Photon Source With Optical Shell For High Power Laser Combining
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Solution Overview
Problem
Semiconductor lasers have low power output compared to other types of lasers, making it desirable to combine the output of multiple semiconductor lasers to achieve high power output while leveraging their high electrical-to-optical efficiency.
Innovation Solution
A photon source comprising a substrate with a planar surface, a plurality of optical sources, and an optical shell with a hollow frustum, where each optical source includes a mirror and an emitter aligned to emit a collimated beam that is reflected onto the shell's annular base surface, with multiple mirrors and emitters arranged in concentric ring-like configurations to focus and combine optical power into an optical fiber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple semiconductor lasers are combined to increase power output, then the power output is improved, but the device complexity increases
Solution Approach 1:
Multiple semiconductor laser emitters are combined in a single device to achieve high power output while maintaining the efficiency benefits of semiconductor lasers. The emitters are arranged in an array configuration and their outputs are merged through optical components.
Solution Approach 2:
The optical components including mirrors, lenses, and the optical shell are nested within a compact housing structure. The mirrors are positioned around the emitters, lenses are integrated near the mirrors, and all components are contained within a single device housing, creating a nested arrangement that reduces overall system complexity.
2Power
If multiple optical sources are combined to achieve high power output, then the power output is improved, but the alignment precision requirements increase
Solution Approach 1:
The mirrors are pre-positioned at specific angles relative to the emitters during manufacturing, and the optical shell is pre-formed with integrated positioning features. This preliminary alignment reduces the need for complex post-assembly adjustments and ensures proper optical path alignment.
Solution Approach 2:
The optical shell acts as an intermediary structure that provides mechanical support and alignment references for all optical components. The shell's internal geometry serves as a master reference frame, ensuring consistent positioning of mirrors, lenses, and emitters without requiring complex alignment procedures.
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 configuration effectively increases the optical power output by combining the power of multiple semiconductor lasers, enhancing the electrical-to-optical efficiency and achieving higher power levels suitable for applications like industrial cutting and welding.
Implementation Method 1
a mirror disposed on the substrate having a reflecting surface defining a first predetermined angle relative to the planar surface of the substrate, and configured to reflect a collimated optical beam incident on the reflecting surface
Implementation Method 2
an optical emitter disposed on the substrate and optically aligned with the mirror along an optical axis and configured to emit the collimated optical beam along the optical axis
Implementation Method 3
an optical shell comprising a hollow frustum... the annular base surface may be disposed above the first ring-like configuration of the plurality of mirrors
Data Source
AI summary
A photon source may be composed of a substrate defining a planar surface, an optical shell having an annular base surface disposed above the substrate, and a plurality of optical sources. Each optical source may be composed of a mirror and an optical emitter aligned with the mirror along an optical axis. The mirror may be configured to reflect a collimated optical beam emitted by the optical emitter onto the annular base surface. The mirrors of the plurality of optical sources may be arranged in a first ring-like configuration. The annular base surface may be disposed above the first ring-like configuration. The optical emitters of the plurality of optical sources may be arranged in a second ring-like configuration. In one aspect, the optical shell may be a hollow frustum. In another aspect, a focus lens may be disposed between the substrate and the optical shell.