The present invention relates to an optical device for processing a beam having a flat cross section into a beam having a less flat cross section, in particular a laser beam, having at least one optical element into which at least one portion of the beam is coupled as an input beam and out of which at least one portion of the beam emerges as an output beam.
The radiation from laser diodes is generally highly astigmatic. This means that, in both spatial directions, the dimension of the radiation source differs, as does the radiation angle of the light. This generally yields beam cross sections which are very substantial in width in comparison to height. For that reason, the radiation from laser diode bars in particular, is not able to be directly coupled into an optical fiber. Therefore, efforts are directed to processing the beam in a way that results in a most symmetrical possible cross section, by reducing the width and increasing the height. An ideal radiation field would be as precisely wide as it is high and have the same divergence angles in both directions. To achieve or at least come close to achieving this goal, “restacking methods” are used. These methods provide for shifting regions of the radiation field of an input beam in such a way that the output beam produced has at least a more or less desired intensity distribution.
From the European Published Patent Application No. 0 731 932, it is known, for example, to arrange two mirrors in parallel to one another and at a certain distance from one another. In addition, the two mirrors are slightly offset from one another. One small region of the radiation field bypasses the two mirrors without being reflected by the same. The larger portion of the radiation field is reflected back and forth between the two mirrors until it emerges in a specific region from the interspace therebetween. The disadvantage associated with this device is the substantial requisite outlay for the mirrors and the mounting thereof and the considerable adjustment requirements.
From the European Published Patent Application No. 0 863 588, a device is known which employs a plate fan. In this connection, the beam offset is utilized during passage of the beam through a plurality of plane-parallel plates. The angle between the beam direction and the surface of the plate inside and outside of the plate is dependent on the refractive index of the plate material. The higher the refractive index of the material, the greater is the deviation of the two angles. Since the plate has parallel side surfaces, the beam does not experience any change in direction after passing through the plate, rather only a parallel lateral shift. For the most part, two plate fans, which are rotated by 90° with respect to each other, are used. Here as well, the manufacturing costs are comparatively high and the precise adjustment of the plate fans is complex.
Also known from the German Published Patent Application No. 199 01 500 is a beam-shaping optical system having an optical element which, on its incident side, has surfaces that are inclined towards each other and are each assigned to a parallel surface on the emergent side. The optical principle is similar to that of the plate fan described above.
The object of the present invention is to further refine a device of the type mentioned at the outset in such a way that it will be able to be manufactured and used less expensively.
This objective is achieved by a device of the type mentioned at the outset in that
The device according to the present invention is able to be manufactured very economically since, instead of mirrors or thin and fan-shaped plates, one single transparent (for example pellucid) member is simply used, which is geometrically tilted and rotated relative to the longitudinal axis of the input beam in such a way that light beams coupled into the same are totally internally reflected by the opposing surfaces, and regions of the beam are “restacked.” Suitable prisms, which may likewise be simply manufactured, are used for coupling in and coupling out the light beam. Thus, to process the beam, at most, only three elements are still needed. Moreover, mutual and geometrically simple adjustments are able to be easily performed on these elements. Thus, the costs to be expended for beam processing, in particular when working with laser diodes, are substantially reduced by the device according to the present invention.
The physical effect employed by the present invention is the total internal reflection within an “optically dense” medium, in which light, which is passing through inside of a member that has a higher refractive index than the medium (for example air) surrounding it, undergoes a total internal reflection within specific limiting angles. The rotation and tilting of the intermediate plane of the member relative to a plane disposed normally to the input beam, as well as the distance between the two mutually opposing surfaces determine the type and the extent of the restacking.
In this context, the rotation of the intermediate plane about an axis disposed normally to the plane of the input beam causes regions of the radiation field to be displaced in the direction of the plane of the input beam (“slow axis”), whereas the tilting of the intermediate plane about an axis which is disposed normally to the longitudinal axis of the input beam and resides in the plane of the input beam yields a certain “thickness” of the output beam. By positioning the incoupling prism and the outcoupling prism in different regions of the optical member, viewed in the direction of the longitudinal axis of the input beam, exposed regions result on both mutually opposing surfaces of the member, so that, in these regions, the radiation coupled into the member may undergo total internal reflection, as desired by the present invention. It this context, it is understood that the different regions may also overlap.
Advantageous further refinements of the present invention are delineated in the dependent claims.
