U.S. patent application number 11/830706 was filed with the patent office on 2008-10-09 for homogenizing optical beam combiner.
Invention is credited to George H. Butler, Frank T. Cianciotto.
Application Number | 20080247047 11/830706 |
Document ID | / |
Family ID | 39870489 |
Filed Date | 2008-10-09 |
United States Patent
Application |
20080247047 |
Kind Code |
A1 |
Cianciotto; Frank T. ; et
al. |
October 9, 2008 |
HOMOGENIZING OPTICAL BEAM COMBINER
Abstract
An optical homogenizing and combining apparatus, comprises a one
piece, hollow, tubular body having a first input leg, a second
input leg and an output leg, each leg having a polygonal
cross-section and highly reflective interior surfaces in accordance
with an embodiment. The body has a shape corresponding to first and
second bent tubes, the tubes being truncated along a plane and
joined at a junction lying in the plane. The a first end of the
first tube defines the first input leg, a first end of the second
tube defines the second input leg, and a second end of the first
tube and a second end of the second tube define the output leg.
Inventors: |
Cianciotto; Frank T.;
(Tehachapi, CA) ; Butler; George H.; (Mesa,
AZ) |
Correspondence
Address: |
MACPHERSON KWOK CHEN & HEID, LLP
2033 GATEWAY PLACE, SUITE 400
SAN JOSE
CA
95110
US
|
Family ID: |
39870489 |
Appl. No.: |
11/830706 |
Filed: |
July 30, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11670320 |
Feb 1, 2007 |
7386214 |
|
|
11830706 |
|
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Current U.S.
Class: |
359/620 ;
359/619; 427/162 |
Current CPC
Class: |
G02B 6/0096 20130101;
G02B 27/14 20130101; G02B 27/0994 20130101; G02B 27/1006 20130101;
G02B 27/0927 20130101 |
Class at
Publication: |
359/620 ;
359/619; 427/162 |
International
Class: |
G02B 27/10 20060101
G02B027/10; B05D 5/06 20060101 B05D005/06 |
Claims
1. An optical homogenizing and combining apparatus, comprising: a
one piece, hollow, tubular body having a first input leg, a second
input leg and an output leg, each leg having a polygonal
cross-section and highly reflective interior surfaces; and wherein
the body has a shape corresponding to first and second bent tubes,
the tubes being truncated along a plane and joined at a junction
lying in the plane, wherein a first end of the first tube defines
the first input leg, a first end of the second tube defines the
second input leg, and a second end of the first tube and a second
end of the second tube define the output leg.
2. The optical homogenizing and combining apparatus of claim 1,
wherein the body is symmetric with respect to the plane of
truncation.
3. The optical homogenizing and combining apparatus of claim 1,
wherein the interior surface comprises one of silver or gold.
4. The optical homogenizing and combining apparatus of claim 1,
wherein the body comprises an exterior layer to provide structural
rigidity.
5. The optical homogenizing and combining apparatus of claim 3,
wherein the exterior layer comprises nickel.
6. The optical homogenizing and combining apparatus of claim 1,
wherein the body comprises an interior surface comprising one of
silver or gold and comprises an exterior layer comprising
nickel.
7. The optical homogenizing and combining apparatus of claim 1,
further comprising a first and second plurality of continuous
panels and a first and second plurality of junction panels,
wherein; the first plurality of continuous panels and first
plurality of junction panels define the first input leg; the second
plurality of continuous panels and second plurality of junction
panels define the second input leg; the first and second plurality
of continuous panels define the output leg.
8. The optical homogenizing and combining apparatus of claim 6,
wherein the first and second plurality of junction panels comprise
edges that defining the junction.
9. The optical homogenizing and combining apparatus of claim 1,
wherein the polygonal cross-section has a width W and a curve
through an interior of the body from the first input opening to the
output opening has a length L1, wherein the ration L1:W is in a
range from about five to one to seven to one.
10. The optical homogenizing and combining apparatus of claim 8,
wherein the ratio L1:W is about six to one.
11. A method of forming a light combining and homogenizing
apparatus, comprising: forming a mandrel, wherein the mandrel has a
shape corresponding to two symmetrical, bent, truncated polygonal
rods joined at a planar truncation face; depositing a body on
lateral surfaces of the mandrel; and removing the mandrel from an
interior of the body.
