RGB Laser Diode Optical Assembly Alignment
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Solution Overview
Problem
Existing optical assemblies using laser diodes for flat panel displays face challenges in achieving precise optical alignment and compact size due to the need for multiple lenses and wavelength selective filters, leading to issues with chromatic aberration and resin oozing, which affects the alignment of red, green, and blue light sources.
Innovation Solution
The method involves mounting red, green, and blue laser diodes on a base with corresponding lenses and wavelength selective filters, aligning them such that the light sources are collimated and multiplexed along a common optical axis, using sub-mounts and filters to ensure precise alignment and suppress chromatic aberration, while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple lenses and wavelength selective filters are used to achieve precise optical alignment, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple optical functions (collimation, wavelength selection, and beam combining) into a single integrated optical assembly structure. The red, green, and blue LDs are mounted on a common base with their respective lenses and wavelength selective filters arranged in an integrated configuration, allowing precise optical alignment while reducing overall system complexity compared to separate packaging approaches
Solution Approach 2:
The optical assembly is segmented into three independent color channels (red, green, blue), each with its own LD, lens, and wavelength selective filter. This segmentation allows for independent optimization and alignment of each color channel while maintaining a compact integrated structure, resolving the contradiction between alignment precision and device complexity
2Ease of manufacture
If three LDs are independently packaged with external optical systems, then the manufacturing flexibility is improved, but the total system size increases
Solution Approach 1:
The patent merges three independently manufacturable LD modules into a single compact optical assembly. By integrating the red, green, and blue LDs with their respective optical components on a common base, the system achieves both manufacturing flexibility (each LD can be sourced independently) and compact size (overall system volume is reduced compared to separate packaging with external optics)
3Ease of manufacture
If resin is used to mount optical components, then the ease of assembly is improved, but chromatic aberration increases due to resin oozing
Solution Approach 1:
The patent introduces precise mechanical mounting structures and alignment features as intermediaries between the resin adhesive and the optical components. These intermediary structures control resin flow and prevent oozing that would cause chromatic aberration, while still allowing the resin to provide easy assembly and bonding functionality
Solution Approach 2:
The patent implements preliminary alignment features and precision mounting structures before applying resin. Optical components are pre-positioned and aligned using mechanical guides and adjustment mechanisms, ensuring that when resin is applied for permanent fixation, the alignment is already established and protected from resin-induced displacement
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 allows for precise alignment of red, green, and blue light sources, effectively suppressing chromatic aberration and maintaining a compact size by ensuring the optical axes are aligned, even with resin oozing, resulting in a stable and efficient optical assembly for flat panel displays.
Implementation Method 1
a first wavelength selective filter to transmit one of a red light and a green light and to reflect another of the red light and the green light
Implementation Method 2
mounting a first lens on the base, the first lens to collimate the red light emitted from the first LD to generate collimated red light
Data Source
AI summary
An optical assembly that installs red, green, blue laser diodes (LDs) within a single package is disclosed. The LDs are mounted on a base via respective sub-mounts. Light emitted from the LDs is collimated by collimating lenses and multiplexed by two wavelength filters so as to align optical axes of the light. The multiplexed light has an axis substantially leveled with the axes of the red, green, and blue light measured from the top of the base.