Abstract:
A modular illumination and aiming apparatus, a preferred embodiment of which includes an optical head module, mounting module, and an end cap module. The modular illumination and aiming apparatus is configured to be quickly and intuitively adjusted by a user in response to changing target and environmental conditions. The modular illumination and aiming apparatus is configured to be ergonomically supportive such that a user may maintain a consistent firing grip while activating the illumination and aiming functions. The optical head module is configured to allow the user to change radiation types by adjusting a cap. The alignment mechanism in the optical head module for the radiation source and optics is configured to provide a robust and zero-play optical mount in order to resist recoil and general physical shock.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    Pursuant to 35 U.S.C. §119(e), this application claims priority from, and the benefit of, U.S. provisional patent application No. 62/155,964 filed on May 1, 2015, the entire contents of which is hereby incorporated by reference for all purposes as if fully set forth herein. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention relates to combined illumination and laser aiming apparatuses. In some preferred embodiments these apparatuses may be mounted to weapons, for example, firearms. 
       BACKGROUND OF THE INVENTION 
       [0003]    Weapon-mounted aiming and illumination apparatuses allow users to rapidly acquire, identify, and engage targets in combat situations. These apparatuses are generally configured to allow for both aiming and illuminating operation in both daytime and nighttime scenarios. As such, these apparatuses often include illumination and aiming laser radiation that is detectable in both the visible and invisible spectrum. Because a user may engage with a target at a variety of distances, these apparatuses are generally configured to be operable in both short-range, immediate combat situations, and longer-range, distant target engagements. These apparatuses may also be used to visually communicate with allies or other non-combatant users over a distance. For example, in a nighttime situation, friendly users may use infrared illumination in combination with night-vision systems in order to communicate with, or identify potential targets to, one another. 
         [0004]    Prior art illumination and aiming systems and apparatuses, while adjustable to different distance and illumination settings, have failed to provide users with intuitive and simple controls that would allow a user to rapidly adjust an illumination and aiming device to appropriate settings for a given situation and environment. Prior art systems are also cumbersome in size and shape, altering the characteristics of a user&#39;s weapon; lack any ergonomic or intuitive features to facilitate usage; and do not provide users with sufficient customization and mounting options. 
         [0005]    There exists a need for an illumination and aiming apparatus that will allow a user to rapidly adjust the settings of the illumination and aiming functions in response to target position and environmental conditions for a particular engagement, without requiring the user to alter or adjust firing grip, or spend unnecessary time adjusting and changing illumination and aiming settings. There is also a need for an illumination and aiming apparatus that is modular and highly adaptable to a user&#39;s specific mission and environmental requirements. Further, there is a need for a compact and accurate apparatus for adjusting the illumination direction that does not change during use. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention provides a robust, customizable, modular, compact, accurate, and ergonomic illumination and aiming apparatus configurable to be mounted on a variety of objects, including, but not limited to, a weapons system, such as a firearm. In other embodiments, the illumination and aiming apparatus may be hand-held, helmet-mounted, or vehicle-mounted. 
         [0007]    It is an object of the present invention to provide an illumination and aiming apparatus that presents a user with intuitive and quick adjustment options in response to specific environmental and targeting conditions. It is a further object of the present invention to allow for modular customization of the functionality and ergonomics of the illumination and aiming apparatus by allowing the user to interchange various modular components, including for example, optical components, power units, and mounting components, among others. 
         [0008]    The present invention also provides a robust, compact, and stable optical assembly for illumination and aiming optics that allows a user to ensure accuracy and repeatability of operation of the illumination and aiming apparatus. 
         [0009]    The present invention further provides seals between apparatus components that shield internal and electrical optical components to harmful environmental conditions. 
         [0010]    The present invention further provides magnetic switches that allow a user to change the modes of the illumination and aiming apparatus without exposing any internal optical or electrical components to environmental degradation. In one example embodiment, a Hall-effect sensor is provided in the lens cap of the optical head module to allow the user to change between visible radiation, invisible radiation, and off-state modes. 
