Laser Array Optics for Alignment-Tolerant Irradiance Mapping
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Solution Overview
Problem
High-density laser arrays face challenges in designing suitable optics and optical components due to increased component density and manufacturing variations, leading to susceptibility to alignment offsets and performance issues, which complicates the creation of compact and cost-effective time-of-flight sensors.
Innovation Solution
The implementation of a laser assembly with a substrate, a lens array, and a laser array, where the lens array includes a combination of positive and negative optics to map irradiance to a common target profile, enhancing alignment tolerance and reducing manufacturing variations, and the use of field mapping optics to refract optical signals to a desired irradiance at a target, allowing for more compact and cost-effective designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If high-density laser arrays are used to reduce component size and cost, then device compactness and cost-effectiveness are improved, but manufacturing precision and alignment tolerance deteriorate due to increased susceptibility to alignment offsets
Solution Approach 1:
The patent changes the optical parameters by introducing a combination of positive and negative optics (concave and convex lenses) to compensate for alignment offsets. This parameter change allows the system to maintain performance despite manufacturing variations in high-density configurations
Solution Approach 2:
The patent uses a composite optical system combining both positive (convex) and negative (concave) lenses in a lens array. This composite structure enables the system to tolerate alignment offsets while maintaining the desired irradiance profile at the target
2Volume of moving object
If high-density laser arrays are used to reduce component size and cost, then device compactness is improved, but reliability deteriorates due to manufacturing variations
Solution Approach 1:
The patent modifies optical parameters by employing both converging and diverging lenses to compensate for manufacturing variations. This parameter adjustment ensures consistent performance across high-density laser arrays despite production tolerances
Solution Approach 2:
The patent preemptively compensates for potential alignment issues by incorporating both positive and negative optics that can counteract manufacturing variations before they affect performance. This prior cushioning approach ensures reliable operation in compact high-density configurations
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 configuration results in a more tolerant and reliable laser assembly that is less susceptible to manufacturing variations, enabling higher optical efficiency and compactness while maintaining low manufacturing costs, thereby improving the performance of time-of-flight sensors.
Implementation Method 1
The lens array may include at least one concave lens and at least one convex lens. The concave and convex lenses may map the irradiance of the lasers to a common target irradiance profile
Implementation Method 2
The field mapping optic may refract optical signals from lasers of the laser array to a desired irradiance at a target
Data Source
AI summary
In one example, a laser assembly may include a substrate, a lens array, and a laser array. The lens array may be positioned on a first side of the substrate. The laser array may be positioned on a second side of the substrate opposite the first side. Lasers of the laser array may be oriented to generate optical signals through the substrate to corresponding lenses of the lens array. The lens array may include at least one concave lens and at least one convex lens. The concave and convex lenses may map the irradiance of the lasers to a common target irradiance profile, resulting in an alignment tolerant laser assembly.