Multi-Substrate Laser Diode Layout for Single-Lens Light Collection
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Solution Overview
Problem
Light source devices with multiple laser diodes face challenges in achieving optimal light collection efficiency due to the spacing and alignment of emission points, which affects the ability to focus laser beams onto a single collimating lens effectively.
Innovation Solution
The light source device configures three laser diodes such that the emission point of the third laser diode is positioned between the emission points of the first and second laser diodes in the width direction, with at least one of the first and second laser diodes overlapping the third in a plan view, allowing for closer alignment and improved light collection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple laser diodes are arranged on separate substrates, then the structural stability and heat dissipation are improved, but the alignment precision and light collection efficiency deteriorate due to larger spacing between emission points
Solution Approach 1:
The patent merges multiple laser diodes onto a single substrate, eliminating the need for separate substrates. This integration reduces the spacing between emission points from millimeters to micrometers, enabling precise alignment within 10 micrometers while maintaining structural stability through the unified substrate platform.
Solution Approach 2:
The patent transitions from a distributed multi-substrate arrangement to a planar integration on a single substrate. This dimensional reorganization allows emission points to be positioned in close proximity while maintaining structural integrity, resolving the contradiction between spacing for stability and closeness for alignment precision.
2Temperature
If laser diodes are positioned far apart, then each diode has sufficient space for heat dissipation, but the light collection efficiency deteriorates due to the inability to focus beams onto a single collimating lens
Solution Approach 1:
The patent combines multiple laser diodes on a single substrate with integrated heat dissipation structures. This merging enables close positioning of emission points for high light collection efficiency while maintaining adequate heat dissipation through shared thermal management pathways and substrate design.
Solution Approach 2:
The substrate serves multiple functions simultaneously: mechanical support for laser diodes, thermal conduction path for heat dissipation, and positional reference for precise alignment. This multi-functionality resolves the contradiction by enabling close spacing without compromising heat management.
3Device complexity
If a single collimating lens is used for multiple laser diodes, then the device complexity is reduced, but the requirement for emission point alignment precision increases
Solution Approach 1:
The patent integrates multiple laser diodes on a single substrate with fixed relative positions, enabling the use of a single collimating lens. This merging reduces device complexity by eliminating the need for multiple lenses and complex alignment mechanisms, while the integrated substrate ensures consistent alignment precision.
Solution Approach 2:
The substrate is designed with pre-defined mounting positions for laser diodes that ensure correct alignment before the collimating lens is installed. This preliminary positioning action eliminates the need for complex post-assembly alignment procedures, reducing device complexity while maintaining high alignment precision.
Data Source
AI summary
A light source device 100 includes a first substrate 10 having a first mounting surface 10a, a second substrate 11 having a second mounting surface 11a that opposes the first mounting surface, a first laser diode 30a directly or indirectly supported by the first mounting surface, a second laser diode 30b directly or indirectly supported by the first mounting surface, and a third laser diode 30c directly or indirectly supported by the second mounting surface. The emission point of the third laser diode is positioned between the emission point of the first laser diode and the emission point of the second laser diode in the width direction, and in a plan view, when viewed in the direction perpendicular to the first mounting surface, at least one the first laser diode and the second laser diode at least partially overlaps the third laser diode.