This invention relates to an apparatus and method for removing unwanted optical radiation from an optical fibre. The invention has application for manufacturing articles using lasers.
High power lasers are used for many applications including welding, cutting, brazing and drilling materials, as well as medical treatments and defence applications. A key requirement for high power lasers is the ability to strip optical power from the cladding of an optical fibre. This is particularly the case where optical power is launched into a fibre, for example at the input to an optical fibre beam delivery optical fibre cable, or at a splice between components in a fibre laser. Prior art cladding mode stripping techniques for removing unwanted high optical powers (>1 W) from optical fibres include surrounding the splice with a high temperature acrylate.
Prior art cladding mode strippers are either refractive index based (polymers, oils) for removing the waveguiding properties of the optical fibre, or absorption based (absorbing coatings, abrasion of the surface to scatter light). Abrasion or etching can lead to weakening of the fibre and resulting reliability failures in the field. Polymers tend to photodarken with the more power put into them, which increases absorption, and therefore absorbs more power in a shorter length. This can then lead to failure.
For high power cladding mode strippers (>1 W), the power stripped from the fibre heats the surrounding material, and the splice can fail. This is a major problem with high power lasers such as fibre lasers. Heating can cause failures during the manufacture of the product and also reliability issues with installed products. The amount of power that can be stripped in many of these schemes has an upper limit. For example it is difficult to strip more than 10 W using a polymer because polymers typically degrade at high temperatures.
For a fibre laser spool, the core absorbs pump light. Residual pump light remains in the cladding and propagates to the output splice. For a splice loss of 0.05 dB (from core to core), there is approximately 1% of power lost from the core into the cladding. Thus the total amount of power to be removed is the sum of the 1% of signal together with the residual pump power. For a 10 W laser, this can be 1 W, for a 100 W laser, this can be 2 W to 10 W, and for a 400 W laser, this can be 5 W to 40 W.
Similar problems occur in splicing the output of the fibre laser to fibre optic beam delivery cables. A 1% splice loss may not be too significant for a 10 W laser, but it is for lasers having output powers of 50 W or more.
Other disadvantages of prior art cladding mode stripping techniques is that the fibres need to be sealed from moisture, and they often use rigid packaging. There are constraints on the ends relating to fixing the fibres to the packages. Pull strength issues, thermal expansion mismatch issues, and the space taken to bend the fibres at either end have to be considered.
An aim of the present invention is to provide an apparatus and method for removing unwanted optical radiation from an optical fibre which reduces the above aforementioned problems.
According to a non-limiting embodiment of the present invention, there is provided apparatus comprising a source of optical radiation, an optical fibre, and an absorbing material, wherein: the optical fibre comprises a core, at least one cladding, and an optical surface; the source of optical radiation provides optical radiation that propagates along the core of the optical fibre, and unwanted optical radiation that propagates along the cladding that surrounds the core; and the absorbing material is in contact with the optical surface over a length of the optical fibre; the apparatus being characterized in that: the absorbing material has a refractive index that is higher than a refractive index of the optical surface within a temperature range thus enabling the unwanted optical radiation to pass from the optical fibre into the absorbing material within said temperature range; the absorbing material is such that it can absorb at least some of the unwanted optical radiation that enters into it from the optical fibre; the absorbing material is such that its temperature increases upon absorption of the unwanted optical radiation; and the absorbing material is such that its said refractive index reduces with increasing temperature thereby limiting the amount of the unwanted optical radiation that can be removed per unit length of optical fibre to a predetermined absorption per unit length; whereby the apparatus is such that it is able to remove the unwanted optical radiation up to a power level substantially equal to the product of the predetermined absorption per unit length and the length over which the absorbing material is in contact with the optical surface.
