Semiconductor Laser Module Hermetic Sealing via Segmentation
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Solution Overview
Problem
Conventional semiconductor laser modules face challenges in maintaining precise positioning and environmental stability due to thermal expansion and contraction during assembly, leading to positional deviations and reduced light intensity, especially when using visible light-emitting lasers, which also suffer from contamination risks from dust and photochemical reactions.
Innovation Solution
A semiconductor laser module design incorporating a laser holder, sleeve, optical fiber, annular member, and flexible member, where the sleeve is fixed with limited laser welding to minimize thermal effects, and a silicon-free sealing system using PET or PET-aluminum films to prevent contamination and maintain a stable atmosphere, ensuring precise alignment and hermetic sealing without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder, adhesive, fusion, or welding is used to fix and hermetically seal the optical fiber section, then hermetic sealing is achieved, but positional deviation between components occurs due to thermal expansion and contraction, degrading coupling precision
Solution Approach 1:
The hermetic sealing function is separated from the positioning function. The optical fiber is positioned and fixed using precision alignment and adhesive bonding first, then hermetic sealing is achieved by forming a seal between the optical fiber coating and the sleeve using fusion or welding, isolating the sealing process from the positioning components
Solution Approach 2:
The optical fiber coating acts as an intermediary element between the optical fiber core and the sleeve. The coating is fused or welded to the sleeve to create hermetic sealing, while the optical fiber positioning is established separately through precision alignment fixtures and adhesive bonding, preventing thermal distortion from affecting the core positioning
2Ease of manufacture
If adhesive is used to fix the optical fiber section, then assembly is simplified, but positional shifts occur during hardening and after residual stress release, reducing light intensity
Solution Approach 1:
The fixing and hermetic sealing functions are segmented into separate processes. Precision positioning is achieved first through alignment fixtures and initial adhesive bonding, then hermetic sealing is performed separately through fusion or welding of the coating to the sleeve, preventing adhesive stress from causing positional shifts
Solution Approach 2:
The mechanical properties of the adhesive are optimized by controlling its viscosity and curing characteristics. The adhesive is formulated to minimize shrinkage during hardening and reduce residual stress, maintaining positioning stability while enabling simple assembly
3Manufacturing precision
If the laser beam is focused to microns onto the optical fiber incident end, then coupling efficiency is improved, but dust accumulation and photochemical reactions occur, contaminating the optical fiber
Solution Approach 1:
The module interior is filled with inert gas (nitrogen or sulfur hexafluoride) to create a chemically inert environment that prevents photochemical reactions between the laser beam and atmospheric contaminants. This eliminates the formation of SiOx and other reaction products while maintaining high coupling efficiency
Solution Approach 2:
The high light energy density that causes optical trapping of dust is converted into a benefit by using it to fuse or weld the optical fiber coating to the sleeve. This hermetic sealing prevents external dust from entering the module interior, transforming the harmful optical trapping effect into a protective sealing mechanism
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 achieves stable light coupling efficiency and intensity by preventing positional shifts and contamination, maintaining precise alignment and hermetic sealing, thus enhancing the reliability of the semiconductor laser module and optical scanner systems.
Implementation Method 1
a flexible member affixed to the sleeve and the annular member for covering the space
Implementation Method 2
The optical fiber is disposed in the insertion hole and has an incident face. The laser beam is capable of entering the incident face
Data Source
AI summary
A semiconductor laser module includes a laser holder, a semiconductor laser, a sleeve, an optical fiber, an annular member, and a flexible member. The laser holder has an end portion and is formed with a through-hole opened on the end portion. The semiconductor laser is provided on the laser holder and has a light-emitting portion for emitting a laser beam passing through the through-hole. The sleeve is fixed to the end portion so as to block the through-hole and is formed with an insertion hole. The optical fiber is disposed in the insertion hole and has an incident face. The laser beam is capable of entering the incident face. The annular member is provided on the end portion of the laser holder to encircle outside of the sleeve to be separated from the sleeve with a space between the annular member and the sleeve. The flexible member is affixed to the sleeve and the annular member for covering the space.