Laser Diode Cap Stack Cutting With Antireflection Front Wall
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Solution Overview
Problem
Existing methods for manufacturing caps to accommodate laser diodes in light source devices face challenges in efficiently producing caps with precise dimensions and antireflection coatings while maintaining structural integrity and optical transparency.
Innovation Solution
A method involving the use of multiple plates bonded together to form a cap with a recess for the laser diode, where the front wall is transparent and features an antireflection coating, and the cap is cut into individual units using specific incisions to maintain alignment and minimize stress on the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple plates are bonded together to form a cap with antireflection coating, then optical performance is improved, but manufacturing complexity increases
Solution Approach 1:
The cap is divided into multiple functional plates (front wall plate with antireflection coating, rear wall plate, and main body plate) that are bonded together. Each plate can be manufactured and coated independently, then assembled into the final cap structure, allowing for precise dimensional control and optical coating application without compromising the overall manufacturing process.
2Strength
If incisions are made along inner wall surfaces of through-holes, then structural integrity is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The incisions are strategically positioned along the inner wall surfaces of the through-holes rather than through the center of the plates. This localized cutting approach maintains the structural integrity of the cap by preserving the outer boundary strength, while the precise positioning along the inner walls ensures proper separation without compromising overall strength.
3Illumination intensity
If antireflection coating is applied to front wall, then optical performance is improved, but manufacturing steps increase
Solution Approach 1:
The antireflection coating is applied to the front wall plate during the manufacturing process before the final assembly. This preliminary coating application ensures optimal optical performance for laser light transmission while integrating the coating step into the overall manufacturing flow, avoiding additional post-assembly operations.
4Productivity
If plates are bonded together to form stack, then production efficiency is improved, but stress concentration increases
Solution Approach 1:
Multiple cap units are formed by bonding plates together to create a stack structure that can be processed and separated in batches. This merging of multiple units into a single stack improves production efficiency by enabling simultaneous handling and processing, while the bonding interfaces are designed to distribute stress evenly across the structure.
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 method ensures accurate production of caps with consistent dimensions and effective antireflection coatings, enhancing the optical performance and structural integrity of the light source device.
Implementation Method 1
an antireflection coating provided on a surface of the front wall
Implementation Method 2
bonding the first plate and the third plate together and bonding the second plate and the third plate together
Data Source
AI summary
A method includes providing a first plate for a front wall that defines a front surface of a recess to accommodate a laser diode, a second plate for a rear wall that defines a rear side of the recess, and a third plate for a main body that defines an upper side and lateral sides of the recess and is connected to the front wall and the rear wall. The third plate has through-holes arranged in a first direction and in a second directions orthogonal to the first direction. The plates are bonded together to produce a stacked body. The stacked body is cut along the first direction and the second direction to produce a plurality of caps from the stacked body. When cutting the stacked body along the first direction, a first incision is made along inner wall surfaces of through-holes adjacent along the first direction.