         [0011]    The present invention also provides a compact solution for implementing different illumination modes of the illumination and aiming apparatus by providing, in one example embodiment, a vertical cavity surface emitting laser (“VCSEL”) array for the illumination source in the optical head module. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The accompanying drawings are fully incorporated in, and form part of, this specification, and illustrate embodiments of the invention that, together with the description, serve to explain principles of the invention: 
           [0013]      FIG. 1A and 1B  depict an example embodiment of a fully assembled modular illumination and aiming apparatus; 
           [0014]      FIGS. 2A and 2B  depict an example embodiment of an optical head module; 
           [0015]      FIG. 3  depicts an example embodiment of a mounting module with low profile activation buttons; 
           [0016]      FIGS. 4A and 4B  depict an example embodiment of an end cap module; 
           [0017]      FIGS. 5A, 5B, and 5C  depict an example embodiment of an optical assembly that may be configured to be integrated into an optical head module; 
           [0018]      FIG. 6  illustrates an example table of function sets for different modes of an example embodiment of a modular illumination and aiming apparatus; and 
           [0019]      FIG. 7  illustrates the illumination and aiming radiation as described in the table of  FIG. 6 . 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    Reference will now be made in detail to embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention is described in conjunction with these embodiments, it will be understood that the descriptions herein are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications, and equivalents that may be included within the spirit and scope of the invention as defined by the appended claims. Detailed description of components that are well known in the art may be omitted if that detailed description would confuse or obscure the description of the embodiments of the present invention. 
         [0021]      FIGS. 1A and 1B  depict an example embodiment of a fully-assembled, modular illumination and aiming apparatus  100  from a top and bottom view perspective. Illumination and aiming apparatus  100  comprises the combination of optical head module  110 , mounting module  111 , and end cap module  112 . Modules  110 ,  111 , and  112  may be aligned by means of an internal alignment mechanism. Modules  110 ,  111 , and  112  may also be configured to be in electrical connection with one another. The connections between modules  110 ,  111 , and  112  may be sealed off from the environment, for example, by o-ring gaskets. Specific features of optical head module  110 , mounting module  111 , and end cap module  112  may each be described in more detail below with respect to other figures. 
         [0022]    In general, optical head module  110  may contain multiple radiation sources, including, for example, both infrared and visible radiation sources. In one example embodiment, the multiple radiation sources may comprise an array of VCSEL elements. In one example embodiment, the user may toggle between radiation sources by changing or rotating the position of lens cap  105 . In some embodiments, lens cap  105  may be a propeller cap that is configured to rotate to different positions that correspond to different illumination modes. In some embodiments, lens cap  105  may include magnets that activate Hall-effect sensors in optical head module  110  that are configured to activate and deactivate different radiation sources within optical head module  110 . Lens cap  105  may also be configured to cover and protect radiation apertures that correspond to inactive radiation modes. For example, when lens cap  105  is positioned in an “off” position, the radiation apertures for both the invisible and visible modes will be at least partially covered and protected. When lens cap  105  is in the position that corresponds to the visible radiation mode, the radiation apertures for the invisible radiation mode will be at least partially covered and protected, while the radiation apertures for the visible radiation will be exposed. When lens cap  105  is in the position that corresponds to invisible radiation mode, the radiation apertures for the visible mode will be at least partially covered and protected, while the radiation apertures for the invisible radiation will be exposed. Mode indicator  108  may be configured to indicate the position of lens cap  105 , thus indicating to the user the current radiation mode configuration of illumination and aiming apparatus  100 . In other example embodiments, optical head  110  may include multiple visible and invisible radiation modes that may be selected by positioning lens cap  105 , e.g., green and red visible light modes. 
