 designates an etching stopper layer, which has a multiple quantum well structure obtained by alternately laminating p-type Ga.sub.0.57 In.sub.0.43 P layers 11a1 to 11a7 having a total thickness of 10 nm and p-type (Al.sub.y Ga.sub.1-y).sub.0.43 In.sub.0.57 P layers (y.gtoreq.0.7) 3c1 to 3c6.

As shown in FIG. 4(a), the etching stopper layer 32 is formed on the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a such that it has a zero net strain structure, in which a stress in the tensile direction (corresponding to a tensile strain of 0.5%) applied to the p-type Ga.sub.0.57 In.sub.0.43 P layers 11a1 to 11a7 acting as a quantum well is canceled by an equal quantity of a stress in the compressive direction (corresponding to a compressive strain of 0.5%) applied to the p-type (Al.sub.y Ga.sub.1-y).sub.0.43 In.sub.0.57 P layers 3c1 to 3c6. Therefore, no transposition is introduced even when the critical thickness is exceeded by the sum of thicknesses of the p-type Ga.sub.0.57 In.sub.0.43 P layers 11a1 to 11a7. Further, etching controllability better than those of the first and second embodiments can be obtained in the process of etching the second p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3b, and it is possible to obtain the increased band gap energy after forming.

According to this third embodiment, since the etching stopper layer 32 having a zero net strain structure and also a multiple quantum well structure is formed, it is possible to increase the thickness or number of the p-type Ga.sub.0.57 In.sub.0.43 P layers 11a1 to 11a7 to enhance etching controllability without generating any transposition. Further, by increasing the multiplicity of the quantum well comprising Ga.sub.0.57 In.sub.0.43 P, it is possible to further increase the band gap energy so as to prevent absorption of the light emitted from the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6.

While the tensile or compressive strain in each layer of the etching stopper layer 32 has been set to 0.5%, this is by no means limiting. If the etching stopper layer comprises a zero net strain structure, and has a larger band gap energy than that of the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6, it is of course possible to change the compositions of the p-type GaInP and AlGaInP layers constituting the etching stopper layer into the predetermined compositions, thereby changing the strain amount.

Embodiment 4

FIG. 5 is a view illustrating the laminated structure of a cladding layer in a visible light laser diode according to a fourth embodiment of the present invention and corresponding to FIG. 2(a) of the first embodiment. In the figure, the same reference numerals designate-the same or corresponding portions as those shown in FIG. 2 of the first embodiment. Reference numeral 8 designates a stress adjustment layer, which is formed with such a thickness that the stress due to the lattice strain in a Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10 that is formed above can be given to a undoped Ga.sub.0.5 In.sub.0.5 P active layer 6 that is formed below that.

In the above-described first embodiment, the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a having a thickness of 250 nm is formed on the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6. In this fourth embodiment, however, the first p-type (Al.sub.0.7 Ga.sub.0.3).sub.0.5 In.sub.0.5 P cladding layer 3a having a thickness of 249 nm is formed and is made a stress adjusting layer 8. Therefore, the Ga.sub.0.57 In.sub.0.43 P etching stopper layer 10, which is formed on the stress adjusting layer 8 and has a lattice constant smaller than that of the GaAs substrate 1, can be used as a stresser to provide a stress in the compressive direction on the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6, thereby increasing the band gap energy of the undoped Ga.sub.0.5 In.sub.0.5 P active layer 6 and decreasing the oscillation wavelength below 633 nm.

According to this fourth embodiment, it is possible to obtain, in addition to the effects in the above-described embodiment 1, an effect of making the oscillation wavelength of the visible light laser diode shorter.

In order to use the etching stopper layer as a stress applying means for making the oscillation wavelength shorter, it has a tensile strain, and it is of course possible to use the etching stopper layer 31 in the above-described second embodiment.