Self-Aligned VCSEL Array Beam Shaping for Precise Optical Alignment
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Solution Overview
Problem
Existing light-based 3D measurement systems face challenges in achieving precise alignment and efficient beam shaping for light emitting devices, such as VCSEL arrays, which are crucial for applications like lidar systems, due to the complexity and cost of traditional alignment methods and the limited performance of integrated optical elements.
Innovation Solution
The use of self-aligned optical elements with structured surfaces and fiducial structures on substrates allows for the precise alignment and beam shaping of light emitting devices, such as VCSEL arrays, without the need for active alignment techniques, using a combination of substrates, pedestals, and adhesive patterns to achieve desired light patterns and beam distributions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional active alignment techniques are used for VCSEL arrays, then precise alignment can be achieved, but the complexity and cost of the system increases
Solution Approach 1:
The patent implements self-aligned optical elements that automatically position themselves relative to the VCSEL array without requiring external active alignment equipment. The optical elements are designed with features that enable them to find and lock onto the correct position autonomously, eliminating the need for complex alignment systems while maintaining precise alignment.
Solution Approach 2:
The patent incorporates pre-formed alignment features and structured surfaces on the optical elements before the actual assembly process. These pre-configured features guide the optical elements into proper alignment with the VCSEL array, performing the alignment function in advance rather than requiring complex real-time adjustment mechanisms.
2Manufacturing precision
If traditional alignment methods are used for VCSEL arrays, then accurate beam shaping can be achieved, but the time and cost required for alignment increases
Solution Approach 1:
The self-aligned optical elements automatically achieve proper positioning and beam shaping configuration without requiring time-consuming manual or machine-based active alignment processes. The elements self-organize into the correct spatial relationship with the VCSEL array, dramatically reducing alignment time while maintaining beam shaping accuracy.
Solution Approach 2:
The patent replaces traditional mechanical alignment systems with optical and geometric self-alignment mechanisms. Instead of using mechanical stages, motors, and sensors for active alignment, the system uses precisely engineered geometric features and optical properties to achieve automatic alignment, eliminating the time required for mechanical adjustment procedures.
3Ease of manufacture
If integrated optical elements are used with VCSEL arrays, then beam shaping capability is provided, but the performance and uniformity of light distribution is limited
Solution Approach 1:
The patent implements optical elements with spatially varying structured surfaces that provide different optical functions at different locations. These locally optimized structures are designed to compensate for variations in the VCSEL array emission patterns, creating uniform light distribution across the entire beam while maintaining ease of manufacture through standardized component production.
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 enables efficient beam shaping and alignment of light emitting devices, providing uniform intensity distributions over a wide field of view, improving the performance and cost-effectiveness of light-based 3D measurement systems while reducing the complexity and time required for alignment.
Implementation Method 1
at least one optical element arranged to receive respective light emissions from the plurality of emitters
Data Source
AI summary
An optical emitter device includes a plurality of emitters on a first substrate, and one or more alignment patterns on the first substrate and positioned relative to the plurality of emitters. At least one optical element is arranged to receive respective light emissions from the plurality of emitters, and is oriented based on the one or more alignment patterns, such that the at least one optical element and the plurality of emitters are self-aligned. Related devices and fabrication methods are also discussed.