Laser Diode Array with Fiber Optic Termination
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Solution Overview
Problem
Conventional laser surface treatment methods are inefficient due to localized thermal gradients and high power requirements, leading to economic and process inefficiencies, and there is a need for improved systems and methods for altering material properties using intense direct irradiation.
Innovation Solution
A laser diode array with fiber optic termination that allows for uniform irradiation and adjustable parameters, enabling efficient treatment of large areas with individually controllable diodes for optimal coupling efficiency, and optional features like motion systems and optical isolation to manage intensity and prevent back reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser beam treatment is used, then localized material property changes can be achieved, but substantial localized thermal gradients and high power requirements result
Solution Approach 1:
The patent divides the laser treatment system into multiple individual laser diodes arranged in an array, where each diode can be independently controlled. This segmentation allows the total energy to be distributed across multiple lower-power sources, reducing thermal gradients while maintaining effective treatment. The array configuration enables parallel processing of multiple areas simultaneously, improving overall energy efficiency.
Solution Approach 2:
The invention transitions from conventional single-point or line laser treatment to a two-dimensional array of laser diodes. This dimensional expansion allows uniform illumination across the entire treatment area, eliminating localized thermal gradients by distributing energy evenly across the surface rather than concentrating it at discrete points.
2Manufacturing precision
If conventional laser treatment with single beam is used, then localized treatment is achieved, but process efficiency and economics are negatively impacted
Solution Approach 1:
The laser treatment system is segmented into multiple independently controllable diodes in an array configuration. This allows simultaneous treatment of multiple locations across the material surface, dramatically increasing productivity while maintaining the ability to precisely control each treatment zone individually through independent diode activation.
Solution Approach 2:
The patent merges multiple laser diodes into a coordinated array system that operates in unison or independently as needed. This combination enables parallel processing of large surface areas while maintaining precise local control, resolving the contradiction between treatment localization and overall process efficiency.
3Illumination intensity
If high power laser is used for surface treatment, then intense irradiation is achieved, but operational cost and energy consumption increase
Solution Approach 1:
The high power requirement is segmented across multiple individual laser diodes, each operating at lower power levels. The cumulative output of the array achieves the necessary irradiation intensity for effective treatment while consuming less total energy than a single high-power laser source, due to reduced thermal losses and more efficient energy distribution.
Solution Approach 2:
The system changes the operational parameters by using multiple low-power diodes instead of one high-power source. This parameter change optimizes energy efficiency while maintaining effective irradiation intensity, as the distributed low-power sources reduce resistive and thermal losses inherent in high-power single-source systems.
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 achieves two-fold energy efficiency and cost-effectiveness, enabling homogenous illumination and improved process efficiency for material processing, including heat treating, hardening, and diffusion, with the ability to treat large surfaces uniformly and efficiently.
Implementation Method 1
intense direct irradiation from individually controllable high power laser diodes... alteration of material properties near the surface or through the entire body of a material
Implementation Method 2
laser diode array with fiber optic termination... incident radiation intensity stays relatively uniform over a range of spacing at the standard small NA's from the light source (fiber terminations)
Data Source
AI summary
Individually operable laser diodes in an array are associated with optical fibers for treatment of a material. Each laser diode has a generally Gaussian or similar profile. A guide block receives optical fiber terminal distal ends and enables irradiation of a surface for treatment with overlapping profiles. A control system controls individual laser diodes to achieve desired illumination profiles for a given process. The process is performed in a suitable environment which may include a vacuum system, controlled gaseous environment, or in a doping medium such as a surface coating or even a liquid. Optional relay optics interposed between the terminal distal ends and the treatment material allows distant relaying and reimaging. An optical isolator assembly may be interposed between the relay optics and the treatment material. The system and related methods allow direct irradiation from laser diodes to treat materials.