Laser assembly with radially combined beams

The laser assembly spatially combines emitter beams using a combiner lens to overcome alignment issues and increase emitter density, resulting in a compact, high-power, and cost-effective design with enhanced reliability.

JP2026520304APending Publication Date: 2026-06-23DAYLIGHT SOLUTIONS INC
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Patent Information

Authority / Receiving Office
JP · JP
Patent Type
Applications
Current Assignee / Owner
DAYLIGHT SOLUTIONS INC
Filing Date
2024-05-01
Publication Date
2026-06-23

AI Technical Summary

Technical Problem

Laser assemblies face limitations in emitter count due to stepped arrangements, alignment issues with small mirrors, and increased spacing requirements, leading to reduced brightness and reliability, with large mirrors being prone to degradation and difficult to repair.

Method used

A laser assembly design that spatially combines emitter beams without intermediate turn mirrors, using a combiner lens to focus beams radially, allowing for a higher density of emitters within a given form factor, improving reliability and power output.

Benefits of technology

The design enables a compact, high-power laser assembly with improved beam quality and reduced manufacturing costs by minimizing components and eliminating alignment sensitivity, while allowing easy addition or removal of emitters for power adjustments.

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Abstract

The laser assembly 12 of system 10 includes a first emitter assembly 30a, a second emitter assembly 30b, and a combiner lens 34. The first emitter assembly 30a generates a first emitter beam 22a directed towards the beam crossing area 31 along the first emitter axis 32a. The second emitter assembly 30b generates a second emitter beam 22b directed towards the beam crossing area 31 along the second emitter axis 32b. The combiner lens 34 receives the first emitter beam 22a and the second emitter beam 22b after the emitter beams 22a and 22b have crossed and passed through the beam crossing area 31 and spatially combines them. The laser assembly 12 includes a laser frame 18, an emitter array 20 that generates multiple emitter beams 22, a combiner lens assembly 24 that converts and combines the multiple emitter beams 22 into an assembly output beam 14, and a system controller 26 that controls the operation of the laser assembly 12. The combiner lens assembly 24, which includes combiner lenses 34, 36, and 38, has a front focus 24a on the velocity axis and rear focus 24b on the velocity and slow axis. The combiner lens assembly 24 is positioned so that its front focus 24a on the velocity axis is approximately in the beam crossing area 31. The optical fiber 16 is positioned so that its incident facet 16A is approximately in the rear focus 24b on the velocity and slow axis.
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