12. The method of claim 11, wherein depositing the body on the
lateral surfaces of the mandrel comprises depositing a first layer
comprising a highly reflective material and then depositing a
second layer over the first layer, the second layer being thicker
than the first layer.
13. The method of claim 12, wherein the first layer comprises at
least one of gold or silver and the second layer comprises
nickel.
14. The method of claim 12, wherein the first layer has a thickness
on the order of a few atomic layers and the second layer has a
thickness of about 0.002 inches.
15. The method of claim 10, wherein the mandrel comprises a first
material and the body comprises a second material, the first
material having a first melting point lower than a second melting
point of the second material; and removing the mandrel comprises
and The optical homogenizing and combining apparatus of claim 1,
wherein the polygonal cross-section comprises a regular
hexagon.
16. The method of claim 10, wherein removing the mandrel comprises
chemically etching the mandrel.
17. The method of claim 10, wherein depositing a body comprises
depositing a first layer comprising highly reflective material and
depositing a thicker, second layer to provide structural support to
the body and wherein removing the mandrel comprises one of melting
or chemically etching the mandrel.
18. A light combining and homogenizing apparatus, comprising: a
first curved, hex-shaped input leg having a first input opening at
one end and a first junction edge at a second end; a second curved,
hex-shaped input leg having a second input opening at one end and a
second junction edge at a second end, wherein the first and second
input legs are joined at the first and second junction edges; a
hex-shaped output leg connected to the first and second input legs;
and wherein the first input leg, the second input leg and the
output leg have highly reflective interior surfaces, wherein a
first input beam received at the first input opening and a second
input beam received at the second input opening are homogenized and
combined into an output beam emitted from the output opening and
having an intensity equal to about the sum of intensities of the
first and second input beams and having a top hat profile.
19. The optical homogenizing and combining apparatus of claim 18,
wherein the first and second input beams have first and second
colors, respectively, and the output beam has a third color that is
different from the first and second colors.
20. The optical homogenizing and combining apparatus of claim 18,
wherein the highly reflective interior surfaces comprise silver for
use with input beams comprising visible light or comprise gold for
use with input beams comprising infra-red radiation.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to U.S. application Ser. No.
11/670,320, filed Feb. 1, 2007, which is incorporated herein by
reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to optical guides,
and more particularly to a homogenizing optical beam combiner.
BACKGROUND
[0003] Optical devices that combine or homogenize an incoming light
beam are known, yet such devices typically include heavy,
expensive, and delicate components that may limit the application
of these useful techniques. Previous attempts have included the use
of a hex-shaped glass rod with an exterior cladding configured to
provide reflection of light within the glass rod. Such a glass rod
is typically very expensive to produce, extremely fragile, and has
the disadvantage that light may leak out of the glass rod if the
exterior cladding is damaged. When an input beam is non-uniform,
additional components are typically required to produce a uniform
intensity distribution. Such additional components contribute to
the increased cost, weight, and complexity of the optical system
since these additional components may be subject to misalignment or
may be more susceptible to optical contamination. Further, the use
of multiple optical elements may lead to substantial intensity
losses as a light beam propagates through the multiple optical
elements. Thus, there remains a need for an apparatus and method to
provide light combining and homogenization in a rugged, compact,
and low cost manner.
SUMMARY
[0004] Systems and methods are disclosed herein to provide an
optical beam combiner. For example, in accordance with an
embodiment, an optical homogenizing and combining apparatus,
comprises a one piece, hollow, tubular body having a first input
leg, a second input leg and an output leg, each leg having a
polygonal cross-section and highly reflective interior surfaces.
The body has a shape corresponding to first and second bent tubes,
the tubes being truncated along a plane and joined at a junction
lying in the plane. A first end of the first tube defines the first
input leg, a first end of the second tube defines the second input
leg, and a second end of the first tube and a second end of the
second tube define the output leg.
[0005] In accordance with another embodiment, a method of forming a
light combining and homogenizing apparatus comprises forming a
mandrel, wherein the mandrel has a shape corresponding to the shape
of two symmetrical, bent, truncated polygonal rods joined at a
planar truncation face, depositing a body on lateral surfaces of
the mandrel, and removing the mandrel from an interior of the
body.
[0006] In accordance with another embodiment, a light combining and
homogenizing apparatus comprises a first curved, hex-shaped input
leg having a first input opening at one end and a first junction
edge at a second end, a second curved, hex-shaped input leg having
a second input opening at one end and a second junction edge at a
second end, wherein the first and second input legs are joined at
the first and second junction edges. The apparatus also comprises a
hex-shaped output leg connected to the first and second input legs.
