METHOD AND ARRANGEMENT FOR GENERATING A LASER BEAM HAVING A DIFFERING BEAM PROFILE CHARACTERISTIC BY A MULTI-CLAD FIBER

Abstract

Methods and systems for generating a laser beam with different beam profile characteristics are provided. In one aspect, a method includes coupling an input laser beam into one fiber end of a multi-clad fiber, in particular a double-clad fiber and emitting an output laser beam from the other fiber end of the multi-clad fiber. To generate different beam profile characteristics of the output laser beam, the input laser beam is electively coupled either at least into the inner fiber core of the multi-clad fiber or at least into at least one outer ring core of the multi-clad fiber, or a first sub-beam of the input laser beam is coupled into at least into the inner fiber core of the multi-clad fiber and a second, different sub-beam of the input laser beam is coupled at least into the at least one outer ring core of the multi-clad fiber.

Claims

1.-27. (canceled)

28. A system for generating a laser beam with different beam profile characteristics, the system comprising: a multi-clad fiber having an inner fiber core and at least one outer ring core; and a first optical fiber configured to guide a first input laser beam to the multi-clad fiber; and a second optical fiber configured to guide a second input laser beam to the multi-clad fiber, wherein the system is configured to couple at least one of: the first input laser beam at least into the inner fiber core of the multi-clad fiber, or the second input laser beam at least into the at least one outer ring core of the multi-clad fiber.

29. The system of claim 28, wherein the system is configured to couple the first input laser beam only into the inner fiber core of the multi-clad fiber.

30. The system of claim 28, wherein the system is configured to couple the second input laser beam only into the at least one outer ring core of the multi-clad fiber.

31. The system of claim 28, wherein the multi-clad fiber comprises one or more claddings respectively around the inner fiber core and the at least one outer ring core, and wherein the system is configured such that no laser beam is coupled into the one or more claddings.

32. The system of claim 28, wherein the multi-clad fiber is configured to have at least one of: the inner fiber core with a diameter of no greater than 200 ?m, the at least one outer ring core with a diameter of no greater than 600 ?m, or an inner cladding with a thickness of no greater than 10 ?m, the inner cladding being between the inner fiber core and the at least one outer ring core.

33. The system of claim 28, wherein the multi-clad fiber comprises the inner fiber core with a refractive index n1, a first cladding with a refractive index n2, and an outer ring core with a refractive index n3, and the first cladding surrounds the inner fiber core and is between the inner fiber core and the outer ring core, and wherein n1=n3 and n1>n2.

34. The system of claim 33, wherein the multi-clad fiber further comprises a second cladding surrounding the outer ring core, and wherein a refractive index n4 of the second cladding is identical to the refractive index of the first cladding n2.

35. The system of claim 28, wherein the multi-clad fiber comprises two or more outer ring cores, and the system is configured to couple two or more corresponding input laser beams into the two or more outer ring cores.

36. The system of claim 28, wherein the system is configured to generate an output laser beam with a power of at least 1 kW.

37. The system of claim 28, further comprising a switchable device coupled between the first and second optical fibers and the multi-clad fiber, wherein the switchable device is configured to electively couple the first input laser beam at least into the inner fiber core of the multi-clad fiber and the second input laser beam at least into the at least one outer ring core of the multi-clad fiber.

38. A method of generating a laser beam with different beam profile characteristics, the method comprising: guiding a first input laser beam by a first optical fiber to a fiber end of a multi-clad fiber, wherein the multi-clad fiber has an inner fiber core and at least one outer ring core; guiding a second input laser beam by a second optical fiber to the fiber end of the multi-clad fiber; coupling the first input laser beam and the second input laser beam into the fiber end of the multi-clad fiber, comprising at least one of: coupling the first input laser beam at least into the inner fiber core of the multi-clad fiber, or coupling the second input laser beam at least into the at least one outer ring core of the multi-clad fiber; and generating an output laser beam by interaction of the first input laser beam and the second input laser beam with the multi-clad fiber, wherein a beam profile characteristic of the output laser beam differs depending upon the coupling of the first input laser beam and the second input laser beam into the fiber end of the multi-clad fiber.