According to another non-limiting embodiment of the invention, there is provided a method comprising the steps of: providing an optical fibre comprising a core, at least one cladding, and an optical surface; providing a source of optical radiation; propagating the optical radiation along the core of the optical fibre, and unwanted optical radiation along the cladding that surrounds the core; providing an absorbing material characterized by a refractive index having a higher refractive index than the optical surface within a temperature range; placing the absorbing material in contact with the optical surface over a length of the optical fibre; the method being characterized in that it includes the following steps: using the refractive index difference between the absorbing material and the optical surface to remove the unwanted optical radiation from the fibre within said temperature range; absorbing at least some of the unwanted optical radiation that has been removed from the fibre by the absorbing material; increasing the temperature of the absorbing material with the unwanted optical radiation that is absorbed by the absorbing material; and reducing the refractive index of the absorbing material and thereby limiting the amount of the unwanted optical radiation that can be removed per unit length of optical fibre to a predetermined absorption per unit length; whereby the method can remove the unwanted optical radiation up to a power level substantially equal to the product of the predetermined absorption per unit length and the length over which the absorbing material is in contact with the optical surface.
The optical fibre may have a coating covering the optical surface, and wherein the coating is removed from the said length of the optical fibre to expose the optical surface.
The absorbing material may have a thermal conductivity in one plane that is different from a thermal conductivity in another plane. The absorbing material may comprise graphite, pyrolytic carbon, metals, carbon matrix composites, metal matrix graphite composites, metal alloys such as AlSiC, CuW, CuMo and high thermal conductivity ceramics.
The absorbing material may be in the form of at least one sheet. The optical fibre may be sandwiched between a plurality of the sheets.
The absorbing material may include an adhesive. The adhesive may be a high temperature polymer, an acrylate, a gel, or an oil.
The pre-determined absorption per unit length may be greater than about 0.5 W/mm. The pre-determined absorption per unit length may be greater than about 1 W/mm.
Temperature control means may be provided for maintaining the absorbing material in close proximity to the optical fibre at a temperature below which the said power level is reached. The temperature control means may comprise a heat sink, and wherein the absorbing material is in thermal contact with the heat sink. The temperature control means may comprise a cold plate, and wherein the absorbing material is in thermal contact with the cold plate.
The absorbing material may be non-planar. Alternatively or additionally, the optical fibre may be curved within the absorbing material.
The invention may be a laser comprising one of the aforementioned apparatus. The laser may have an output power greater than about 50 W. The optical fibre may form part of a beam delivery cable.
Embodiments of the invention will now be described solely by way of example and with reference to the accompanying drawings in which:
Referring to
The refractive index 100 of the cladding 38 at the optical surface 3, the refractive index 101 of the absorbing material 2, and the temperature range 102 are shown with reference to
The thermally-limiting power limitation provided by the apparatus of
The optical fibre 1 is shown having a coating 4, which has been removed to expose the optical surface 3 within the length 5. The optical surface 3 may be the glass surface of the optical fibre 1 within which the unwanted optical radiation 14 is propagating. In certain optical fibres, the optical surface 3 could be the outer surface of a polymer cladding within which the unwanted optical radiation 14 is propagating. The absorbing material 2 is shown having dimensions comprising a width 6, a length 7, and a thickness 8.
A cross-section (not to scale and parts separated for clarity) of an apparatus 30 is shown in
By film, strip, foil or sheet, it is meant a foil, sheet, strip, tape or a layer of material that is thin in comparison with its lateral dimensions.
Surprisingly, the apparatus 30 has a much higher efficiency than prior art cladding mode strippers. In addition, the apparatus 30 has more efficiency than was achieved by simply placing the optical fibre 1 onto a metal surface such as copper. Efficiencies greater than 99% have been achieved over a 5 mm length 5.
The graphite sheets 20, 21, 22 shown in
In order to strip 80 W of power with a predetermined absorption per unit length 62 of 1 W/mm with the apparatus of
Although the example was for an apparatus 30 having a predetermined absorption per unit length 62 of approximately 1 W/mm, the materials and dimensions of the sheets 20 to 23 can be selected to provide different values of the predetermined absorption per unit length 62. For example, reducing the width 6 of the sheets can reduce the predetermined absorption per unit length 62. Preferably, the dimensions (width 6 and thickness 8) and materials of the apparatus 30 should be selected to give a predetermined absorption per unit length 62 of at least 0.5 W/mm, and preferably at least 1 W/mm, the exact figure being dependent upon the thermal degradation properties of the materials, and in particular the adhesive 35.