One first especially-preferred embodiment has the distinguishing feature that the mutually opposing surfaces of the optical member are at least essentially plane-parallel and flat. Fundamentally, the result is a flat plate or a flat square, which is especially simple to manufacture. Moreover, in the context of plane-parallel surfaces which produce the total internal reflection of the radiation, the path of the radiation is readily determinable in advance.
It is especially preferred when the angle between the intermediate plane and the first spatial axis is within the range of 40° to 50°, and the angle between the intermediate plane and the second spatial axis within the range of 5° to 60°, in particular within the range of 30° to 40°, the first spatial axis residing in the plane of the input beam. Most notably, such angles make possible a very efficient processing of the input beams produced by laser diode bars, while simultaneously allowing for small dimensions of the device and easy and thus also economical producibility.
Another advantageous embodiment of the optical device according to the present invention has the distinguishing feature that the incoupling prism is located in the region of a longitudinal edge of the member that is most proximate to the input beam, and the outcoupling prism in the region of a side edge of the member that is the most remote from the input beam. In this configuration, the light beam is processed using the least possible amount of total internal reflections, thereby enhancing the beam quality.
The optical device may be produced by joining the incoupling prism and/or the outcoupling prism to the member using an optical cement. This enables the incoupling prism, the outcoupling prism, and the member to be manufactured as separate elements that may be assembled as a modular system in conformance with the individual usage requirements. It is conceivable, for example, to manufacture different sets of incoupling prisms, outcoupling prisms, and members and then to combine them with one another in any desired manner. This allows optimal results to be achieved under very different operating conditions and at low costs. As a cement, a material is suited whose refractive index corresponds as precisely as possible to that of the member and of the prisms. An example of such a material is a UV-hardening adhesive.
Alternatively, it is possible for the incoupling prism and/or the outcoupling prism to be integrally formed in one piece with the member and preferably of the same material as the member. The thus realized integral one-piece design of the optical device facilitates handling during installation and reduces the risk of optical losses when the beam is coupled into and out of the member. In addition, the need is eliminated for separate installation elements.
The optical device according to the present invention may be manufactured very economically when the member, the incoupling prism, the outcoupling prism or the one-piece unit including at least two of the former elements are, respectively is, manufactured as an injection-molded part, preferably of plastic.
In addition, it is especially advantageous when a collimating device is optically connected to the incoupling prism or is integrated in the same and/or when a focusing device is optically connected to the outcoupling prism or is integrated in the same. In such a case, the optical device not only assumes the “restacking” function, but also the collimation of the fast axis, in particular, and/or the coupling of the beam into an optical fiber, for example. Thus the need is eliminated for separate devices which fulfill these tasks, thereby further reducing the manufacturing costs.
To this end, one practical embodiment proposes that the focusing device include a toroidally curved emergent face on the outcoupling prism. This results in a toroidal lens that is integrally formed in one piece with the outcoupling prism and that has different focal lengths for the two spatial directions. These unequal focal lengths are essential since the divergence angles are distinctly different for the two spatial directions, especially in the context of laser radiation. A toroidally curved emergent face on the outcoupling prism may be realized simply and economically.
The focusing device may optionally include a light concentrator which is connected to the outcoupling prism, is designed as a monolithic component, and which focuses the radiation by way of the plurality of total internal reflections at its outer limiting surfaces. Such a focusing device, also described as a “lens duct”, may likewise be manufactured very simply. The dimensions of the light concentrator must be adapted to the focusing requirements of the light beam. In most cases, it is necessary to reduce the width of the radiation field for both spatial directions. To this end, the outer surfaces of the light concentrator, where the total internal reflections take place, must be designed to be both plane as well as curved. The use of a light concentrator in the manner proposed advantageously eliminates the need for adjusting the fibers when coupling the light into an optical fiber. In the simplest case, the fibers may be adhesively bonded to the end of the light concentrator. This also economizes on the costs entailed in the manufacturing and assembling of the optical device.
It is also proposed that the collimating device include an incident face on the incoupling prism that is designed as a convexly curved lens. In this manner as well, a lens is produced which collimates the radiation in the direction of the fast axis. A lens of this kind has a very large acceptance angle, so that only an aspherical surface is suited.
The present invention also relates to a beam-shaping device for laser diode stacks. It is proposed that the device include a plurality of optical devices of the above type which are placed one over the other to form a stack. A beam-shaping device of this kind makes it possible for the radiation field from a stack of laser diode bars to be processed in a simple manner.
