Methods for optical system manufacturing

Patent metadata

Field	Value
Publication number	US-11460648-B2
Application number	US-202117234960-A
Country	US
Kind code	B2
Filing date	Apr 20, 2021
Priority date	Sep 20, 2018
Publication date	Oct 4, 2022
Grant date	Oct 4, 2022

Abstract

Systems and methods described herein relate to the manufacture of optical elements and optical systems. An example method includes providing a first substrate that has a plurality of light-emitter devices disposed on a first surface. The method includes providing a second substrate that has a mounting surface defining a reference plane. The method includes forming a structure and an optical spacer on the mounting surface of the second substrate. The method additionally includes coupling the first and second substrates together such that the first surface of the first substrate faces the mounting surface of the second substrate at an angle with respect to the reference plane.

First claim

What is claimed is:

1. An optical system, comprising:
a first substrate, wherein the first substrate has a first surface and a second surface opposite the first surface;
at least one light-emitter device disposed on the first surface of the first substrate;
a second substrate, wherein the second substrate has a mounting surface;
a spacer coupled to the mounting surface of the second substrate; and
a lens coupled to the mounting surface of the second substrate, wherein the first substrate and the second substrate are coupled together such that the spacer is in physical contact with the at least one light-emitter device.

2. The optical system of claim 1 , further comprising:
at least one spring structure disposed on the first surface of the first substrate.

3. The optical system of claim 2 , wherein the at least one spring structure comprises a looped wire bond.

4. The optical system of claim 2 , wherein the at least one spring structure comprises a polymer material.

5. The optical system of claim 2 , wherein the first substrate and the second substrate are coupled together such that the at least one spring structure is in physical contact with the lens.

6. The optical system of claim 1 , further comprising:
a plurality of three-dimensional alignment structures disposed on the mounting surface of the second substrate, wherein the three-dimensional alignment structures position the spacer and the lens on the mounting surface.

7. The optical system of claim 1 , further comprising:
an optical waveguide disposed on the mounting surface of the second substrate, wherein the first and second substrates are coupled together such that the at least one light-emitter device is optically coupled to the optical waveguide via the lens.

8. The optical system of claim 1 , wherein the spacer comprises an optical fiber.

9. The optical system of claim 1 , wherein the first substrate comprises a printed circuit board.

10. The optical system of claim 1 , wherein at least a portion of the second substrate is transparent.

11. The optical system of claim 10 , wherein the second substrate comprises glass.

12. The optical system of claim 1 , wherein the lens is a cylindrical lens.

13. The optical system of claim 12 , wherein the cylindrical lens comprises an optical fiber.

14. The optical system of claim 1 , wherein the mounting surface of the second substrate defines a reference plane, and wherein the first surface of the first substrate faces the mounting surface of the second substrate at an angle with respect to the reference plane.

15. The optical system of claim 1 , wherein the at least one light-emitter device comprises a laser diode.

16. The optical system of claim 15 , wherein the at least one light-emitter device comprises a device surface in contact with the spacer and an epitaxially-grown laser diode region located a known distance from the device surface.

17. The optical system of claim 1 , further comprising:
a plurality of light-emitter devices disposed on the first surface of the first substrate.

18. The optical system of claim 17 , wherein the spacer is in physical contact with each light-emitter device of the plurality of light-emitter devices.

19. The optical system of claim 17 , wherein the lens is optically coupled to each light-emitter device of the plurality of light-emitter devices.

20. The optical system of claim 17 , further comprising:
control circuitry disposed on the first surface of the first substrate and electrically connected to the plurality of light-emitter devices.

Assignees

• Waymo Llc

Inventors

• Droz Pierre-Yves
• Schleuning David

Classifications

• G02B6/4221

  involving a visual detection of the position of the elements, e.g. by using a microscope or a camera · CPC title

• G02B6/4226 Primary

  Positioning means for moving the elements into alignment, e.g. alignment screws, deformation of the mount · CPC title

• G01S7/4815

  using multiple transmitters · CPC title

• G01S7/4818

  using optical fibres · CPC title

• G02B6/4206

  Optical features (G02B6/4207, G02B6/421 take precedence) · CPC title