VCSEL Mounting via Intermediate Holder for Beam Alignment
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Solution Overview
Problem
Conventional two-dimensional array devices in light source apparatuses for optical-beam scanning systems face challenges in accurate positioning due to variations in height during soldering, leading to suboptimal image quality and beam spot diameter, especially when coupled with a coupling lens, which affects the precision of beam pitch and spot size.
Innovation Solution
A light source apparatus with a circuit board-mounted vertical-cavity surface-emitting light source, an optical element holder, and an intermediate holder that contacts the package and optical elements, ensuring precise positioning and fixation of the light source and optical elements, thereby maintaining accurate beam alignment and image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-dimensional array device is directly soldered onto a circuit board, then the light source can be mounted, but the height variation due to soldering work causes inaccurate positioning of the light source
Solution Approach 1:
A positioning structure is introduced as an intermediary component between the circuit board and the two-dimensional array device. This positioning structure includes positioning protrusions that engage with positioning recesses, providing a reference surface that ensures accurate positioning of the light source while allowing the soldering process to proceed without precision constraints
Solution Approach 2:
The mounting structure is divided into separate functional components: the circuit board, the positioning structure (with protrusions and recesses), and the package member. This segmentation allows each component to perform its specific function independently - the circuit board provides electrical connection, the positioning structure ensures accurate positioning, and the package member houses the light source
2Ease of operation
If the light source is positioned with reference to the circuit board surface, then assembly is simplified, but positioning accuracy deteriorates because the circuit board surface is not a reliable reference due to soldering variations
Solution Approach 1:
The positioning structure serves as a mediator that decouples the positioning function from the circuit board surface. It provides a dedicated reference surface through its positioning protrusions and recesses, maintaining assembly simplicity while ensuring accurate positioning independent of circuit board soldering variations
Solution Approach 2:
The positioning reference is shifted from the two-dimensional circuit board surface to a three-dimensional positioning structure with specific geometric features (protrusions and recesses). This dimensional change provides more reliable positioning references that are not affected by the flatness or soldering variations of the circuit board surface
3Illumination intensity
If a coupling lens is coupled to the two-dimensional array device, then optical beam control is improved, but positioning accuracy deteriorates because the lens requires precise alignment within several micrometers which is difficult to maintain
Solution Approach 1:
The positioning structure is designed with pre-formed positioning protrusions and recesses that establish the correct relative positions of the light source and coupling lens before final assembly. This preliminary positioning action ensures that when the lens is coupled to the light source, the alignment is already within the required several micrometers precision, maintaining both optical quality and positioning accuracy
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 stabilizes the position of the vertical-cavity surface-emitting light source and optical elements, ensuring consistent beam alignment and high-definition image formation, reducing the risk of component defects and maintaining reliable image quality over time.
Implementation Method 1
a vertical-cavity surface-emitting light source (VCSEL) and a package (10b) housing the vertical-cavity surface-emitting light source
Implementation Method 2
at least a coupling lens that collimates the optical beam or diverges or converges the optical beam with a predetermined convergence or divergence angle
Data Source
AI summary
A light source apparatus includes a circuit board on which a light source unit including a vertical-cavity surface-emitting light source and a package that houses the vertical-cavity surface-emitting light source is mounted, an optical element holder that holds a plurality of optical elements including at least a coupling lens, and an intermediate holder that is arranged between the circuit board and the optical element holder. The intermediate holder is joined to the circuit board to cover an area of the circuit board on which the light source unit is mounted to thereby make contact with the package such that the vertical-cavity surface-emitting light source is positioned and fixed and joined to the optical element holder to thereby position the optical elements to the vertical-cavity surface-emitting light source.