Self-aligning Laser Assembly with Non-circular Heatsink
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Solution Overview
Problem
Conventional methods for aligning laser diodes with non-radially symmetric optical outputs, such as those using cylindrical tubes, require active alignment and precision fixtures, which increase complexity and cost and can lead to misalignment issues.
Innovation Solution
A submount assembly with a TO-can having notches or keys that mate with a non-circular tubular heatsink, allowing for passive and precise radial alignment of the laser diode and lens, eliminating the need for precision machining and active alignment, using a slot or spacer for fixed radial and rotational alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cylindrical tubes with precision machining are used for laser diode alignment, then radial alignment precision can be achieved, but device complexity and manufacturing cost increase due to required active alignment and precision fixtures
Solution Approach 1:
The patent applies asymmetry by transitioning from a symmetric cylindrical tube to a non-circular tube cross-section that matches the asymmetric laser diode emission pattern. The tube's cross-section is shaped to correspond to the fast and slow axis divergences, creating an asymmetric geometry that passively guides and centers the laser diode output without requiring additional alignment fixtures or active adjustment mechanisms.
Solution Approach 2:
The non-circular tube geometry serves as a self-aligning structure where the asymmetric shape automatically positions the laser diode and lens elements in the correct radial orientation. The tube's internal geometry provides self-centering features that eliminate the need for external precision fixtures or manual active alignment procedures, allowing the system to self-align during assembly.
2Manufacturing precision
If conventional cylindrical tubes with precision machining are used for laser diode alignment, then radial alignment precision can be achieved, but manufacturing cost increases due to precision machining requirements
Solution Approach 1:
The asymmetric non-circular tube cross-section is designed to match the laser diode's emission characteristics, allowing the tube to be manufactured using less precise, more cost-effective processes. The asymmetric geometry can be created through forming or extrusion methods rather than requiring expensive precision machining of a cylindrical tube, thereby reducing manufacturing costs while maintaining alignment precision.
Solution Approach 2:
The self-aligning non-circular tube geometry eliminates the need for costly precision machining operations and specialized alignment fixtures. The tube's inherent asymmetric shape provides the alignment function, allowing standard manufacturing processes to achieve the required precision, thereby significantly reducing manufacturing costs compared to conventional precision-machined cylindrical tubes.
3Manufacturing precision
If active alignment and precision fixtures are used for laser diode and lens alignment, then precise optical alignment can be achieved, but the alignment process becomes more complex and time-consuming
Solution Approach 1:
The non-circular tube cross-section is designed with asymmetric geometry that corresponds to the laser diode's fast and slow axis divergences. This asymmetric shape passively guides the laser diode and lens elements into their correct radial positions and orientations, eliminating the need for time-consuming active alignment procedures and precision fixtures, thereby significantly reducing alignment process time while maintaining optical precision.
Solution Approach 2:
The non-circular tube geometry is pre-designed with built-in alignment features that automatically position the laser diode and lens elements in the correct radial orientation during assembly. This preliminary geometric configuration performs the alignment function in advance, eliminating the need for subsequent active alignment adjustments and reducing the overall alignment process time.
4Ease of manufacture
If a cylindrical tube with radially symmetric geometry is used, then simple manufacturing is possible, but it cannot properly align laser diodes with non-radially symmetric optical outputs
Solution Approach 1:
The patent resolves this contradiction by replacing the symmetric cylindrical tube with a non-circular tube whose cross-sectional geometry is specifically designed to match the asymmetric laser diode emission pattern. This asymmetric geometry enables proper alignment of the fast and slow axes while still allowing for relatively simple manufacturing through forming or extrusion processes, thus maintaining ease of manufacture while achieving the required optical alignment precision.
Data Source
AI summary
A self-aligning laser system that is capable of accurate placement for xyz coordinate and rotational alignment and registration of optical lens or lenses in relation to a laser diode without the need for active alignment. This approach reduces complexity, assembly time and costs without sacrifice to precision of alignment and optical performance.