Directly Written Waveguide for Laser-to-PIC Coupling
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Solution Overview
Problem
Conventional laser projectors face challenges in aligning laser diodes, focusing lenses, and controllable mirrors to achieve optimal spot size and convergence, especially in applications where form factor is a critical design consideration, such as wearable heads-up displays, leading to bulkier and less comfortable devices.
Innovation Solution
The optical engine integrates a base substrate with bonded laser diodes, a photonic integrated circuit, and a waveguide medium, including directly written waveguides, to achieve hermetic sealing and precise alignment of laser beams, allowing for compact and efficient laser projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional separate packaging of laser diodes with focusing lenses and controllable mirrors is used, then alignment of laser beams can be achieved, but the form factor becomes large and bulky
Solution Approach 1:
The patent integrates laser diodes, focusing lenses, and controllable mirrors into a single integrated package structure, merging previously separate components into one unified assembly. This combining approach maintains the necessary alignment relationships while dramatically reducing the overall form factor to enable wearable applications.
Solution Approach 2:
The patent employs three-dimensional positioning and alignment of components within the integrated package, utilizing vertical and lateral spatial arrangements to achieve precise beam alignment while minimizing the horizontal footprint. This dimensional optimization allows compact packaging without sacrificing alignment precision.
2Manufacturing precision
If laser diodes are housed in separate packages with focusing lenses, then optical alignment can be achieved, but the device becomes less comfortable for wearable applications
Solution Approach 1:
By consolidating laser diodes, focusing lenses, and mirrors into one integrated package, the patent eliminates the need for multiple separate components that would increase device bulk and weight. This merging directly improves wearable comfort while maintaining precise spot size alignment through carefully designed internal component geometry.
3Reliability
If multiple laser diodes are aligned with the same spot size and convergence rate, then optical performance is improved, but the configuration complexity increases
Solution Approach 1:
The patent applies different local optical properties to different regions within the integrated package, with each laser diode and its associated focusing lens and mirror configured for its specific wavelength and beam characteristics. This localized optimization allows each component to be precisely tuned for its function while the overall integration maintains consistent spot size and convergence across all beams.
Solution Approach 2:
The patent adjusts key optical parameters such as focusing lens focal lengths, mirror curvatures, and component spacing to achieve uniform spot size and convergence rate across multiple laser diodes with different wavelengths. By carefully controlling these parameters during the integration process, the patent achieves consistent optical performance without requiring complex active control mechanisms.
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
This solution enables smaller, lighter, and more comfortable wearable heads-up displays with improved optical performance and manufacturability, while maintaining the reliability and efficiency of laser projection.
Implementation Method 1
a waveguide medium disposed between the optical window of the cap and the photonic integrated circuit, the waveguide medium including at least one directly written waveguide that is operative to couple the plurality of beams of light emitted by the plurality of laser diodes from the optical window of the cap to the input facets of the photonic integrated circuit
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. Photonic integrated circuits having grating or edge couplers thereon may be used to wavelength multiplex beams of light emitted by the plurality of laser diodes into a coaxially superimposed aggregate beam. A waveguide medium having one or more directly written waveguides may couple light from laser diodes to a photonic integrated circuit, and may optionally hermetically or partially hermetically seal the laser diodes, eliminating the need for a separate seal. Such optical engines may have 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.