Optical Fiber Bending Mechanisms for Laser Beam Control

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Solution Overview

Problem

Current laser systems for materials processing require adjustable beam characteristics, but existing solutions either compromise on performance and flexibility or incur significant costs, complexity, and reliability issues due to the use of free-space optics and complex add-on mechanisms.

Innovation Solution

A fiber-based system that uses a first fiber with a refractive index profile and a fiber shaping surface to perturb the input optical beam, with a bend controller adjusting the fiber's curvature to produce a modified optical beam, which is then maintained by a second fiber with a selected refractive index profile, eliminating the need for free-space optics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If free-space optics or complex add-on mechanisms are used to vary beam characteristics, then beam adjustability is improved, but device complexity and cost increase significantly

Engineering Contradiction:

Improvebeam adjustabilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts the beam adjustment function from external free-space optics and integrates it directly into the optical fiber through a fiber shaping surface. This eliminates the need for separate adjustment mechanisms while maintaining beam characteristic variability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fiber shaping surface is integrated within the optical fiber structure itself, with the fiber core nested within the shaped cladding region. This nested configuration allows beam adjustment functionality to be embedded within the fiber, reducing overall system complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If free-space optics or complex add-on mechanisms are used to vary beam characteristics, then beam adjustability is improved, but reliability decreases due to additional components

Engineering Contradiction:

Improvebeam adjustabilityVSAvoidsystem reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the beam adjustment function with the optical fiber transmission function into a single integrated component. The fiber shaping surface is formed as part of the fiber structure, eliminating separate adjustment mechanisms and improving reliability by reducing the number of components.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If free-space optics are used to vary beam characteristics, then beam adjustability is improved, but optical loss increases

Engineering Contradiction:

Improvebeam adjustabilityVSAvoidoptical loss

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent replaces mechanical free-space optics with a geometric fiber shaping approach. The fiber shaping surface directly modifies the optical mode through its geometric configuration, eliminating the need for mechanical adjustment components that would introduce optical losses through misalignment and interfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 adjustable beam characteristics without the drawbacks of free-space optics, reducing costs, complexity, and improving reliability by maintaining optimized beam properties for various materials processing tasks.

Implementation Method 1

the flexible plate includes an ionic-polymer composite

Methodology Applied

Scientific EffectIonic-polymer composite actuation: Electroactive Polymer

Implementation Method 2

a piezo-bending actuator is used that can include one or more piezoelectric plates bonded together

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 3

a first fiber situated to receive an input optical beam, the first fiber having a first refractive index profile

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS11858842B2Optical fiber bending mechanisms

Publication Date: 2024.01.02 NLIGHT INC

AI summary

Fiber bending mechanisms vary beam characteristics by deflecting or bending one or more fibers, by urging portions of one or more fibers toward a fiber shaping surface having a selectable curvature, or by selecting a fiber length that is to be urged toward the fiber shaping surface. In some examples, a fiber is secured to a flexible plate to conform to a variable curvature of the flexible plate. In other examples, a variable length of a fiber is pulled or pushed toward a fiber shaping surface, and the length of the fiber or a curvature of the flexible plate provide modification of fiber beam characteristics.