The first input leg, the second input leg and the output leg have
highly reflective interior surfaces. A first input beam received at
the first input opening and a second input beam received at the
second input opening are homogenized and combined into an output
beam emitted from the output opening and having an intensity equal
to about the sum of intensities of the first and second input beams
and having a top hat profile.
[0007] The scope of the disclosure is defined by the claims, which
are incorporated into this section by reference. A more complete
understanding of embodiments will be afforded to those skilled in
the art, as well as a realization of additional advantages thereof,
by a consideration of the following detailed description of one or
more embodiments. Reference will be made to the appended sheets of
drawings that will first be described briefly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a light homogenizing and combining
apparatus, in accordance with an embodiment of the present
invention.
[0009] FIG. 1A illustrates an overhead view of the light
homogenizing and combining apparatus of FIG. 1.
[0010] FIG. 2 illustrates a side view of the light homogenizing and
combining apparatus of FIG. 1.
[0011] FIG. 3 illustrates a light homogenizing and combining
apparatus in accordance with an embodiment of the present
invention.
[0012] FIG. 3A illustrates an overhead view of the light
homogenizing and combining apparatus of FIG. 3.
[0013] FIG. 4 illustrates an open, cross-sectional view of the
light homogenizing and combining apparatus of FIG. 1.
[0014] FIG. 5 illustrates a graphical intensity depiction including
three plane views of an input Gaussian light beam, in accordance
with an embodiment.
[0015] FIG. 6 illustrates a graphical intensity depiction including
three plane views of an output top hat light beam from a tubular
member having a hollow polygonal cross-section and a highly
reflective interior surface, in accordance with an embodiment.
[0016] FIG. 7 illustrates a graphical sum illustrating an exemplary
combination of a first input beam and a second input beam, where a
combined output beam has an intensity that is the sum of the
intensities of the input beams, in accordance with an
embodiment.
[0017] FIG. 8 illustrates an exemplary embodiment of a method of
using an exemplary embodiment of a light homogenizing and combining
apparatus.
[0018] FIG. 9 illustrates an exemplary embodiment of a method of
fabricating a light combining and homogenizing apparatus in
accordance with an embodiment of this disclosure.
[0019] FIG. 10 illustrates an overhead view of an exemplary
embodiment of a bent polygonal rod shape for used in the
fabrication of a light combining and homogenizing apparatus.
[0020] Embodiments and their advantages are best understood by
referring to the detailed description that follows. It should be
appreciated that like reference numerals are used to identify like
elements illustrated in one or more of the figures.
DETAILED DESCRIPTION
[0021] FIG. 1 shows a side view of a light homogenizing and
combining apparatus (LHCA) 100, in accordance with an embodiment of
the present invention. LHCA 100 may comprise a one-piece, closed,
hollow tubular member, or tubular body 102 having legs 104, 112 and
120. Each leg 104, 112 and 120 may have a polygonal cross-section,
for example hexagonal, and have highly reflective interior
surfaces.
[0022] The body 102 may include a first leg 104 or first input leg
having an opening 106 configured to receive a first Gaussian light
beam 110 of a first intensity and spectral content S.sub.1 or color
.lamda..sub.1. The light beam 110 is reflected within first leg 104
to provide a first leg output beam 110' (FIG. 4) that is at least
partially homogenized.
[0023] Similarly, body 102 may also include a second leg 112, or
second input leg, having an opening 114 configured to receive a
second Gaussian light beam 118 of a second intensity and spectral
content S.sub.2 or color .lamda..sub.2. Light beam 118 may be
reflected within second leg 112 to produce a second leg output beam
118' that is at least partially homogenized. While two input legs
are shown, this is not considered limiting.
[0024] Body 102 may also include a third leg 120, or output leg
with an output opening 124. The input legs 104, 112 and the output
leg 120 are joined so that substantially all of the energy of the
first leg output beam 110' (FIG. 4) and the second leg output beam
118' (FIG. 4) combine at a junction 130, reflect within the third
leg 120, resulting in a third leg output beam 126 emitted from the
third leg second end 124.
