Laser Diode Dummy Bar Alignment for Accurate End-Face Film Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The wear of the plate during cleaning causes the laser diode bar to sink, leading to displacement from the dummy bar, resulting in inaccurate control of the insulating-film deposition on the end faces of the laser diode bar, which decreases the reliability of the insulating film.
Innovation Solution
A dummy bar with a body part having a longitudinal length equal to that of the laser diode bar and handle parts on the side surfaces, allowing for precise alignment and handling, even on a worn plate, to ensure accurate deposition of the insulating film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the dummy bar has a longitudinal length longer than the laser diode bar to improve handleability, then the dummy bar is easier to handle during arrangement, but the laser diode bar sinks on a worn plate causing displacement and inaccurate film deposition
Solution Approach 1:
The patent replaces the conventional dummy bar structure with a new design where the dummy bar has the same longitudinal length as the laser diode bar. The handling function is transferred to a separate holder that engages with the dummy bar, separating the alignment function (dummy bar length matching) from the handling function (holder with engagement structure). This resolves the contradiction by allowing precise alignment while maintaining ease of operation through the holder mechanism.
Solution Approach 2:
The patent segments the dummy bar system into two functional components: the dummy bar itself (responsible for alignment with length matching) and the holder (responsible for handling and engagement). This segmentation allows each component to optimize its specific function without compromise, resolving the contradiction between handleability and alignment precision.
2Productivity
If the plate is cleaned repeatedly to enable multiple uses, then the plate can be reused, but the periphery of the opening becomes worn causing the laser diode bar to sink and displace
Solution Approach 1:
The patent applies preliminary anti-action by designing the dummy bar and holder system to compensate for and prevent the harmful effect of plate wear. The engagement structure between holder and dummy bar, combined with length matching, proactively counteracts the sinking and displacement that would otherwise occur on worn plates, maintaining alignment precision despite repeated cleaning and reuse of the plate.
3Manufacturing precision
If the dummy bar length is made equal to the laser diode bar length for precise alignment, then film deposition accuracy is maintained even on worn plates, but the handleability during arrangement becomes more difficult
Solution Approach 1:
The patent replaces the direct handling of the dummy bar with a separate holder mechanism. The holder engages with the dummy bar and provides the handling function, while the dummy bar focuses solely on alignment through length matching with the laser diode bar. This substitution resolves the contradiction by transferring handling difficulties to the holder design while maintaining precise alignment through the dummy bar geometry.
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 dummy bar with a body part matching the length of the laser diode bar and handle parts for improved handleability, allows for precise control of insulating-film deposition, maintaining the reliability of the film even when the plate is worn.
Implementation Method 1
an insulating film is sequentially deposited on both end faces of each laser diode bar
Data Source
AI summary
A dummy bar is used to align a laser diode bar during deposition of an insulating film on a front end face (32) and a rear end face (34) of a laser diode bar (30), the dummy bar including a body part (12) having a plate shape, and including a pair of side surfaces (14), an upper surface (16), and a lower surface (18), the body part having a longitudinal length equal to a longitudinal length of the laser diode bar (30), the pair of side surfaces (14) being orthogonal to a longitudinal direction and opposite each other, the upper surface (16) and the lower surface (18) being orthogonal to the pair of side surfaces, parallel to a thickness direction of the plate shape, and opposite each other and a handle part (20) provided at a position separated from the lower surface (18) on each of the pair of side surfaces (14).