The cladding mode stripping performance of the apparatus shown in
The underlying physics behind the invention is not fully understood. Without intending to limit the invention in any way, it is currently believed that the graphite sheet 20 that is in contact with the optical surface 3 of the optical fibre 1 has a real refractive index that is greater than the refractive index of silica. Thus placing the fibre 1 in contact with the graphite sheet 20 will lead to a loss of guidance at the glass/graphite sheet surface. Light is thus lost into the graphite sheet 20, whereupon the imaginary refractive index leads to a high levels of absorption. The absorbed power heats the graphite sheet 20. The limiting power level 45 is believed to occur because the heat changes the real and imaginary refractive indices of the graphite sheet 20, which affects the amount of power coupling from the fibre 1 into the graphite sheet 20. It is believed that it is the refractive index of the adhesive layers 35 of the graphite sheets 20 and 21 that are pressed against the fibre 1 that are mainly responsible for the removal of light from the fibre 1, the graphite material of the graphite sheets 20 and 21 are mainly responsible for the absorption of the light and the consequent heating of the adhesive 35 that contacts the glass surface 3. Additionally, the graphite advantageously conducts heat laterally away from the fibre 1. Hence further optimization should be possible by using different polymers, gels, adhesives and oils, either alone or in combination, as the material comprising the adhesive 35 that is in contact with the fibre 1. Preferably the adhesive 35 should surround the optical fibre 1 in order to maximize the removal of the unwanted optical radiation 14 and thus increase the power level 45 at which the device saturates. Additionally, bending the fibre 1 can be used to increase the amount of light coupled out. The fibre 1 can be non-planar. The fibre 1 can be bent with a radius of curvature 71 within the plane of the apparatus as shown with reference to
Similar devices have been made in which the graphite sheets 20, 21, 22 have been replaced with metal foil such as aluminum or copper. The devices display a similar behaviour, exhibiting power levels 45 above which the amount of unwanted optical radiation 14 removed from the optical fibre 1 saturates. However, the power levels 45 at which saturation occurs is very much lower than with the apparatus 30 of
Properties of graphite which makes it ideal in this application include the fact that graphite is extremely difficult to burn, has a very high thermal conductivity particularly in the plane of the sheet, and is flexible.
The high thermal conductivity in plane means that heat dissipates laterally from the fibre 1 very efficiently. This leads to a more reliable package because heat is transmitted laterally away from the fibre 1. Hot spots near the fibre 1 are thus avoided, which removes a failure mechanism observed in high power lasers.
The flexibility of the graphite sheets 20, 21, 22 assists greatly in packaging since the fibres 1 are not contained in rigid packages and can be positioned with great ease, for example, within a laser. For example, the apparatus 30 can be built upon a flat surface such as a cold plate, or a curved surface such as a coil former. It is also relatively simple to build the apparatus 30 such that it can be bent with, or is constructed with, a radius of curvature of 1 m or less. Radii of curvature less than 10 mm can be achieved.
Preferably, the temperature of the graphite sheet 20 in contact with the fibre 1 should be less than a temperature (not shown) corresponding to the power 45 shown in
The apparatus 30 has been proven over long term test trials in which a fibre laser comprising the apparatus 30 has undergone environmental testing appropriate for the industrial laser market. The invention thus extends to lasers such as the laser 91 shown with reference to
Other materials which may be substituted for graphite would include materials having high thermal conductivity (>50 W/m/K) and high absorption. Suitable materials include pyrolytic carbon, metals, carbon matrix composites, metal matrix graphite composites, metal alloys such as AlSiC, CuW, CuMo and high thermal conductivity ceramics.
It is to be appreciated that the embodiments of the invention described above with reference to the accompanying drawings have been given by way of example only and that modifications and additional components may be provided to enhance performance.
Number | Date | Country | Kind |
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0800976.3 | Jan 2008 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB09/00134 | 1/19/2009 | WO | 00 | 7/15/2010 |