[0025] The third leg output beam 126 may have a third intensity and
spectral content S.sub.3 or color .lamda..sub.3 that is a
combination of the first intensity and spectral content S.sub.1 and
the second intensity and spectral content S.sub.2. The third leg
output beam 126 may have a homogenized top hat profile. In one
alternative, a third leg output beam from a first LHCA 100 may be
applied as an input beam to a second LHCA 100, so that three or
more Gaussian light beams may be combined in a sequential or serial
manner.
[0026] While the LHCA 100 may have a hexagonal cross-section, other
geometrical cross-sections may also be used including triangular,
square, pentagonal, heptagonal, and octagonal, for example.
Further, first leg 104, second leg 112, and third leg 120 may each
have the same or a different geometrical cross-sections.
[0027] In this disclosure, the color of light refers to the
wavelength or frequency distribution, band, or spectral content of
the light and may include both visible and invisible wavelengths.
While a particular spectra or wavelength is described for each
beam, it is understood that the color of a beam refers equally to
its frequency components and associated intensity for each
component, and may also be referred to as frequency profile,
spectral content, or spectral power distribution (SPD) for the
associated beam.
[0028] In an example embodiment, the LHCA 100 has a shape
corresponding to truncated, bent tubes joined along a junction to
define an enclosed LCHA. The bent tubes may have a polygonal
cross-section, for example hexagonal. The tubes may be truncated
along a plane parallel with the axis 144 (FIG. 2) of the output leg
124. The tubes are truncated such that the edges of one of the bent
tubes along the plane of truncation match up with the edges of the
other bent tube along the corresponding plane of truncation so that
the two truncated, bent tube shapes form a closed LCHA with
multiple input openings 106, 112 and an output opening 124 when
joined.
[0029] The LCHA 100 may include a plurality of side members 160.
The side members may include junction side panels 164 and
continuous side panels. The junction panels 164 have junction edges
165 that all lie in a common plane. The plane is parallel to the
axis 144 of the output leg 120. The joined junction edges 165
define the junction 130.
[0030] First ends of some of the continuous panels 168 together
with first ends of some of the junction panels 164 to define the
first input tube 104 and the first input opening 106. First ends of
other continuous panels 168 together with first ends of other
junction panels 164 define the second input leg 112 and the second
input opening 114. Second ends of all of the continuous panels 168
may be joined together to define the output leg 120 and output
opening 124.
[0031] FIG. 2 illustrates a side view of the LHCA 100 of FIG. 1.
The opening 106 may be arranged along a central, longitudinal axis
140 normal or perpendicular to the planar cross-section of the
opening 106. The opening 114 may be arranged along a central,
longitudinal axis 142. The second end 124 of the third leg 120 may
be arranged along a central, longitudinal axis 144. The axes 140,
142 may be arranged at angles 151, 152 with respect to the axis
144.
[0032] In one embodiment, the angles 151, 152 may be the same
angles. In other embodiments, the axes 140, 142 may be at different
angles with respect to the axis 144. The angles 151, 152 may be,
for example, right angles. In other embodiments, the central,
longitudinal axes 140, 142 may be arranged at angles 151, 152 from
90 degrees to 180 degrees up to right angles with respect to the
central, longitudinal axis 144.
[0033] In one embodiment, the axes 140, 142 may be parallel and
co-linear when viewed from a perspective normal to the axis 144, as
shown, for example in FIG. 1a. In other embodiments, the axes 140,
142 may be arranged with an angle 145 from zero to 180 degrees
between the axes 140, 142 when viewed from a perspective normal to
the axis 144, for example 120 degrees, as shown for example in
FIGS. 3 and 3b.
[0034] FIG. 4 illustrates a view of an open cross-section of the
LCHA 100 of FIG. 1. The tubular leg portions 104, 112 and 120 of
body 102 may have polygonal cross-section shapes. They may also
each have a plurality of side members 160 having highly reflective
interior surfaces 103, so that light beams reflecting off an
interior surface of these planar side members are reflected or
folded over at least five times.
[0035] First input leg 104 and output leg 120 define a curved shape
for which the geometric center of the polygonal cross-section of
the curved shape defines a curve 141. Second leg 112 and third leg
120 define a curved shape, where the geometric center of the curved
shape defines a curve 143. The curves 141 and 143 merge into the
same curve at some point before or at the opening 124.
