Patent ID: 7088383

Claim:
A method of registering a molded lenslet array with an array of light emitting elements comprising: etching an array of light source alignment recesses in a silicon pad; etching at least two registration recesses in said silicon pad; wherein said registration recesses and said light source alignment recesses have a same depth; wherein sidewalls of said registration recesses and said light source alignment recesses have a same slope angle; locating a light emitting element in at least two of said light source alignment recesses; locating said molded lenslet array a predetermined distance from said bottoms of said registration recesses; locating said molded lenslet array in an x-direction by matching a first tapered locating surface of a first registration pin to a first tapered locating sidewall of a first registration recess and a second tapered locating surface of a second registration pin to a second tapered sidewall of a second registration recess; and locating said molded lenslet array in a y-direction by matching a first tapered locating surface of said first registration pin to a second tapered locating sidewall of said first registration recess.