         [0023]    Optical head module  110  may also include a range switch  106  that allows a user to select a range mode, depending on the distance from which the user is engaging a target or depending on the environment in which the user finds himself In some embodiments, range switch  106  may be a linear, three-position switch that allows a user to toggle between short-range, mid-range, and long-range illumination and aiming modes. The switch may be configured to provide tactile feedback to the user to confirm the mode to the user. Range switch  106  may work in combination with lock-out switch  107  to prevent a user from inadvertently switching the device into a long range mode. In some embodiments, a user may be required to depress lock-out switch  107  in order to move range switch  106  into a position that activates the long-range mode. The user may select the position of range switch  106  in combination with the position of lens cap  105  in order to configure illumination and aiming apparatus  100  with the appropriate radiation and range modes for the user&#39;s particular environment and distance to a target. 
         [0024]    Optical head module  110  may also include a rubberized covering in order to protect illumination and aiming apparatus  100  from shocks, scratches, dents, and/or physical damage. Similar protective coatings or coverings may be provided to protect the other modules that are combined to form illumination and aiming apparatus  100 . 
         [0025]    Optical head module  110  may include adjustment screws  115  for adjusting the alignment of the optical assembly that includes the radiation sources, including adjustments to both azimuth and elevation. Optical head module  110  may also include positive contact or terminal  218  for the voltage source that may be housed in mounting module  111 . Optical head module  110  may also include a training mode switch. In one example embodiment, the training mode switch may comprise engagement ports  116  and  117  configured to allow a user to toggle illumination and aiming apparatus  100  into a training mode by moving a set screw from one training engagement port to the other. In one example embodiment, configuring the illumination and aiming apparatus into training mode may reduce the power of the illumination and aiming apparatus. 
         [0026]    In general, mounting module  111  may include mounting hardware, activation buttons, and may also be configured to house an electrical power source for supplying a voltage to the radiation sources, for example, a lithium ion battery. Mounting module  111  may also include activation buttons  101  and  102 , and mount screw  103 . Activation buttons  101  and  102  may be configured to provide a user with different operation functions for illumination and aiming apparatus  100 . These operation functions may depend on the settings the user has selected for the type of radiation and the range to the target by way of lens cap  105  and range switch  106 , respectively. For example, for a given radiation and range setting, activation button  101  may activate a first operation function comprising a continuous aiming pointer and a higher power illumination beam, while activation button  102  may activate a second operation function comprising a pulsed aiming pointer and a lower power illumination beam. In an example embodiment, activation buttons  101  and  102  may be double clicked to enable illumination and aiming apparatus  100  to remain in a continuous “on” state for a given operation function. In other example embodiments, triple clicks on activation buttons  101  and  102  may provide a user with additional functionalities. 
         [0027]    Activation buttons  101  and  102  may have a low-profile height that will allow a user to maintain a comfortable and effective firing grip while activating illumination and aiming apparatus  100 . In other example embodiments, additional or fewer activation buttons may be provided on mounting module  111  in order to provide a user with additional or fewer operation function options. In some example embodiments, mounting module  111  allows the bulk of the illumination and aiming apparatus  100  to be mounted off-axis from the central axis of a firearm so that interference between any additional adjacent components may be prevented (e.g., white light source, powered optics, etc.). Similarly, in some example embodiments, mounting module  111  allows activation buttons  101  and  102  to be mounted on axis with the firearm, so that the user may easily locate and activate illumination and aiming apparatus  100 . 
         [0028]    Mount screw  103  may be configured, in combination with other hardware, to allow a user to clamp, or mount, illumination and aiming apparatus  100  to an object. In one example embodiment, mount screw  103  may be connected to a rail grabber  114  that is configured to mount illumination and aiming apparatus  100  to a 1913 Picatinny rail system or other alternative rail systems. In other example embodiments, mount screw  103  may be connected to a clamping system appropriate for mounting to a helmet, vehicle, or other firearm. In further example embodiments, mount screw  103  may be configured to match the thread and diameter of a mounting hole provided on an object upon on which illumination and aiming apparatus  100  is to be directly mounted. 
