Optical Member Alignment for Consistent Laser Divergence Angles
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Solution Overview
Problem
Existing light-emitting devices face significant variations in divergence angles due to dimensional variance in optical members, leading to inconsistent performance within a single device and among mass-produced devices.
Innovation Solution
A manufacturing method that adjusts the inclination and height of an optical member with a non-lens section, using an adhesive to fix it to a base body, ensuring consistent light emission by optimizing the optical path length and reducing deviations in the optical axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an optical member with lens sections is fixed to a base body using a simple screwing method, then the device structure is simple and easy to manufacture, but the divergence angle of light varies significantly within a single device and among mass-produced devices due to dimensional tolerance
Solution Approach 1:
The optical member is designed with a tiltable structure that allows dynamic adjustment of its inclination angle. The optical member can be tilted relative to the base body within a predetermined angle range, enabling optimization of the optical path. This dynamic adjustment capability resolves the contradiction by allowing the system to adapt to dimensional variations while maintaining consistent divergence angles across mass-produced devices.
Solution Approach 2:
The invention changes the inclination angle parameter of the optical member to compensate for dimensional tolerance variations. By adjusting the tilt angle within a predetermined range, the optical path length and alignment are optimized, ensuring consistent divergence angles. This parameter adjustment resolves the manufacturing precision issue while maintaining ease of manufacture through simple angular adjustment mechanisms.
2Manufacturing precision
If the optical member is fixed with rigid dimensional constraints, then the divergence angle consistency is improved, but the device complexity increases due to additional adjustment mechanisms
Solution Approach 1:
Rather than using complex rigid constraints, the invention employs a simple tiltable joint that allows the optical member to rotate within a predetermined angle range. This dynamic joint is mechanically simple yet effective in achieving divergence angle consistency, avoiding the need for complex adjustment mechanisms while maintaining manufacturing precision.
Solution Approach 2:
The invention uses a single adjustable parameter (inclination angle) to achieve divergence angle consistency. This simple angular adjustment is far less complex than implementing multiple dimensional constraints or sophisticated alignment mechanisms, thus resolving the contradiction between precision and complexity.
3Manufacturing precision
If the optical member is made with tight dimensional tolerances, then the divergence angle variance is reduced, but the manufacturing cost and difficulty increase
Solution Approach 1:
Instead of requiring tight dimensional tolerances on the optical member itself, the invention compensates for dimensional variations by adjusting the inclination angle parameter. This approach allows the use of optically member with standard, easier-to-manufacture tolerances while achieving consistent divergence angles through angular adjustment, thereby reducing manufacturing difficulty and cost.
Solution Approach 2:
The tiltable structure allows the optical member to dynamically adjust its position to compensate for manufacturing variations. This dynamic compensation eliminates the need for precision manufacturing, as the adjustment mechanism absorbs the dimensional tolerances, making the optical member easier and less costly to manufacture.
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 method reduces variance in divergence angles within individual light-emitting devices and among mass-produced devices, maintaining consistent optical performance by adjusting the optical member's inclination, height, and planar position.
Implementation Method 1
an adhesive is interposed between the base body and the non-lens section or an adhesive is interposed between the base body and the non-lens section after adjusting the inclination and the height of the optical member; and subsequently, the adhesive is cured to fix the optical member to the base body
Data Source
AI summary
A method of manufacturing a light-emitting device includes providing a base body including a base section; fixing a plurality of semiconductor laser elements on an upper surface of the base section; and fixing an optical member to the base body, the optical member including a plurality of lens sections, and a non-lens section disposed at a periphery of the plurality of lens sections in a top view. In the step of fixing the optical member: the optical member is arranged above the base body; (i) an inclination and a height of the optical member are adjusted after interposing an adhesive between the base body and the non-lens section, or (ii) an adhesive is interposed between the base body and the non-lens section after adjusting the inclination and the height of the optical member; and subsequently, the adhesive is cured to fix the optical member to the base body.