Semiconductor Laser Lens Array Layout for Rotation-Tolerant Collimation
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Solution Overview
Problem
Conventional light source devices with collimator lens arrays are prone to significant deviations in positional relationships between light sources and lens elements when mounted slightly rotated, leading to changes in light intensity distribution.
Innovation Solution
A light-emitting device featuring a substrate with a lens array having lens sections in a matrix pattern, where each lens section has a greater width in the column direction than in the row direction, with inter-vertex distances and curvature uniformity in both directions, minimizing positional deviations and intensity distribution changes even when the lens array is mounted slightly rotated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lens elements have a plurality of curvatures in accordance with sectional shapes of laser beams, then the collimation of light can be improved, but when the collimator lens array is mounted even only slightly rotated from a prescribed direction, a significant deviation may occur in a positional relationship between the light sources and the lens elements and the intensity distribution of light emitted from the collimator lens array may change
Solution Approach 1:
The patent applies asymmetry by configuring the lens array with different inter-vertex distances in the row direction versus the column direction. Specifically, the inter-vertex distance in the row direction is set to be smaller than the inter-vertex distance in the column direction, creating an asymmetric pattern that provides a detectable orientation reference. This asymmetric geometry allows the system to maintain reliable positional relationships even when mounted at slight rotations, as the orientation can be identified and compensated for based on the distinctive inter-vertex distance pattern.
2Manufacturing precision
If lens elements have a plurality of curvatures to match laser beam shapes, then light collimation is improved, but the device complexity increases due to the need for precise orientation and mounting
Solution Approach 1:
The asymmetric inter-vertex distance configuration serves as an built-in orientation marker, eliminating the need for complex external alignment tools or procedures. The distinctive pattern of smaller inter-vertex distances in the row direction versus larger distances in the column direction provides an unambiguous reference that simplifies the mounting process while maintaining high collimation precision.
Solution Approach 2:
The lens array structure itself provides the orientation information needed for correct mounting through its asymmetric inter-vertex distance pattern. This self-service approach eliminates the need for external alignment fixtures, complex mounting procedures, or additional orientation markers, thereby reducing device complexity while maintaining precise collimation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures a stable light intensity distribution and reduced positional deviations between light sources and lens elements, enhancing the reliability of the light-emitting device by maintaining consistent performance despite minor rotational misalignments.
Implementation Method 1
a light source device that collimates light emitted from a plurality of light sources with a collimator lens array
Data Source
AI summary
A light-emitting device includes: a substrate including a base and a side wall; a plurality of semiconductor laser elements arrayed in a first direction on an upper surface of the base; a sealing member fixed to the substrate, wherein the sealing member and the substrate define a sealed space in which the semiconductor laser element is located; and a lens array disposed above the sealing member, the lens array including a plurality of lens sections arrayed in the first direction. In the lens array, a maximum outer diameter of each lens sections is 1.25 times or more than an inter-vertex distance between adjacent ones of the lens sections in the first direction.