System and method for generating intense laser light from laser diode arrays

• US 7,881,355 B2
• Filed: 12/15/2005
• Issued: 02/01/2011
• Est. Priority Date: 12/15/2005
• Status: Active Grant

• Current Assignee: Mind Melters, Inc.
• Original Assignee: Mind Melters, Inc.
• Inventors: Sipes, Donald L. Jr.
• Primary Examiner(s): Harvey; Minsun
• Assistant Examiner(s): Golub-Miller; Marcia A.
• Application Number:
  US11/300,726
• Publication Number:
  US 20080101429A1
• Time in Patent Office: 1,874 Days
• Field of Search: 372/50.12
• US Class Current: 372/50.12
• CPC Class Codes: G02B 19/0014 at least one surface having optical power
• CPC Class Codes: G02B 19/0057 in the form of a laser diode array, e.g. laser diode bar semiconductor laser arrays with beam combining arrangement H01S5/4012
• CPC Class Codes: G02B 27/0961 Lens arrays lens arrays per se G02B3/0006
• CPC Class Codes: G02B 27/0966 Cylindrical lenses cylindrical lenses per se G02B3/06
• CPC Class Codes: G02B 27/283 used for beam splitting or combining
• CPC Class Codes: G02B 6/4296 coupling with sources of high radiant energy, e.g. high power lasers, high temperature light sources
• CPC Class Codes: H01S 5/4012 Beam combining, e.g. by the use of fibres, gratings, polarisers, prisms
• CPC Class Codes: H01S 5/405 Two-dimensional arrays

Abstract

Laser modules using two-dimensional laser diode arrays are combined to provide an intense laser beam. The laser diodes in a two-dimensional array are formed into rows and columns, and an optical assembly images light generated by laser diodes in a column into an optical fiber. The laser light outputs of the laser modules are combined by a spectral combiner into an optical fiber to form an intense laser beam.

Claims

1. An apparatus for generating laser light, comprising:

a stack of one-dimensional laser diode array bars forming a two-dimensional laser array having laser diodes arranged in rows and columns, where laser diodes in each of the one-dimensional laser diode array bars comprise the laser diodes in one of the rows of the two-dimensional laser array and laser diodes aligned across the stacked one-dimensional laser diode array bars comprise the laser diodes in one of the columns of the two-dimensional laser array, each laser diode having a fast axis oriented in a column direction and a slow axis oriented in a row direction;

an optical assembly for collimating laser light from the stack in both the fast and slow axes and focusing the laser light from each of two or more groups of columns from the two dimensional laser array into a corresponding one of two or more optical fibers without rotating the fast and slow axes, where there is a one-to-one correspondence between the number of groups of columns and the number of fibers such that each fiber receives the focused laser light from only one of the groups of columns; and

means for compensating for spherical aberration in the focused laser light from each group of columns in order to match the focused laser light to a diameter and numerical aperture of the corresponding optical fiber, wherein the means includes an arrangement of the stack of one-dimensional laser diode array bars that aligns individual emitters along a surface of a cylinder of radius R such that an axis of propagation from each of the emitters is directed to the center axis of the cylinder.

2. The apparatus of claim 1, wherein the optical assembly includes optics for imaging laser light from one of the groups of columns into an entrance end of the corresponding optical fiber to form a summed beam whose brightness is substantially equal in the row and column directions.

3. The apparatus of claim 1, wherein the optical assembly includes multiple optical elements disposed between the two-dimensional laser array and an entrance end of each of the two or more optical fibers for focusing laser light from each of the groups of the laser sources.

4. The apparatus of claim 3, further including a fiber combiner for combining the two or more optical fibers into a single fiber.

5. The apparatus of claim 1, wherein each of the one-dimensional laser bars has multiple laser diodes photolithographically formed therein, each one-dimensional laser bar forming a row of the two-dimensional laser array.

6. A method of generating laser light, comprising:

energizing a stack of laser sources to generate laser light, wherein each layer in the stack comprises a multi-emitter laser bar forming a row of the laser sources and columns of the laser sources extend across the layers such that a fast axis of each laser sources is oriented in a column direction of the stack and a slow axis of each laser source is oriented in a row direction of the stack and;

collimating the laser light from the stack in both the fast and slow axes;

focusing laser light from one or more of the columns of the laser sources into an optical fiber without rotating the fast and slow axes of the laser sources in the column, where a brightness of the focused light is substantially equal in the fast and slow axes directions; and

compensating for spherical aberration in the focused laser light in order to match the focused laser light to a diameter and numerical aperture of the optical fiber by aligning individual emitters of the stack of laser sources along a surface of a cylinder of radius R such that an axis of propagation from each of the emitters is directed to the center axis of the cylinder.

