VCSEL Illuminator Package

• US 20170353004A1
• Filed: 05/25/2017
• Published: 12/07/2017
• Est. Priority Date: 06/03/2016
• Status: Active Grant

• Current Assignee: Princeton Optronics Inc (Ams-Osram AG)
• Original Assignee: Princeton Optronics Inc (Ams-Osram AG)
• Inventors: Chen, Tong, Ghosh, Chuni, Wang, Qing, Kovsh, Alexey, Watkins, Laurence
• Granted Patent: US 10,290,993 B2
• Time in Patent Office: Days
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01S 5/0014 Measuring characteristics or properties thereof measuring techniques per se G01J, G01K, G01N, G01R
• CPC Class Codes: H01S 5/02234 Resin-filled housings; the housings being made of resin
• CPC Class Codes: H01S 5/02253 using lenses
• CPC Class Codes: H01S 5/02257 using windows, e.g. specially adapted for back-reflecting light to a detector inside the housing
• CPC Class Codes: H01S 5/0239 Combinations of electrical or optical elements
• CPC Class Codes: H01S 5/06825 Protecting the laser, e.g. during switch-on/off, detection of malfunctioning or degradation
• CPC Class Codes: H01S 5/183 having only vertical cavities, e.g. vertical cavity surface-emitting lasers [VCSEL]
• CPC Class Codes: H01S 5/18311 using selective oxidation
• CPC Class Codes: H01S 5/1833 with more than one structure
• CPC Class Codes: H01S 5/4025 Array arrangements, e.g. constituted by discrete laser diodes or laser bar H01S5/42 takes precedence
• CPC Class Codes: H01S 5/423 having a vertical cavity

Abstract

A VCSEL illuminator module includes a module forming a physical cavity having electrical contacts positioned on an inner surface of the module that feed through the module to electrical contacts positioned on an outer surface of the module. A VCSEL device is positioned on the inner surface module and includes electrical contacts that are electrically connected to the electrical contacts on the inner surface of the module. The VCSEL device generates an optical beam when current is applied to the electrical contacts. An optical element is positioned adjacent to an emitting surface of the VCSEL device and is configured to modify the optical beam generated by the VCSEL device.

Claims

1. A Vertical Cavity Surface Emitting Lasers (VCSEL) illuminator module comprising:

a) a module forming a physical cavity having electrical contacts positioned on an inner surface of the module that feed through the module to electrical contacts positioned on an outer surface of the module;

b) a VCSEL device positioned on the inner surface of the module, the VCSEL device comprising electrical contacts that are electrically connected to the electrical contacts positioned on the inner surface of the module, the VCSEL device generating an optical beam when current is applied to the electrical contacts; and

c) an optical element positioned adjacent to an emitting surface of the VCSEL device, the optical element being configured to modify the optical beam generated by the VCSEL device.

2. The VCSEL illuminator module of claim 1 wherein a lateral dimension of the VCSEL illuminator module is less than or equal to 3 mm and a thickness of the VCSEL illuminator module is less than or equal to 1.375 mm.

3. The VCSEL illuminator module of claim 1 wherein the module forming the cavity is formed of thermal setting plastic suitable for surface mounting.

4. The VCSEL illuminator module of claim 1 wherein the VCSEL illuminator module is environmentally sealed.

5. The VCSEL illuminator module of claim 1 wherein the electrical contacts positioned on the outer surface of the module are configured for surface mounting to a printed circuit board.

6. The VCSEL illuminator module of claim 1 wherein a bottom contact of the VCSEL device is electrically bonded to an electrical contact on the inner surface of the module.

7. The VCSEL illuminator module of claim 1 wherein the electrical contacts positioned on the inner surface of the module that feed through the module to the electrical contacts positioned on the outer surface of the module are formed from at least one of copper and aluminum.

8. The VCSEL illuminator module of claim 1 wherein the VCSEL device comprises a surface mount VCSEL device.

9. The VCSEL illuminator module of claim 1 wherein the optical element comprises a lens that reduces a divergence angle of the optical beam generated by the VCSEL device.

10. The VCSEL illuminator module of claim 1 wherein the optical element comprises a diffuser that increases a divergence angle of the optical beam generated by the VCSEL device.

11. The VCSEL illuminator module of claim 10 wherein the diffuser increases the divergence of the optical beam generated by the VCSEL device to an angle that is greater than or equal to 110 degrees.

12. The VCSEL illuminator module of claim 1 wherein the VCSEL device comprises an array of VCSEL devices.

13. The VCSEL illuminator module of claim 12 wherein the optical element comprises a microlens array aligned to the array of VCSEL devices.

14. The VCSEL illuminator module of claim 1 wherein the optical element is positioned on the module.

15. The VCSEL illuminator module of claim 1 further comprising a detector that monitors an output intensity of the optical beam generated by the VCSEL device.

