Vacuum Fixture Aligning Laser Diode Front Edges
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Solution Overview
Problem
Existing methods for aligning the front edges of stacked laser diode bars are inefficient, leading to suboptimal beam quality due to misalignment, and require redesigning microhole sizes and positions for varying diode thicknesses.
Innovation Solution
A vacuum fixture with an alignment plate and suction fixture is used, featuring microholes arranged in patterns like linear arrays or random distributions, to align and clamp the laser diode bars, ensuring precise alignment and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment methods are used for stacked laser diode bars, then the alignment process is simple, but the alignment precision is insufficient leading to suboptimal beam quality
Solution Approach 1:
The patent employs a vacuum fixture with suction ports to hold and align laser diode bars during stacking. The vacuum suction provides precise positioning of the diode bars against a reference surface, enabling high alignment precision without complex mechanical adjustment mechanisms. This pneumatic approach resolves the contradiction by achieving precise alignment through vacuum field control rather than mechanical means.
2Manufacturing precision
If microhole sizes and positions are redesigned for each diode thickness variation, then alignment precision can be optimized, but the manufacturing complexity and time increase
Solution Approach 1:
The vacuum fixture is designed with a fixed pattern of suction ports that can accommodate laser diode bars of varying thicknesses. The universal design allows the same fixture to hold and align different diode configurations without requiring redesign of microhole sizes and positions. This resolves the contradiction by maintaining alignment precision across variable thicknesses through a single versatile fixture design.
Solution Approach 2:
The patent utilizes the vacuum pressure parameter to adapt to different diode thicknesses. By adjusting the vacuum suction strength rather than physical fixture dimensions, the system maintains precise alignment for varying diode configurations. This parameter-based adjustment resolves the contradiction by decoupling alignment precision from fixed geometric constraints.
3Productivity
If laser diode bars are stacked without vacuum fixation, then the stacking process is faster, but the alignment and electrical contact quality deteriorate
Solution Approach 1:
The vacuum fixture performs preliminary positioning and alignment of laser diode bars before they are permanently stacked. By pre-aligning the bars using vacuum suction against a reference surface, the system ensures precise front edge alignment is achieved before final assembly. This preliminary action resolves the contradiction by establishing accurate alignment early in the process, enabling subsequent rapid stacking.
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 achieves precise alignment of laser diode bars, improving beam quality and allowing for the stacking of diodes of varying thickness without redesigning microhole sizes, while facilitating good electrical contact and structural rigidity.
Implementation Method 1
suction may be provided through the microholes to pull the laser diode bars against the alignment plate, thereby aligning their respective light-emitting edges in the common plane
Data Source
AI summary
An example method includes stacking a plurality of laser diode bars proximate an alignment plate. Each respective laser diode bar has a front edge through which the respective laser diode bar emits light. The alignment plate has a first side that provides a common plane for aligning the front edges of the laser diode bars and a second side opposite the first side. The alignment plate has a plurality of microholes extending between the first and second sides. The method also includes applying suction to the plurality of laser diode bars through the plurality of microholes. The suction draws the front edges of the laser diode bars against the first side of the alignment plate such that the front edges of the laser diode bars are aligned in the common plane. Conductive plates used to clamp the plurality of laser diodes therebetween may be aligned in a similar fashion.