External Resonant Laser Grating Mount for Precise Alignment
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Solution Overview
Problem
Existing external resonant laser modules face yield reduction due to variations in the mounting accuracy of components like lenses and diffraction gratings, which can lead to defective products when mass-produced.
Innovation Solution
The laser module incorporates a mount member with specific mounting portions and a protruding portion on the diffraction grating unit that allows for precise positioning and sliding insertion, ensuring high accuracy in mounting the diffraction grating unit, thereby reducing variations and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mounting methods are used for diffraction grating units, then manufacturing process is simple, but mounting accuracy varies and yield decreases
Solution Approach 1:
The diffraction grating unit's own protruding portion serves as the positioning and mounting feature, eliminating the need for separate positioning mechanisms. The protruding portion is formed as an integral part of the diffraction grating unit, allowing it to self-position within the hole portion of the mounting structure, thereby achieving high mounting accuracy without adding external positioning devices.
Solution Approach 2:
The protruding portion is pre-formed on the diffraction grating unit during manufacturing, establishing the positioning geometry in advance. This preliminary formation of the mounting feature ensures that when the diffraction grating unit is installed, the positioning is already determined by the pre-formed protruding portion, reducing variability in mounting accuracy.
2Reliability
If high mounting accuracy is required for all components, then laser oscillation performance is ensured, but manufacturing cost and complexity increase
Solution Approach 1:
The diffraction grating unit self-positions through its protruding portion fitting into the hole portion, ensuring accurate positioning without requiring complex external positioning fixtures or procedures. This self-positioning mechanism maintains reliable laser oscillation performance while simplifying the manufacturing process.
3Manufacturing precision
If multiple separate positioning features are used, then positioning accuracy is high, but device structure becomes complex
Solution Approach 1:
The positioning function is merged into the diffraction grating unit itself through the protruding portion, combining the diffraction grating functionality with the positioning feature. This integration eliminates the need for separate positioning elements, reducing structural complexity while maintaining positioning accuracy.
Solution Approach 2:
The protruding portion serves multiple functions: it acts as both the diffraction grating mounting feature and the positioning element. This multi-functionality reduces the number of separate components needed, simplifying the overall structure while ensuring accurate positioning of the diffraction grating unit.
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 easy and accurate mounting of the diffraction grating unit, enhancing the yield of the external resonant laser module by minimizing mounting inaccuracies and simplifying the structure while reducing manufacturing costs.
Implementation Method 1
a quantum cascade laser element
Implementation Method 2
light from the quantum cascade laser element is diffracted and reflected by the diffraction grating
Implementation Method 3
a lens for passing a first outgoing light from the quantum cascade laser element
Data Source
AI summary
The laser module includes a QCL element, a diffraction grating unit, a first lens holder, a second lens holder, and a mount member. The fourth mounting portion of the mount member is provided with a placement hole into which the protruding portion of the diffraction grating unit is inserted. The placement hole is longer than the protruding portion so that the protruding portion can be slid in the X-axis direction relative to the placement hole. A wall surface for positioning the diffraction grating unit is provided between the third mounting portion and the fourth mounting portion. The diffraction grating unit includes a positioning surface facing the wall surface. The diffraction grating unit is fixed to the fourth mounting portion in a state where the protruding portion is inserted into the placement hole and the positioning surface is in surface contact with the wall surface.