Birefringent Prism Beam Splitter for Variable Laser Spot Patterns
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Solution Overview
Problem
Conventional methods for laser material processing, such as multi-faceted optical elements and Diffractive Optical Elements (DOE), face challenges including complexity, high manufacturing costs, limited efficiency, sensitivity to misalignments, and inability to efficiently handle high-power lasers and variable spot patterns.
Innovation Solution
A beam splitter system using birefringent wedge-shaped prisms and dual waveplates for angular polarization splitting, allowing for lossless redistribution of energy and flexible geometry of spot patterns, suitable for high-power lasers and multiple wavelengths, with air-spaced optical elements for robustness and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-faceted optical elements are used for beam splitting, then beam splitting is achieved, but manufacturing complexity and adjustment complexity increase
Solution Approach 1:
The patent divides the beam splitting function into multiple independent wedge-shaped prisms arranged in series. Each prism splits the beam into two, and by combining multiple prisms, any number of beamlets can be generated. This segmentation replaces complex multifaceted elements with simple, modular prisms that are easier to manufacture and adjust.
Solution Approach 2:
The patent introduces rotatable waveplates between the wedge prisms that can be dynamically adjusted to control the polarization state and energy distribution among beamlets. This dynamic control allows flexible adjustment of spot intensities and patterns without changing the physical arrangement of prisms, reducing manufacturing complexity while maintaining versatility.
2Adaptability or versatility
If Diffractive Optical Elements (DOE) are used for beam splitting, then beam splitting is achieved, but manufacturing cost increases and resistance to high-power laser radiation decreases
Solution Approach 1:
The patent uses simple wedge-shaped prisms made from common optical materials that can withstand high power lasers. These prisms are easier and cheaper to manufacture than DOE, and their simple geometry makes them more resistant to damage from high-power laser radiation, including ultra-short pulse lasers.
Solution Approach 2:
The system combines multiple optical elements (wedge prisms, waveplates) made from different materials optimized for specific functions. The wedge prisms use materials with high damage thresholds for high-power laser resistance, while waveplates use materials optimized for polarization control, creating a composite system that is both reliable and versatile.
3Adaptability or versatility
If conventional beam splitting methods are used, then beam splitting is achieved, but sensitivity to misalignments increases
Solution Approach 1:
The patent uses multiple simple wedge prisms instead of complex multifaceted elements. Each prism has simple geometry with large tolerance margins, and they are arranged in series with alignment markers. This segmentation reduces the cumulative alignment sensitivity compared to single complex elements, as each simple prism is less sensitive to misalignment.
4Adaptability or versatility
If multi-faceted optical elements are used, then beam splitting is achieved, but resistance to modern multi-kW continuous wave and powerful ultra-short pulse lasers is low
Solution Approach 1:
The patent uses simple wedge-shaped prisms made from robust optical materials that can withstand high power laser radiation. These prisms have simple geometry without complex facets or diffractive structures that are vulnerable to damage, making them suitable for multi-kW continuous wave and powerful ultra-short pulse laser applications.
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
Enables efficient, flexible, and reliable formation of multiple separate light spots with controlled intensity and geometry, optimizing temperature distribution and reducing porosity and spatter in laser processing, while being insensitive to misalignments and compatible with various laser sources.
Implementation Method 1
angular polarization splitting of the said light beam into several beamlets using a beam splitter
Implementation Method 2
optical system of the specified beam splitter built using optical prisms, prism groups and waveplates, and contains at least one birefringent wedge-shaped prism
Implementation Method 3
the said beam splitter can include one or more dual waveplates implementing the phase front retardation effect simultaneously at two operating wavelengths
Implementation Method 4
subsequent focusing these beamlets onto a workpiece using a focusing optical system
Data Source
AI summary
Systems, devices, apparatuses and methods for formation of multiple separate light spots with adjustable intensity due to lossless redistribution of the light energy between the separate spots, and with a variable geometry of the multi-spot pattern; advantageously, for laser processing of materials by focusing the laser radiation on a workpiece. The multi-spot pattern is created due to angular polarization splitting of the light beam into several beamlets using a beam splitter and further focusing these beamlets onto a workpiece by a focusing optical system, advantageously by the scanning focusing optics. The beam splitter can include optical birefringent prisms, prism groups and waveplates capable to operate simultaneously at two different wavelengths. Some of these optical elements are rotatable, and their rotations are used for lossless redistribution of light energy between the spots and for a change in the geometric shape of the multi-spot patterns. Embodiments can provide various geometrical configurations of 2, 3, 4, 9 and more separate focused spots: linear, rhombus-shaped, square, parallelogram, rectangular patterns composed in the form of a line or a matrix, with the ability to vary portions of the light energy at the specified separate spots.