Coherent Laser Beam Combination via Two-Stage Microlens Arrays

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Solution Overview

Problem

Existing methods for combining coherent laser beams often result in a loss of beam quality and power, particularly in reducing divergence and increasing beam cross-section, which is challenging to achieve without compromising the quality of the combined laser beam.

Innovation Solution

A microlens arrangement with at least two microlens arrays is used to combine coherent laser beams, where the phase settings and focal lengths of the microlenses are carefully designed to maintain high beam quality, allowing for the formation of a combined laser beam with minimal loss of power and quality by adhering to specific equations and configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If coherent laser beams are combined using conventional methods (tiled aperture or filled aperture), then the power of the combined beam is increased, but the beam quality deteriorates due to loss of power or increased divergence

Engineering Contradiction:
Improvepower of combined laser beamVSAvoidbeam quality
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The invention divides the beam combination process into two independent stages: first, multiple laser beams are combined in the transverse direction using a microlens array to form an intermediate beam; second, multiple intermediate beams are combined in the longitudinal direction using another microlens array to form the final combined beam. This segmentation allows each stage to optimize for its specific direction, maintaining beam quality while achieving high power combination.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The invention transitions from conventional single-plane beam combination to a two-dimensional combination approach. The first microlens array combines beams in the transverse dimension, while the second microlens array combines intermediate beams in the longitudinal dimension. This dimensional separation resolves the contradiction by allowing power accumulation without compromising beam quality in either direction.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Speed

If the beam cross section is increased to reduce divergence, then the combined beam has lower divergence, but power is lost

Engineering Contradiction:
Improvedivergence of combined beamVSAvoidpower loss
Core Design Contradiction:
SpeedVSLoss of energy

Solution Approach 1:

The invention dynamically adjusts the beam parameters through a two-stage microlens array system. The first stage creates intermediate beams with specific cross-sectional characteristics, while the second stage further shapes the final combined beam. This dynamic control allows the system to achieve low divergence without the power losses associated with simple beam expansion, as each stage optimizes the beam parameters for the next.

Inventive Principle:
Principle #15Dynamics

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

The solution effectively maintains the beam quality of individual laser beams during combination, achieving high coupling efficiency and forming a combined laser beam with improved power and quality by precisely setting the phases and focal lengths of the microlens arrangement.

Implementation Method 1

a microlens arrangement with at least two microlens arrays for forming the at least one combined laser beam

Methodology Applied
Scientific EffectOptical focusing: Focusing

Data Source

PatentUS11796720B2Apparatus, laser system and method for combining coherent laser beams
Publication Date: 2023.10.24 TRUMPF LASER GMBH CO KG
  • US11796720B2 patent drawing
  • US11796720B2 patent drawing
  • US11796720B2 patent drawing

AI summary

An apparatus for combining a plurality of coherent laser beams includes at least N−1 phase setting devices configured to set a respective phase (δφn) of a respective one of the plurality of coherent laser beams, and a beam combination device configured to combine the plurality of coherent laser beams to form at least one combined laser beam. The beam combination device includes a microlens arrangement having at least two microlens arrays configured to form the at least one combined laser beam.