Method and apparatus for making an electromagnetic beam combiner

Abstract

A beam combiner includes a first beam-input face, a beam-output face, and first and second reflectors. The first beam-input face receives first and second beams of electromagnetic energy respectively having a first and second wavelengths. The first reflector reflects the first received beam toward the beam-output face, and the second reflector passes the first beam from the first reflector and reflects the received second beam toward the beam-output face. In one alternative, the first beam-input face also receives a third beam of electromagnetic energy having a third wavelength, the beam combiner includes a third reflector that reflects the received third beam toward the beam-output face, and the first and second reflectors pass the third beam from the third reflector. In another alternative, the beam combiner includes a second beam-input face that receives a third beam directed toward the beam-output face, and the first and second reflectors pass the third beam

1 - 59 . (canceled)  
   
   
       60 . A method, comprising: 
 attaching an hypotenuse of a triangular first slab of transparent material to a first side of a rectangular second slab of transparent material to form an interface operable to reflect a first wavelength of electromagnetic energy and to pass second and third wavelengths of electromagnetic energy, the second slab having a second side opposite the first side; and    attaching a first side of a third slab of transparent material to the second side of the second rectangular slab to form an interface operable to reflect the second wavelength and to pass the first wavelength.    
   
   
       61 . The method of  claim 60 , further comprising: 
 wherein the third slab is rectangular; and    planing beam-input ends of the second and third slabs such that the beam-input ends are substantially coplanar with a beam-input end of the first slab.    
   
   
       62 . The method of  claim 60  wherein the first, second, and third slabs comprise glass.  
   
   
       63 . The method of  claim 60  wherein: 
 the third slab is substantially triangular; and    the first side of the third slab comprises the hypotenuse of the third slab.    
   
   
       64 . The method of  claim 60 , further comprising coating the hypotenuse of the first slab with a material operable to reflect the first wavelength of electromagnetic energy and to pass the second and third wavelengths of electromagnetic energy.  
   
   
       65 . The method of  claim 60 , further comprising coating the first side of the second slab with a material operable to reflect the first wavelength of electromagnetic energy and to pass the second and third wavelengths of electromagnetic energy.  
   
   
       66 . The method of  claim 60 , further comprising coating the first side of the third slab with a material operable to reflect the second wavelength of electromagnetic energy and to pass the third wavelength of electromagnetic energy.  
   
   
       67 . The method of  claim 60 , further comprising coating the second side of the second slab with a material operable to reflect the second wavelength of electromagnetic energy and to pass the third wavelength of electromagnetic energy.  
   
   
       68 . A method, comprising 
 attaching a first side of a rectangular first slab of transparent material to a first side of a rectangular second slab of transparent material to form an interface operable to reflect a first wavelength of electromagnetic energy and to pass second and third wavelengths of electromagnetic energy;    attaching a second side of the rectangular first slab to a first side of a rectangular third slab of transparent material to form an interface operable to reflect the first wavelength and to pass the second and third wavelengths;    attaching a second side of the rectangular second slab to a first side of a rectangular fourth slab of transparent material to form an interface operable to reflect the second wavelength and to pass the third wavelength;    attaching a second side of the rectangular third slab to a first side of a rectangular fifth slab of transparent material to form an interface operable to reflect the second wavelength and to pass the third wavelength;    cutting through the attached first, second, third, fourth, and fifth slabs to form a combination slab;    cutting the combination slab in sections such that a first section includes portions of the first, second, and fourth slabs and that a second section includes portions of the first, third, and fifth slabs;    polishing the cut edges and the largest surfaces of the first and second sections of the combination slab; and    forming beam combiners by cutting the first and second sections of the combination slab in directions substantially perpendicular to the respective cut edges of the sections.    
   
   
       69 . The method of  claim 68 , further comprising planing edges of the first and second sections of the combination slab opposite the respective cut edges after cutting the combination slab in sections.  
   
   
       70 . The method of  claim 68 , further comprising planing opposite edges of the combination slab before cutting the combination slab in sections.  
   
   
       71 . The method of  claim 68  wherein the first, second, third, fourth, and fifth slabs have substantially equal thicknesses.  
   
   
       72 . The method of  claim 68  wherein the first slab is thicker than the second, third, fourth, and fifth slabs.  
   
   
       73 . The method of  claim 68  wherein: 
 the first slab is thicker than the second, third, fourth, and fifth slabs; and    the second, third, fourth, and fifth slabs have substantially equal thicknesses.    
   
   
       74 . The method of  claim 68 , further comprising treating second sides of the fourth and fifth slabs to reflect the third wavelength.  
   
   
       75 . The method of  claim 68 , further comprising: 
 prior to cutting the first, second, third, fourth, and fifth slabs to form the combination slab, 
 attaching a second side of the rectangular fourth slab to a first side of a rectangular sixth slab of transparent material to form an interface operable to reflect the first wavelength of electromagnetic energy and to pass the second and third wavelengths of electromagnetic energy, and  
 attaching a second side of the rectangular sixth slab to a first side of a rectangular seventh slab of transparent material to form an interface operable to reflect the second wavelength and to pass the third wavelength;  
   wherein cutting through the attached first, second, third, fourth, and fifth slabs further comprises cutting through the sixth and seventh slabs to form a combination slab;    wherein cutting the combination slab in sections further comprises cutting the combination slab in sections such that a third section includes portions of the fourth, sixth, and seventh slabs;    wherein polishing the cut edges further comprises polishing the cut edges and the largest surface of the third section of the combination slab; and    wherein forming beam the combiners further comprises forming the combiners by cutting the third section of the combination slab in directions substantially perpendicular to the respective cut edges of the third section.    
   
   
       76 . A method, comprising 
 attaching a first side of a rectangular first slab of transparent material to a first side of a rectangular second slab of transparent material to form an interface operable to reflect a first wavelength of electromagnetic energy and to pass second and third wavelengths of electromagnetic energy;    attaching a second side of the rectangular second slab to a first side of a rectangular third slab of transparent material to form an interface operable to reflect the second wavelength and to pass the third wavelength;    cutting through the attached first, second, and third slabs to form a combination slab;    cutting an edge of the combination slap formed by a second side of the first slab;    polishing the cut edge and the largest surface of the combination slab; and    forming beam combiners by cutting the combination slab in directions substantially perpendicular to the cut edge.