[0036] In an example embodiment, there is a distance L1 along the
curve 141 from the opening 106 to the opening 124 and a distance L2
along the curve 143 from the opening 114 to the opening 124. The
distances L1 and L2 may be sufficiently long to permit incoming
light beams 110, 118 to reflect off the interior surfaces 103 of
the side members 160 and be reflected or folded over at least five
times before exiting the opening 124 as output beam 126.
[0037] In another embodiment, the distances L1 and L2 may be
sufficiently long to permit the incoming light beams 110, 118 to
reflect off an interior surface of the side members and be
reflected or folded over at least five times, or be nearly
completely homogenized, before being combined with each other and
to permit the combined light beams to reflect off the interior
surfaces of side members of the output leg and be reflected or
folded over at least five times again before exiting as output beam
126.
[0038] In an example embodiment, the first and second input beams
110, 118 may have non-homogenized intensity profiles, for example
Gaussian profiles. First input leg 104 may be configured to receive
and reflect the first input light beam 110 to produce at least a
partially homogenized beam 110' within the first leg 104 as first
input light beam 110 is reflected by the highly reflective interior
surfaces 103 of leg 104. Similarly, second input leg 112 may be
configured to receive and reflect the second input light beam 118
to produce at least a partially homogenized input beam 118' within
the second leg 112.
[0039] The first and second leg output beams 110' and 118' may be
combined at a junction portion 130 of the LHCA 100. The combined,
at least partially homogenized beams 110' and 118' may reflect on
the highly reflective interior surfaces 103 of the second leg. The
third leg 120 may provide an output beam 126 which may be a new
single homogenized output beam 126. The intensity or amplitude of
the output beam may be the sum of the plurality of input beams
minus a negligible loss of about 5%. In addition, if the
wavelengths (color) of the plurality of input beams are different
from each other, then the output beam will have a new, derivative
wavelength (color) so LHCA 100 may function as a wavelength
blender. In this manner, LHCA 100 performs at least two functions
that traditionally may require a minimum of three separate optical
components. Therefore, LHCA 100 may provide homogenization and
optical combining operations in a more compact, lower weight, and
rugged manner while eliminating alignment requirements.
[0040] As used in this disclosure, homogenization includes a
process of reflecting light off highly reflective interior surfaces
of body 102 a minimum of five times in order to produce an output
beam having a top hat profile. In one example, homogenization
includes converting a smaller diameter light beam with a Gaussian
intensity distribution into a larger diameter light beam with a top
hat intensity distribution.
[0041] The term Gaussian, or the phrase Gaussian distribution,
refers generally to a normal or bell-shaped spatial intensity
distribution characterized by a location of higher intensity near
the center of a region or cross-section that may fall off uniformly
towards the sides of the region. In this case, the mode of the
Gaussian curve corresponds to the center part of the input light
beam. The phrase top hat, or top hat distribution, refers to a
substantially equal spatial intensity distribution along the region
or cross-section in a direction perpendicular to the output beam
path. Additionally, the input light source may be composed of
wavelengths corresponding to one specific color, a plurality of
specific colors, or may comprise white light.
[0042] With reference again to FIG. 4, in an example embodiment, a
desired combination of efficiency and beam quality may be achieved
when the lengths L1 and L2 along the curves 141, 143 from the
openings 106, 114, respectively, relate to the width W (see FIG. 6)
of each leg 104, 112 and 120 with a ratio of approximately 6:1
(L:W). Where the lengths L1 and L2 and the width W have a ratio of
approximately 6:1, the efficiency of the beam combining may be at a
desirable efficiency, for example optimal homogenization at minimal
cost. The desired or optimal efficiency may occur where a top hat
profile is uniform to within excess of 98 percent of the optimum
design. Stated differently, the measured intensity difference
across the homogenized output beam may be uniform to within 2%.
However, a range of L:W of about 5:1 to about 7:1 may also be
acceptable. In a given embodiment, a designer may determine
acceptable or desirable parameters for a given application. In an
example embodiment, the width W may be in a range from about 4-6 mm
or about one quarter of an inch. The lengths L1, L2 may be in a
range from about 20-42 mm or about one and a half inches.