7. The method of claim 6, wherein the focusing of laser light forms a summed beam in the optical fiber and a brightness of the summed beam in the column direction is substantially equal to a brightness of the summed beam in the row direction.

8. A system for producing a beam of laser light from laser sources, comprising:

each of a plurality of laser modules comprising rows and columns of laser sources whose fast axes are oriented in a column direction and slow axes oriented in a row direction, where each of the rows comprises a multi-emitter laser bar and each of the columns comprises laser sources aligned across laser bars, and an optical assembly for focusing laser light along the columns of the laser sources into two or more optical fibers without rotating the fast and slow axes such that the focused laser light entering each of the fibers has substantially equal brightness in the slow and fast axes directions;

the optical assembly for each of the modules including optics for collimating the laser light in both the fast and slow axes and an arrangement aligning individual laser diodes in the rows and columns of the module along a surface of a cylinder of radius R such that an axis of propagation from each of the laser diodes is directed to the center axis of the cylinder, where the arrangement compensates for spherical aberration in the focused laser light in order to match the focused laser light to a diameter and numerical aperture of the optical fiber;

a plurality of fiber combiners for combining the optical fibers from each of the plurality of laser modules into a combined optical fiber; and

a spectral combiner receiving the combined optical fiber from each of the modules such that laser light generated by multiple laser modules is spectrally combined into a final output optical fiber.

9. The system of claim 8, wherein the optical assembly of each laser module images laser light produced by laser sources in two or more groups of contiguous columns of laser sources, with laser light from each of the groups dedicated to one of the two of more optical fibers such that there is a one-to-one correspondence between the groups and the optical fibers in each laser module.

10. The system of claim 9, wherein the optical assembly of each laser module assembly includes multiple optical elements disposed between the laser sources and entrance ends of the optical fibers.

11. An apparatus for generating laser light, comprising:

a two-dimensional laser array having laser sources arranged in rows and columns, each laser source having a fast axis oriented in a column direction and a slow axis oriented in a row direction;

an optical assembly for collimating laser light from the array in both the fast and slow axes and focusing the laser light along the columns of the array and from two or more groups of columns such that laser light from each of the groups is focused into its own optical system without rotating the fast and slow axes, where each group comprises one or more contiguous columns but less than all of the columns and each of the groups is associated with one or more optical elements for focusing laser light in the slow axis that are not shared with any of the other groups; and

an arrangement of the laser sources that aligns individual sources along a surface of a cylinder of radius R such that an axis of propagation from each of the sources is directed to the center axis of the cylinder, thereby compensating for spherical aberration in the focused laser light from each group of columns in order to match the focused laser light to a desired diameter.

12. The apparatus of claim 11, wherein the optical assembly includes optics for imaging laser light produced by each of the two or more groups of columns into an entrance end of one of the optical systems to form a combined light beam, wherein a number of the contiguous rows in each column is selected so that a brightness of the combined light beam in the direction of the fast axis is substantially equal to a brightness of the combined light beam in the direction of the slow axis.

13. The apparatus of claim 11, wherein at least one of the groups of columns comprises two or more of the contiguous columns for focusing laser light into an entrance end of the optical system.

14. The apparatus of claim 13, wherein the optical system is an optical fiber.

15. The apparatus of claim 11, wherein the optical assembly includes multiple optical elements disposed between the two-dimensional laser array and entrance ends of the optical systems for focusing laser light from the laser sources of each group into a combined light beam whose Symmetric Brightness Unit (SBU) is substantially one and is matched in its physical dimensions to a numerical aperture of one of the entrance ends of a selected one of the optical systems in order to efficiently couple the combined light beam to the selected optical system.

16. The apparatus of claim 12, where the entrance end of each of the two or more optical systems is an end of an optical fiber.

17. The apparatus of claim 16, further including a fiber combiner for combining the optical fibers whose entrance ends receive focused laser light from the two or more groups of columns of laser sources.

18. The apparatus of claim 11, wherein the two-dimensional laser array comprises a stack of laser bars having multiple laser diodes formed therein in one dimension such that each laser diode bar forms a row of the two-dimensional laser array.