Segmented Laser Diode Layout for Warpage-Stable Beam Alignment
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Solution Overview
Problem
In laser processing systems, the warpage of laser diodes leads to deviations in laser beam alignment, resulting in poor beam quality and reduced yield rates due to increased warpage with more emitters, which affects the condensation of laser beams and overall processing efficiency.
Innovation Solution
A light emitting device with a divided structure for laser diodes, where each diode has a shorter dimension in the array direction, combined with beam twister units that adjust the orientation and position of laser beams to minimize warpage and improve beam quality, allowing for better condensation of laser beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of emitters in a laser diode is increased to improve light output, then the light output is improved, but the warpage of the laser diode increases leading to beam alignment deviations
Solution Approach 1:
The patent divides a single laser diode with many emitters into multiple separate laser diodes, each containing a smaller number of emitters. This segmentation reduces the warpage in each individual laser diode, thereby maintaining beam alignment precision while collectively achieving high light output through the combination of multiple diodes.
2Power
If the number of emitters in a laser diode is increased to improve light output, then the light output is improved, but the yield rate decreases due to increased warpage
Solution Approach 1:
By segmenting the laser diode structure into multiple smaller diodes, each with fewer emitters, the warpage-induced defects are reduced in each unit. This increases the manufacturing yield rate for each laser diode while the aggregate light output remains high due to the combined emission from multiple diodes.
3Quantity of substance
If the dimension of laser diode in array direction is increased to accommodate more emitters, then the number of emitters is increased, but the warpage increases leading to poor beam quality
Solution Approach 1:
The patent segments the laser diode array into multiple smaller laser diodes, each with a reduced dimension in the array direction. This reduces the warpage in each individual diode while maintaining a high total number of emitters across the segmented structure, thereby preserving beam quality.
4Manufacturing precision
If beam twister units are used to adjust laser beam orientation, then the beam quality is improved, but the device complexity increases
Solution Approach 1:
The patent applies beam twister units selectively to specific laser diodes or emitter groups that require beam orientation adjustment. By applying the beam twisting function locally rather than uniformly across all emitters, the patent improves beam quality where needed while minimizing the overall device complexity.
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 solution enhances beam quality and increases the yield rate by reducing warpage in laser diodes, enabling more emitters to be arranged without impairing beam quality, thus improving the light output and efficiency of the laser processing system.
Implementation Method 1
a first beam twister unit provided to correspond to the first laser diode, and a second beam twister unit provided to correspond to the second laser diode
Data Source
AI summary
A light emitting device includes a first laser diode including a plurality of emitters that emit first laser beams, a second laser diode including a plurality of emitters that emit second laser beams, the second laser diode being different from the first laser diode, a first beam twister unit provided to correspond to the first laser diode, and a second beam twister unit provided to correspond to the second laser diode, the second twister unit being different from the first beam twister unit.