FAC Beam Steering for Flat-Mounted Diode Beam Stacking
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Solution Overview
Problem
Existing laser diode packages face challenges in achieving high brightness and minimizing losses due to stair-step architectures that increase thermal resistance, manufacturing complexity, and material limitations, leading to reduced power and reliability.
Innovation Solution
The use of flat-mounted diode packages with fast axis collimators that redirect and stack beams vertically, eliminating stair-steps and allowing for improved thermal management and beam alignment, using optical methods to separate beams in a vertical direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If stair-step architecture is used to separate laser diodes vertically, then beam separation is achieved, but thermal resistance increases and manufacturing complexity increases
Solution Approach 1:
The patent transitions from vertical separation in the Z-dimension (stair-step architecture) to angular separation in the X-Y plane. Multiple laser diodes are mounted on a flat substrate and their beams are redirected at different angles by FACs to achieve spatial separation without increasing height or thermal resistance.
Solution Approach 2:
The patent replaces the mechanical stair-step structure with an optical beam steering system using FACs. Instead of physically elevating diodes to separate beams, the system uses optical elements to redirect beams at different angles, eliminating the need for complex mechanical positioning while achieving the same beam separation effect.
2Shape
If stair-step architecture is used to separate laser diodes vertically, then beam separation is achieved, but device complexity increases
Solution Approach 1:
The patent uses angular separation in the X-Y plane instead of vertical separation in the Z-dimension. This allows all diodes to be mounted on a flat substrate at the same height, simplifying the mechanical structure and manufacturing process while still achieving beam separation through optical redirection.
Solution Approach 2:
The FACs serve multiple functions: they collimate the fast axis of each laser diode's beam and simultaneously redirect the beam at a specific angle. This dual functionality eliminates the need for separate collimation and steering elements, reducing overall device complexity.
3Shape
If FACs are arranged at off-axis angles to redirect beams, then beam stacking is improved, but optical alignment complexity increases
Solution Approach 1:
The patent optimizes the FAC angle parameter to balance beam stacking quality and alignment tolerance. By selecting specific off-axis angles for the FACs, the system achieves effective beam separation and stacking while maintaining reasonable alignment tolerances that are compatible with standard manufacturing capabilities.
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
This approach reduces junction temperatures, simplifies manufacturing, and enhances laser diode performance by improving thermal dissipation and beam quality, enabling efficient beam stacking and coupling into optical fibers.
Implementation Method 1
a first fast axis collimator (FAC) optically coupled to the beam as emitted from the exit facet and configured to direct the beam along a redirected beam axis having a non-zero angle with respect to the optical axis of the first laser diode, wherein the first FAC has an optical axis arranged at an angle with respect to the optical axis of the first laser diode to produce the non-zero angle of the redirected beam axis
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
Apparatus include a first laser diode situated to emit a beam from an exit facet along an optical axis, the beam as emitted having perpendicular fast and slow axes perpendicular to the optical axis, a first fast axis collimator (FAC) optically coupled to the beam as emitted from the exit facet and configured to direct the beam along a redirected beam axis having a non-zero angle with respect to the optical axis of the first laser diode, a second laser diode situated to emit a beam from an exit facet of the second laser diode along an optical axis parallel to the optical axis of the first laser diode and with a slow axis in a common plane with the slow axis of the first laser diode, and a second fast axis collimator (FAC) optically coupled to the beam as emitted from the exit facet of the second laser diode and configured to direct the beam along a redirected beam axis having a non-zero angle with respect to the optical axis of the second laser diode.