[0043] Light sources 510, 511 emit or conduct the input light beams
110, 118 having a Gaussian intensity distribution 218 (FIG. 5) and
applied to openings 106, 114 of LHCA 100. Light beams 110, 118 may
have cone patterns where the light may be applied to a
substantially central portion of openings 106, 114 equidistant from
each side of openings 106, 114, as illustrated, for example, in
FIG. 5. Referring again to FIG. 4, light beams 110, 118 may then be
applied to the highly reflective interior surfaces 103 of the LHCA
100. As the applied light beam travels down the lengths L1, L2,
they undergo numerous reflections, combine at the junction 130 and
emerge as an output beam having a top hat profile 318, 322 (FIG. 6)
from an output end 124 of LHCA 100. During each of the reflections
within an interior region of LHCA 100, the beam actually folds over
onto itself resulting in the creation of a highly-uniform,
homogenous top hat profile. After a minimum of five such
reflections, the beam may be considered homogenous. The lengths L1,
L2 may be, for example about 42 mm (millimeters) while the width
(or diameter) of the legs 104, 112, 120 may be about 7 mm.
[0044] FIG. 5 shows a graphical intensity depiction 200 including
three plane views (202, 204, 206) of an input Gaussian light beam
208, in accordance with an embodiment of the present invention.
Depiction 200 includes a frontal plane view 202 showing a
two-dimensional intensity distribution of an exemplary
cross-section of the input Gaussian light beam 208, a profile plane
view 204 showing a Gaussian distribution curve 218 depicting the
intensity across a central vertical diameter 220 or span, and a
horizontal plane view 206 showing a Gaussian distribution curve 222
depicting the intensity across a central horizontal diameter 224 or
span.
[0045] As shown in FIG. 5, the light intensity profile varies
across the diameter of the optical channel, in a direction
perpendicular to the cross section of the channel, with a typical
Gaussian intensity distribution. The light source may be a single
point source such as a fiber optic cable, multiple point sources
such as a fiber bundle, or an omni-directional source where only a
portion of the emitted light from the source is received by the
homogenizing and combining device. The wavelength of each light
source may be monochromatic or polychromatic, coherent or
incoherent.
[0046] FIG. 6 shows a graphical intensity depiction 300 including
three plane views (302, 304, 306) of an output top hat light beam
308 from a tubular member 310 having a hollow polygonal
cross-section 312 and a highly reflective interior surface 314, in
accordance with an embodiment of the present invention. In this
example, the polygonal cross-section of tubular member 310 may be a
hexagon comprising six, equal-size planar side members, but this is
not considered limiting. Specifically, depiction 300 includes a
frontal plane view 302 showing an end view of a tubular member
having a two-dimensional intensity distribution for an exemplary
cross-section of the output top hat light beam 308, a profile plane
view 304 showing a top hat distribution curve 318 depicting the
intensity across a central vertical diameter 320 or span, and a
horizontal plane view 306 showing a top hat distribution curve 322
depicting the intensity across a central horizontal diameter 324 or
span of the polygonal cross-section.
[0047] As shown in FIG. 6, the light intensity profile of output
light beam 308 does not substantially vary across the diameter of
the optical channel, in a direction perpendicular to the cross
section of the channel, with a typical top hat intensity profile or
distribution. The top hat intensity profile may be provided for all
homogenized output light beams. This conversion to a top hat
profile is important especially when LHCA 100 (FIGS. 1, 4) is used
to project an output beam 308 (126 in FIGS. 1, 4) into a bundle of
fibers. The homogenous nature of the output beam will assure that
each individual fiber within the bundle will receive the same
intensity of light. In this manner, the highly reflective interior
surfaces 314 of tubular member 310 or body 102 (FIGS. 1, 4) may
cause a light beam to fold over onto itself numerous times while
passing through body 102, thus reshaping the original input
Gaussian profile beam into a highly-uniform, homogenous top hat
profile beam.
[0048] Input light beams 110, 118 (FIGS. 1, 4) may each be a point
source of white light having a wavelength range from about 380 nm
to 780 nm covering the spectrum of visible light. For visible light
or for white light, a silver reflective surface within tubular body
102 will provide the highest efficiency. Alternatively, input light
beams (110, 118) may include any light components above and/or
below the visible spectrum. For this disclosure, white light may
include a light beam that includes a plurality of wavelengths, and
is thereby differentiated from single wavelength light beam having
a particular color. In another example embodiment, the reflective
surface within a tubular body 102 may be gold. Gold may provide a
desired efficiency, for example, where the input light beams are in
the infra-red region of the spectrum. Other materials may be used
as desired depending on the wavelength of the input/output
light.