         [0029]    Because illumination and aiming apparatus  100  may be mounted in a number of orientations (e.g., left-handed or right-handed directions), it is understood that the functionalities provided by activation buttons  101  and  102  may remain in the same order relative to the user. For example, in a first mounting orientation, activation button  102  may be closest to the user and may provide a first operation function, while activation button  101  may be further from the user and may provide a second operation function. In a second mounting orientation, where activation button  101  is closest to the user, and activation button  102  is further from the user, activation button  101  may provide the first operation function while activation button  102  may provide the second operation function. In this way, the operation functions of activation buttons  101  and  102  may be configured to remain consistent across all orientations. This allows illumination and aiming apparatus  100  to be configured to accommodate both right-handed and left-handed user preferences. 
         [0030]    In general, end cap module  112  may include latching hardware and ports for remote activation systems. In one example, end cap module  112  may include end cap screw  109 , end cap latch  104 , and remote fire switch ports  113 . End cap latch  104  may be configured to engage with a set of alignment rails that are attached to optical head module  110  and extend internally through the body of mounting module  111 . End cap screw  109  may be configured to allow a user to fix the position of end cap latch  104  through tightening. Once end cap latch  104  is engaged with the alignment rails, this may allow the user to fix the combination of modules that comprise illumination and aiming apparatus  100  by tightening end cap screw  109 . 
         [0031]    End cap module  112  may also include remote fire switch ports  113  that are configured to allow the user to activate illumination and aiming apparatus  100  remotely. In one example embodiment a user may attach tape switches to remote fire switch ports  113  in order to configure illumination and aiming apparatus  100  for remote activation. 
         [0032]    End cap module  112  may also include the negative terminal or contact for the voltage source that may be housed in mounting module  111 . 
         [0033]      FIGS. 2A and 2B  depict an example optical head module  210  configured to be combined with other modular components to form an illumination and aiming apparatus. As described above with respect to  FIGS. 1A and 1B , an example embodiment of an optical head module may include lens cap  205 , range switch  206 , lock-out switch  207 , and mode indicator  208 . 
         [0034]    Optical head module  210  may also include alignment rails  219  that are, upon insertion, configured to align optical head module  210  with other modules in a fully combined illumination and aiming apparatus. Alignment rails  219  are also configured to engage with an end latch in an end cap module, in order to allow a user to fix the arrangement of modules. Optical head module  210  also includes electrical contacts  218  that may be configured to provide electrical connections between optical head module  210  and the other modules that comprise a fully assembled illumination and aiming apparatus. 
         [0035]      FIG. 3  depicts an example mounting module  311  that may be configured to be combined with an optical head module and an end cap module. As described above with respect to  FIGS. 1A and 1B , example mounting module  311  may include mounting screw  303  and activation buttons  301  and  302 . As described above with respect to  FIGS. 2A and 2B , mounting module  311  may be configured to allow for insertion of alignment rails in order to align modules that in combination comprise an illumination and aiming apparatus. Mounting module  311  may also be configured to be in electrical contact with other modules, for example, by accepting insertion of electrical contacts  218  from optical head module  210 . 
         [0036]      FIGS. 4A and 4B  depict an example end cap module that may be configured to be combined with an optical head module and a mounting module. As described above with respect to  FIGS. 1A and 1B , example end cap module  412  may include end cap screw  409 , end cap latch  404 , and remote fire switch ports  413 . End cap module  412  may also include electrical contacts  420 , lanyard screw  421 , and sealing member  422 . 
         [0037]    Retention screw  421  may be configured to attach a retention wire or catch, so that when the user removes the end cap, for example to replace the voltage source, the end cap will remain connected to another object or module. Sealing member  422  may comprise an o-ring gasket, and may be configured to seal the chamber encasing the voltage source against the mounting module. Electrical contacts  420  may be configured to maintain the end cap module in electrical connection with other modules that are combined to comprise the illumination and aiming apparatus. As described above with respect to  FIGS. 2A and 2B , alignment rails  219  from an optical head module may terminate in end cap module  412 , and end cap latch  404  may be configured to latch into the alignment rails. When end cap screw  409  is tightened, end cap latch  404  may serve to lock the modules in place that comprise the illumination and aiming apparatus. 
