VCSEL Illuminator Package With Integrated Encapsulant Optical Structure
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Solution Overview
Problem
Current miniature illuminator modules for applications like LIDAR and structured light projection are complex, costly, and lack robustness, requiring separate optical components that can cause backreflections and increase noise in VCSEL operation.
Innovation Solution
Integration of optical structures within an optically transparent encapsulant covering the VCSEL device, eliminating the need for separate optical elements by forming optical functions like lenses, mirrors, or diffusers directly in the encapsulant material, which also provides protection against harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate optical components are used to modify VCSEL beam properties, then beam modification capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the optical component functions (lens, mirror, diffuser) directly into the encapsulant material that already surrounds the VCSEL. This integration eliminates the need for separate optical components and their mounting structures, reducing packaging complexity while maintaining beam modification capabilities. The encapsulant is formulated with particles or structures that provide optical functions internally.
Solution Approach 2:
The encapsulant serves multiple functions simultaneously: it provides mechanical protection for the VCSEL, acts as a mounting medium, and incorporates optical modification capabilities through embedded particles or structures. This multi-functionality eliminates the need for separate dedicated optical components, simplifying the overall device structure.
2Adaptability or versatility
If separate optical components are used to modify VCSEL beam properties, then beam modification capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions (protection, mounting, optical modification) into a single encapsulant component that can be manufactured as one integrated piece. This eliminates the need for assembling multiple separate components, reducing manufacturing steps and costs while maintaining beam modification capabilities through embedded optical particles or structures.
Solution Approach 2:
The patent uses inexpensive particles or structures embedded in the encapsulant to provide optical functions, replacing expensive precision optical components. These embedded elements can be incorporated during encapsulant manufacturing, significantly reducing overall device cost while maintaining functional capability.
3Adaptability or versatility
If separate optical components are used to modify VCSEL beam properties, then beam modification capability is improved, but reliability decreases due to backreflections and noise
Solution Approach 1:
The patent integrates optical modification functions directly into the encapsulant surrounding the VCSEL, eliminating air-glass interfaces and separate component mounts that cause backreflections. The embedded particles or structures within the encapsulant modify beams without creating the reflective interfaces present in traditional separate-component designs.
4Reliability
If robust encapsulation is provided for harsh environments, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The encapsulant is designed to perform multiple functions simultaneously: providing environmental protection, serving as a mounting medium, and incorporating optical modification capabilities through embedded particles or structures. This multi-functionality achieves robust protection without increasing packaging complexity, as all functions are integrated into a single component.
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 simplifies the packaging, reduces costs, enhances reliability, and minimizes noise by eliminating backreflections, enabling robust, low-cost, high-volume manufacturing of miniature VCSEL illuminators suitable for harsh environments and mobile devices.
Implementation Method 1
an optical structure integrated in the encapsulant... disposed in a path of the VCSEL output radiation beam and operable to change at least one of a propagation characteristic or intensity distribution
Implementation Method 2
optical structure integrated in the encapsulant... for modifying the characteristics of the VCSEL output beam
Data Source
Figure 1(a)~1(d)
Figure 2
Figure 3(a)~3(b)
AI summary
A VCSEL illuminator package includes one or more VCSELs in a substrate. The one or more VCSELs are operable to generate a VCSEL output radiation beam. An encapsulant covers the one or more VCSELs, and an optical structure is integrated in the encapsulant. The optical structure is disposed in a path of the VCSEL output radiation beam and is operable to change at least one of a propagation characteristic or intensity distribution of the VCSEL output radiation beam exiting the encapsulant.