VCSEL Flood Illuminator Micro-Optics for Compact Beam Shaping
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Solution Overview
Problem
The standard package for VCSEL-based flood illuminators is too large and requires robustness for harsh environments, while also needing integrated beam shaping diffusers to meet application requirements for high power, low divergence, and single-mode operation.
Innovation Solution
A method of fabricating laser assemblies by integrating micro-optic elements directly onto a substrate with VCSEL emitters, using nano-imprinting to form concave and convex lenses, prisms, and beam transformation surfaces to shape optical signals, reducing the need for external optics and shrinking the package size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard package with housing and air cavity is used to protect the diffuser, then the diffuser is protected from damage, but the package size becomes too large
Solution Approach 1:
The patent merges the diffuser protection function directly into the substrate structure by forming an integrated cavity within the substrate itself, eliminating the need for a separate housing. The cavity is formed by removing material from the substrate and filling it with protective material, thereby combining structural support and diffuser protection into a single integrated component that reduces overall package size.
Solution Approach 2:
The patent implements nesting by placing the diffuser within a cavity that is nested inside the substrate structure. The cavity is formed within the substrate volume, and the diffuser is positioned inside this nested cavity, allowing the protective structure to be contained within the existing substrate boundaries rather than requiring external housing.
2Ease of operation
If external optics are used to shape the laser beam, then the illumination pattern requirements are met, but the device complexity and package size increase
Solution Approach 1:
The patent merges the beam shaping function directly into the substrate by forming micro-optical elements (such as lenses or prisms) within the substrate material itself. These micro-optical elements are created by depositing or forming optical material directly on the substrate surface, integrating the beam shaping capability into the structural substrate rather than requiring separate external optical components.
Solution Approach 2:
The substrate is designed to perform multiple functions simultaneously: it provides structural support, contains the integrated cavity for diffuser protection, and incorporates micro-optical elements for beam shaping. This multi-functional integration eliminates the need for separate components and reduces overall device complexity.
3Reliability
If the diffuser is positioned at a minimum distance from the VCSEL apertures, then the diffuser functions properly, but the package size increases
Solution Approach 1:
The patent positions the diffuser within a cavity that is nested inside the substrate, allowing the diffuser to be placed at the required minimum distance from the VCSEL apertures while keeping the overall package compact. The cavity provides the necessary space for proper diffuser positioning without requiring external housing extensions.
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 integration of micro-optic elements on the substrate enhances optical signal control, allowing for higher density, lower costs, and improved optical efficiency, meeting application requirements while minimizing package size and enhancing robustness.
Implementation Method 1
configuring second arrays of micro-optical elements in optical communication with the optical signals emitted from the laser emitters of the first arrays
Data Source
AI summary
A laser assembly, such as a flood illuminator, has laser (e.g., VCSEL) emitters on a substrate configured to emit optical signals. An optic structure of optically transparent material, such as a polymer, is formed directly on the substrate, and micro-optic elements are nano-imprinted on the optic structure. The micro-optic elements are arranged in optical communication with the optical signals emitted from the laser emitters to perform field mapping or other optical functions. The laser emitters are on the same surface of the substrate as the optic structure along with electrical contacts so forming the optic structure involves covering the electrical contacts with a protective layer, dispensing a polymer for the optic structure, cutting away portions of the optic structure, removing the remaining protective layer, and exposing the electrical contacts.