Laser Module Detachable Transparent Window for Contamination Control
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Solution Overview
Problem
Conventional laser modules face issues with contamination of optical components due to high optical power density, leading to reduced transmittance and potential breakage, and are costly due to the need for hermetically sealed packages and non-replaceable protective members.
Innovation Solution
A laser module design featuring a hermetically sealed package with a detachable transparent member that covers the light-output window and a detachable optical fiber end face, allowing for easy cleaning and replacement, and using a ferrule system for precise alignment, reducing costs by avoiding expensive hermetic sealing requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hermetically sealed package is used to protect optical components, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent divides the protective function into two separate components: a hermetically sealed package for the semiconductor laser elements and a separate transparent member (glass window or plate) that covers the light-output window. This segmentation allows the hermetic sealing to be applied only where necessary (inside the package) while the external transparent member provides additional protection without requiring the entire assembly to be hermetically sealed, thus reducing overall device complexity.
Solution Approach 2:
The transparent member acts as an intermediary between the hermetically sealed package and the external environment. It provides mechanical protection and contamination barrier for the light-output window without requiring direct hermetic sealing of the external interface, thereby reducing the complexity of the package structure while maintaining reliability.
2Reliability
If a transparent member is fixed to protect the light-entrance end face, then reliability is improved, but ease of repair deteriorates
Solution Approach 1:
The patent employs a detachable connection mechanism between the transparent member and the chassis, allowing the transparent member to be easily removed and replaced. This dynamic design enables maintenance and repair operations without permanent fixation, thus improving ease of repair while maintaining the protective function for the light-entrance end face.
Solution Approach 2:
The detachable design allows the transparent member to be discarded (removed) when contaminated or damaged and replaced with a clean one, while the main chassis and optical fiber assembly remain intact and recoverable. This approach maintains reliability through easy replacement while avoiding permanent attachment that would complicate repair.
3Reliability
If the glass window is pressed to maintain hermetic sealing, then reliability is improved, but strength requirements and cost increase
Solution Approach 1:
The patent separates the hermetic sealing function (inside the package) from the protective covering function (external transparent member). The ferrule presses against the transparent member which is external to the hermetic seal, so the pressing force does not compromise the hermetic sealing integrity. This segmentation allows the transparent member to be thinner and weaker without affecting the hermetic seal, reducing material strength requirements and cost.
Solution Approach 2:
The transparent member serves as an intermediary that absorbs the mechanical pressing force from the ferrule, protecting the hermetic seal from direct pressure. This intermediary function allows the hermetic seal to maintain reliability without requiring excessive strength in the glass window or sealing portions, as the transparent member bears the mechanical load.
4Productivity
If high optical power density is used, then productivity is improved, but harmful factors increase due to contamination
Solution Approach 1:
The patent introduces transparent members (glass window covering the light-output window and glass plate covering the light-entrance end face) as intermediary protective barriers. These intermediaries prevent contaminants from directly contacting the critical optical surfaces where high power density exists, thus allowing high optical power density to be maintained without proportionally increasing contamination-related harmful factors.
Solution Approach 2:
The transparent members are positioned in advance to prevent contamination before it can occur on the critical optical surfaces. By providing this preliminary protective action, the system can operate at high optical power density without the contaminants that would otherwise be attracted by or deposited on the high-power-density surfaces, thus maintaining productivity while reducing harmful factors.
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 design provides long-term reliability and cost-effectiveness by protecting the optical fiber end face from contaminants, allowing for easy maintenance and precise alignment, while maintaining high optical power density below 10 W/mm² to minimize contamination and extend module lifetime.
Implementation Method 1
contaminants such as organic materials are likely to deposit on surfaces of optical components at which the optical power density is high, and cause troubles such as the lowering of the transmittance
Implementation Method 2
an optical condensing system which couples a laser beam emitted from the semiconductor laser element, to a light-entrance end face of the optical fiber
Implementation Method 3
an optical fiber the tip of which is inserted into the ferrule is connected with the receptacle by using a connector which can fit into the receptacle
Data Source
AI summary
A laser module includes: a chassis having a light-output window from which one or more laser beams are outputted; a hermetically sealed package which is fixed to the chassis; one or more semiconductor laser elements which are arranged in the hermetically sealed package, and emit the one or more laser beams; a transparent member which is arranged to cover the light-output window; an optical fiber which has a light-entrance end face, and is arranged outside the chassis so that the light-entrance end face is in contact with the transparent member; and an optical condensing system which is arranged inside the chassis, and makes the one or more laser beams pass through the transparent member and be condensed on the light-entrance end face. The transparent member and the optical fiber are detachably attached to the chassis.