39. The method of claim 38, wherein coupling the first input laser beam at least into the inner fiber core of the multi-clad fiber comprises: coupling the first input laser beam only into the inner fiber core of the multi-clad fiber.

40. The method of claim 38, wherein coupling the second input laser beam at least into the at least one outer ring core of the multi-clad fiber comprises: coupling the second input laser beam only into the at least one outer ring core of the multi-clad fiber.

41. The method of claim 38, wherein the multi-clad fiber comprises one or more claddings respectively around the inner fiber core and the at least one outer ring core, and wherein coupling the first input laser beam and the second input laser beam into the fiber end of the multi-clad fiber comprises: coupling no laser beam into the one or more claddings.

42. The method of claim 38, wherein the multi-clad fiber comprises an inner cladding between the inner fiber core and the at least one outer ring core, and wherein the multi-clad fiber is configured to have at least one of: the inner fiber core with a diameter of no greater than 200 ?m, the at least one outer ring core with a diameter of no greater than 600 ?m, or the inner cladding with a thickness of no greater than 10 ?m.

43. The method of claim 38, wherein the multi-clad fiber comprises the inner fiber core with a refractive index n1, a first cladding with a refractive index n2, and an outer ring core with refractive index n3, and the first cladding surrounds the inner fiber core and is between the inner fiber core and the outer ring core, and wherein n1=n3 and n1>n2.

44. The method of claim 43, wherein the multi-clad fiber further comprises a second cladding surrounding the outer ring core, and wherein a refractive index n4 of the second cladding is identical to the refractive index of the first cladding n2.

45. The method of claim 38, wherein the multi-clad fiber comprises two or more outer ring cores, and the method comprises: coupling two or more corresponding input laser beams into the two or more outer ring cores.

46. The method of claim 38, wherein the output laser beam has a power of at least 1 kW.

47. The method of claim 38, wherein coupling the first input laser beam and the second input laser beam into the fiber end of the multi-clad fiber comprises: electively coupling, by a switchable device coupled between the first and second optical fibers and the fiber end of the multi-clad fiber, one of the first input laser beam at least into the inner fiber core of the multi-clad fiber and the second input laser beam at least into the at least one outer ring core of the multi-clad fiber.

Description

DESCRIPTION OF DRAWINGS

[0029] FIGS. 1, 2A, 2B, and 3 show three arrangements in accordance with the invention for generating a laser beam with different beam profile characteristics, in which a laser beam is coupled into the fiber end of a double-clad fiber and emitted from the other fiber end of the double-clad fiber.

[0030] FIG. 4 shows the radial course of the refractive index of the double-clad fiber shown in FIGS. 1 to 3.

[0031] FIGS. 5A, 5B and 5C show various possible beam profiles of the laser beam emitted from the double-clad fiber in FIGS. 1 to 3.

[0032] FIG. 6 shows another arrangement in accordance with the invention for generating a laser beam with different beam profile characteristics, whereby, electively, a first laser beam is coupled into the inner fiber core of a double-clad fiber and a different, second laser beam is coupled both into the inner fiber core and into the outer ring core of the double-clad fiber.

DETAILED DESCRIPTION

[0033] FIGS. 1 to 3 show three different arrangements 10, 20, 30 for generating a laser beam with different beam profile characteristics, whereby the laser beam is coupled into one fiber end 1a of a multi-clad fiber 1, which is a double-clad fiber 1 in the present case, and is emitted from the other fiber end 1b of the double-clad fiber 1. The input laser beam is labelled 2 and the emitted laser beam is labelled 3.

