Laser Module Emitter Pitch and Width Optimization
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Solution Overview
Problem
Conventional laser modules fail to consistently produce high output laser light of high beam quality due to the wide range of emitter width and pitch between emitters, which are not sufficiently defined, affecting the output and beam quality in applications like laser cutting and laser welding.
Innovation Solution
A laser module with specifically defined emitter width and pitch between emitters, utilizing a fast collimating lens and beam twister to collimate and rotate the laser light, minimizing divergence and overlapping, thereby achieving high output and beam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the emitter width and pitch between emitters are defined in a wide range, then the design flexibility is improved, but the beam quality and output consistency deteriorate
Solution Approach 1:
The patent applies parameter changes by establishing specific numerical ranges for emitter width (50-300 μm) and pitch between emitters (300-500 μm). These defined parameters transform the design from flexible but inconsistent to constrained but consistent, ensuring high beam quality while maintaining reasonable design adaptability within the specified ranges.
2Power
If the emitter width is increased to achieve higher output, then the output power is improved, but the beam quality deteriorates due to increased divergence
Solution Approach 1:
The patent resolves this contradiction by optimizing the emitter width parameter within a specific range (50-300 μm). This parameter optimization allows the system to achieve high output power while maintaining acceptable beam quality, as the width is sufficient for high power generation but not excessive to cause severe divergence.
Solution Approach 2:
The patent introduces a beam conditioning optic as an intermediary component that processes the laser beam after emission. This beam conditioning optic corrects beam quality issues arising from emitter width variations, allowing high power output to be achieved while maintaining consistent beam quality through active correction.
3Power
If the pitch between emitters is decreased to increase the number of emitters, then the total output is improved, but the beam quality deteriorates due to increased overlapping
Solution Approach 1:
The patent optimizes the pitch parameter within a specific range (300-500 μm) to balance two competing requirements: decreasing pitch increases the number of emitters and total output, while increasing pitch reduces beam overlapping. The defined range finds the optimal compromise point where high total output is achieved without excessive beam quality degradation.
Solution Approach 2:
The beam conditioning optic serves as an intermediary that compensates for beam overlapping effects. Even when emitters are closely spaced to increase total output, the beam conditioning optic processes and corrects the combined beam, maintaining acceptable beam quality despite the challenging emitter arrangement.
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 laser module achieves high output laser light of high beam quality by precisely defining emitter width and pitch, ensuring effective collimation and rotation of laser light, suitable for industrial applications such as laser cutting and welding.
Implementation Method 1
fast collimating lens provided at a first distance away from a light emission surface of the laser diode to parallelize the FA beam divergence
Implementation Method 2
beam conditioning optic rotates incident laser light approximately 90 degrees and emits the resulting laser light
Data Source
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AI summary
A laser module according to the present disclosure includes a laser diode, a first collimating lens, and a beam twister. The laser diode includes a plurality of emitters and emits laser light from each of the plurality of emitters through a light emission surface. The first collimating lens is provided at a first distance from the light emission surface of the laser diode and parallelizes a fast-axis-wise divergence of the laser light. The beam twister is provided at a second distance away from the first collimating lens and turns the laser light approximately 90 degrees. Each of the plurality of emitters has a width of 5 µm to 120 µm on the light emission surface. The plurality of emitters have a pitch of 295 µm to 305 µm on the light emission surface.