[0049] The source of input light beams (110, 118) may be any light
conductor or light emitter including a light conducting tubular
member placed adjacent to or partially within an input end portion
opening 106, 114 (FIGS. 1, 4), an output end portion of an optical
cable such as a fiber-optic cable or bundle placed adjacent to or
partially within an input end portion (106, 114), and/or a white
light emitter such as an incandescent lamp, a fluorescent lamp, an
Organic Light Emitting Diode (OLED), a chemical light source
including a flame, the sun, and/or any other source of illumination
directed toward, placed adjacent to, or partially within an input
end portion (106, 114). The insertion distance partially within an
input end portion (106, 114) may be up to about twice the diameter
of an input light beam (110, 118) through an insertion plane that
may be parallel to an outer edge of planar input end portions (106,
114).
[0050] FIG. 7 shows a graphical sum 400 illustrating an exemplary
combination of a first input beam 402 and a second input beam 404,
where a combined output beam 406 has an intensity that is the sum
of the intensities of the input beams (402, 404), according to an
embodiment of the present invention. When the input beams are of
different wavelengths (i.e. are of different colors) the output
beam will be of a third wavelength that is a combination of the
input wavelengths. In this manner, a homogenized output beam having
a third color may be generated (color generator) based on two
Gaussian input beams having two different colors.
[0051] FIG. 8 illustrates a method 600 of using a light
homogenizing and combining apparatus, according to an embodiment of
the present invention. In an example embodiment, input light beams
110, 118 (FIG. 4) are received 602, 606 in first and second input
legs 104, 112 (FIG. 4), respectively. The input light beams 110,
118 may have Gaussian intensity profiles 218, 222 (FIG. 5). In an
example embodiment, the light beams 110, 118 may be emitted from a
light sources 510, 511 (FIG. 4), for example fiber optic cables,
and be applied to input openings 106, 114 (FIG. 4), respectively.
The input light beams 110, 118 may be reflected within the legs
104, 112 to produce 604, 608 first and second leg output beams
110', 118'. In this manner, the Gaussian first input light beams
may be reshaped into at least partially homogenized top hat profile
beams after repeated reflections from the inside surfaces of
tubular body 102 (FIG. 4). In an example embodiment, the first and
second leg output beams 110', 118' may be homogenized, for example
completely homogenized in the first and second legs.
[0052] In an example embodiment, the at least partially homogenized
beams 110', 118' may be combined 610 in the output leg 120 (FIG. 4)
of the tubular body 102. The combined beam may be reflected and
homogenized 612 within the output leg 120 to produce a combined
homogenized output beam 126 at the output opening 124 (FIG. 4). In
this manner, combined homogenized output beam 126 or 406 (FIG. 7)
may have a top hat profile and amplitude that is nearly the sum of
the amplitudes of the input beams. Further, when the input beams
(110, 118) have different wavelengths, the combined beams may be
blended 614 so that the output beam 126 has a new color that is a
combination of the wavelengths present in the input beams.
[0053] Although an exemplary embodiment of the method 600 shows a
combination of two Gaussian light sources, this process may be
utilized for three or more input beams, where the transmitted beam
from a prior homogenization and combination stage (i.e. a first
LHCA 100) may be asserted to a latter homogenization and
combination stage (i.e. a second LHCA 100) so that more than two
input beams may be homogenized and combined to produce a top hat
profile output beam that is a combination of all input beams. In an
example embodiment, the overall system will have an efficiency of
at least 92.5 percent, for example greater than 93 percent.
[0054] FIG. 9 illustrates an exemplary method 800 of fabricating an
LHCA 100. In one embodiment, a body 102 (FIG. 1) may be fabricated
in an electroplating or electroforming process 800 using a shaped
form or mandrel, the exterior shape of the mandrel corresponding to
the shape of interior reflective surfaces of the LHCA to be formed.
The method may include providing 802 the mandrel. The mandrel may
be formed from a material onto which a metal which can provide a
highly reflective interior surface may be electroplated. For
example, the mandrel may be formed from material which is metal,
for example aluminum. The melting point of the material from which
the mandrel is formed may have a lower melting point than the metal
used to form the body 102.
[0055] The mandrel may be provided 802 or formed by any process of
casting, forming, injection molding or tooling to provide a
non-metal mandrel 803 with the desired shape to provide a desired
shape of the interior surfaces. In an example embodiment, the
mandrel may be formed in a die by injection molding. The form may
be, for example, wax. Aluminum may be deposited 804 on the form and
the form melted away 806. The resulting aluminum mandrel may be
used for fabricating the body of the LCHA.