[0034] As shown in FIG. 1, the double-clad fiber 1 has an inner fiber core 4 (for example of undoped quartz glass) with a refractive index n1 and thin first cladding 5 (for example of doped quartz glass) surrounding the inner fiber core 4, the refractive index n2 of which is lower than n1. This is followed by an outer ring core 6 (for example of undoped quartz glass) with refractive index n3 which is also surrounded by low-refractive second cladding 7 (for example of doped quartz glass) with refractive index n4. The refractive indices n1 and n3 can be the same or different; the same applies to the refractive indices n2 and n4. This may be followed by an additional layer of glass (not shown) which determines the external diameter of the fiber but has no influence on its function in terms of beam guidance. This is typically completed by a coating (not shown) of a synthetic material such as silicone and/or nylon which serves to protect the fiber.

[0035] FIG. 4 shows an outline of the radial dependence of the refractive index n within the double-clad fiber 1, where n1=n3 and n2=n4. The figure shows an area with radius r1 and high refractive index n1 corresponding to the inner fiber core 4, a ring area between radii r1 and r2 with lower refractive index n2 corresponding to the first cladding 5, a ring area with external radius r3 and high refractive index n1 corresponding to the outer ring core 6 and, finally, the second cladding 7 with low refractive index n2. On account of the lower refractive index of the cladding 5, 7, light is guided in the inner fiber core 4 and in the outer ring core 6 by means of total reflection.

[0036] To change the beam profile characteristics of the emitted laser beam 3, it is possible, as described below in detail, for the input laser beam 2 striking the coupling-side face 8 of the double-clad fiber 1 to be coupled, by means of a switchable device, electively either into the inner fiber core 4 or into the outer ring core 6 or both into the inner fiber core 4 and into the outer ring core 6 of the double-clad fiber 1.

[0037] In the arrangement 10 shown in FIG. 1, the switchable device for electively coupling the laser beam 2 into the double-clad fiber 1 is formed by adjustable deflection optics 11 with two switch positions, which are represented by continuous and dotted lines. In these two switch positions, the laser beam 2 focused on the coupling-side face 8 is deflected in a direction 12 transverse to the axis of the coupling-side face 8 to varying extents, in particular displaced in parallel to varying extents. In one switch position, the laser beam 2 is coupled centrically or eccentrically to the fiber axis only into the inner fiber core 4 and in the other switch position it is coupled eccentrically to the fiber axis only into the outer ring core 6. In the first case, the emitted laser beam 3 has the beam profile shown in FIG. 5A, i.e. a narrow filled circular profile 51 corresponding to the inner fiber core 4, and a comparatively high beam quality with a sharp focus, as is required for material processing, for example for a laser cutting process. In the second case, the emitted laser beam 3 has the wider beam profile shown in FIG. 5B, i.e. a ring profile 52 corresponding to the outer ring core 6, and a comparatively lower beam quality, as is required for material processing, for example for a laser welding process. Under suitable coupling conditions into the outer ring core 6, the emitted laser beam 3 has a top hat ring beam profile, the quality of which is suitable for many applications.

[0038] The deflection optics 11, the components of which are not shown individually in FIG. 1, are based on beam deflection principles familiar to an expert. In particular, a deflection mirror can be used here. The location of the coupling into the coupling-side face of the double-clad fiber 1 can be determined by the angular position of the deflection mirror or the deflection mirror can deflect the beam, depending on position, to various outputs which, in turn, define various coupling areas. A semireflecting deflection mirror or a deflection mirror that is only partially in the beam path can also perform the described function of a beam divider. Preferably, the deflection optics 11 contain additional means for coupling the laser beam 2 into the coupling-side face 8 of the double-clad fiber 1, such as, for example, a focusing lens, which can alternatively also be arranged before or after the deflection optics 11.

[0039] A sufficiently long double-clad fiber 1 also allows for angularly homogeneous intensity distribution in the output laser beam 3 with eccentric coupling of the laser beam 2 to the fiber axis into the inner fiber core 4 or the outer ring core 6.

[0040] If, however, the beam is coupled both into the inner fiber core 4 and into the outer ring core 6 of the double-clad fiber 1, the output laser beam 3 has the uniformly filled wide beam profile 53 shown in FIG. 5C with an omitted ring corresponding to the first cladding 5.

