Laser Component Assembly with Stop Surfaces for Lens Alignment
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Solution Overview
Problem
Laser components with semiconductor-based laser chips face challenges due to high beam divergence, requiring large or closely positioned optical lenses, which demands stringent positioning accuracy and is prone to impairment from slight inaccuracies.
Innovation Solution
A laser component assembly with a carrier having component portions with chip and lens mounting surfaces and stop surfaces, where a lens bar with optical lenses bears against the stop surfaces, ensuring precise positioning and orientation of the lenses relative to the laser chips, allowing for high-quality beam shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If optical lenses are arranged very near the laser chip to handle high beam divergence, then the lens size can be reduced, but the positioning accuracy requirements become much more stringent
Solution Approach 1:
The carrier is divided into multiple component portions (first component portion, second component portion, etc.), each with dedicated chip mounting surfaces and lens mounting surfaces. This segmentation allows independent positioning of lenses relative to their respective laser chips while maintaining overall system compactness.
Solution Approach 2:
Stop surfaces and stop elements are introduced as intermediary reference features between the lenses and laser chips. These stop surfaces provide precise mechanical reference points that define the relative positioning of lenses to chips, enabling accurate alignment without requiring direct measurement or adjustment.
2Manufacturing precision
If optical lenses are made very large to handle high beam divergence, then positioning accuracy requirements are relaxed, but the device size and complexity increase
Solution Approach 1:
The problem is solved by adding a vertical dimension through elevated chip mounting surfaces and elevated lens mounting surfaces. This multi-level arrangement allows compact horizontal footprint while maintaining precise optical alignment through controlled vertical spacing and stop surface references.
3Reliability
If stringent positioning accuracy is required for optical lenses, then beam quality is improved, but production costs and complexity increase
Solution Approach 1:
Stop surfaces are pre-formed on the carrier during carrier fabrication, establishing precise reference positions before lens mounting. This preliminary action embeds the positioning information directly into the carrier structure, eliminating the need for separate positioning fixtures or complex alignment procedures during assembly.
Solution Approach 2:
The stop surfaces serve multiple functions: they define lens positioning, establish orientation references, and provide mechanical stopping points for assembly tools. This multi-functionality reduces the number of separate reference features needed, simplifying the overall positioning system.
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 achieves accurate positioning and orientation of optical lenses, resulting in high-quality beam shaping and minimizing production costs by enabling parallel production of laser components with reduced tolerance effects.
Implementation Method 1
optical lenses provided to collimate divergent laser beams
Data Source
AI summary
A laser component assembly includes a carrier including first and second component portions wherein each component portion has a chip mounting surface, a lens mounting surface and a stop surface, the stop surface of each component portion includes first and second stop partial surfaces, the first stop partial surface is formed on a first stop element and the second stop partial surface is formed on a second stop element, the chip mounting surface is arranged between the first stop element and the second stop element, the stop surface is oriented perpendicularly to the chip mounting surface, a laser chip arranged on the chip mounting surface, the laser component assembly as a lens bar comprising an optical lens component portion and the lens bar is arranged on the lens mounting surfaces of the component portions and bears against the stop surfaces of the component portions.