Multi-channel Laser Device with Thermal Expanded Fiber Array
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Solution Overview
Problem
Existing fiber laser devices have low coupling efficiency and are sensitive to precise manufacturing, leading to high production costs and limitations in coupling multiple laser components due to their narrow coupling area and high precision requirements.
Innovation Solution
A multi-channel laser device with a fiber array that uses thermal expanded fibers and optical isolators to achieve higher coupling efficiency and reduced precision requirements, allowing for the efficient coupling of multiple laser components with a wider coupling area and lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a general single-mode optical fiber with an angled cross-section is used for coupling, then the fiber can be manufactured with standard processes, but the coupling efficiency is low (40-50%) and the coupling area is narrow
Solution Approach 1:
The patent applies parameter changes by modifying the fiber core diameter from standard single-mode dimensions to a larger mode field diameter (2.5-3.5 times larger), which fundamentally changes the coupling characteristics. This parameter change enables higher coupling efficiency (exceeding 50%) while maintaining ease of manufacture through thermal expansion processing.
Solution Approach 2:
The patent utilizes thermal expansion to create the enlarged mode field diameter in the optical fiber. By thermally expanding the fiber during manufacturing, the mode field diameter is increased, which broadens the coupling area and improves coupling efficiency without requiring complex manufacturing processes.
2Device complexity
If a general single-mode optical fiber with an angled cross-section is used for coupling, then the fiber structure is simple, but the coupling position sensitivity is high (light power reduces by more than 3 dB with a 1 um position shift)
Solution Approach 1:
By changing the mode field diameter parameter to a larger value through thermal expansion, the patent reduces the sensitivity to coupling position shifts. The larger mode field provides a more tolerant coupling interface, reducing the precision requirements while maintaining structural simplicity.
3Power
If a laser chip with high output power is used to achieve high product output power, then the product output power requirement is met, but the cost increases significantly since laser chip price is directly proportional to output light power
Solution Approach 1:
The patent replaces the need for high-power laser chips with a combination of lower-power laser chips and high-efficiency optical coupling. By substituting the mechanical/power-based approach (using high-power chips) with an optical efficiency-based approach (using thermal expanded fibers with >50% coupling efficiency), the system achieves the same output power with lower-cost components.
Solution Approach 2:
The patent converts the previously harmful low coupling efficiency (which required high-power chips) into a benefit by using thermal expanded fibers. The same coupling interface that previously caused power loss now becomes a high-efficiency power transfer mechanism, allowing the use of lower-power, lower-cost laser chips.
4Ease of manufacture
If a general single-mode optical fiber with a narrow coupling area is used, then the fiber can be manufactured with standard tolerances, but the fiber cannot be used to implement the coupling of an array of laser components
Solution Approach 1:
The patent applies thermal expansion to create fibers with enlarged mode field diameters, which provides a sufficiently wide coupling area to accommodate array configurations. This allows multiple laser components to be coupled simultaneously while maintaining ease of manufacture with standard tolerances.
Solution Approach 2:
The thermal expanded fiber serves multiple functions: it provides high coupling efficiency for single components, enables array coupling configurations, and maintains ease of manufacture. This multi-functionality makes the fiber suitable for both single-channel and multi-channel laser devices.
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 high coupling efficiency and reduced manufacturing costs by using thermal expanded fibers and optical isolators, enabling the production of multi-channel laser devices with improved light coupling and reduced equipment precision, suitable for various channel configurations.
Implementation Method 1
The fiber array module includes a plurality of thermal expanded fibers
Implementation Method 2
Each of the laser components is connected to a fiber array module through an optical isolator
Data Source
AI summary
A multi-channel laser device with a fiber array includes a housing and a ferrule. In the housing, laser components are arranged side by side, and each of the laser components is connected to a fiber array module through an optical isolator. The fiber array module includes thermal expanded fibers, and fibers out of the fiber array module are collected by the ferrule. The laser components are disposed on the same module board, and laser light radiated from the front end of a laser chip in each of the laser components is projected onto the optical isolator through a convex lens and then enters into the thermal expanded fiber. Such a structure may reach a relatively-high coupling efficiency and implement the coupling of arrayed laser components.