         [0038]      FIGS. 5A, 5B, and 5C  depict optical assembly  500  that may be integrated into an optical head module, for example, optical head module  110  of  FIGS. 1A and 1B  or optical head module  210  of  FIGS. 2A and 2B . 
         [0039]    Optical assembly  500  is configured to provide alignment for the radiation sources that may be integrated into an optical head assembly. Optical assembly  500  may be configured to provide zero-play adjustment that is capable of maintaining zero movement of optics  523 , even when subjected to heavy and sustained recoil, for example, as created by a firearm. Main flexure shaft  522  is configured to constrain optics  523  in an axial direction, while threaded flexure shafts  515  are configured to be adjusted to provide alignment of both azimuth (windage) and elevation of optical assembly  500 . Adjusting threaded flexure shafts  515  allows the user to align the radiation sources so that the radiation sources may emit radiation in a direction parallel to the bore axis of the weapon on which the illumination and aiming apparatus is mounted. In an example embodiment, the divergence of the illumination radiation sources may be fixed. In other example embodiments, the divergence of the illumination radiation sources may also be adjusted by optical assembly  500 . The threaded flexure shafts maintain the optics  523  under tension, thus eliminating any need for spring mounts and removing any possibility of free play or bounce from optics  523 . In an example embodiment optics  523  may comprise both illumination and aiming radiation sources in combination with Risley prisms that are configured to allow the user to steer the aiming and illumination radiation in the desired direction. 
         [0040]    As depicted in  FIG. 5C , threaded flexure shafts  515  may comprise a compound thread system that is configured to allow a user to achieve the required resolution for radiation beam adjustment. Compound thread systems eliminate the need for unreasonably fine thread pitch that would be necessary to achieve comparable resolution in adjustment by exploiting a differential thread pitch of a first threaded flexure shaft element  524  and the adjoining second threaded flexure shaft element  525  to increase the effective thread pitch In one example embodiment, the optical source in optics  523  may comprise an array of VCSEL sources that are configured at fixed illumination power and divergences. These VCSEL sources may be configured to be used in combination to achieve desired illumination and aiming radiation as determined by the settings selected by the user. In other example embodiments, other radiation sources may be used such as LEDs, solid-state laser sources, arc lamps, etc. 
         [0041]    The modules described above with respect to  FIGS. 1-5  are understood to be exemplary. Other modules may be used in other embodiments of the invention, and the modules may be selected by the user in order to meet specific environmental and mission requirements. For example, alternative to the optical head module described in  FIGS. 1 and 2  may include functionalities based on white light illumination, short-wave infrared (SWIR) aiming and illuminating lasers, joint terminal attack controller (JTAC) marking lasers; laser range finders; hail and warning systems; long-range precision engagement aiming and illumination; crew-served weapon aiming and illumination, or even non-optical functionalities, such as TASER or oleoresin capsicum (OC) spray functions. Alternative end cap modules may include configurations that allow for remote power, alternative tape switch plug, additional direct fire buttons, a user interface display, or other mission-critical, user-selected options. Alternative mounting modules may include mounting configurations that are specific to the particular weapon or system upon which the illumination and aiming apparatus is to be mounted (e.g., M-LOK, KeyMOD, direct mount, etc.). As discussed above, alternative mounting modules may also include different button configurations, as appropriate to the head and end cap module functionalities, or other desired functions sets. 
         [0042]    It will be appreciated that there exist additional advantages of using separate modules to comprise an illumination and aiming apparatus. Modularity allows damaged or outdated component modules to be individually replaced without the need to replace the entire apparatus. A user may also install separate mounting modules on multiple weapons, allowing the user to share the same end cap and optical head modules amongst multiple weapons. 
         [0043]    It will also be appreciated that the preset combination of settings provided to the user by the positions of the end cap, the range switch, and the activation buttons are configured to allow the user to quickly identify the settings of the illumination and aiming apparatus. Because a user may be wearing gloves and/or be in a situation with limited visibility, it is important that the user be able to quickly identify the apparatus settings in order to quickly adjust to a changing environment or moving targets. Providing simple and intuitive setting options also minimizes the risk that the user may accidentally trigger a visible radiation mode that may inadvertently reveal the user&#39;s position. 