16. The VCSEL illuminator module of claim 15 wherein the detector detects a reflection of the optical beam generated by the VCSEL device from an optical component.

17. The VCSEL illuminator module of claim 1 further comprising a safety lock cover positioned adjacent to the emitting surface of the VCSEL device.

18. The VCSEL illuminator module of claim 17 wherein the safety lock cover is electrically connected to the VCSEL illuminator module and configured so that detaching the safety lock cover from the VCSEL illuminator module breaks an electrical contact with the module.

19. The VCSEL illuminator module of claim 1 wherein the optical element further comprises an electrical trace that provides a laser safety interlock function.

20. The VCSEL illuminator module of claim 19 wherein the electrical trace is electrically connected to an electrical circuit and is configured so that dislodging the optical element from the VCSEL illuminator module causes the VCSEL device to be turned off.

21. A Vertical Cavity Surface Emitting Lasers (VCSEL) illuminator module with integral safety lock, the VCSEL illuminator module comprising:

a) a module forming a physical cavity having electrical contacts positioned on an inner surface of the module that feed through the module to electrical contacts positioned on an outer surface of the module;

b) a VCSEL device positioned on the inner surface module, the VCSEL device comprising electrical contacts that are electrically connected to the electrical contacts positioned on the inner surface of the module, the VCSEL device generating an optical beam when current is applied to the electrical contacts; and

c) an optical element positioned on the module adjacent to an emitting surface of the VCSEL device and comprising electrical contacts on a surface that are configured to electrically connect to electrical contacts positioned on the outer surface of module so as to complete an electrical circuit, the optical element configured to modify the optical beam generated by the VCSEL device.

22. The VCSEL illuminator module with integral safety lock of claim 21 wherein the electrical contacts on the surface of the optical element are aligned to the electrical contacts on the outer surface of the module.

23. The VCSEL illuminator module with integral safety lock of claim 21 wherein the electrical contacts on the surface of the optical element are electrically connected to the electrical contacts positioned on the outer surface of the module with one or more conducting layer traces.

24. The VCSEL illuminator module with integral safety lock of claim 23 wherein the one or more conducting traces are positioned outside an optical path of the optical beam generated by the VCSEL device.

25. The VCSEL illuminator module with integral safety lock of claim 21 further comprising a detector that monitors an output intensity of the optical beam generated by the VCSEL device.

26. The VCSEL illuminator module with integral safety lock of claim 25 wherein the detector detects a reflection of the optical beam generated by the VCSEL device from an optical component.

27. The VCSEL illuminator module of claim 21 wherein the electrical contacts positioned on the outer surface of the module are configured for surface mounting to a printed circuit board.

28. The VCSEL illuminator module of claim 21 wherein the VCSEL device comprises a surface mount VCSEL device comprising electrical contacts electrically connected to the electrical contacts positioned on the inner surface of the module.

29. The VCSEL illuminator module of claim 21 wherein the optical element comprises a lens that reduces a divergence angle of the optical beam generated by the VCSEL device.

30. The VCSEL illuminator module of claim 21 wherein the optical element comprises a diffuser that increases a divergence angle of the optical beam generated by the VCSEL device.

31. The VCSEL illuminator module of claim 21 wherein the VCSEL device comprises an array of VCSEL devices.

32. The VCSEL illuminator module of claim 31 wherein the optical element comprises a microlens array aligned to the array of VCSEL devices.

33. A Vertical Cavity Surface Emitting Lasers (VCSEL) illuminator module with integral safety lock, the VCSEL illuminator module comprising:

a) a substrate comprising electrical contact pads positioned on a top surface that are electrically connected to electrical contact pads on a bottom surface of the substrate;

b) a VCSEL device positioned on the top surface of the substrate and being electrically connected to the electrical contact pads positioned on the bottom surface of said substrate;

c) a cover comprising side walls bonded to the substrate, the side walls comprising electrical conducting sections that are electrically connected to contact pads positioned on bottom of the substrate; and

d) an optical element positioned in the side walls of the cover and comprising an electrical conducting trace that is electrically connected to the electrical conducting side walls, the optical element configured to modify the characteristics of an optical beam generated by the VCSEL device.

34. The VCSEL illuminator module with integral safety lock of claim 33 wherein the cover comprises a two part cover.

35. The VCSEL illuminator module with integral safety lock of claim 33 wherein the cover seals the VCSEL device.

36. The VCSEL illuminator module with integral safety lock of claim 33 wherein the sidewall extends up to become level with a top surface of the optical component.

37. The VCSEL illuminator module with integral safety lock of claim 33 further comprising a detector positioned on the substrate that monitors an output intensity of the optical beam generated by the VCSEL device.

38. The VCSEL illuminator module with integral safety lock of claim 37 wherein the detector provides a common electrical connection and a thermal conduction path to the VCSEL device.