[0056] FIG. 10 illustrates an overhead view of a bent rod shape
900. The bent rod shape has a first end 902, corresponding to an
opening of a first or second leg of an LHCA. The shape has a second
end 904 corresponding to an exit opening of an LHCA. In the
embodiment shown in FIG. 10, the rod shape 900 is bent at a 90
degree angle with an axis 940 of the first end 902 being at about
90 degrees with respect to an axis of the second end.
[0057] In an example embodiment, the shape may be truncated along
any plane that bisects the end portion of the rod shape
corresponding to the output beam opening 904. Two rod shapes
truncated along the plane A, A' may be placed together to form a
mandrel corresponding to the LHCA of FIG. 1. In an example
embodiment, the two bent rod shapes truncated along the planes B,
B' may be joined together to form the shape of a mandrel
corresponding the the LHCA of FIG. 3A with an angle 145 of 120
degrees between the axes 140 and 142 with respect to the axis 144.
Two bent rod shapes truncated along the plance C, C' may be placed
together to form a mandrel corresponding to an LHCA in which the
angle 145 is 60 degrees (not shown). For shapes having other
polygonal cross-sections, other angles may be achieved.
[0058] Referring again to FIG. 9, in an example embodiment, the
body may be plated 810 onto the mandrel to build up a "stand alone"
thickness where the highly reflective interior surface plating
surrounding the mandrel is structurally self-supporting. In one
embodiment, plating 810 the body onto the mandrel may include
coating 812 the aluminum form or mandrel with a highly reflective
layer corresponding to the highly reflective interior surface of an
LHCA to be formed. The highly reflective layer may include, for
example, silver, gold, or other highly reflective plating material.
The highly reflective layer may then be coated 814 with an outer
layer. The outer layer may be a stronger material, for example
nickel, that may bond with and/or structurally support the highly
reflective plating to provide structural rigidity for the body
having a highly reflective interior surface. The highly reflective
layer may be very thin because the majority of structural support
for body is provided by an outer plating layer.
[0059] In an exemplary embodiment, the highly reflective layer may
only be a few atomic layers thick while the outer layer may be
composed of nickel that may be approximately 0.002-inches thick.
The thickness of the outer layer may be determined by the
properties of the selected material and the rigidity requirements
of a particular mission or application. By reducing the thickness
of the highly reflective layer, the cost of the manufactured device
may be kept low when the highly reflective material layer may be
composed of silver, gold, or other precious metal. Generally, the
composition of the highly reflective material depends upon the
wavelength of light being reflected within the tubular member being
formed. In one preferred embodiment, the highly reflective material
layer is composed of silver to reflect white light with maximum
efficiency.
[0060] The mandrel may then be removed 816, for example by melting
818, chemically etching 820, and/or exploiting some other property
such as a difference between the thermal coefficients of expansion
between the mandrel and the plating in order to remove the mandrel
and form body. Once the outer layer is formed, the aluminum form or
mandrel may then be chemically melted away leaving the highly
reflective, or highly polished, interior surface within body
102.
[0061] In an example embodiment, light combining and homogenizing
apparatuses according to the disclosure may solve several problems
without the use of any optical or glass elements such as
beamsplitters, mirrors and the like. The LCHA may convert Gaussian
profile input light beams to a highly homogeneous, top hat profile
beam. It may combine the intensity of each initial light beam into
a new single higher intensity output beam. It may also be used to
combine two beams of different wavelengths (colors) into a new
single output beam with a totally different wavelength (color). In
this mode, the LCHA may act as a wavelength/color generator,
enabling the operator to generate a new colored light beam
depending strictly upon the wavelength (color) of the two initial
light sources. A LCHA according to the disclosure may not require
initial alignment steps and may therefore be less susceptible to
misalignment and possible optical contamination than other
approaches. An LCHA according to an embodiment of the disclosure
may avoid the costs of additional hardware or components of other
approaches and may be smaller and more compact. It may also avoid
intensity losses that may occur in the multiple optical elements
used in other approaches.
[0062] Embodiments described above illustrate but do not limit the
invention. It should also be understood that numerous modifications
and variations are possible in accordance with the principles of
the present invention. Accordingly, the scope of the invention is
defined only by the following claims.
* * * * *