Fiber output coupler with beam shaping optics for laser materials processing system

Claim 2

A coupler apparatus for supporting an output end of an optical fiber, said coupler apparatus comprising: first lens means for collimating as a first collimated beam portion a high power laser beam emitted from the output end of the fiber; second lens means for expanding the first collimated beam portion into a second collimated beam portion having a larger diameter than the first collimated beam portion; third lens means for shaping the second collimated beam portion into a shaped materials processing beam portion; and fourth lens means for focusing onto a surface the shaped materials processing beam portion.

Claim 3

A coupler apparatus in accordance with claim 1 wherein said third lens means comprises: a diverging axicon mounted to intercept the second collimated beam portion and provide an annulus-shaped diverging beam portion; and a converging axicon mounted to intercept the annulus-shaped diverging beam portion and provide a substantially uniform annulus-shaped beam, said diverging axicon and said converging axicon being separated by a first separation distance.

Claim 4

A coupler apparatus in accordance with claim 2 wherein said first separation distance is adjustable.

Claim 5

A coupler apparatus in accordance with claim 3 wherein said converging axicon is mounted to a linear translator.

Claim 6

A coupler apparatus in accordance with claim 4 wherein operation of said linear translator is computer controlled.

Claim 7

A coupler apparatus in accordance with claim 1 wherein said third lens means comprises a diverging bi-prism mounted to intercept the second collimated beam portion and provide split diverging beams, said diverging bi-prism and fourth lens means being separated by a second separation distance.

Claim 8

A coupler apparatus in accordance with claim 6 wherein said second separation distance is adjustable.

Claim 9

A coupler apparatus in accordance with claim 7 wherein said diverging bi-prism is mounted to a linear translator.

Claim 10

A coupler apparatus in accordance with claim 7 wherein said diverging bi-prism is mounted to a rotation stage.

Claim 11

A coupler apparatus in accordance with claim 9 wherein said rotation stage is mounted to a linear translator and operation of said linear translator and said rotation stage is computer controlled.

Claim 12

A coupler apparatus in accordance with claim 1 wherein said third lens means comprises a converging bi-prism mounted to intercept the second collimated beam portion and provide split converging beams, said converging bi-prism and fourth lens means being separated by a third separation distance.

Claim 13

A coupler apparatus in accordance with claim 11 wherein said third separation distance is adjustable.

Claim 14

A coupler apparatus in accordance with claim 12 wherein said converging bi-prism is mounted to a linear translator.

Claim 15

A coupler apparatus in accordance with claim 12 wherein said converging bi-prism is mounted to a rotation stage.

Claim 16

A coupler apparatus in accordance with claim 14 wherein said rotation stage is mounted to a linear translator and operation of said linear translator and said rotation stage is computer controlled.

Claim 17

A coupler apparatus in accordance with claim 1 wherein said third lens means comprises a wedge prism mounted to intercept the second collimated beam portion and provide a diverging beam, said wedge prism and fourth lens means being separated by a fourth separation distance.

Claim 18

A coupler apparatus in accordance with claim 16 wherein said fourth separation distance is adjustable.

Claim 19

A coupler apparatus in accordance with claim 17 wherein said wedge prism is mounted to a linear translator.

Claim 20

A coupler apparatus in accordance with claim 17 wherein said wedge prism is mounted to a rotation stage.

Claim 21

A coupler apparatus in accordance with claim 19 wherein said rotation stage is mounted to a linear translator and operation of said linear translator and said rotation stage is computer controlled.

Claim 22

A coupler apparatus in accordance with claim 1 wherein said third lens means comprises a split lens mounted to intercept the second collimated beam portion and prove a split beam, said split lens and said second lens means being separated by a fifth separation distance.

Claim 23

A coupler apparatus in accordance with claim 21 wherein said split lens comprises two split lenses.

Claim 24

A coupler apparatus in accordance with claim 21 wherein said split lens comprises three split lenses.

Claim 25

A coupler apparatus in accordance with claim 21 wherein said split lens comprises four split lenses.

Claim 26

A coupler apparatus in accordance with claim 21 wherein said fifth separation distance is adjustable.

Claim 27

A coupler apparatus in accordance with claim 25 wherein said split lens is mounted to a linear translator.

Claim 28

A coupler apparatus in accordance with claim 25 wherein said split lens is mounted to a rotation stage.