[0041] Alternatively (or in addition) to the deflection optics 11, the switchable device for electively coupling the laser beam 2 into the double-clad fiber 1 can also be formed, for example, by a motor-driven control device 13 which displaces the coupling-side face 8 of the double-clad fiber 1 in a direction 12 transverse to the input laser beam 2 to varying extents, whereby the laser beam 2 focused on the coupling-side face 8 can be coupled either into the inner fiber core 4 or into the outer ring core 6.

[0042] In the arrangement 20 shown in FIG. 2A, the switchable device for electively coupling the laser beam 2 into the double-clad fiber 1 is formed by adjustable telescopic/expansion optics 21 which are shown here only in outline. In their switch positions, not shown here, the telescopic/expansion optics 21 expand the input laser beam 2 to different beam diameters. Depending on the beam diameter, the laser beam 2 is then projected by coupling optics (for example a lens) 22 with different beam diameters, in this case different focal diameters, onto the coupling-side face 8 of the double-clad fiber 1. As shown with continuous and dotted lines, the laser beam 2 is, for example, coupled centrically only into the inner fiber core 4 in one switch position of the telescopic/expansion optics 21 and coupled centrically both into the inner fiber core 4 and into the outer ring core 6 in another switch position. In the first case, the output laser beam 3 has beam profile 51 and in the second case beam profile 53.

[0043] Via the diameter of the expanded laser beam 2, the proportion of the laser beam coupled into the outer ring core 6 can be set continuously and thus also the intensity distribution into the inner fiber core 4 and the outer ring core 6, allowing the beam profile of the output laser beam 3 to be adapted to each application optimally.

[0044] In the arrangement 20 shown in FIG. 2B, the switchable device for electively coupling the laser beam 2 into the double-clad fiber 1 is formed by focusing optics 23 shown here as a lens which can be displaced along the laser beam axis to various switch positions, which are represented by continuous, dotted, and dashed and dotted lines. In these switch positions, the input laser beam 2 is coupled by the focusing optics 23 with different beam diameters onto the coupling-side face 8 of the double-clad fiber 1. In one switch position, the focused laser beam 2 is coupled centrically only into the inner fiber core 4. In the two other switch positions, the defocused laser beam 2 is coupled centrically both into the inner fiber core 4 and into the outer ring core 6. In the first case, the output laser beam 3 has beam profile 51 and in the second case beam profile 53.

[0045] In the arrangement 30 shown in FIG. 3, the switchable device for electively coupling the laser beam 2 into the double-clad fiber 1 is formed by a beam switch implemented here only by way of example as an optical wedge plate 31 which can be adjusted continuously between two end positions that are shown with continuous and dotted lines. In one of its end positions, the optical wedge plate 31 is arranged outside the beam path of the input laser beam 2 so that the entire input laser beam 2 is coupled via coupling optics (for example a lens) 32 only into the inner fiber core 4, whereby the output laser beam 3 has beam profile 51. In its other end position, shown by the dotted line, the wedge plate 31 is arranged in the entire beam path of the laser beam 2 so that the entire laser beam 2 is deflected by the wedge plate 31 and is coupled via the coupling optics 32 only into the outer ring core 6, whereby the output laser beam 3 has beam profile 52.

[0046] Moving/displacing the coupling optics 32 transverse to the optical axis of the laser beam 2 causes a comparable effect. In this version, the coupling optics 32 are located in the beam path in the switchable states, producing different beam deflections, depending on the position of the coupling optics 32. As the beam is not divided here and the intensities cannot be divided via sub-beams, it is preferred to deflect either into the inner fiber core 4 or into the outer ring core 6 and to switch between at least two states representing these positions.

