Laser Diode Out-of-Plane Beam Stacking for Symmetric Output
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current laser diode module designs face challenges in achieving symmetric beam quality between the fast and slow axes, leading to complex optical systems and reduced efficiency, particularly in fiber-coupled systems, due to asymmetric beam divergence and thermal issues.
Innovation Solution
A diode laser apparatus that reflects parallel diode laser beams at a small angle out of the emission plane using reflective slow axis collimators and planar or non-planar reflectors, allowing for a stacked configuration that reduces complexity and improves etendue preservation while maintaining high-power, low-divergence output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional bar-based laser diode systems are used to achieve high power output, then power density increases, but beam quality deteriorates due to asymmetric beam divergence and thermal effects
Solution Approach 1:
The patent transitions from planar in-plane beam stacking to three-dimensional out-of-plane beam stacking. By reflecting laser beams at angles out of the emission plane, the system achieves spatial separation of beams without requiring complex in-plane rearrangement, thereby maintaining beam quality while enabling high power density through vertical stacking configuration.
Solution Approach 2:
The patent exploits the asymmetric beam divergence characteristics of laser diodes (different divergence angles in fast and slow axes) by using anamorphic optical elements to independently control each axis. This asymmetric optical treatment converts the naturally asymmetric beam profile into a symmetric output beam, resolving the beam quality deterioration issue while maintaining high power output.
2Manufacturing precision
If expensive micro-optical beam shaping systems are used to correct asymmetric beam quality, then beam quality improves, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple optical functions into integrated optical elements. The anamorphic beam shaping optics are merged with the beam stacking architecture, and reflective elements are integrated directly into the housing structure. This consolidation reduces the number of discrete components and simplifies the overall optical system while maintaining beam quality correction capabilities.
Solution Approach 2:
The optical elements in the patent serve multiple functions simultaneously. The anamorphic lens array performs both beam shaping and collimation, while the reflective housing structure provides both mechanical support and optical reflection. This multi-functionality reduces the need for separate dedicated components, thereby reducing device complexity and cost.
3Manufacturing precision
If multiple optical interfaces and beam rotation techniques are used to achieve symmetric beam output, then beam quality improves, but optical efficiency decreases
Solution Approach 1:
The patent extracts and eliminates unnecessary optical interfaces from the beam path. By using reflective elements integrated into the housing and direct out-of-plane stacking, the system removes intermediate beam manipulation stages, reducing the number of optical interfaces where energy loss occurs while maintaining the required beam quality through selective optical element placement.
4Power
If emitter arrays are densely packed to increase power density, then power output increases, but beam quality deteriorates due to dead-space and cross-heating effects
Solution Approach 1:
The patent uses three-dimensional out-of-plane stacking to separate laser beams spatially after emission. This vertical separation in the stacking dimension allows dense emitter packing in the emission plane to achieve high power density, while the out-of-plane reflection and stacking maintain beam quality by preventing dead-space interference and reducing thermal crosstalk between adjacent emitters.
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 simplifies the laser diode module design, reduces machining requirements, and enhances optical efficiency by minimizing dead-space and thermal limitations, resulting in improved beam quality and brightness.
Implementation Method 1
a plurality of reflectors situated with respect to the diode lasers and configured to receive respective diode laser beams and to reflect the respective diode laser beams substantially parallel and out of the emission plane at a small angle therewith
Data Source
AI summary
A diode laser apparatus includes a plurality of spaced apart diode lasers, each of the diode lasers situated and configured to emit a diode laser beam substantially parallel to each other diode laser beam in an emission plane in a first direction, and a plurality of reflectors situated with respect to the diode lasers and configured to receive respective diode laser beams and to reflect the respective diode laser beams substantially parallel and out of the emission plane at a small angle therewith in a second direction such that the reflected diode laser beams are in a stacked configuration.