Claim 29

A coupler apparatus in accordance with claim 27 wherein said rotation stage is mounted to a linear translator and operation of said linear translator and said rotation stage is computer controlled.

Claim 30

A coupler apparatus in accordance with claim 1 wherein said apparatus is substantially L-shaped and a mirror is disposed between said third lens means and said fourth lens means.

Claim 31

A coupler apparatus in accordance with claim 1 wherein said apparatus is substantially L-shaped and a mirror is disposed between said second lens means and said third lens means.

Claim 32

A coupler apparatus in accordance with claim 1 wherein said third and fourth lens means comprise a focus lens mounted to an x-y translator.

Claim 33

A coupler apparatus in accordance with claim 1 wherein said third lens means comprises an x-y galvanometer.

Claim 34

A coupler apparatus for supporting an output end of an optical fiber, said coupler apparatus comprising: a first plano-convex lens for intercepting a first diverging beam portion emitted from the output end of the fiber and for providing a first collimated beam portion; a plano-concave lens for intercepting the first collimated beam portion and for providing a second diverging beam portion; a second plano-convex lens for intercepting the second diverging beam portion and for providing a second collimated beam portion; a diverging axicon for intercepting the second collimated beam portion and for providing a diverging annulus-shaped beam portion; a converging axicon for intercepting the diverging annulus-shaped beam portion and for providing a substantially uniform annulus-shaped beam portion; and a third plano-convex lens for intercepting the substantially uniform annulus-shaped beam portion and for focusing a beam portion onto a workpiece.

Claim 35

A coupler apparatus for supporting an output end of an optical fiber, said coupler apparatus comprising: a first plano-convex lens for intercepting a first diverging beam portion emitted from the output end of the fiber and for providing a first collimated beam portion; a plano-concave lens for intercepting the first collimated beam portion and for providing a second diverging beam portion; a second plano-convex lens for intercepting the second diverging beam portion and for providing a second collimated beam portion; a diverging axicon for intercepting the second collimated beam portion and for providing a diverging annulus-shaped beam portion; a converging axicon for intercepting the diverging annulus-shaped beam portion and for providing a substantially uniform annulus-shaped beam portion; and a third plano-convex lens for intercepting the substantially uniform annulus-shaped beam portion and for focusing a beam portion onto a workpiece.

Claim 36

A coupler apparatus in accordance with claim 33 wherein said converging axicon is mounted on a linear translator and a separation distance between said diverging axicon and said converging axicon is adjustable.

Claim 37

A coupler apparatus in accordance with claim 34 wherein said linear translator is computer controlled.

Claim 38

A coupler apparatus in accordance with claim 33 further comprising: a nozzle mounted to an output end of said coupler, said nozzle including at least one flow path for directing a gas towards an output end of said nozzle.

Claim 39

A coupler apparatus for supporting an output end of an optical fiber, said coupler apparatus comprising: a first plano-convex lens for intercepting a first diverging beam portion emitted from the output end of the fiber and for providing a first collimated beam portion; a plano-concave lens for intercepting the first collimated beam portion and for providing a second diverging beam portion; a second plano-convex lens for intercepting the second diverging beam portion and for providing a second collimated beam portion; a diverging bi-prism for intercepting the second collimated beam portion and for providing two split beams; and a third plano-convex lens for intercepting the split beams and for focusing beam portions onto workpiece.

Claim 40

A coupler apparatus for supporting an output end of an optical fiber, said coupler apparatus comprising: a first plano-convex lens for intercepting a first diverging beam portion emitted from the output end of the fiber and for providing a first collimated beam portion; a plano-concave lens for intercepting the first collimated beam portion and for providing a second diverging beam portion; a second plano-convex lens for intercepting the second diverging beam portion and for providing a second collimated beam portion; a diverging bi-prism for intercepting the second collimated beam portion and for providing two split beams; and a third plano-convex lens for intercepting the split beams and for focusing beam portions onto workpiece.

Claim 41

A coupler apparatus in accordance with claim 37 wherein said diverging bi-prism is mounted in a rotation stage, said rotation stage, said rotation stage being mounted in a linear translator.

Claim 42

A coupler apparatus in accordance with claim 38 wherein said rotation stage and said linear translator are computer controlled.

Claim 43

A coupler apparatus in accordance with claim 37 further comprising: a nozzle mounted to an output end of said coupler, said nozzle including at least one flow path for directing a gas towards an output end of said nozzle.