Laser Assembly with Raised Reflective Feature for Beam Convergence
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Solution Overview
Problem
Existing laser assemblies that integrate multiple semiconductor lasers face challenges in directing their beams to approximate a single laser source, particularly due to difficulties in manufacturing and complexity, especially when using conventional silicon substrates and processing techniques, which hinder mass production and increase costs.
Innovation Solution
A laser assembly with a substrate featuring a planar surface and a raised feature with angled reflective surfaces, where semiconductor lasers are tilted to direct their beams normal to the substrate, allowing them to converge and mimic a single laser source, using conventional substrates and processing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single set of steering optics is used for multiple semiconductor lasers, then device complexity is reduced, but it becomes difficult to direct beams from multiple lasers to approximate a single laser source
Solution Approach 1:
The single set of steering optics is segmented into multiple independent steering paths, each capable of independently directing beams from different semiconductor lasers. This allows each laser beam to be precisely controlled to converge at the same output point, approximating a single laser source while maintaining manageable device complexity.
Solution Approach 2:
A beam combining optical element is introduced as an intermediary component that receives beams from multiple semiconductor lasers and combines them into a single output beam. This mediator enables precise beam convergence while simplifying the overall steering optics architecture.
2Ease of manufacture
If conventional silicon substrates and processing techniques are used to pattern triangular features with 45-degree oblique angles, then manufacturing simplicity is maintained, but manufacturing precision deteriorates due to difficulty in patterning
Solution Approach 1:
The substrate material parameter is changed from conventional silicon to a material that can be easily patterned with precise 45-degree oblique angles using standard processing techniques. This parameter change enables both manufacturing simplicity and high patterning precision to be achieved simultaneously.
Solution Approach 2:
A composite substrate structure is employed that combines materials with different properties - one layer optimized for easy patterning with 45-degree angles and another layer providing the necessary mechanical support. This composite approach maintains ease of manufacture while achieving high patterning precision.
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
Enables easy manufacturing and efficient beam convergence, reducing complexity and cost, while allowing for the optical coupling of multiple laser outputs, enhancing print speed in printers and compatibility with various optical disc formats.
Implementation Method 1
The laser beams of the two opposing semiconductor lasers are reflected by the oblique surfaces of the patterned feature so that the reflected laser beams approximate the light emitted from one laser
Data Source
AI summary
A laser assembly comprises a substrate and two or more lasers. The substrate has a substantially planar surface region and a raised feature. The raised feature comprises two or more reflective surfaces. Each of the two or more lasers is mounted to the substantially planar surface region and is configured to emit a laser beam directed towards the raised feature at a nonzero tilt angle in relation to the substantially planar surface region.