Electronic spot light control

• US 6,426,840 B1
• Filed: 02/23/2001
• Issued: 07/30/2002
• Est. Priority Date: 02/23/2001
• Status: Expired due to Term

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Partanen, Jouni P., Wu, Xingkun, Tang, Nansheng
• Primary Examiner(s): Epps, Georgia
• Assistant Examiner(s): Seyrah, Saeed
• Application Number:
  US09/791,346
• Time in Patent Office: 522 Days
• Field of Search: 359/668, 359/689, 359/670, 359/671, 359/822, 359/823, 359/621, 359/619, 359/710, 359/290, 359/298, 359/223, 359/268, 359/399, 359/433, 359/293, 204/157.61
• US Class Current: 359/823
• CPC Class Codes: B23K 26/04 Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
• CPC Class Codes: B23K 26/0617 and with spots spaced along the common axis
• CPC Class Codes: B23K 26/066 by using masks
• CPC Class Codes: B23K 26/067 Dividing the beam into multiple beams, e.g. multifocusing
• CPC Class Codes: B23K 26/073 Shaping the laser spot
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/382 by boring
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/268 using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/273 pulsed; frequency modulated
• CPC Class Codes: G02B 19/0014 at least one surface having optical power
• CPC Class Codes: G02B 19/0052 the light source comprising a laser diode coupling into light guides using intermediate optical elements G02B6/4204; semiconductor lasers having optical devices external to the laser cavity H01S5/005
• CPC Class Codes: G02B 19/0095 for use with ultraviolet radiation
• CPC Class Codes: G02B 26/128 Focus control
• CPC Class Codes: G02B 27/09 Beam shaping, e.g. changing the cross-sectional area, not otherwise provided for adapting the beam shape of a laser diode G02B19/0052; adapting the beam shape of an LED G02B19/0061; coupling into light guides using intermediate optical elements G02B6/4204; beam shaping specially adapted for lasers H01S3/005
• CPC Class Codes: G02B 27/0955 Lenses lenses per se G02B3/00
• CPC Class Codes: G02B 27/40 Optical focusing aids
• CPC Class Codes: G02B 7/102 controlled by a microcomputer cameras with interchangeable lenses G03B17/14

Abstract

An illumination system includes optics capable of adjusting the size of a beam of light and adjusting the focus of the beam of light. Spot size control optics adjusts the overall size of the beam of light and separately adjusts the ellipticity of the beam, primarily in one dimension. Light from the spot size control optics passes to focus control optics that control the overall focus of the beam of light and adjust the astigmatism of the beam by altering the focus position of the beam of light in one dimension. The laser system, the spot size control optics and the focus control optics are within an enclosure. Actuators under remote control from outside of the enclosure adjust both of the spot size control optics and focus control optics in the thermal environment of the illumination system.

Claims

1. An optical system, comprising:

spot size control optics receiving a beam of light, adjusting a lateral extent of the beam of light and outputting the beam of light, the beam of light having a first extent in a first lateral direction and a second extent in a second lateral direction perpendicular to the first lateral direction, the spot size control optics coupled to an actuator and responsive to electrical signals to adjust an ellipticity of the beam, wherein movement of the actuator alters the first lateral extent of the beam of light more than the second lateral extent; and

focus control optics receiving the beam of light, altering a position of a focus of the beam of light and outputting the beam of light.

2. The optical system of claim 1, further comprising an enclosure around the spot size control optics and the focus control optics, the enclosure having walls opaque to the beam of light and having at least an output port to output the beam of light.

3. The optical system of claim 2, wherein the spot size control optics are coupled to a second actuator responsive to electrical signals to adjust the first and second lateral extents of the beam of light substantially equally.

4. The optical system of claim 2, wherein the spot size control optics includes a second actuator responsive to electrical signals to adjust an overall spot size of the beam.

5. The optical system of claim 4, wherein the second actuator adjusts the overall spot size substantially independently of the ellipticity.

6. The optical system of claim 5, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electrical signals automatically establishing the first state or the second state in response to control signals.

