Compact Optical Engine Packaging for Precise Laser Beam Alignment
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Solution Overview
Problem
Conventional laser projectors face challenges in aligning laser diodes, focusing lenses, and controllable mirrors to meet form factor constraints, particularly in applications like wearable heads-up displays, where aesthetics and comfort are crucial, leading to bulkier and less stylish designs.
Innovation Solution
A method of manufacturing an optical engine involves bonding laser diodes to chip submounts on a base substrate, aligning collimation lenses, and combining light beams into a single aggregate beam within a hermetically sealed package using materials like low temperature co-fired ceramic, with optical director elements and laser diode driver circuits for precise alignment and modulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional laser projectors use separate packages for laser diodes and focusing lenses with traditional alignment methods, then alignment flexibility is maintained, but device size and weight increase making it unsuitable for wearable applications
Solution Approach 1:
The patent combines laser diodes, focusing lenses, and beam combining optics into a single integrated optical engine package. Multiple laser diodes (red, green, blue) are mounted on a common substrate with integrated focusing lenses and beam combining prisms, eliminating the need for separate packages and reducing overall device volume while maintaining alignment precision through the integrated design
Solution Approach 2:
The optical engine package serves multiple functions simultaneously: it houses multiple laser diodes, provides focusing for each wavelength, combines multiple beams into a single output, and maintains precise alignment. This multi-functional integration resolves the contradiction by achieving compact size without sacrificing alignment capability
2Ease of manufacture
If conventional laser projectors use traditional packaging and alignment methods, then alignment is achievable, but device complexity and manufacturing difficulty increase
Solution Approach 1:
By merging multiple optical components into a single integrated package with standardized mounting interfaces and alignment features, the patent simplifies the manufacturing process. The integrated design reduces the number of assembly steps and eliminates the need for complex alignment procedures required in conventional separate-package designs
Solution Approach 2:
The optical engine is designed as a modular integrated package that can be manufactured as a single unit or in standardized modules. This segmentation approach allows for simplified manufacturing and assembly while reducing overall structural complexity compared to conventional designs requiring multiple separate components
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 results in a compact, lightweight, and stylish optical engine suitable for wearable heads-up displays, offering improved optical performance, manufacturability, and reduced cost.
Implementation Method 1
bonding a plurality of laser diodes to a first base substrate
Implementation Method 2
bonding a plurality of collimation lenses to a second base substrate, each of the plurality of collimation lenses being respective to a corresponding one of the plurality of laser diodes
Implementation Method 3
bonding a cap comprising at least one wall and at least one optical window to the first base substrate, the at least one wall, the at least one optical window, and at least a portion of the first base substrate together delimit an interior volume... providing a hermetic or partially hermetic seal
Data Source
AI summary
Systems, devices, and methods of manufacturing optical engines and laser projectors that are well-suited for use in wearable heads-up displays (WHUDs) are described. Generally, the optical engines of the present disclosure integrate a plurality of laser diodes (e.g., 3 laser diodes, 4 laser diodes) within a single, hermetically or partially hermetically sealed, encapsulated package. Such optical engines may have various advantages over existing designs including, for example, smaller volumes, better manufacturability, faster modulation speed, etc. WHUDs that employ such optical engines and laser projectors are also described.