Free Space Laser Diode Module with Curved Reflective Collimator
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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 multiple laser diodes within a hermetically or partially hermetically sealed package with an optical director element featuring a curved reflective surface, such as a parabolic cylinder, to collimate laser light along its fast axes, combined with collimation lenses and a beam combiner, allowing for compact and efficient light projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser projectors use separate packages for each laser diode with individual focusing lenses and controllable mirrors, then the alignment of laser beams can be tuned, but the form factor becomes large and bulky
Solution Approach 1:
The patent combines multiple laser diodes (red, green, blue) and their corresponding focusing lenses into a single integrated laser module package. The laser diodes are mounted on a common substrate with precise relative positioning, eliminating the need for separate packages and individual alignment procedures. This merging approach maintains manufacturing precision through integrated design while significantly reducing the overall device form factor for wearable applications.
Solution Approach 2:
The patent employs a three-dimensional arrangement of laser diodes and optical elements within the compact module, utilizing vertical stacking and angular positioning to achieve precise beam alignment in multiple dimensions. This dimensional approach allows complex optical paths to be compressed into a small footprint, resolving the contradiction between alignment precision and compact size.
2Volume of moving object
If the laser module is compacted for wearable applications, then the form factor is reduced, but the alignment precision of laser beams deteriorates
Solution Approach 1:
The laser diodes and focusing lenses are pre-aligned and fixed relative to each other during module assembly, establishing precise optical paths before the entire module is integrated into the wearable device. This preliminary alignment action ensures that beam convergence and spot size parameters are optimized in advance, maintaining manufacturing precision despite the compact final form factor.
Solution Approach 2:
The patent replaces traditional mechanical adjustment mechanisms (such as movable mirrors and adjustable lenses) with fixed, precision-machined optical elements integrated into the module substrate. This substitution eliminates the need for post-assembly alignment adjustments, ensuring consistent beam alignment precision while enabling a compact, sealed design suitable for wearable applications.
3Reliability
If wearable heads-up displays use larger components for optimal optical performance, then the optical performance is improved, but the comfort and style of the device deteriorates
Solution Approach 1:
The patent integrates multiple laser diodes and optical elements into a single compact module, dramatically reducing the overall component size and weight. This merging maintains optical performance through precise internal alignment while enabling the device to be worn comfortably on the head for extended periods, directly addressing the contradiction between optical quality and wearable comfort.
Solution Approach 2:
The patent optimizes key optical parameters (beam spot size, convergence angle, collimation) through precision engineering of the integrated optical elements rather than through larger component dimensions. By changing the parameters of the optical design rather than the scale of components, the patent achieves high optical performance in a compact form factor that is comfortable and stylish for wearable applications.
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 enables smaller, lighter, and more stylish wearable heads-up displays with improved optical performance and comfort by ensuring precise alignment and convergence of laser beams within a compact form factor.
Implementation Method 1
an optical director element including a curved reflective surface to reflect and collimate the laser light along the fast axes
Data Source
AI summary
Systems, devices, and methods for 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. The optical engines include an optical director element that includes a curved reflective surface (e.g., parabolic cylinder) that redirects laser light beams and collimates the same along the fast axes thereof. Such optical engines may have various 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.