7. The optical system of claim 1, wherein the focus control optics comprise an actuator responsive to electrical signals to adjust an overall focus position of the beam of light.

8. The optical system of claim 7, wherein he electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second late in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electric signals automatically establishing either of the first state or the second state in response to control signals.

9. The optical system of claim 7, wherein the spot size control optics are coupled to a second actuator responsive to the electrical signals, the second actuator adjusting both of the first lateral extent and the second lateral extent of the beam of light.

10. The optical system of claim 9, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electric signals automatically establishing either of the first state or the second state in response to control signals.

11. The optical system of claim 1, wherein the spot size control optics comprise a lens mounted on a pivot and a linear translation stage, a first actuator coupled to rotate the lens on the pivot and a second actuator coupled to translate the lens along the linear translation stage, the first and second actuator responsive to electrical signals.

12. The optical system of claim 11, wherein the lens is a positive lens and is positioned so that the beam passes through center of the lens.

13. The optical system of claim 11, wherein the electrical signals selectively define a first state in which the beam of light as a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the state beam location different from the first selectable lateral extent, the electric signals automatically establishing either of the first state or the second state in response to control signals.

14. The optical system of claim 13, further comprising an enclosure around the spot size control optics, the first and second actuator and the focus control optics, the control signals generated outside the enclosure.

15. The optical system of claim 14, further comprising a solid state laser within the enclosure, the solid state laser out outputting the beam of light.

16. An optical system, comprising:

spot size control optics receiving a beam of light, adjusting a lateral extent of the beam of light and outputting the beam of light; and

focus control optics coupled to an actuator responsive to electrical signals, the focus control optics receiving the beam of light, altering a position of a focus of the beam of light and outputting the beam of light, the beam of light having a first focus position for a first lateral component of the beam of light and having a second focus position for a second lateral component of the beam of light, the first lateral component perpendicular to the second lateral component, the focus control optics adjusting the first focus position to a greater extent than the second focus position in response to the electrical signals supplied to the actuator.

17. The optical system of claim 16, further comprising an enclosure around the spot size control optics and the focus control optics, the enclosure having walls opaque to the beam of light and having at least an output port to output the beam of light.

18. The optical system of claim 17, wherein a lens within the actuator adjusts an astigmatism of the beam of light responsive to electrical signals to reduce a separation between the first focus position and the second focus position.

19. The optical system of claim 17, wherein the focus control optics are coupled to a second actuator responsive to electrical signals to adjust the first focus position of the beam of light and the second focus position of the beam of light simultaneously.

20. The optical system of claim 17, wherein the focus control optics are coupled to two actuators within the enclosure responsive to electrical signals to remotely adjust both of the first lateral extent and the second lateral extent of the beam of light.

21. The optical system of claim 20, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electrical signals automatically establishing the first state or the second state in response to control signals.

22. The optical system of claim 16, wherein the focus control optics are coupled to a second actuator responsive to electrical signals to adjust the an overall focus position of the beam of light.

23. The optical system of claim 22, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electrical signals automatically establishing either of the first state or the second state in response to control signals.

24. The optical system of claim 22, wherein the focus control optics are coupled to a second actuator responsive to the electrical signals, the second actuator adjusting both of the first focusing position and the second focusing position of the beam of light substantially equally.

25. The optical system of claim 24, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electrical signals automatically establishing either of the first state or the second state in response to control signals.

26. The optical system of claim 16, wherein the focus control optics comprise a lens mounted on a pivot and a linear translation stage, a first actuator coupled to rotate the lens on the pivot and a second actuator coupled to translate the lens along the linear translation stage, the first and second actuator responsive to electrical signals.

27. The optical system of claim 26, wherein the lens is a negative lens.

28. The optical system of claim 26, wherein the electrical signals selectively define a first state in which the beam of light as a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electrical signals automatically establishing either of the first state or the second state in response to control signals.

29. The optical system of claim 28, further comprising an enclosure around the spot size control optics, the focus control optics and the first and second actuators, the control signals generated outside of the enclosure.