In
Optical device 16 is shown in greater detail in
Also mounted on base plate 20 is an incoupling prism 24, which has approximately the basic shape of a right-angled triangle and is laid flat on base plate 20. A hypotenuse face 26 of incoupling prism 24 (
Situated at a rear surface 32 of optical member 22 on base plate 20 is an outcoupling prism 34. It is designed as an irregular octagonal block. The side, top, and bottom surfaces of the outcoupling prism that are not provided with reference numbers are oriented on the whole in parallel to the axis of input beam 14 and also of output beam 18. A contact surface 36 facing optical member 22 has an oblique, respectively tipped form in the two spatial directions such that, following application of an optical cement, it rests, at least in some areas, flat on rear surface 32 of optical member 22 where it covers a region 37. An emergent face 38 of outcoupling prism 34 opposing contact surface 36, in turn, is disposed normally to the axis of output beam 18.
Incoupling prism 24, outcoupling prism 34, as well as plate-shaped optical member 22 are each fabricated as separate parts out of glass. The purpose of incoupling prism 24 is to couple input beam 14 into optical member 22. Analogously, outcoupling prism 34 has the function of coupling output beam 18 out of optical member 22. The actual processing or restacking of the laser radiation in a process involving a multiplicity of total internal reflections, is carried out in optical member 22. This is described with reference to
Use is made of the total internal reflection principle for beam processing within optical member 22. This means that light that is passing through inside of optical member 22, whose material has a higher refractive index that the medium (generally air) surrounding it, undergoes a total reflection at the exposed regions of surfaces 28 and 32, within specific limiting angles. On the other hand, at the unexposed regions of surfaces 28 and 32 of optical member 22, namely at region 27 covered by hypotenuse face 26 of incoupling prism 24 and at region 37 covered by contact surface 36 of outcoupling prism 34 (compare
One first considers the path of rays of partial beam 14a of input beam 14: This path of rays is coupled through incoupling prism 24 (not shown in
Partial input beam 14b is likewise coupled via incoupling prism 24 into optical member 22. However, this occurs at a position 52 where rear surface 32 is exposed. Due to the inclined position of optical member 22 and thus also of rear surface 32, partial input beam 14b undergoes total reflection at a position 54a at the exposed rear surface 32. Due to the rotation of intermediate plane 48 and, as a result, also of two surfaces 28 and 32 by angle B about Y-axis 46, input beam 14b does not impinge normally on rear surface 32, but rather obliquely, and is therefore reflected laterally. Due to the tilting of intermediate plane 48 and, as a result, also of rear surface 32 by angle A about X-axis 44, partial input beam 14b is moreover reflected obliquely upwards relative to intermediate plane 48 at point of reflection 54a.
At 54b, partial input beam 14b again impinges on front surface 28 of optical member 22. This position is located outside of region 27 covered by hypotenuse face 26 of incoupling prism 24 on front surface 28 of optical member 22. Thus, partial input beam 14b is reflected, in turn, at position 54b in the direction of original axis 40 and then impinges again at 54c on rear surface 32 of optical member 22. Input beam 14b continues to be reflected back and forth in this manner within optical member 22 until it arrives in region 37 of rear surface 32 of optical member 22 covered by contact surface 36 of outcoupling prism 34. In this region, input beam 14b is coupled out of optical member 22 at position 58 and arrives in outcoupling prism 34. There, it emerges as partial output beam 18b from emergent face 38.
As is apparent from
In the following, other specific embodiments of optical devices 16 are described. In this context, those elements and regions, whose functions are equivalent to those of elements and regions of previously described exemplary embodiments, are denoted by the same reference numerals. They are generally not explained in detail again.
In the case of optical device 16 shown in
In addition to the restacking function, optical device 16 may also assume other functions, such as coupling the output beam into an optical fiber 60, in accordance with
In the specific embodiment shown in
Another task that may be additionally assumed by the optical device is the collimation of the fast axis of input beam 14. To this end, incident face 30 on incoupling prism 24 is designed as an aspherical lens 66 in that it is convexly curved, as is apparent from
To achieve high power densities, laser diode bars are also stacked in the manner of a laser diode stack. In the specific embodiment shown in
Number | Date | Country | Kind |
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10 2004 016 835.0 | Apr 2004 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP05/50851 | 2/28/2005 | WO | 7/30/2007 |