Light-Emitting Assembly With Stacked Mirrors for Beam Alignment
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Solution Overview
Problem
Existing light-emitting devices face challenges in aligning the traveling direction of laser beams emitted from semiconductor laser elements with the designed direction, leading to deviations that can reduce the effectiveness of beam combination and output power.
Innovation Solution
A light-emitting device configuration featuring a substrate, a semiconductor laser element, a first mirror member with an inclined reflective surface, a cover, and a second mirror member with a reflective surface positioned above the first, where the laser beam is reflected to change its direction, allowing for precise alignment and combination of laser beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple mirror configuration is used, then device complexity is reduced, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The optical system is divided into multiple independent mirror members (first mirror member with first reflective surface, second mirror member with second reflective surface) instead of using a single complex mirror. Each mirror member can be independently manufactured, adjusted, and replaced, reducing overall device complexity while maintaining high alignment precision through individual optimization of each segment.
Solution Approach 2:
The patent introduces a vertical dimension by positioning the second mirror member above the first mirror member, creating a multi-level optical path. This three-dimensional arrangement allows for better control of beam direction and reduces sensitivity to manufacturing tolerances compared to a planar configuration, as adjustments can be made in multiple spatial dimensions.
2Manufacturing precision
If multiple mirror members are used, then beam direction control precision is improved, but device complexity increases
Solution Approach 1:
The complex beam direction control function is segmented across multiple mirror members, with each mirror responsible for a specific reflection and direction adjustment. This segmentation allows each component to be simpler in design while collectively achieving high precision, as the total angular control is distributed across multiple smaller reflection angles rather than requiring one large precision mirror.
Solution Approach 2:
The mirror members are positioned and oriented in advance during device assembly to pre-establish the correct optical path. The first mirror member is positioned to reflect the laser beam at a predetermined angle, and the second mirror member is positioned above it to perform a second reflection. This preliminary positioning reduces the need for complex real-time adjustments and simplifies the overall control system.
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 configuration effectively reduces deviation between the laser beam direction and the designed direction, enabling efficient combination and increasing the output power of the combined light.
Implementation Method 1
the first reflective surface reflects the laser beam to change a traveling direction of the laser beam to a direction away from the mounting surface of the substrate
Implementation Method 2
the second reflective surface reflects the laser beam reflected by the first reflective surface to further change the traveling direction of the laser beam
Data Source
AI summary
A light-emitting device includes: a substrate having a mounting surface; a semiconductor laser element supported by the mounting surface; a first mirror member supported by the mounting surface and having a first reflective surface oriented obliquely upward; a cover that has a facing surface facing the mounting surface of the substrate, has an upper surface positioned on a side opposite to the facing surface, and is positioned above the semiconductor laser element and the first mirror member; and a second mirror member supported by the upper surface of the cover and having a second reflective surface. The first reflective surface reflects a laser beam to change a traveling direction of the laser beam to a direction away from the mounting surface of the substrate. The cover transmits the laser beam reflected by the first reflective surface. The second reflective surface reflects the laser beam reflected by the first reflective surface.