Surface-Emitting Laser Alignment via Engaging Portions
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Solution Overview
Problem
The accuracy of positioning surface-emitting lasers in light-emitting modules is compromised due to cumulative errors during the mounting process, affecting the alignment with optical components and overall light output.
Innovation Solution
The use of engaging portions with specific geometries, such as protruded and recessed apices or arcs, on adjacent surface-emitting lasers allows for precise alignment and accurate positioning on a substrate, improving the alignment with optical components like lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If surface-emitting lasers are mounted on a substrate using conventional methods, then the mounting process can be completed, but cumulative positioning errors occur affecting alignment accuracy
Solution Approach 1:
The engaging portions on adjacent surface-emitting lasers automatically align and position each other through their geometric shapes (protruded and recessed apices or arcs), eliminating the need for external positioning fixtures or complex alignment procedures. This self-positioning mechanism reduces cumulative errors while maintaining efficient manufacturing throughput
2Manufacturing precision
If conventional mounting methods are used for surface-emitting lasers, then the process is simple, but alignment with optical components deteriorates due to positioning errors
Solution Approach 1:
The positioning function is merged into the surface-emitting laser components themselves through the engaging portions with specific geometries. This integration eliminates the need for separate positioning fixtures or complex mounting structures, achieving high alignment accuracy while maintaining structural simplicity
Solution Approach 2:
The engaging portions utilize asymmetric geometric shapes (protruded and recessed apices or arcs) that provide unique alignment characteristics. This asymmetry ensures precise orientation and positioning of adjacent lasers, improving alignment accuracy with optical components without requiring complex symmetric fixture systems
Data Source
AI summary
A light-emitting module includes a substrate, a first surface-emitting laser mounted on the substrate, the first surface-emitting laser having a first engaging portion protruded outward at an end, and a second surface-emitting laser mounted on the substrate, the second surface-emitting laser having a second engaging portion recessed inward at an end. The first surface-emitting laser and the second surface-emitting laser are adjacent to each other. The first engaging portion and the second engaging portion are engaged with each other.