Micro-Prism Reflector Array for Multi-Diode Beam Combining

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Solution Overview

Problem

Existing beam combining methods for laser diodes are complex and costly, and there is a need for a more effective solution to combine beams of two or more laser diodes, particularly to achieve high intensity radiation with a broad range of correlated color temperature and high color rendering index.

Innovation Solution

A light generating device comprising a plurality of light sources and an array of prismatic elements, where the light sources irradiate non-parallel prismatic faces, reflecting or refracting collimated light to produce coincident beams, preserving polarization and achieving high intensity radiation with a broad range of correlated color temperature and high color rendering index.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multi-core fibers, patched reflectors, or polarization- and dichroic filters are used to combine laser beams, then beam combining is achieved, but device complexity and cost increase significantly

Engineering Contradiction:

Improvebeam combining capabilityVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention divides the beam combining function into multiple independent prismatic elements, each handling a portion of the light path. This segmentation allows complex beam combining to be achieved through simple, replicated units rather than complex integrated components, reducing overall system complexity while maintaining combining capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces complex mechanical/optical systems (multi-core fibers, patched reflectors, dichroic filters) with a simpler prismatic element system that uses basic reflection and refraction principles. This substitution eliminates the need for expensive and complex specialized components while achieving the same beam combining function

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If multiple laser diodes are combined to generate desired lumen flux, then light output increases, but system complexity and cost increase

Engineering Contradiction:

Improvelumen fluxVSAvoidnumber of components

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The invention merges multiple laser diode beams into a single unified output using the prismatic element array. Instead of requiring complex individual handling of each laser diode, the prismatic elements collectively combine all beams in one location, simplifying the overall system architecture while achieving the desired total light output

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The prismatic element array serves multiple functions simultaneously: beam combining, beam steering, and light distribution. This multi-functionality eliminates the need for separate components for each function, reducing the total number of components required while maintaining high lumen flux output

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 device efficiently combines collimated laser beams to produce high-intensity radiation with a broad range of correlated color temperature and high color rendering index, ensuring even distribution and preservation of polarization without overlap or dark gaps.

Implementation Method 1

the prismatic elements are configured to reflect or refract the collimated first light source light and the collimated second light source light as coincident beams

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

the prismatic elements are configured to reflect or refract the collimated first light source light and the collimated second light source light as coincident beams

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 3

preserving polarization

Methodology Applied

Scientific EffectPolarization: Polarisation

Data Source

PatentEP4070154B1Compact laser beam combiner with micro-prism reflector

Publication Date: 2025.10.22 SIGNIFY HOLDING BV

Figure 1A~1B
Figure 1C~1D
Figure 1E~1G

AI summary

The invention provides a light generating device (1000) comprising (i) a plurality of n light sources (100), and (ii) an optical component (1200) comprising an array (200) of prismatic elements (300), wherein: (a) the plurality of n light sources (100) comprise a first subset of one or more first light sources (110) configured to generate collimated first light source light (111) and a second subset of one or more second light sources (120) configured to generate collimated second light source light (121), wherein n>2; (b) the array (200) of prismatic elements (300) is configured in a light receiving relationship with the n light sources (100), wherein the array of prismatic elements (300) comprises k 1 parallel arranged first prismatic faces (201) and k2 parallel arranged second prismatic faces (202), wherein kl>2 and wherein k2>2, wherein the first prismatic faces (201) and the second prismatic faces (202) are not mutually parallel; (c) the first light sources (110) are configured to irradiate the first prismatic faces (201) and the second light sources (120) are configured to irradiate the second prismatic faces (202); and (d) the prismatic elements (300) are configured to reflect or refract the collimated first light source light (111) and the collimated second light source light (121) as coincident beams of first light source light (111) and second light source light (121).