DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0021] Exemplary embodiments of the invention can be used to increase the average source radiance and decrease the source size of a laser diode bar , comprised of an array of emitters, by optically reimaging and combining the emitters in such a way as to remove or reduce the non-emitting space between adjacent emitters and by optionally applying nonsymmetric (anamorphic) magnification to the superimposed image.

[0022] An exemplary embodiment of the invention, the multiple emitters of a laser diode bar configuration are reimaged and superimposed into a single emitter image with much smaller length so that the irradiance is increased and the image dimensions are more nearly equal in the orthogonal directions. If this image were reimaged to infinity, good collimation could be achieved in both the slow and fast axis directions of the emitter. A device produced in accordance with exemplary embodiments of the invention optically removes the non-emitting space between the emitters so that the intensity profile of the collimated beam is more uniform. The images of all the emitters are optically superimposed, effectively producing a single emitter. Furthermore, the long dimension of the single emitter image can be reduced with a lens (e.g., simple cylindrical lens, anamorphic lens, . . . ) so that the numerical apertures (NAs) of the emitter image are nearly identical in both orthogonal directions.

[0023] Although this invention applies to and illustrates focused beams (see FIG. 3 ), the same advantages also apply to collimated beams with the emitter imaged to infinity. Applications for focused beams include laser welding, marking, and materials processing. A smaller, more uniform source is more useful to these applications. Collimated beam applications include targeting and illumination of distant objects.

[0024] For the purposes of describing the present invention, a typical high power laser diode bar in linear configuration, comprising of an array of 11 emitters on a 708-micron pitch, with each emitter having dimensions of 1 micron by 100 microns, will be described in this disclosure. The wavelength is 980 nm and the beam divergences in the slow and fast axis directions are 10 deg and 28 deg FWHM respectively. Each emitter produces 1 W of power. However, it is clear that this invention can be used with numerous other laser diode bars with different parameters (e.g. the laser diodes can have different dimensions, pitches, and wavelengths). With the above described laser diode bar, 608 microns of space between emitters is non-radiant or non-emitting. It is desired to remove this non-radiant space and superimpose all emitters into real or virtual image of a single uniform emitter.

[0025] Examples according to exemplary embodiments of the invention are illustrated in FIGS. 3, 7 , and 8 . In one exemplary embodiment of the invention, due to its ease of fabrication, separates the microlens array from the image rotator array. (It is clear that these elements could be combined into a single monolithic element.) The image rotator array described here consists of an optical array ( e.g., an array of micro-dove prisms). Each optical array element (e.g. prism) consists of refractive wedges on each side of the array with a reflective mirror between the wedges. The dove prism array may be fabricated by polishing the edges of strips of glass plates to the proper wedge angle, then coating one side of each glass plate with silicon, and then anodically bonding the strips into a stack. The wedge can be non-symmetric. Alternatively, the plates can be optically cemented. In order to combine the microlens array and dove prism array into one element, the wedge or tilt would be fabricated into the microlens surface profile FIGS. 3 and 7 show a ray trace of an embodiment of the present invention with the emitter array source 17 on the left side of the figures and the superimposed image 90 on the right. The emitters 15 are stacked end-to-end in the vertical or y-direction, with the fast axis divergence in the x-direction. A magnified image of the emitter, is formed on the image plane. All the individual images of the emitters are superimposed on the image plane forming a single magnified bar image of the emitter, as illustrated in FIGS. 4, 5 , and 6 .

[0026] FIG. 4 shows the image with the anamorphic lens included to reduce the image size. FIGS. 5 and 6 show the image irradiance without the anamorphic lens. The image is proportional in shape to source emitter. FIG. 5 includes the dove prism array showing rotation of the image by 90 degrees; FIG. 6 results when the dove prism array is removed. Light emitted from the laser diode bar is first collimated by the microlens array into eleven collimated beamlets. Each beamlet is directed onto the angled face of a micro-dove prism. The tilted face refracts the beamlet toward the reflective face of the dove prism, which then reflects the beamlet toward the second face of the dove prism. The second angled face bends the collimated beam back into the original direction of travel from the microlens. The mirror face is parallel to the optical axis (z-axis) but angled by 45 degrees in the x-y plane. The integrator lens 60 combines all eleven beamlets to a single image of the emitter at image plane 80 .

[0027] FIG. 7 illustrates a beam integrator system 10 according to an exemplary embodiment according to the invention. The laser diode bar 17 includes a plurality of emitters 15 which are located in an end-to-end position with respect to the neighboring emitter. In the exemplary embodiment each individual emitter 15 aperture can be of variable size (e.g. 1 micron wide by 100 microns). The spacing between emitters 15 can vary (e.g 400 microns).

[0028] Each of the emitters 15 can have a corresponding micro-lens 20 so as to collimate the light being emitted from the emitters 15 . Alternative embodiments do not have a corresponding micro-lens 20 , instead the optical array 30 can be designed to collimate the laser diode light. Each micro-lens 20 has a first side 25 and a second side 27 , wherein the first side 25 and second side 27 generally opposite to one another. The emitters 15 are located on the first side 25 of the micro-lens 20 and a corresponding dove micro-prism 30 is located on the second side 27 of each micro-lens 20 . As shown in FIG. 7 , the optical elements 30 (e.g. dove micro-prisms) are stacked top to bottom upon one another. In alternative embodiments the micro-prisms can be staggered (not shown).

[0029] In an exemplary embodiment the optical element is a dove micro-prism 30 have a general three dimensional trapezoidal shape having a top side 32 and bottom side 34 and two sloped sides 36 , 38 . The top side 32 of each dove micro-prism 30 can be connected to the bottom side 34 of the neighboring dove micro-prism 30 to form the stacked array as shown in FIG. 7 . Alternatively there can be a spacing between optical elements 30 . Furthermore, each of the corresponding emitters 15 , micro-lens 20 and dove micro-prisms 30 all share an axis. The array of dove micro-prisms 30 can optically rotate the individual emitter images by a chosen angle (e.g. 90 degrees). Such rotation can be used in conjunction with a lens to reduce the long dimension of the long dimension of the emitter image (e.g. a rotation of 90 degrees allows an anamorphic lens (discussed later) to easily reduce the long dimension of the emitter image).

[0030] The beam integrator system 10 also includes an integrator lens 60 . In the exemplary embodiment, the diameter of the integrator lens 60 can be greater than or equal to the height of the stacked dove micro-prisms 30 . In the exemplary embodiment the integrator lens is comprised of a normal plano-convex lens. However, this could be a bi-convex lens, a meniscus lens, or combination of elements to minimize aberrations. The specific shape or number of elements is not germane to the invention, only that it has positive optical power and combines the beams in an aberration-free manner. The integrator lens 60 combines the light beams exiting emitters and overlap the real images of the emitters at the focal point of the integrator lens.

[0031] FIG. 8 illustrates an exemplary embodiment of the invention having an anamorphic lens 70 and a asymmetric optical array 30 .

[0032] Once the beams of light exit the integrator lens 60 , the beams of light can be passed through an anamorphic lens—to reduce the long dimension of the emitter image. In exemplary embodiments of the present invention spots or linear images formed in the image plane 80 can have sizes between 1-1000 microns, with peek power densities from 10-1000 kW/cm2. Other exemplary embodiments have various peek powers and sizes and the discussion herein should not be interpreted to limit the image formed on the image plane, for example the image can be a few microns in width and millimeters in length having a peek power of hundreds of kW/cm2.

[0033] Variations in the shape and type of optical arrays are intended to fall within the scope of the invention. For example the optical array can be a diffractive array as opposed to the refractive array.