Efficient coupling and relaxed alignment tolerances in pigtailing of a laser diode using dual ball lenses

In this paper, we report an efficient coupling scheme with relaxed misalignment tolerances. The proposed coupling scheme consists of two ball lenses of same diameter (1 mm) and different refractive indices. The second ball lens which is facing the fiber tip has a higher refractive index (1.833), whereas the first one which faces the laser diode has a refractive index of 1.5. Employing Gaussian and ABCD ray tracing optics, the theoretically obtained coupling efficiency can reach a unity with relaxed working distance (separation of the coupling system from the fiber tip) in the range between 1 and 4 mm at some optimum positions of the coupling lenses with regard to each other and to the facet of the laser diode. It has been found that if the distance between the first ball lens and the laser diode (d1) is fixed at 1.1 mm, which is twice its focal length, the coupling efficiency and the working distance as well as the misalignment tolerances are greatly affected by variation of the separation between the two ball lenses (s), and for this proposed coupling scheme the highest coupling efficiency and largest working distance are obtained when s is in the range of 0.3–0.35 mm. Above and below this range there is a significant reduction in the values of the above-mentioned parameters. Experimentally, the Nd:YAG laser welding system has been used for the alignment and welding of the coupling components in a butterfly configuration; the experimentally obtained coupling efficiency of the proposed coupling system was around 75% with relaxed working distance. From the effect of lateral and angular offsets on coupling efficiency, it is clearly noticed that the mode field of laser diode is transformed from elliptical into circular and hence effectively matched with that of the single-mode fiber.