Laser Module Athermalized Frame Large Focal Length Lens
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Solution Overview
Problem
Existing solid state laser modules face challenges in achieving a compact, lightweight, and efficient design while maintaining reliability and performance, particularly in applications requiring reduced cross-sectional area, volume, and weight, along with resistance to environmental extremes and thermal variations.
Innovation Solution
The use of a lens with a focal length greater than 10 mm that can collimate divergent laser light into a collimated beam with minimal divergence, combined with an athermalized frame that maintains optical alignment over a wide temperature range, reducing the complexity and size of the laser system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small focal length lens is used to reduce system footprint, then the device size is reduced, but the manufacturing precision and alignment tolerance become extremely tight
Solution Approach 1:
Instead of using a small focal length lens to achieve compact size, the patent inverts the approach by using a large focal length lens (greater than 10mm, preferably 20mm or more). This inversion resolves the contradiction because the larger focal length naturally provides greater alignment tolerance and relaxed manufacturing precision requirements while still achieving compact overall device design through different optical geometry
Solution Approach 2:
The patent changes the key optical parameter from small focal length to large focal length (greater than 10mm). This parameter change fundamentally alters the system's sensitivity to misalignment and manufacturing variations, providing inherent robustness without requiring complex alignment procedures or ultra-precise manufacturing
2Illumination intensity
If lens positioning is held within tight tolerances to maintain collimation, then beam quality is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent inverts the conventional approach by deliberately allowing larger lens positioning tolerances (±5mm or more) while using a large focal length lens to maintain beam collimation quality. This inversion simplifies assembly procedures, reduces the need for complex alignment mechanisms, and lowers device complexity while preserving illumination quality
Solution Approach 2:
The patent accepts less precise, easier-to-manufacture lens mounting structures that would be rejected in traditional designs. By using a large focal length lens, the system can tolerate cheaper, simpler mounting hardware with larger tolerances, reducing overall device complexity and assembly difficulty
3Length of moving object
If the lens is positioned close to the laser source to minimize device length, then the device becomes more compact, but thermal management becomes more difficult
Solution Approach 1:
The patent changes the optical parameter to use a large focal length lens, which inherently positions the lens farther from the laser source. This parameter change resolves the thermal management contradiction by providing natural thermal separation between the heat-generating laser diode and the lens, while the overall device length remains compact through optimized optical geometry and housing design
4Weight of moving object
If downscaling of components is used to reduce system size, then portability is improved, but reliability under shock and vibration deteriorates
Solution Approach 1:
The patent inverts the downscaling approach by using a large focal length lens that provides inherent mechanical robustness. The larger component dimensions and relaxed tolerances create a more rigid, shock-resistant structure that maintains reliability under vibration and shock conditions while still achieving portability through optimized overall system design rather than aggressive miniaturization
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 approach results in a more portable, efficient, and reliable laser system with improved collimation and reduced thermal sensitivity, allowing for increased robustness and ease of manufacturing without compromising performance.
Implementation Method 1
a lens with a focal length greater than 10 mm that can collimate divergent laser light into a collimated beam having less than a predetermined divergence
Implementation Method 2
an athermalized frame that maintains optical alignment over a wide temperature range
Data Source
AI summary
Laser modules and systems are provided that are smaller, lighter, and less complex and while more reliably generating collimated laser beams having limited divergence.