30. The optical system of claim 29, further comprising a solid state laser within the enclosure, the solid state laser out cutting the beam of light.

31. An optical system, comprising:

spot size control optics receiving a beam of light, adjusting a lateral extent of the beam of light and outputting the beam of light, the beam of light having a first extent in a first lateral direction and a second extent in a second lateral direction perpendicular to the first lateral direction, the spot size control optics coupled to a spot size actuator and responsive to electrical signals to adjust an ellipticity of the beam, wherein movement of the spot size actuator alters the first lateral extent of the beam of light more than the second lateral extent; and

focus control optics coupled to a focus actuator responsive to electrical signals, the focus control optics receiving the beam of light, altering a position of a focus of the beam of light and outputting the beam of light, the beam of light having a first focus position for a first lateral component of the beam of light and having a second focus position for second lateral component of the beam of light, the first lateral component perpendicular to the second lateral component, the focus control optics adjusting the first focus position to a greater extent than the second focus position in response to the electrical signals supplied to the focus actuator.

32. The optical system of claim 31, further comprising an enclosure around the spot size control optics and the focus control optics, the enclosure having walls opaque to the beam of light and having at least an output port to output the beam of light.

33. The optical system of claim 32, wherein the spot size control optics are coupled to a first actuator responsive to electrical signals to adjust the first lateral extent of the beam of light and wherein the focus control optics are coupled to a second actuator responsive to the electrical signals to adjust the first focus position.

34. The optical system of claim 32, wherein the spot size control optics are coupled to a first actuator responsive to electrical signals to adjust the first lateral extent of the beam of light without adjusting the second lateral extent of the beam of light and wherein the focus control optics are coupled to a second actuator responsive to electrical signals to adjust the first focus position of the beam of light without adjusting the second focus position of the beam of light.

35. The optical system of claim 32, wherein the spot size control optics are coupled to a first actuator within the enclosure responsive to electrical signals to remotely adjust the first lateral extent of the beam of light and wherein the focus control optics are coupled to a second actuator within the enclosure responsive to electrical signals to remotely adjust the first focus position.

36. The optical system of claim 35, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electrical signals automatically establishing the first state or the second state in response to control signals.

37. The optical system of claim 31, wherein the spot size control optics are coupled to a first actuator responsive to electrical signals to adjust the first lateral extent of the beam of light and wherein the focus control optics are coupled to a second actuator responsive to electrical signals to adjust the first focus position of the beam of light.

38. The optical system of claim 37, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electric signals automatically establishing either of the first state or the second state in response to control signals.

39. The optical system of claim 38, wherein the spot size control optics are coupled to a third actuator responsive to the electrical signals, the third actuator adjusting both of the first lateral extent and the second lateral extent of the beam of light and wherein the focus control optics are coupled to a fourth actuator responsive to the electrical signals, the fourth actuator adjusting both of the first focusing position and the second focusing position of the beam of light.

40. The optical system of claim 39, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at a first beam location and a second state in which the beam of light has a second selectable lateral extent at the first beam location different from the first selectable lateral extent, the electric signals automatically establishing either of the first state or the second state in response to control signals.

41. The optical system of claim 31, wherein the spot size control optics comprise a first lens mounted on a pivot and a linear translation stage, a first actuator coupled to rotate the first lens on the pivot and a second actuator coupled to translate the first lens along the linear translation stage, the first and second actuator responsive to electrical signals, and

wherein the focus control optics comprise a second lens mounted on a pivot and a linear translation stage, a third a actuator coupled to rotate the second lens on the pivot and a fourth actuator coupled to translate the second lens along the linear translation stage, the third and fourth actuators responsive to electrical signals.

42. The optical system of claim 41, wherein the first lens is a positive lens and the second lens is a negative lens.

43. The optical system of claim 41, wherein the electrical signals selectively define a first state in which the beam of light as a first selectable lateral extent at a first beam location and a second ate in which the beam of light has a second selectable lateral extent at the fist beam location different from the first selectable lateral extent, the electrical signals automatically establishing either of the first state or the second state in response to control signals.