[0047] As indicated with a dotted line, partially introducing the wedge plate 31 into the input laser beam 2 creates two sub-beams 2a, 2b, so that here, for example, the optical wedge plate 31 acts as a beam divider. The first sub-beam 2a is not influenced by the wedge plate 31 and thus continues to be coupled via the coupling optics 32 into the inner fiber core 4, while the second sub-beam 2b is deflected by the wedge plate 31 in relation to the first sub-beam 2a and coupled via the coupling optics 32 into the outer ring core 6. The output laser beam 3 has beam profile 53. Partially introducing the wedge plate 31 into the input laser beam 2 therefore creates two sub-beams 2a, 2b, with a division of intensity between the inner fiber core 4 and the outer ring core 6, depending on the degree of introduction, whereby the beam profile of the output laser beam 3 can be optimally adapted to each application.

[0048] Moreover, the two sub-beams 2a, 2b offer the significant advantage that they omit the area of the first cladding 5 in connection with coupling. Specifically for applications in the high-power area, it is important that no laser beam is coupled into the inner or outer cladding 5, 7. This beam is propagated with a large angle in the inner core or outer ring core and emerges at the fiber end also with a large angle, as a result of which connecting optics can become heated. In addition, the beam in the outer cladding 7 can destroy the coating of the fiber 1.

[0049] A diameter of the inner fiber core 4 of approximately 100 ?m guarantees, for typical applications with high power in the kW range, the production of good beam profile quality in connection with coupling the laser beam 2 into the inner fiber core 4. The first cladding 5 is already sufficiently thick, at approximately 10 ?m, preferably at approximately 5 ?m, to guide the laser beam well. With a ring thickness of the outer ring core 6 of approximately 240 ?m, the external diameter of the outer ring core 6 is approximately 600 ?m. For certain applications, such as laser welding, this corresponds to the necessary widening of the laser beam profile.

[0050] FIG. 6 shows another arrangement 60 for generating a laser beam with different beam profile characteristics, whereby, electively, a first laser beam 61 is coupled into the inner fiber core 4 of the double-clad fiber 1 and a different, second laser beam 62 is coupled both into the inner fiber core 4 and into the outer ring core 6 of the double-clad fiber 1. The two laser beams 61, 62, which can, for example, have different beam qualities, are guided in optical fibers 63, 64 to switching optics 65 (for example an optical switch system), shown here only in outline, which can be switched between two switch positions. In one switch position, the first laser beam 61 with the higher beam quality is coupled into the inner fiber core 4 of the double-clad fiber 1 and, in the second switch position, the second laser beam 62 is coupled both into the inner fiber core 4 and into the outer ring core 6 of the double-clad fiber 1. In the first case, the output laser beam 3 has beam profile 51 and in the second case beam profile 53. The double-clad fiber 1 leads to a laser processing machine (not shown) so that the arrangement 60 is used to switch laser beams 61, 62 with different beam qualities for the laser processing machine. However, the laser beam 62 can also only be directed at the outer ring core 6 of the double-clad fiber 1 via the switching optics 65.

[0051] Up to now, laser processing machines that are to be supplied with several laser beams of different beam qualities needed several sockets for the various optical fibers and a corresponding optical switch system to allow the various laser beams to be coupled into the following beam path. For a desired laser beam, the appropriate optical fiber cable has to be manually replugged, which is undesirable on account of an increased risk of soiling, or beam guidance optics are required on the laser processing machines themselves. This is disadvantageous as several optical fiber cables have to be laid within the laser processing machine, the entire switching optics have to be mounted and moved on the axis system of the laser processing machine and the size of the switching optics, in connection with the space available, limits the possibilities or the possible optical concepts.

[0052] In the arrangement 60, the switching optics 65 are supplied on the input side by two lasers with the two laser beams of different beam qualities, and the respective laser beams 61, 62 are coupled into the central double-clad fiber 1 via the switching optics 65. In this way, the switching between the two laser beams 61, 62 is separated from the axis system of the laser processing machine and takes place outside the laser processing machine itself. The laser beams are then supplied to the machine via the double-clad fiber 1. One or more additional light-guiding ring cores around the outer ring core 6 are also conceivable so that additional laser beams with different beam qualities can be guided via the switching optics 65.

[0053] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.