Fiber Laser Module Planar Optical Layout for Low-Cost Assembly
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Solution Overview
Problem
Conventional laser modules require recesses and projections on the substrate to accommodate semiconductor laser devices and reflection mirrors, leading to increased manufacturing costs.
Innovation Solution
A laser module design where semiconductor laser devices and reflection mirrors are arranged on the same plane, eliminating the need for recesses or projections, and incorporating an optical parallelization, combiner, and focusing components on the same plane for efficient beam combination and coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If semiconductor laser devices and reflection mirrors are arranged on different surfaces of the substrate with recesses and projections, then the laser beams can be reflected toward inclined directions, but the substrate requires sufficient thickness and complex structure which increases manufacturing cost
Solution Approach 1:
The patent merges the arrangement of semiconductor laser devices and reflection mirrors onto the same placement surface of the base portion. This eliminates the need for recesses and projections that were required when these components were placed on different surfaces, thereby simplifying the substrate structure and reducing manufacturing cost while maintaining the optical functionality of reflecting laser beams at inclined angles
2Manufacturing precision
If recesses and projections are formed on the substrate to accommodate laser diodes and reflection mirrors, then the components can be properly positioned, but the substrate thickness must be sufficient which increases manufacturing complexity
Solution Approach 1:
By combining the placement of all optical components (laser diodes and reflection mirrors) on the same surface plane, the patent eliminates the need for complex substrate processing such as forming recesses and projections. This approach maintains precise component positioning through surface-level arrangement while significantly simplifying substrate processing requirements
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
Facilitates low-cost and easy manufacturing of the laser module with improved beam quality and coupling efficiency by reducing the substrate thickness and optical path lengths.
Implementation Method 1
a plurality of first mirrors each arranged on the placement surface of the base portion and configured to reflect the first emission laser beam emitted from the first semiconductor laser device of a corresponding one of the plurality of first laser sections, toward a direction inclined with respect to the placement surface of the base portion
Implementation Method 2
a plurality of second mirrors each arranged on the placement surface of the base portion and configured to reflect the second emission laser beam emitted from the second semiconductor laser device of a corresponding one of the plurality of second laser sections, toward a direction inclined with respect to the placement surface of the base portion
Implementation Method 3
an optical parallelization portion configured to generate first parallel laser beams propagating in a direction parallel to the placement surface of the base portion, from the first emission laser beams reflected by the plurality of first mirrors
Implementation Method 4
a focusing portion configured to focus and couple the combined laser beams to the optical fiber
Data Source
Figure 1
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AI summary
A laser module that can be manufactured readily and at low cost is provided. A laser module 1 has first laser sections 21 including first semiconductor laser devices 11 capable of emitting first emission laser beams L1 in the +X-direction, second laser sections 22 including second semiconductor laser devices 12 capable of emitting second emission laser beams L2 in the -X-direction, first mirrors 51 configured to reflect the first emission laser beams L1 toward a direction inclined with respect to a placement surface 5A of a base portion 5, second mirrors 52 configured to reflect the second emission laser beams L2 toward a direction inclined with respect to the placement surface 5A of the base portion 5, a glass block 60 configured to generate parallel laser beams P1 and P2 from the emission laser beams L1 and L2, respectively, a beam splitter 64 configured to combine the parallel laser beams P1 and P2 into combined laser beams C, and a focusing portion 67 configured to focus and couple the combined laser beams C to an optical fiber 3. All of the laser sections 21 and 22 and the mirrors 51 and 52 are arranged on the placement surface 5A of the base portion 5.