44. The optical system of claim 43, further comprising an enclosure around the spot size control optics, the focus control optics and the first, second, third and fourth actuators, the control signals generated outside of the enclosure.

45. The optical system of claim 44, further comprising a solid state laser within the enclosure, the solid state laser out outputting the beam of light.

46. An optical system, comprising:

a laser system including a solid state laser, the laser system outputting a beam of light;

spot size control optics receiving the beam of light, adjusting a lateral extent of the beam of light and outputting the beam of light, the spot size control optics including a first lens mounted on a pivot and a linear translation stage, a first actuator coupled to rotate the first lens on the pivot and a second actuator coupled to translate the lens along the linear translation stage, the first and second actuator responsive to electrical signals;

focus control optics receiving the beam of light adjusted by the spot size control optics, the focus control optics altering a position of a focus of the beam of light and outputting the beam of light; and

beam positioning optics receiving the beam of light altered by the focus control optics, the beam positioning optics laterally positioning the beam of light.

47. The optical system of claim 46, wherein the beam positioning optics scan the beam of light in an x and y direction on a receiving surface.

48. The optical system of claim 47, wherein the first lens is a positive lens.

49. The optical system of claim 48, wherein the laser system, the spot size control optics and the focus control optics are within an enclosure.

50. The optical system of claim 49, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at the receiving surface and a second state in which the beam of light has a second selectable lateral extent at the receiving surface different from the first selectable lateral extent, the electrical signals automatically establishing either of the first state or the second state in response to control signals.

51. The optical system of claim 46, wherein the focus control optics comprise a second lens mounted on a pivot and a linear translation stage, a third actuator coupled to rotate the second lens on the pivot and a fourth actuator coupled to translate the second lens along the linear translation stage, the third and fourth actuators responsive to electrical signals.

52. The optical system of claim 51, further comprising an enclosure around the spot size control optics, the focus control optics and the first, second, third and fourth actuators, the control signals generated outside of the enclosure.

53. The optical system of claim 51, wherein the beam positioning optics scan the beam of light in an x and y direction on a receiving surface.

54. The optical system of claim 53, wherein the first lens is a positive lens and the second lens is a negative lens.

55. The optical system of claim 53 wherein the laser system, the spot size control optics and the focus control optics are within an enclosure.

56. The optical system of claim 55 wherein the electrical signals selectively define a first state in which the beam of light as a first selectable lateral extent at the receiving surface and a second state in which the beam of light has a second selectable lateral extent at the receiving surface different from the first selectable lateral extent, the electrical signals automatically establishing either of the first state or the second state in response to control signals.

57. An optical system, comprising:

a laser system including a solid state laser, the laser system outputting a beam of light;

spot size control optics receiving the beam of light, adjusting a lateral extent of the beam of light and outputting the beam of light;

focus control optics receiving the beam of light adjusted by the spot size control optics, the focus control optics altering a position of a focus of the beam of light and outputting the beam of light, the focus control optics comprising a first lens mounted on a pivot and a linear translation stage, a first actuator coupled to rotate the first lens on the pivot an a second actuator coupled to translate the first lens along the linear translation stage, the first and second actuators responsive to electrical signals; and

beam positioning optics receiving the beam of light altered by the focus control optics, the beam positioning optics laterally positioning the beam of light.

58. The optical system of claim 57, wherein the beam positioning optics scan the beam of light in an x and y direction on a receiving surface.

59. The optical system of claim 58, wherein the first lens is a negative lens.

60. The optical system of claim 58, wherein the laser system, the spot size control optics and the focus control optics are within an enclosure.

61. The optical system of claim 60, wherein the electrical signals selectively define a first state in which the beam of light has a first selectable lateral extent at the receiving surface and a second state in which the beam of light has a second selectable lateral extent at the receiving surface different from the first selectable lateral extent, the electrical signals automatically establishing either of the first state or the second state in response to control signals.