VCSEL Metalens Array Packaging for Precise Collimation Alignment
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Solution Overview
Problem
Existing optical modules with metalens arrays face challenges in achieving sufficient collimation due to difficulties in aligning the centers of VCSELs and metalenses, leading to inefficient packaging and reduced collimation performance.
Innovation Solution
The optical module design includes a VCSEL array and a collimating metalens array, where the centers of the VCSELs are aligned with the centers of the metalenses by using a package module with a ring-shaped structural element that forms a step structure, allowing for accurate positioning and alignment of the metalens array.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the metalens is reduced to decrease volume and cost, then the volume and cost are reduced, but the alignment difficulty with the light source increases
Solution Approach 1:
A positioning structure comprising a positioning hole and positioning protrusion is introduced as an intermediary mechanism. The positioning hole in the lower substrate and the positioning protrusion on the metalens array substrate work together to provide mechanical alignment, enabling precise positioning of the small-sized metalens relative to the VCSEL array without requiring complex alignment procedures
Solution Approach 2:
The positioning structures (positioning hole and positioning protrusion) are pre-designed and pre-positioned in the substrates before final assembly. This preliminary arrangement of positioning features ensures that when the metalens array substrate is mounted, the alignment between the metalens and VCSEL is automatically established, reducing the difficulty of the actual alignment process
2Reliability
If the number of metalenses in the metalens array is increased to improve collimation performance, then the collimation performance is improved, but the alignment difficulty and packaging complexity increase
Solution Approach 1:
The optical system is segmented into distinct functional modules: the VCSEL array substrate, the metalens array substrate, and the lower substrate with positioning structures. This segmentation allows each component to be optimized and prepared separately, with the positioning structures ensuring that even with multiple metalenses, the overall assembly remains manageable and alignable
Solution Approach 2:
The positioning structure acts as a mediator between the VCSEL array and the metalens array. By providing a common reference framework (positioning hole and protrusion), it simplifies the packaging process for multi-element arrays, reducing the complexity that would otherwise arise from aligning multiple small components
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 design ensures an adequate degree of collimation for the optical module by accurately aligning the VCSELs and metalenses, thereby improving packaging efficiency and reducing the complexity of aligning the small metalens array.
Implementation Method 1
the collimating metalens array includes an effective region for light modulation
Data Source
AI summary
An optical module and a package module are provided, and the optical module includes a VCSEL array, a collimating metalens array; and the collimating metalens array is set on an outgoing side of the VCSEL array and are parallel to the VCSEL array. The VCSEL array includes a plurality of VCSELs, and the metalens array includes a plurality of collimating metalenses; the collimating metalens array includes an effective region for light modulation; a projection of an illumination region of the VCSEL array on the collimating metalens array is inside the effective region of the collimating metalens array.