         [0044]    Example functionalities of illumination and aiming device  100  will now be discussed in more detail with reference to  FIGS. 6 and 7 . As explained above, the following example configuration merely illustrates a possible combination of function sets, and is not intended to limit the scope of the invention.  FIG. 6  depicts a table of example function sets for which an example embodiment of illumination and aiming apparatus  100  can be configured. In all of the following examples, activation button  101  will be configured to provide the user with a mode that corresponds to an immediate threat, and activation mode  102  will be configured to provide the user with a mode that corresponds to a more administrative task. 
         [0045]    When range switch  106  is fully extended over lock-out switch  107 , illumination and aiming device  100  will be in the “long-range” mode for both the visible and IR radiation positions of lens cap  105 . As  FIG. 6  shows, in long-range mode, activation buttons  101  and  102  will provide different operation functions. In  FIG. 6 , activation button  102  is referred to as the “Front (KILL)” button, while activation button  101  is referred to as the “Rear (ADMIN)” BUTTON. In this example mode, activation button  102  is configured to provide both a high power, 15 mW aiming pointer beam and a high power 150 mW narrow illumination beam with 4 degrees divergence. Activation button  101  is configured to provide only a 15 mW aiming beam without illumination. In this example, the aiming beam has a range exceeding 1000 meters, and the illumination beam will have a range of approximately 400 meters. This mode provides function sets that will likely be useful to a user in an exterior environment, engaging with targets at a distance. 
         [0046]    When range switch  106  is in the middle position, illumination and aiming device will be in the “mid-range” mode for both the visible and IR radiation positions of lens cap  105 . In this example mid-range mode, activation button  102  is configured to provide both a medium power, 10 mW aiming pointer beam in combination with a high power, wide spill, 20 mW illumination beam with 4 degrees divergence and a 150 mW illumination beam with 16 degrees divergence. Activation button  101  is configured to provide a medium power, 10 mW aiming pointer beam in combination with a low power, wide spill 80 mW illumination beam with 4 degrees divergence and a 40 mW illumination beam with 16 degrees divergence. In this example, the aiming pointer beam has a range of approximately 500 meters, while the illumination beams have a range of approximately 50 to 100 meters. This mode of the illumination and aiming device provides function sets that could be used in both exterior and interior settings, where a target is likely to be engaged at a middle distance. 
         [0047]    When range switch  106  is in the position that is closest to the user, illumination and aiming device  100  will be in the “short-range” mode for both the visible and IR radiation positions of lens cap  105 . As  FIG. 6  shows, in short-range mode, activation buttons  101  and  102  will provide different operation functions. In this example mode, activation button  102  is configured to provide both a low power, 1 mW aiming pointer beam and a smooth 40 mW illumination beam with 60 degrees divergence. Activation button  101  is configured to provide only a 5 mW illumination beam with 60 degrees divergence intended for use as a navigation light for covert maneuvering through difficult terrain. In this example, the aiming beam has a range of approximately 100 meters, and the illumination beam will have a range of approximately 0-15 meters. This mode of the illumination and aiming device provides function sets that could be used in environments where the user is likely to immediately engage with a target, for example, in a room clearing scenario. 
         [0048]    It will be appreciated that the user will be able to quickly and easily switch between these function sets, and as such quickly adapt to a changing environment and changing target distance. 
         [0049]      FIG. 7  provides a visual depiction of the different radiation modes described above with respect to the table of  FIG. 6 . As illustrated, the differing ranges and divergence angles of the combinations of radiation sources provided by each operation function set can be seen relative to each other. As illustrated in  FIG. 7 , the illumination and aiming radiation provided in each operation function set may substantially share the same optical axis. Although a number of example embodiments of the invention have been described, it should be understood that numerous other modifications and embodiments of the invention can be devised by those skilled in the art that will fall within the scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the inventive subject matter within the scope of the disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses and applications of the invention will also be apparent to those skilled in the art.